OM Manual 3243773 - 10

Bulletin No.
3243773- 10
Foreword
Dear Customer,
Congratulations and thank you for purchasing a piece of equipment powered by Cummins. We believe we make
the best Diesel engines in the country and each time you purchase a piece of equipment, you reaffirm your
confidence. But far more important than the product, is the customer support we provide. Ownership of a Cummins
engine, entitles you to,
• The best warranty policy in the industry
• Largest dealer network
• 24 hour customer assistance cell
• Various training program
We hope you will take advantage of all we offer.
We again thank you for your purchase and hope you will write back with lots of suggestions and feedback. This
is an engine operation and maintenance manual, not a repair manual. This O&M Manual is for all applications
of the models mentioned on inner cover page. The design of Cummins engines makes it possible to replace worn
or damaged parts with new or rebuilt parts with a minimum of down time. Contact the nearest Cummins dealer for
parts replacement as they are equipped and have well informed, trained personnel to perform this service. If your
shop is properly equipped to perform either maintenance, unit replacement and/or complete engine rebuild, contact
the nearest Cummins dealer to obtain available repair manuals and arrange for training of personnel.
Engine Identification
For model identification of an engine, check the dataplate. The letter and number code indicates breathing (naturally
aspirated except when letter “T” for turbocharged is present), cubic inch displacement, application and maximum
rated horsepower.
Note: The below Engine model identification covers Fire pump, Compressor, Mining, Marine, Locomotive, and
Power Generation for NTA-855, N-14, V-28, K-19, KTA-38 and KTA-50 Engine Models.
Examples:
NTA-855-C NTA-14 - C VTA-28 - G

N = Engine Series N = Engine Series V= Engine series
T = Turbocharged T = Turbocharged T = Turbocharger
A = Aftercooled A = Aftercooled A = Aftercooled
855 = Cubic Inch C = Construction Application G = Power Generation
Displacement 14 = Liters Application
C = Construction Application 28 = Liters
14 = Liters
KTAA - 19 - G10 KTA-50 - G

KTA -38 – G14
K = Engine Series K = Engine Series K - Engine Series
T = Turbocharger T = Turbocharged T = Turbocharged
AA = Doubled Aftercooled A = Aftercooled
A = Aftercooled
G = Power Generation G = Power Generation
G = Power Generation
Application Application
Application
19 = Liters 50 = Liters
38 = Liters
Engine Data Plate: Engine Model - N T A - 8 5 5 – C
Engine Data Plate: Engine Model - N T A - 1 4 - C
Engine Data Plate: Engine Model - V T A - 2 8 - G
Engine Data Plate: Engine Model - K T A A - 1 9 – G 1 0
Engine Data Plate: Engine Model - K T A - 3 8 – G 1 4 & K T A - 5 0 – G

Table of Contents
Foreword
Table of Contents Section 3 - Maintenance Operation
Cummins Owner Assistance
Cummins Engine Service Training Courses Preventive Maintenance ......................................... 3-1
Customer Assistance Cell Maintenance Schedule............................................ 3-3
24 Hour Emergency Service Maintenance Schedule For Starter & Alternator .... 3-4
10 Maintenance Steps for Cummins Engine Engine Daily Log Book .......................................... 3-5
Engine Diagrams Scheduled Maintenance ......................................... 3-6
Stand-by Duty Generator Set Maintenance ........... 3-7
Continuous Duty Generator Set Maintenance ........ 3-8
Section i - Introduction
To the Owner and Operator ...................................... i-2

Section 4 - “A” Maintenance Checks-Daily
About the Manual ..................................................... i-2
How to Use the Manual ............................................ i-2
Daily Report ............................................................ 4-1
Illustrations .............................................................. i-3
Check Engine Oil Level ......................................... 4-1
General Safety Instructions ...................................... i-4
Drain Sediments ..................................................... 4-1
Important Safety Notice ........................................ i-4
Fill Marine Gear ..................................................... 4-2
Definition of Terms ................................................... i-6
Check Air Cleaner .................................................. 4-3
Engine Operating Range .......................................... i-7
Clean or Replace of Air Cleaner Element ............. 4-3
Engine Shut-Down ................................................... i-7
Air Cleaner Service Tips ........................................ 4-4
Check Engine Coolant Level .................................. 4-6
Section 1 - Operating Instructions Check for Damage ................................................. 4-6
Drain Air Tank ........................................................ 4-6
General Information ................................................ 1-1
Starting the Engine ................................................ 1-2
Normal Starting Procedure ..................................... 1-2 Section 5 - “A” Maintenance Checks-Weekly
Cold Weather Engine Operation ............................. 1-5
Cold Weather Starting ............................................ 1-5 Fuel – W ater Separator….................................... 5-1
Cold Weather Starting Aids ................................... 1-6 Lubricating Oil Level................................................. 5-1
Engine Warm-up ..................................................... 1-8 Air Intake Restriction............................................... 5-2
Oil Temperature Specification ................................ 1-9 Water Pump and Drive Belts ....................................... 5-2
Water Temperature Specifications ......................... 1-9 Coolant Level……………........................................ 5-2
Oil Pressure Specifications .................................... 1-9 Air Tank and Reservoirs.......................................... 5-3
Oil Pan Capacity .................................................. 1-11
Priming the Lubricating System ........................... 1-11
Checking Engine Oil ............................................ 1-12 Section 6 - “B” Maintenance Checks
Other Checks ....................................................... 1-12
Operating the Engine ........................................... 1-13 Lubricating oil change
Engine Operating Range ...................................... 1-14 interval..................................................................... 6-1
Engine Shut Down ............................................... 1-15 Engine Mounts…………………............................... 6-1
Step Timing Control ............................................. 1-16 Water Pumps…………............................................ 6-1
Power take-off Application ................................... 1-16 Coolant Concentration............................................ 6-2
Electronic Control Panel ....................................... 1-17
Engine Preservation Procedure ............................ 1-18
Section 2 - Industrial Fire Pump Engines
Engine Starting Procedure ..................................... 2-1

Initial Start-up ......................................................... 2-1
Normal Operation .................................................... 2-1
Engine Cooling System .......................................... 2-2
Reverse Rotation of Pump ..................................... 2-2
Water Heater Tank ................................................. 2-2
Use of Water Heater Tank ..................................... 2-3
Section 7 – “ C ” M a i n t e n a n c e Checks
Crankcase Breather Element ................................... 7-1

Air Cleaner Element …................... ........................ 7-2
Zinc Anode Plug...................................................... 7-2
Section 12 – Torque Values
Section 8 - “D” Maintenance Checks
Capscrew Marking and Torque Values …............. 12-1
Fuel Pump…………………...................................... 8-1
Cooling System ………………................................. 8-1
Vibration Damper…………...................................... 8-2
Air Compressor………………………….................... 8-3
Water Pump ………………...................................... 8-4
Turbocharger…………............................................ 8-5 Section 13 - Troubleshooting
Cummins Diesel Engines ................................... 13-1
Section 9 - Seasonal Maintenance Checks
Replace hose ......................................................... 9-1

Check pre-heater cold starting air .......................... 9-1
Check thermostats and seals ................................ 9-1
Checking mountings ............................................... 9-1
Check fan & drive pulley mounting ....................... 9-1
Check crankshaft end clearance ........................... 9-1
Check raw (sea) water pump ................................. 9-2
Section 10 – Major Engine Overhaul
In-Frame overhaul / Major Engine Overhaul ........ 10-1
Section 11 – Specification and Torque
Lubricating Oil ....................................................... 11-1

Fuel Oil ................................................................. 11-2
Cooling System ……………………………..………11-3
Test Strip ............................................................. 11-5
Test Kit ................................................................ 11-5
Coolant Top Up .................................................... 11-7
Coolant Checking ................................................. 11-7
Coolant Replacement ........................................... 11-7
Conversion of field engines ................................. 11-7
Coolant capacities ................................................ 11-8
CUMMINS OWNER ASSISTANCE CUMMINS ENGINE SERVICE
TRAINING COURSES
Cummins India Limited backs its engines with expert service
and complete parts support. W e built a service network of
Services Training Courses are available for customer’s
Cummins dealers, the largest in INDIA devoted exclusively
technical personnel involved in Cummins Engine
to Cummins diesel engines. We trained our people to provide
Maintenance, Operation and Repair. These courses are
the Cummins owner with sound advice, expert service and
conducted on a scheduled basis in Pune Service Training
professional treatment at all Cummins locations.
Schools, by
Any problem that you have in connection with the sale,
operation or service of your engine can be handled at the Cummins India Ltd
nearest Cummins location. Occasionally, you may feel a (Distribution Business Unit)
problem has not b e e n handled to your satisfaction. At those Tower A, Survey No. 21 Balewadi, Pune – 411045, Maharashtra.
times, we urge you to pursue the problem until you are
satisfied.
Customers, desirous of availing the training facilities may
Not all problems are of engineering nature, several arise from
contact the Training Manager, at above address.
communication gaps or sheer misunderstanding; either or
both the parties may be involved in the procedures to see
a simple way out. The field person may also be immobilized The service training courses offered are:
if he faces a real policy decision.
1. Engine Familiarization and Maintenance Course
In all such events, we sincerely request you to take your
problem to the higher levels till you are fully satisfied. 2. Engine Rebuild Course
We suggest the following points of contact: 3. Cummins PT Fuel System Course

1. If problem originates with a salesperson or service
4. Correspondence Course Part I & II.
technician, talk to the sales or service manager.
2. If problem originates with a sales or service manager, The service Training School also makes available Service
talk to the owner of the service location who is the dealer. Training Publications pertaining to Cummins Engine
Maintenance, Operation Repair. The list is available with,
3. If problem originates with a dealer, please call the nearest
Cummins Regional Office.
Training Manager,
Most problems are solved at or below the regional
office level. Their phone numbers and addresses
are listed. However, before you can, please write Cummins India Ltd
down the following information and have it ready. Technical Training Center.
Plot No. A1 & A1/2
A. Name and location of the Cummins dealer.
MIDC, Survadi,
B. Type and make of equipment.
Lonand Road, Phaltan Taluka,
C. Engine model and serial number.
Phaltan, Dist. Satara.
D. Total miles/ kms. or hours of operation.
E. Nature of problem.
F. Summary of the current problem arranged in the
order of occurrence.
If you still have problems please write to:

Service Engineering
Cummins India Limited

Cummins India Office Campus
Tower A, Survey No 21, Balewadi,
Pune – 411045, Maharashtra.
Tel: +91 – 20 – 67067000.
W e 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.
CUSTOMER ASSISTANCE CELL
Customer Assistance Cell Parts Assistance
Have a Question or comment, need information or When you need help to locate correct part numbers,
want assistance for your Cummins Engine or just w a n t want a copy of Engine Build Record, need more
to talk to some on e w h o w il l li ste n a nd promptly information on genuine spares or you are eager to
resolve a problem then please know about new development in parts for your
engine, Cummins Customer Assistance Cell is there
Dial : 020 (PUNE) 25436680
to help you. Also when you want to know the dispatch
Fax : 020 (PUNE) 25445916 details for parts of under warranty engines, please call
Toll Free : 1-800-2332000 - BSNL/MTNL or us.
020-25436680
e-mail : Powermaster-India@Cummins.com
Technical Information & Service Assistance

W hen you need to know the warranty coverage,
operation an d ma intena nce practice s or rep air
procedures, want to carry out diagnosis, Customer
Assistance Cell will give you the details you need
like Fuel Pump & Injector Calibration, Control Parts list.
CMYK
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.
Cu m min s In dia L i mi t e d
Registered Office : Kothrud, Pune 411 038 (India)
Phones : 25380240, 25385435, 25381105 Fax : (020) 25387125
Visit us at : www.cumminsindia.com
Cummins Indi a Ltd

(Distribution Business Unit)
Cummins Group in India, Corporate Office:
Cummins India Office Campus
Survey No.21 Balewadi, Pune * 411045.
Maharashtra, India
Toll Free: 1-800-210-2525. Tel.
No. 67607000/ Extn. 7979
YK
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.

Engine Diagrams
NTA-855 Engine Model

VTA-28 Engine Model
KTA-19 Engine Model
K38 Engine Model
K50 Engine Model

NOTES
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Page i-1
Section Contents
Page
To the Owner and Operator ................................................................................................................................... i-2
About the Manual ................................................................................................................................................. i-2
How to Use the Manual ........................................................................................................................................ i-2
Illustrations …....................................................................................................................................................... i-3
General Safety Instructions ................................................................................................................................... i-4
Important Safety Notice ...................................................................................................................................... i-4
Definition of Terms .............................................................................................................................................. i-6
Engine Operating Range ..................................................................................................................................... i-7
Engine Shut-Down ............................................................................................................................................... i-7
i-2 To the Owner and Operator
To the Owner and Operator

Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance schedule
recommendations outlined in Maintenance Guidelines.
Keep records of regularly scheduled maintenance.
Use the correct fuel, oil, and coolant in your engine as specified in Engine Specifications.
Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. If
you have a problem that cannot be resolved by a Cummins Authorized Repair Location.
About the Manual

This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins
India Ltd. Additional service literature can be ordered from your Cummins distributor. For problems with literature orders,
contact Cummins India Ltd., Kothrud, Pune 411 038.
This manual does not cover vehicle or equipment maintenance procedures. Consult the vehicle or equipment
manufacturer for specific maintenance recommendations.
Each section is preceded by a “Section Contents” to aid in locating information.
How to Use the Manual

This manual is organized according to intervals at which maintenance on your engine is to be performed. A table that
states the required intervals and the checks to be made is located in Section 3. Locate the interval at which you are
performing maintenance. Then follow the steps given in that section for all the procedures to be performed. In addition,
all of the procedures done under previous maintenance intervals must be performed.
Keep a record of all the checks and inspections made. A record form for recording date, mileage/kilometer or hours, and
what maintenance checks were performed.
For specifications recommended by Cummins India Ltd., for your engine / Specifications and torque values for each
engine system are given in Engine Specification section.
Section i - Introduction i-3
Illustrations
Use the illustrations in this manual as a guide to perform
the action or the repair described. Many illustrations are
generic and will not look exactly like the engine or the
parts used in your application. In order to provide clarity
to illustrations, some illustrations show parts removed
that are not related to the specific parts given in the text.
Most of the illustrations contain symbols to indicate an
action required or to indicate an acceptable (OK) or
unacceptable (not OK) condition.
The illustrations are intended to show repair or replacement

procedures. The illustration can differ from your application,
but the procedure given will be the same.
i-4 General Safety Instructions
General Safety Instructions

Important Safety Notices
WARNING
Improper practices, carelessness, or ignoring the warnings can cause burns, cuts, mutilation,
asphyxiation or other personal injury or death.
Read and understand all of the safety precautions and warnings before performing any repair. This list contains the
general safety precautions that must be followed to provide personal safety. Special safety precautions are included in
the procedures when they apply.
• Work in an area surrounding the product that is dry, well lit, ventilated, free from clutter, loose tools, parts, ignition
sources and hazardous substances. Be aware of hazardous conditions that can exist.
• Always wear protective glasses and protective shoes when working.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewelry when working.
• Disconnect the battery (negative [-] cable first) and discharge any capacitors before beginning any repair work.
Disconnect the air starting motor if equipped to prevent accidental engine starting. Put a "Do Not Operate" tag
in the operator's compartment or on the controls.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate the
crankshaft by pulling or prying on the fan. This practice can cause serious personal injury, property damage,
or damage to the fan blade(s) causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the engine to cool before slowly loosening the filler
cap to relieve the pressure from the cooling system.
• Always use blocks or proper stands to support the product before performing any service work. Do not work on
anything that is supported ONLY by lifting jacks or a hoist.
• Relieve all pressure in the air, oil, fuel, and cooling systems before any lines, fittings, or related items are
removed or disconnected. Be alert for possible pressure when disconnecting any device from a system that
utilizes pressure. Do not check for pressure leaks with your hand. High pressure oil or fuel can cause personal
injury.
• To reduce the possibility of suffocation and frostbite, wear protective clothing and ONLY disconnect liquid
refrigerant (Freon) lines in a well ventilated area. To protect the environment, liquid refrigerant systems must
be properly emptied and filled using equipment that prevents the release of refrigerant gas (fluorocarbons) into
the atmosphere. Federal law requires capturing and recycling refrigerant.
• To reduce the possibility of personal injury, use a hoist or get assistance when lifting components that weigh
23 kg [50 lb] or more. Make sure all lifting devices such as chains, hooks, or slings are in good condition and
are of the correct capacity. Make sure hooks are positioned correctly. Always use a spreader bar when
necessary. The lifting hooks must not be side-loaded.
• Corrosion inhibitor, a component of SCA and lubricating oil, contains alkali. Do not get the substance in eyes.
Avoid prolonged or repeated contact with skin. Do not swallow internally. In case of contact, immediately wash
skin with soap and water. In case of contact, immediately flood eyes with large amounts of water for a minimum
of 15 minutes. IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH OF CHILDREN.
• Naptha and Methyl Ethyl Ketone (MEK) are flammable materials and must be used with caution. Follow the
manufacturer's instructions to provide complete safety when using these materials. KEEP OUT OF REACH OF
CHILDREN.
• To reduce the possibility of burns, be alert for hot parts on products that have just been turned off, exhaust gas
flow, and hot fluids in lines, tubes, and compartments.
Section i - General Safety Instructions i-5
• Always use tools that are in good condition. Make sure you understand how to use the tools before performing
any service work. Use ONLY genuine Cummins® or Cummins ReCon® replacement parts.
• Always use the same fastener part number (or equivalent) when replacing fasteners. Do not use a fastener of
lesser quality if replacements are necessary.
• When necessary, the removal and replacement of any guards covering rotating components, drives, and/or belts
should only be carried out be a trained technician. Before removing any guards the engine must be turned off
and any starting mechanisms must be isolated. All fasteners must be replaced on re-fitting the guards.
• Do not perform any repair when fatigued or after consuming alcohol or drugs that can impair your functioning.
• Some state and federal agencies in the United States of America have determined that used engine oil can be
carcinogenic and can cause reproductive toxicity. Avoid inhalation of vapors, ingestion, and prolonged contact
with used engine oil.
• Do not connect the jumper starting or battery charging cables to any ignition or governor control wiring. This can
cause electrical damage to the ignition or governor.
• Always torque fasteners and fuel connections to the required specifications. Overtightening or under tightening
can allow leakage. This is critical to the natural gas and liquefied petroleum gas fuel and air systems.
• Always test for fuel leaks as instructed, as odorant can fade.
• Close the manual fuel valves prior to performing maintenance and repairs, and when storing the vehicle inside.
• Coolant is toxic. If not reused, dispose of in accordance with local environmental regulations.
• The catalyst reagent contains urea. Do not get the substance in your eyes. In case of contact, immediately flood
eyes with large amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of
contact, immediately wash skin with soap and water. Do not swallow internally. In the event the catalyst reagent
is ingested, contact a physician immediately.
• The catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State
of California to cause cancer. Always wear protective gloves and eye protection when handling the catalyst
assembly. Do not get the catalyst material in your eyes. In Case of contact, immediately flood eyes with large
amounts of water for a minimum of 15 minutes. Avoid prolonged contact with skin. In case of contact,
immediately wash skin with soap and water.
• The Catalyst substrate contains Vanadium Pentoxide. Vanadium Pentoxide has been determined by the State
of California to cause cancer. In the event the catalyst is being replaced, dispose of in accordance with local
regulations.
• California Proposition 65 Warning - Diesel engine exhaust and some of its constituents are known to the State
of California to cause cancer, birth defects, and other reproductive harm.
i-6 Section i - Definition of Terms
Definition of Terms
AFC Air Fuel Control
API American Petroleum Institute

ASA Air Signal Attenuator
ASTM American Society of Testing and Materials
C Celsius
CARB California Air Resources Board
C.I.D. Cubic Inch Displacement
cm Centimeter
CPL Control Parts List
cSt Centistokes
DCA Diesel Coolant Additive
E.C.S. Emission Control System
EPA Environmental Protection Agency
F Fahrenheit
ft-lb Foot Pound
GVW Gross Vehicle Weight
Hg Mercury
HP Horsepower
H2O Water
in-lb Inch Pound
kg Kilograms
km Kilometers
km/I Kilometers per Liter
kPa Kilopascal
I Liter
m Meter
mm Millimeter MPa
Megapascal
MPH Miles Per Hour
MPQ Miles Per Quart
N•m Newton-meter
OEM Original Equipment Manufacturer
ppm Parts Per Million
psi Pounds Per Square Inch
RPM Revolutions Per Minute
S.A.E. Society of Automotive Engineers
Engine Shut-Down i-7
Engine Operating Range

CAUTION
Operating the engine beyond high idle speed can cause severe engine damage. The engine speed must not
exceed 1850 RPM under any circumstances. When descending a steep grade, use a combination of transmission
gears and engine or service brakes to control the vehicle and engine speed.
Cummins heavy-duty engines are designed to operate successfully at full throttle under transient conditions down to peak
torque engine speed (RPM). This is consistent with recommended operating practices for good fuel economy.
Excessive full throttle operation below peak torque RPM will shorten engine life to overhaul, can cause serious engine
damage, and is considered engine abuse. Peak torque RPM varies from 1,100 RPM to 1,500 RPM, depending upon rated
engine speed.
Engine Shut-Down
Engine Operation before Shutdown
It is important to idle the engine 3 to 5 minutes before shutting it down to allow the lubricating oil and water to carry heat
away from the combustion chamber, bearings, shafts, etc. This is especially important with turbocharged engines.
The turbocharger contains bearings and seals that are subject to the high heat of combustion exhaust gases. While the
engine is running, this heat is carried away by oil circulation; but if the engine is stopped suddenly, the turbocharger
temperature can rise as much as 38° C [100°
F]. The results of the extreme heat can be seized bearings or loose oil seals.
NOTE: Do not idle for excessively long periods.
Long periods of idling are not good for an engine because the combustion chamber temperatures drop so low the fuel
cannot burn completely. This will cause carbon to clog the injector spray holes and piston rings and can result in stuck
valves.
If the engine coolant temperature becomes too low, raw fuel will wash the lubricating oil off the cylinder walls and dilute
the crankcase oil so all moving parts of the engine will suffer from poor lubrication.
If the engine is not being used, shut it down.
Practically all failures give some warning to the operator before the parts fail and ruin the engine. Many engines are saved
because alert operators heed warning signs (sudden drop in oil pressure, unusual noises, etc.) and immediately shut down
the engine.
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Operation Instructions 1-a
Section 1 - Operating Instructions

Section Contents
Page
General Information .............................................................................................................................................. 1-1
Starting the Engine .............................................................................................................................................. 1-2
Normal Starting Procedure ................................................................................................................................... 1-2
Cold Weather Engine Operation ........................................................................................................................... 1-5
Cold Weather Starting .......................................................................................................................................... 1-5
Cold Weather Starting Aids ................................................................................................................................. 1-6
Engine Warm-up ................................................................................................................................................... 1-8
Oil Temperature Specification .............................................................................................................................. 1-9
Water Temperature Specifications ....................................................................................................................... 1-9
Oil Pressure Specifications .................................................................................................................................. 1-9
Oil Pan Capacity ................................................................................................................................................ 1-11
Priming the Lubricating System ......................................................................................................................... 1-11
Checking Engine Oil .......................................................................................................................................... 1-12
Other Checks ..................................................................................................................................................... 1-12
Operating the Engine ......................................................................................................................................... 1-13
Engine Operating Range .................................................................................................................................... 1-14
Engine Shut Down ............................................................................................................................................. 1-15
Step Timing Control ........................................................................................................................................... 1-16
Power take-off Application ................................................................................................................................. 1-16
Electronic Control Panel ..................................................................................................................................... 1-17
Engine Preservation Procedure .......................................................................................................................... 1-18
1-b Operation and Maintenance
THIS PAGE LEFT INTENTIONALLY BLANK

Operation Instructions 1-1
Section 1
The engine operator must assume responsibility

Operating of engine care while engine is being operated.
There are comparatively few rules which operator
Instructions must observe to get best service from a Cummins
Diesel Engine.
General - AII Applications

1.0 GENERAL INFORMATION
Correct care of your engine will result in longer life,

better performance and more economical operation.
• Follow the daily maintenance checks listed in
Maintenance Guidelines.
• Check the oil pressure indicators, temperature

indicators, warning lights and other gauges daily
to make sure they are operational.
WARNING
DO NOT OPERATE A DIESEL ENGINE WHERE
TH ERE AR E O R CAN BE CO M BU STIB LE
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 e n g i n e .
TH E EQ U I PM EN T OW N E R AN D OPERATOR
ARE RESPONSIBLE FOR SAFE OPERATION IN
A HOSTILE ENVIRONMENT. CONSULT YOUR
CUMMINS AUTHORIZED REPAIR LOCATION FOR
FURTHER INFORMATION.
1-2 Operation and Maintenance
1.1 Starting the Engine
The engine requires clean air and fuel to be supplied to

the combustion chambers in proper quantities at the
correct time.
CAUTION
While starting the engine do not touch the Throttle
or Throttle Lever.
Normal Starting Procedure
WARNING
Before starting, check to make sure everyone is
clear of engine and equipment, to prevent accidents.
If fuel system is equipped with overspeed stop, push

“Reset” button before attempting to start engine. CAUTION
1.1.1 On units equipped with air activated prelube To prevent permanent cranking motor damage, do
device, open air valve until oil pressure is not crank engine for more than 10 seconds
registered on oil pressure gauge to activate piston continuously. If the engine does not start after about
in prelube device which will lubricate all moving three repeated attempts, with an interval of two
parts in engine. minutes between successive starts then the starter
should not be operated and the fuel system has to
be checked for any faults.
Note: On engines equipped with an oil pressure
safety switch, hold the fuel by-pass switch in “start”
position until engine oil pressure reaches 7 to 10 psi 1.1.6 At the initial start or after oil or filter changes and
(48 to 69 kPa); then, move to “run” position. after engine has run for a few minutes, shut it
down and wait for 15 minutes for oil to drain back
1.1.2 Set throttle for idle speed and disengage driven into pan. Check engine oil level again, add oil as
Unit. necessary to bring oil level to “H” mark on dipstick.
The drop in oil level is due to absorption by oil
1.1.3 For marine engines open sea cocks to permit raw filters.
water flow through heat exchanger and marine gear
oil cooler. Place marine gear in neutral.
CAUTION
Protect the turbocharger during start-up by not
opening throttle or accelerating above 1000 rpm until
idle speed oil pressure registers on gauge.
1.1.4 Open manual fuel shut-down valve, if so equipped.

Electric shut-down valves operate as switch is
turned on. A manual override knob provided on
forward end of electric shut-down valve allows valve
to be opened in case of electric power failure. To
use, turn fully clockwise; return to “run” position
after electric repair.
1.1.5 Press starter button or turn switch key to “start”

position and crank the engine till it fires.
1.2 Normal Starting Procedure (Above O°

C [32°
F])
• Disengage the driven unit, or if equipped, put
the transmission in neutral.
• Start the engine with the throttle in the idle
position.
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 for more than 30 seconds. Wait two (2)
minutes between each attempt to start engine (electrical
starting motors only).
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.
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.
• Idle the engine three (3) to five (5) minutes at

approximately 1,000 RPM before operating with
a load.
• 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.
Do not idle the engine for excessively long periods.

Long periods of idling, more than 10 minutes, can
damage an engine because combustion chamber
temperatures drop so low the fuel will not burn
completely. This will cause carbon to clog the injector
spray holes and piston rings, and can cause the valves
to stick.
If the engine coolant temperature becomes too low,

60° C [140° F], raw fuel will wash the lubricating oil off
the cylinder walls and dilute the crankcase oil; therefore,
all moving parts of the engine will not receive the
correct amount of lubrication.
1.4 Cold Weather Starting
Using Starting Fluid with Mechanical or Electrical

Metering Equipment
• Set the throttle at idle.

• Disengage the driven unit, or if equipped, put
the transmission in neutral.
• Activate the switch to open the fuel pump
shutoff valve.
• While cranking the engine, inject a metered

amount of starting fluid.
• Engine oil pressure must be indicated on the
gauge within 15 seconds after starting.
Using Starting Fluid without Metering Equipment

WARNING
Do not use volatile cold starting aids in underground
mine or tunnel operations due to the potential of an
explosion. Check with the local Mines Inspector for
instructions.
CAUTION
Do not use excessive amounts of starting fluid when
starting an engine. The use of too much starting
fluid will cause engine damage.
Due to increased safety hazards and potential for

engine damage, Cummins India Limited does NOT
recommend the use of starting fluid without metering
1.3 Cold Weather Engine Operation equipment.
Satisfactory performance of a diesel engine operating There are three basic objectives to be accomplished:
in low ambient temperature conditions requires
1. R easonable starting characteristics followed by
modification of the engine, surrounding equipment,
practical and dependable warm-up of the engine
operating practices and maintenance procedures. The
and equipment.
colder the temperatures encountered, the greater the
amount of modification required and yet with the 2. A unit or installation which is as independent as
modifications applied, the engine must still be capable possible from external influences.
of operation in warmer climates without extensive
changes. The following information is provided to 3. Modifications which maintain satisfactory operating
engine owners, operators and maintenance personnel temperatures with a minimum increase in
on how the modifications can be applied to get maintenance of the equipment and accessories.
satisfactory performance from their diesel engines. If satisfactory engine temperature is not maintained,
higher maintenance cost will result due to the increased
engine wear, poor performance and formation of e. Heating to be provided to increase the engine
excessive carbon, varnish and other deposits. Special block and component temperature to a minimum of
provisions to overcome low temperatures are definitely -32°C [-25° F] for starting in lower temperatures.
necessary, whereas a change to warmer climate
f. Proper external heating source available.
normally requires only a minimum of revision. Most of
the accessories will be designed in such a way that they g. Electrical equipment capable of operating in the
can be disconnected so there is little effect on the lowest expected temperature.
engine when they are not in use.
Arctic specifications refer to the design material and
The two most commonly used terms associated with specifications of the components necessary for
preparation of equipment for low temperature operation satisfactory engine operation in extreme low temperature
are Winterization and Arctic specifications. -54° C [65° F]. Contact Cummins Engine Company, Inc.
or the equipment manufacturer to obtain the special
Winterization of the engine and/or components so that items required.
starting and operation are possible in the lowest
temperature to be encountered requires: For additional information on cold weather operation,
obtain Service Bulletin No. 3379009, Engine Operation
a. use of correct materials. in Cold Weather, from the nearest Cummins distributor
b. Proper lubrication, low temperature lubricating oils. or dealer.
It is possible to operate diesel engine in extremely cold
environments if they are properly prepared and
c. Protection from the low temperature air. The metal
maintained. The correct lubricants, fuels and coolant
temperature does not change, but the rate of heat
must be used for the cold weather range for which the
dissipation is affected.
vehicle is being operated. Refer to the chart below for
d. Fuel of a proper grade for the lowest temperature. recommendations in different operating ranges.
Winterize Winterize Winterize

0°to -23°C -23°to -32° C -32°to -54° C
[32°to -10°F] [-10°to -25° F] [-25°to -65° F]
Use ethylene glycol antifreeze to Use 50 percent ethylene glycol Use 60 percent ethylene glyco
protect to -29°C [-20°
F] antifreeze, 50 percent water mixture. antifreeze 40 percent water mixture.
Use multi viscosity oils meeting Use multi viscosity oil meeting API, Use Artic oil meeting API, CE or
API, CE or CH4 specifications. CE or CH4 specifications. CH4 specifications.
Fuel to have maximum cloud and Fuel to have maximum cloud and Fuel to have maximum cloud and
pour points 6°C [10° F] lower than pour points 6°C [10° F] lower than pour points 6°C [10° F] lower than
ambient temperature in which engine ambient temperature in which engine ambient temperature in which engin
operates. operates. operates.
1.4.1 Cold Weather Starting Aids

Ether Starting Aids
WARNING CAUTION
Starting fluid contains ether and is extremely Using too much starting fluid will cause extremely
flammable. Misuse or mishandling can cause an high pressures and detonation in the engine cylinders,
explosion. NEVER handle starting fluid near an resulting in damage to the cylinder parts and
open flame. NEVER use starting fluid with a bearings. Too much starting fluid can also cause
preheater, glow plug, flame thrower or other type of damage from engine overspeed.
electrical starting equipment. Do NOT breathe the
fumes as serious injury to the human respiratory
system will result. Fuel oil or volatile fuel cold
starting aids are NOT to be used in underground
mine or tunnel operations.
1.4.2 Manually Operated Ether Valve

The manually operated ether valve includes the valve
body assembly (5), clamp (2), and nylon tube (3). The
fuel cylinder (1), atomizer fitting (4) and pull control (6)
must be ordered separately.
Standard pull or throttle control cables can be used to
actuate the manual valve, if desired.
1.4.3 Electrically Operated Ether Valve

The electrically operated ether valve includes the valve
body (7), 90 degree elbow (5), clamp (2), push button
switch (6), and nylon tube (3). A thermostat is mounted
to the cylinder block or coolant passage and stops
electrical power to the atomizer solenoid when the
engine is warm. See the Parts Catalog for fuel cylinder
91) and fuel atomizer fittings (4). These fittings must
be ordered separately, as required.
1.4.4 Atomizer Installation Recommendations

The atomizer fittings must be mounted in the engine air
intake manifold to provide an equal distribution of
starting fuel to each cylinder. The atomizer holes are
180 degrees apart and must be mounted so the spray
is injected the long way of the manifold. If incorrectly
installed, the spray goes crosswise of the manifold.
1.4.5 Preheater Glow Plug Type System

The glow plug system supplies heat to the combustion
chambers, so compression temperatures are sufficient
to ignite fuel.
To aid in starting engine when temperature is 50°
F (10°
C)
or below, an intake air preheater is recommended. The
Preheater equipment consists of a hand priming pump to
pump fuel into intake manifold, and a switch to turn on
glow plug which is electrically heated by battery. Fuel
burns in intake manifold and heats intake air.
WARNING
Do not use vapor in conjunction with preheater as it
could result in a fire.
To use preheater for cold starting: manual switch for 15 seconds and observe glow plug
through 1/8 inch pipe plug hole. The glow plug should
a. Set throttle in idle position. Turn glow plug toggle
be white hot; if not, connect wiring to a 6- or 12-volt
switch to ‘ON’ position. Red indicator light must be
(as used) source and check amperage; it should be
on.
30 to 32 (min.) amperes. If glow plug is all right,
b. After red light has been on for 20 seconds, start check manual switch and resistor (if used) and
cranking engine. As soon as engine begins rotating, replace if necessary.
operate preheater priming pump to maintain 80 to Note: Preheater priming pump, switches and resistor
100 psi (552 to 689 kPa) fuel pressure. Use of primer are located at the instrument panel and are to be
before the 20-second interval will wet glow plug and checked during engine starting.
prevent heating.
The cold starting aid approved for use on Cummins
c. If engine does not start within 30 seconds, stop Engines, has been based upon starting aid capabilities
cranking. Wait one or two minutes and repeat cranking to –25°
F (–32°C).
operation.
2.0 ENGINE WARM-UP
d. After engine starts, pump primer slowly to keep
engine idling smoothly. In cold weather this may
When the engine is started, it takes a while to get the
require 4 to 5 minutes or longer. Do not accelerate
lubricating oil film re-established between shafts and
engine.
bearings and between pistons and liners. The most
e. When the engine has warmed up so it does not falter favorable clearances between moving parts are obtained
between primer strokes, stop pumping. Close and only after all engine parts reach normal operating
lock primer. Turn off glow plug toggle switch. (Red temperature. Avoid seizing pistons in liners and running
indicator light will go out.) dry shafts in dry bearings by bringing the engine up to
f. If engine gives no indication of starting during first operating speed gradually as it warms up.
three full strokes of preheater pump, touch-check
intake manifold for heat. If no heat check electrical On some emergency equipment (such as fire pump
wiring. If wiring is all right, remove 1/8 inch pipe plug engines) warm-up may not be necessary due to
from manifold near glow plug and close glow plug equipment being housed inside a heated building. For an
Typical Cold Starting Aid Arrangement

engine starting with a parasitic load, such as a fire pump, 2.5 Oil Pressure
coolant temperature must be a minimum of 120° F (49° C).
Normal engine oil pressure at 221° F (105°C) should be
2.1 Speed Pattern for Marine application – Pleasure between 3 to 7 kg/cm2 at rated speed and 1 to
Boat or Light Duty 2 kg/cm2 at low idle speed. If your engine is provided
For normal cruising operation; maintain engine rpm at with DFC system, pressure at rated speed should be 2.4
approximately 90 percent of rated rpm. This will give to 3.1 kg/cm2 and 0.7 kg/cm2 minimum at idle speed.
adequate power as well as economical fuel consumption.
Note: Please note that oil pressure will vary with
2.2 Continuous Duty temperature.
For continuous duty operation, engine governors are Note : Individual engines may vary from above normal
normally set for reduced rpm and fuel rate. Therefore a pressures. Observe and record pressure when engine
reduced cruise speed is not necessary.
is new to serve as a guide for indication of progressive
Marine Gear Operation engine condition. (High oil pressure during start-up
Movement of a single lever on the control valve to neutral, is not a cause for alarm.) For record purposes these
forward or reverse controls the marine gear operation. If readings are more accurate and reliable when taken
so desired, the control lever may be interlocked with the immediately after an oil change.
throttle; therefore, the marine gear should be shifted to 2.6 Engine Exhaust
forward or reverse before the throttle is moved from idle
position and returned to neutral when the throttle is closed. The engine exhaust is a good indicator of engine operation
and performance. A smoky exhaust may be due to a
WARNING poor grade of fuel, dirty air cleaner, over fueling, or poor
Never shift the control lever to any position with the mechanical conditions.
engine running faster than 1000 rpm. If engine exhaust is smoky, corrective action should be
Refer to gear manufacturer’s manual for procedures, taken.
temperatures and recommended oil pressures.
2.7 High Altitude Operation
2.3 Oil Temperature
Some engines, particularly naturally aspirated, lose
The oil temperature gauge normally should read between horsepower when operated at high altitude because
167°F (75°C) and 221°F (105°C). Under full load the air is too thin to burn as much fuel as at sea level.
F (116°
conditions, an oil temperature of 240° C) for a short This loss is about 3 percent for each 1000 ft (304.8 m) of
period is not a cause for alarm. altitude above sea level for a naturally aspirated engine.
Operate the engine using a lower power requirement at
CAUTION
high altitude to prevent smoke and over-fueling.
Any sudden increase in oil temperature which is not
caused by load increase is a warning of possible 2.8 Power Take-Off Application With PT (type G) VS
mechanical failure and should be investigated at Fuel Pump
once. The VS fuel pump governor lever is used to change
During warm-up period, apply load gradually until oil standard governed speed of engine from rated speed to
temperature reaches 140° F (60° C). While oil is cold it an intermediate power take-off speed.
does not do a good job of lubricating. Continuous operating
or long periods of idle with oil temperatures below 140° F When changing from standard speed range to power take-
(60° C) may cause crankcase dilution and acids in the off speed with engine idling on standard throttle, operate
lubricating oil which quickly accelerate engine wear. as follows:
2.4 Water Temperature a. Place the VS speed control lever in operating
A water temperature of 75° C to 95° C (167°to 203° F) is position.
the best assurance that working parts of the engine have b. Lock the standard throttle in full-open position.
expanded evenly to the most favorable oil clearances.
Maximum engine coolant temperatures should not c. Engage power take-off.
exceed 95° C (203°F).
To return to standard throttle:
Keep thermostats always in the engine, avoid long periods
of idling, and take necessary steps to keep water a. Disengage power take-off.
temperature up to a minimum of 75°C (167°F). If b. Return standard throttle to idle position.
necessary in cold weather, use radiator shutters or cover a c. Lock the VS speed control lever in maximum speed
part of the radiator to prevent overcooling. position.
2.9 Stop engine immediately if any parts fail
Practically all failures give some warning to the

operator before the parts fail and ruin the engine. Many
e n g in e s a r e sa ve d b e ca u s e a le r t o p e r a t o r s
heed warning signs (sudden drop in oil pressure, unusual
noises, etc.) and immediately shut down the engine.
2.10 Engine Coolant
a. For cold-weather operation, use of permanent type

a n t if r e e ze w it h r u s t i n h ib i t o r a d d it i v e s i s
recommended.
b. Drain cylinder block and heads on all engines by

opening petcocks and removing drain plugs as shown
in Fig’s. 1-2 to 1-6. If an air compressor (Fig. 1-6),
heat exchanger or other ‘water cooled’ accessory is
used, open petcock and drain. Failure to properly
drain engine and accessories may cause serious
damage during freezing weather.
c. Immersion-type water and oil heaters are available

for engines used in cold-weather operations.
3. OIL PAN CAPACITIES

CAUTION
Oil Pan Capacities Do not prime engine lubricating system from by-
pass filter.
Engine Engine Lub oil
c. Connect a hand or motor-driven priming pump line
Liters C.I.D. Capacity
from source of clean lubricating oil to plug boss in
High Low
housing.
U.S. gal. U.S. gal.
d. Prime until a 30 psi (207 kPa) minimum pressure
(Liters) (Liters)
is obtained. Bar engine for 2 or 3 rotations while
priming.
14 855 7 (27) 5 (19)
19 1150 10 (38) 8.5 (32)
28 1710 18 (68) 16 (61)
38 2300 30 (114) 23 (87)
50 3067 40 (152) 32 (122)
Capacities listed are for oil pan used only on G-drive

applications. Total system capacities vary with filter
sizes and length of oil lines. Please refer to Engine
Data Sheet for Oil capacities on other application.
4. PRIMING THE LUBRICATING SYSTEM
Note : On turbocharged engines, remove oil inlet line

from the turbocharger and prelubricate bearing by
adding 2 to 3 oz. (50 to 60 cc) of clean lubricating oil.
Reconnect oil supply line.
a. Fill crankcase to “L” (low) mark on dipstick. See

“Lubricating Oil Specifications”, Section.
b. Remove plug from head of lubricating oil filter housing
or filter can to prime system.
CMYK
Use of Lub Oil By-Pass Filter

5.1. All engines manufactured by Cummins India
Limited must be fitted with by-pass filter
EXCEPT for engines for following applications
where the by-pass filter may be used as
“Optional” part.
a) All natural aspirated engines.
b) All engines for firef ighting pumps
c) All stand-by turbine starting engines.
5.2 Fill Marine Gear (for Marine Engines only)
The marine gear is a separate unit and carries its own
lubrication. Fill housing according to manufacturer’s
d. Crank engine at least 15 seconds (with fuel shut-off recommendations.
valve closed or disconnected to prevent starting), while
maintaining external oil pressure at a minimum of 15 Start engine and briefly operate the gear in both forward
and reverse.
psi (103 kPa). Check that oil has reached up to all
points in tappets (Remove Tappet covers). CAUTION
f. Remove external oil supply and replace plug in Never operate marine gear with oil level below “L”
lubricating oil filter housing, torque 15 to 20 ft-lbs (20 mark or above “H” mark on dipstick.
to 27 N•m).
Check Raw Water Pump Oil Level (If oil sump is
CAUTION provided)
Clean areas of any lubricating oil spilled while (For Marine Engines only)
priming or filling crankcase.
Check oil level in raw water pump if pump has an oil
sump.
g. Fill crankcase to “H” (high) mark on dipstick with oil
meeting specifications, listed in Section 11. No a. Remove pipe plug from side of pump.
change in oil viscosity or type is needed for new or b. Fill housing with hypoid SAE 90 oil; replace plug.
newly rebuilt engines.
6. OTHER CHECKS
5. CHECKING ENGINE OIL LEVEL 6.1 Check Air Connections
A dipstick oil gauge is located on the side of the engine. Check air connections to compressor and air equipment,
The dipstick has an “H” (high) and “L” (low) level mark to as used, and to air cleaners and air crossovers to
indicate lubricating oil supply. The dipstick must be kept assure all are secured.
with the oil pan, or engine, with which it was originally 6.2 Check Engine Coolant Supply
supplied. Cummins oil pans differ in capacity with
a. Remove the radiator or heat exchanger cap and
different type installations and oil pan part numbers.
che ck eng in e coola nt leve l. Add co ol ant a s
needed.
b. Make visual check for leaks and open water filter
shut-off valves.
6.3 Prime Raw Water Pump (For Marine Engines

Only)
The Gillmec Type pumps require initial priming. The pump
will continue to self-prime at all subsequent starts unless
the pump body has been emptied deliberately. Fill pump
body prior to connecting inlet connection.
CMYK
Note: Prior to initial priming/commissioning ensure

that sea water supply line/piping is thoroughly flushed
and clean to ensure that system is free from any metal
particles or burrs.
7. 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.
• Do not operate the engined at full throttle below
peak torque engine speed (RPM) for extended
periods (more than 30 sec) of time.
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.
a. Monitor the oil pressure and coolant temperature
gauges frequently. Refer to Lubricating Oil system
Coolant Temperature / Oil Pressure
Specifications or Cooling System Specifications,
Section V, for recommended operating pressures
and temperatures. Shut off the engine if any
pressure or temperature does not meet the
specifications.
b. If an overheating condition starts to occur, reduce

the power output of the engine by releasing the
throttle pressure or shifting the transmission to a
lower gear or both until the temperature returns
to normal operating range. If engine temperature
does not return to normal, shutoff the engine and
refer to Troubleshooting, Section T, or contact a
Cummins Authorized Repair Location.
CMYK
• Most failures give an early warning. Look and

listen for changes in performance, sound or
engine appearance that can indicate service or
engine repair is needed. Some changes to look
for are as follows:
– Engine misfires
– Vibration
– Unusual engine noises
– Sudden change s in eng ine operating
temperature or pressure
– Excessive smoke
– Loss of power
– An increase in oil consumption
– An increase in fuel consumption
– Fuel, oil or coolant leaks.
7.1 Engine Operating Range

Excessive full throttle operation below peak torque RPM
(lugging) will shorten engine life to overhaul, can cause
serious engine damage and is considered engine abuse.
Cummins engines are designed to operate successfully
at full throttle under transient conditions down to peak
torque engine speed.
Operation of the engine below peak torque RPM can

occur during gear shifting due to the difference of ratios
between transmission gears, but engine operation must
not be sustained more than 30 seconds at full throttle
below peak torque RPM.
CAUTION
Operating the engine beyond high idle speed can
cause severe engine damage. The engine speed
MUST NO T exceed 2,400 R PM under an y
circumstances. When descending a steep grade,
use a combination of transmission gears or vehicle
braking systems to control the vehicle and engine
speed.
8. ENGINE SHUT-DOWN
• Allow the engine to idle three (3) to five (5) minutes
after a full load operation before shutting it off.
This allows the engine to cool gradually and
uniformly.
• Turn the ignition key switch to the OFF position.
If the engine fails to stop running, rotate the
manual fuel shutoff thumb screw counter-
clockwise to make sure the valve is not being
held open by the manual override screw.
8.1 Idle Engine A Few Minutes before Shut-Down
It is important to idle an engine 3 to 5 minutes before

shutting it down to allow lubricating oil and water to carry
heat away from the combustion chamber, bearings, shafts,
etc. This is especially important with turbocharged
engines.
The turbocharger contains bearings and seals that are

subject to the high heat of combustion exhaust gases.
While the engine is running, this heat is carried away by
oil circulation, but if the engine is stopped suddenly, the
turbocharger temperature may rise above 360° F. The
results of extreme heat may be seized bearings or loose
oil seals.
8.2 Do Not Idle Engine for Excessively Long

Periods
Long periods of idling are not good for an engine because
combustion chamber temperatures drop so low the fuel
may not burn completely. This will cause carbon to clog
the injector spray holes and piston rings and may result
in stucked valves.
If engine coolant temperature becomes too low, raw fuel

will wash lubricating oil off cylinder walls and dilute
crankcase oil so all moving parts of the engine will suffer
from poor lubrication.
Ref. Fig. 1-13. Power Take-off Application
If the engine is not being used, shut it down.
8.3 Turn Switch Key to ‘Off’ Position to Shut

Down the Engine
The engine can be shut-down completely by turning off

the switch key on installations equipped with an electric
shut-down valve, or by turning the manual shut-down
valve knob. Turning off the switch key which controls
the electric shut-down valve always stops the engine
unless override button on shut-down valve has been
locked in open position. If manual override on electric
shutdown valve is being used, turn butt on full y c. Adjust the variable speed control lever (2) to the
counterclockwise to stop engine. Refer to ‘Normal Starting speed desired.
Procedure’. VALVE CANNOT BE REOPENED BY
SW ITCH KEY UNTIL AFTER ENGINE COMES TO To return to standard throttle operation:
COMPLETE STOP. NEVER TURN OFF THE SWITCH
KEY WHILE GOING DOWN HILL. With the engine still a. Return the standard throttle lever (1) to the idle
in gear, fuel pressure will build up against the shut-down position.
valve and may prevent it from operating when the switch
key is turned on. b. Lock the variable speed control lever (2) in the
maximum speed position.
CAUTION
Never leave switch key or override button in valve 10. STEP TIMING CONTROL (STC)
‘open’ or in ‘run’ position when engine is not running.
With overhead tanks this would allow fuel to drain Some engine models are equipped with step timing
into cylinders, causing hydraulic lock. control (STC), formerly called HVT (Hydraulic Variable
Timing). STC allows the engine to operate in advanced
Do Not Use the Compression Release Lever to Stop injection timing immediately after start-up and light
the Engine duty engine load conditions, and to return to normal
timing during medium and high engine load conditions.
Some old engines are equipped with a compression
release lever. Pulling this lever lifts the intake or exhaust Benefits include:
(depending on engine model) valve push tubes and opens
the valves. The push tubes are lifted off their sockets • Improved cold weather idling characteristics.
and extensive wear on the balls and sockets will result
• Reduced cold weather white smoke.
from using the compression release to stop the engine.
• Improved light load fuel economy.
The compression release lever can be used as an aid in
cranking, before starting, or while making injector
and valve adjustment, but not to stop the engine.
STC
However CIL has obsoleted use of decompression
system.
Advanced Normal
9. POWER TAKEOFF APPLICATION WITH
Starting and High Load
Light Load
Variable Speed Controls
The variable speed governor on power takeoff

applications is used to control engine speed at the
desired RPM.
To engage the variable speed governor with the engine

idling on standard throttle:
a. Put the variable speed control lever (2) in the

idle position.
b. Lock the standard throttle lever (1) in the full

open position.
11. ENGINE CONTROLS
The Electronic Control Panel (ECP) or Electronic Control Panel with Speed Governor (ECPG) was being supplied
with CIL Engine earlier. The most advance engine controls are being supplied with CIL engines now. The details of
the engine controls and the respective bulletin nos. for Users’ Manual are listed below. Please refer to the
specific bulletin numbers for information on engine controls supplied with your engine.
Note : The Users’ Manual applicable for your engine is supplied with the engine.
Controller O&M manual

Sr.
Engine Model KVA rating
No. Old * Current -1 Current -2 Old Current -1 Current -2
1 NTA-855-G2-I 320 ECPG Powercom - 3243803 0914-0101 -

2 NTA-14-G3 380 ECPG Powercom PCC3100 3243803 0914-0101 3243804
3 KTA-19-G9 500 ECPG Powercom PCC3100 3243803 0914-0101 3243804
4 VTA-28-G3-I 600 ECPG Powercom PCC3100 3243803 0914-0101 3243804

5 VTA-28-G5-I 625 ECPG Powercom PCC3100 3243803 0914-0101 3243804
6 KTA-38-G2-I 750 ECP + EFC PCC2100 PCC3100 3243782 0900-0534 3243804

7 KTA-38-G3-I 800 ECP + EFC PCC2100 - 3243782 0900-0534 -
8 KTA-38-G5 1010 ECP + EFC PCC2100 PCC3100 3243782 0900-0534 3243804

Note : *These controls are not supplied now on engines.

Engine Preservation Procedure iii) Engine preservation procedure for engines installed
in equipment.
Introduction
NOTE :
On any engine not in service, whether installed in The rate of corrosion varies with climatic condition.
equipment or waiting to be installed, the unpainted surfaces Variance in climatic condition makes it very difficult
and various internal passages are subject to rust and to state the length of time an engine can be stored
corrosion. without rust and corrosion damage. However the
procedures outlined below are useful for various
Every engine going out of factory is processed and is climatic conditions except for arctic conditions and
suitable for storage upto six months from the date of vary low temperatures. For such conditions, please
despatch. However sometimes engines are required to be refer to Cummins India Limited for engine storage
stored for more than six months, also on many occasions requirements.
engines as installed in equipment are not put in service.
Hence it is necessary to process such engines for 1) Engine preservation procedure for engines to be
storage. Based on above the procedure for preservation stored upto six months, from the date of engine
can be catagorised as below. shipment from factory.
i) Engine preservation procedure for engines to be
NOTE:
stored upto six months, from the date of engine
shipment from factory.
Every engine going out of factory is processed for storage
ii) Engine preservation procedure to be carried out for upto six months. Hence no additional processing is
engine storage beyond six months from date of required except proper storage, as given on next page.
shipment from factory.
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.
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:
THE ENGINE HAS BEEN TREATED FOR

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.)
ii) Fuel Passage:
No external treatment is required.

iii) 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. (CH-4 category) 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: b) Loosen the belt tension on fan belt, alternator

belt, water pump belt and other accessories
a) The above procedure for engine preservation
driven by belt.
is to be carried out / repeated at the end of
every six months during the storage period. c) Tag the engine indicating preservation process
The procedure may have to be done at OEM date and due date for next preservation (6
works or at customer's place depending upon months period).
location of engine.
ENGINE PRESERVATION PROCESS

DATE :
T H E E N G I N E H A S B EEN T R E A T ED F O R
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 engines ii) Remove all protective caps, tape and wrappings
installed in equipment. from connections such as Breathers, Fuel in and
out, connection, Water in and out connections etc.
Many times, the engines shipped from factory are
installed on the equipment or Genset within six iii) Use suitable solvent, cleaner or degreaser to remove
months from date of shipment from factory. However rust preventive compound from unpainted external
these engines as installed in the equipment are not surfaces of the engine
put in the service for a long period. For such engines iv) Refill oil pan with fresh lubricating oil. Replace the
the engine coolant and engine lub oil is generally fuel, lub oil filters and lub oil bypass filters, only in
filled in the engine. Hence no special ensis process case wherein engine is stored beyond six months
is required, but periodic running of engine as given from the date of shipment.
below is mandatory requirement.
v) Check and correct the engine belt tensioning. vi)
Run the engine once in every week for 5 to 10 efer Section 1 for engine starting instructions. vii)
min. at Low Idle RPM. "B" check to be carried
out at every six months as mentioned in Section 6. In case of any doubts, contact CSS& S / Dealer.
4) Preparing a preserved (treated) engine for Down-Hill Operation

putting in service.
The Cummins Diesel Engine is effective as a brake
When an engine is removed from storage and put on downhill grades, but care must be exercised not
into service the operation listed below should be to over speed the engine going downhill. The
performed. governor has no control over engine speed when it
i) Clean off all accumulated dirt from exterior of is being pushed by the loaded vehicle. Over speeding
engine will cause severe damage to the engine.
Section 2 - Industrial Fire Pump Engines

Section Contents
Page
Engine Starting Procedure ................................................................................................................................... 2-1
Initial Start-up ....................................................................................................................................................... 2-1
Normal Operation .................................................................................................................................................. 2-1
Engine Cooling System ........................................................................................................................................ 2-2
Reverse Rotation of Pump ................................................................................................................................... 2-2
Water Heater Tank ............................................................................................................................................... 2-2
Use of Water Heater Tank ................................................................................................................................... 2-3
Section 2 Maintenance Instructions 2-1
Industrial Fire Pump Engines

Fire pump engines are built and applied under g. Idle speed may be adjusted by turning the
conditions set down by agencies such as Tarif governor idle adjustment screw counter-clockwise
Advisory Committee (TAC), National Fire Protection to decrease RPM or clockwise to increase RPM.
Association-20 (NFPA-20), Underwriters Laboratory
and Factory Mutual Research; therefore, parts h. Verify that the lube oil system is under pressure.
originally supplied must not be deviated from
without qualifying agency approval. The following i. Operate the engine for 8-10 minutes and look for
instructions are those special items necessary to leaks, unusual noises or other indications of
this application, and should be used in conjunction improper operation. The engine should be run
with those previously stated.
long enough to open the thermostat(s).
1. ENGINE STARTING PROCEDURE
j. Set the over speed stop switch. Refer to the
sections on over speed switches following this
1.1 Initial Start-Up
section.
Note : Contact operating personnel responsible for
fire protection system before starting. Obtain k. Stop the engine and check the engine oil and
approval to service or repair. Make sure that the expansion tank coolant levels. Top up if
connecting lines to and from the fire pump are open necessary. Clean the raw water strainer.
and that there is water to the pump.
l. Start the engine and bring it to the fire pump
a. Close all cooling system drains. required operating speed.
b. Remove the heat exchanger cap, check or fill the m. Adjust the raw water pressure regulator to obtain
engine coolant supply; open the water filter inlet the required pressure.
and outlet valves.
n. Readjust the engine speed if necessary.
c. Prelubricate the engine with oil meeting API
Class CH4 and viscosity of SAE 15W40. This o. Once engine speed and water pressure are
includes removal of the turbocharger oil inlet line set, lock the governor lever in position on
on turbocharged engines to prelubricate the housing naturally aspirated models, and the max. speed
by adding 2 to 3 oz. (60 cc) of clean engine screw on turbocharged models.
lubricating oil.
p. Shut off the engine. Contact operating personnel
d. Check the crankcase oil level and fill to the ‘H’
responsible for fire protection system that engine
mark on the dipstick.
is ready for service. Obtain authorized signature
of acceptance.
e. Remove the fuel pump solenoid wire and crank the
engine through two cranking cycles using the fire
pump controller. Make sure that the fuel pump 1.2 Normal Operation
solenoid wire terminal does not touch the engine.
The unit should be operated at least once a week,
f. T u r n t h e g o ve r n o r id l e a d j u s t in g s c re w during this, the engine must reach normal operating
counter-clockwise 6 turns. This will permit the temperature. The engine is started and stopped under
engine to run at or near idle speed at the initial load on some installations. High water temperature
start-up. alarm if provided may activate after stopping due to
after boiling.
On turbocharged models, removal of the delay
cylinder and bracket from the fuel pump will permit In addition to engine operation, routine examination of
operation of the engine at idle speed. the engine should be made to see that oil and water
levels are maintained, and that the battery specific
Maintenance Instructions 2-3
gravity remains within the battery manufacturer’s Generally, combination of multiple motor driven pumps
specifications. along with engine driven pumps are utilised which are
fed with positive suction and deliver to common header/
2. ENGINE COOLING SYSTEM hydrant. Whenever such installations are made,
manually operated gate valves and / or nonreturn
2.1. Heat Exchanger valves (NTVs) are provided in the individual delivery line
These engines are cooled by a heat exchanger in which of the each pump. Similar arrangements are made for
the engine cooling water circulating around the heat city water supply schemes when water source is at
exchanger tube bundle is cooled by raw water (from the lower level and city is located at height.
discharge side of the fire pump) flowing through the
It has been noticed over the years that operational /
tubes of the heat exchanger bundle.
installation lapses i.e. wrong positioning of manual
2.1.2 Radiator Cooling control valve, quality issues related to functioning of
NRVs and growth of sea mass, debris, entrapment of
Radiator type of cooling is also used based upon the sea shells cause improper sealing of NTV. Water in
customer requirement. the delivery pipe flows back to in-operative pump
By radiator, the hot engine coolant is cooled by ambient causing the pump to rotate it in reverse direction. As
air as medium through fan. The coolant is passed generally pump to engine coupling used are of direct
through radiator in coolant circuit & the ambient air is drive type, the engine also starts rotating in reverse
forced through the radiator by a centrifugal fan for direction along with the pump. All gear pumps of the
cooling of the engine cooling with radiator type engine i.e. lubricating oil & PT fuel pump rotate in
installation, at least 1 metre space should be maintained reverse. This in turn leads to rotation of various engine
in front of the radiator for proper ventilation. parts with out lubrication causing severe damages to
components mainly, camshaft, cambushes, cylinder
2.2. Water Flow blocks, connecting rod bearing, main bearings &
crankshaft etc.
The engine water flows through the heat exchanger to
the engine water pump, through the engine around the The solutions to this problem are:
cylinder liners, through the heads, out to the water-
cooled exhaust manifolds (if provided), through the - Training and awareness of the operating staff of
thermostats and finally back to the heat exchanger for consequences in case manual gate valves are not
cooling before it starts its return trip through the positioned appropriately as per safety & operational
engine. requirements.
Raw water used for cooling the engine water is supplied - Use good quality non return valves and manual
from the fire pump prior to the pump discharge flange. gate valves and their maintenance.
It is forced through a cooling loop, by fire pump pressure - Ensure NRV sealing while commissioning new
to the heat exchanger where it flows through the tubes engines.
in the bundle and is discharged to an open waste cone.
- Do periodic inspection and maintenance of NRVs
and gate valves to prevent occurrences of such
NOTE: It is recommended that the fire pump engine failure.
must be test at least once in a week. The test should
be carried out at engine operating temperature. 5. WATER HEATER TANK:
Guidelines for connecting water heater to engines.
3. USE OF LUB OIL BY-PASS FILTER
- Mount water heater tank along the base rail.
The engines for fire pump applications are not provided - Connect the adaptors, thermostat, heater etc., as
with lub oil by-pass filter. per layout diagram.
4. REVERSE ROTATION OF PUMP - Ensure that the water heater is always on, so that
the desired engines water temperature (38-49oC) is
Engines are used as prime movers on various fire
maintain. This is important. The water heater tank
fighting installations as well as for city water supply
is provided so that engine is always ready to take
schemes.
instant load, in case of fire alarm.
- Part Nos & their position in the circuit

Use of water heater tank: - Electrical specifications for heater & thermostatic
switch
Please refer to the Sketch for typical mounting of the
water heater tank. The details of per connecting The Thermostat provided for coolant heaters is to be
water heater tank are given below. adjusted in the field in such a way that water temperature
is maintained between 38oC & 49oC. This adjustment
- Typical schematic for cooling circuit depends upon working environments of the fire pump
application engines (ambient temperature), quantity of
coolant in the cooling system etc.
Typical sketch for connecting Water Heater Tank
Tank Water Heater Part No. 21/24/3247847 consists of
Sr. Part Description Qty. Sr. Part Description Qty.

No. No. No. No.
1 3226056 Tank, Water Heater 1 11 S904A Bushing, Reducing Pipe 2

2 3226144 Bracket, Water Heater 1 12 S966E Plug, Pipe 1
3 0067622 Plug, Pipe 1 13 S988 Elbow, Plain Street Pipe 4
4 3226055 Valve, Thermost 1
14 S981 Tee 1
5 S670 Washer, Plain 10
15 S939B Nipple, Plain Pipe 1
6 S106 Screw, Hexagon 4
16 119984 Connector, Male 4
7 S200 Nut, Regular 10
8 S608 Washer, Lock 10 17 S962 Plug, Pipe 2
9 3226053 Heater, Engine 1 18 AK16100SS Hose, Flexible 1
10 S145 Screw, Hexagon Head Cap 6 19 AK16070SS Hose, Flexible 1
Maintenance Instructions 2-3
NOTES
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3-b
Section 3 - Maintenance Operation

Section Contents
Page
Preventive Maintenance ....................................................................................................................................... 3-1
Maintenance Schedule……………………………………………………….............................................................. 3-2
Maintenance Schedule f or Starter & Alternator ................................................................................................... 3-4
Engine Daily Log Book ........................................................................................................................................ 3-5
Scheduled Maintenance ....................................................................................................................................... 3-6

3-b
Maintenance Operation 3-1
Section 3
Maintenance is the key to lower operating costs. A

Maintenance diesel engine requires regul arly sched uled
maintenance to keep it running efficiently.
Operations
Maintenance Schedule
1. PREVENTIVE MAINTENANCE The check-sheet shown can be reproduced by any
printer. The person making each check can then
Preventive maintenance is the easiest and least indicate directly on the sheet that the operation has
expensive type of maintenance. It permits the been completed. When a complete column (Under A.
Maintenance Department to do the work at a convenient B, C, etc.) of checks is indicated, the engine will be
time. ready for additional service until the next check is due.
a. A good Maintenance Schedule Depends on c. Storage for Engines Out of Service

Engine Application
If an engine remains out of service and its use is not
Actual operating environment of the engine governs the immediately forthcoming, special precautions should be
maintenance schedule. The suggested check-sheet on taken to prevent rust as per procedure given in Section
the following page indicates some checks have to be 1.
performed more often under heavy dust or other special
conditions.
b. Using the Suggested Schedule Check Sheet
The maintenance schedule check-sheet is designed

as a guide until adequate experience is obtained to
establish a schedule to meet a specific operation.
A detailed list of component checks is provided through

several check periods; also a suggested schedule basis
is given for hours of operation, or calendar of time.
A maintenance schedule should be established using

the check-sheet as a guide; the result will be a
maintenance program to fit a specific operation.
MAINTENANCE STEPS
1 KEEP DIRT OUT OF

THE ENGINE
2 MAINTAIN A LUBRICAT-
ING FILM ON ALL
Cummins MAINTENANCE
MAINTENANCE STEPS
6 LET THE ENGINE

BREATHE
7 PREVENT
OVERSPEEDING
BEARING SURFACES
8 KNOW YOUR
3 REGULATE THE ENGINE’S CONDITION
ENGINE’S FUEL
IMPORTANT INSTRUCTIONS AND RECOMMENDATIONS
1. This maintenance schedule is applicable for NTA-855, N-14, V-28, K-19, K-38 & K-50. 9 CORRECT TROUBLES
4 CONTROL OPERATING 2. Recommended Engine Oil API 15W40 CH4. WHILE THEY ARE
TEMPERATURES 3. Recommended Coolant Premix Fleetguard Compleat EG 50:50. SIMPLE
4. Do not intermix different brands or grades of oil or coolant.
5 GUARD AGAINST 10 SCHEDULE AND
5. Refer the Operation and Maintenance Manual supplied with the engine for detail instructions.
CORROSION CONTROL
YOUR MAINTENANCE
Contact nearest Cummins Authorised Service Office for any clarification.
“A” Check “B” Check “C” Check “D” Check

Every 300 Hours / 6 Every 1500 Hours / 12 Every 6000 Hours / 24
Daily Interval
Months Months Months
z FUEL-WATER z REPEAT “A” CHECK z REPEAT “A” & “B z REPEAT “A”, “B” & “C”
SEPARATOR - DRAIN CHECK
z FUEL FILTER - CHANGE CHECK
z LUBRICATING OIL z INJECTOR AND
LEVEL CHECK - TOP z LUBRICATING OIL - VALVES2- ADJUST z FUEL PUMP AND
CHANGE INJECTOR CALIBRATION
UP IF APPLICABLE
z CRANKCASE - CHECK, IF REQUIRED
z LUBRICATING OIL FILTER - CALIBRATE
z AIR INTAKE BREATHER
CHANGE
RESTRICTION1 - ELEMENT- CHECK,
VISUAL CHECK IF REQUIRED z DESCALE COOLING
z LUBRICATING OIL BYPASS - CHANGE SYSTEM
z WATER PUMP AND CHANGE
ALTERNATOR DRIVE z AIR CLEANER z COOLING SYSTEM -
BELTS - CHECK ELEMENT - CHANGE FLUSH AND FILL UP
z ENGINE MOUNTS - CHECK WITH FRESH PREMIX
z RADIATOR CORE FLEETGUARD
z WATER PUMP - CHECK z STRAY VOLTAGE IN COMPLEAT
LEAKAGE OR CHOKE-
CHECK CASE OF EG 50:50
z COOLANT CONCENTRATION ALLUMINIUM
- CHECK RADIATOR - CHECK z VIBRATION DAMPER,
z COOLANT AND FUEL
AND RECORD VISCOUS - CHECK
LEAKAGES - CHECK
z COOLANT PIPES
z COOLANT LEVEL - CONDITION- CHECK, IF z ANEROID OIL - z AIR COMPRESSOR -
CHECK, TOP UP IF REQUIRED REPLACE CHANGE, IF CHECK
APPLICABLE. APPLICABLE
z BALL JOINTS OF THE z WATER PUMP AND
z ELECTRICAL THROTTLE LINKAGE - ALTERNATOR DRIVE
CONNECTIONS - LUBRICATE, IF z ANEROID BELTS - REPLACE
INSPECT AND CHECK BREATHER -
APPLICABLE REPLACE, IF zTURBOCHARGER -
z BATERY TERMINAL APPLICABLE INSPECT
CONDITION -
INSPECT AND CHECK z FUEL TANK - CLEAN zTURBOCHARGER
FOR CORROSION / RADIAL BEARING
VOLTAGES / CLEARING - INSPECT
CONNECTIONS z CORROSION
RESISTANCE zTURBOCHARGER AXIAL
z COMPRESSOR AND FILTER - CHANGE CLEARANCE - INSPECT
GOVERNOR OIL -
CHECK, TOP UP IF
APPLICABLE z ZINC ANODE /
PLUG - CHECK
z AIR TANK - DRAIN
z CHARGE-AIR-
COOLER - CLEAN
1. When the Red Band appears on the indicator Change the air filter primary element. The safety element to be replaced at the time of 3rd replacement of
primary element.
2. After an initial adjustment at 1500 hours, it is recommended that the valves and injectors not be adjusted again prior to injector calibration at the 6000 hours
or 24 months interval.
Cummins India Limited

Registered Office : Kothrud, Pune 411 038 (India) BULLETIN No. 3243609 -09
3-4
4. MAINTENANCE SCHEDULE FOR STARTER AND BATTERY CHARGING ALTERNATOR
Operation and Maintenance

PRODUCT DAILY WEEKLY MONTHLY QUARTERLY
MAINTENANCE MAINTENANCE MAINTENANCE MAINTENANCE
BS5 Starter Check tightness of Check battery specific Top up *DE Shield Remove **CE cover and smear
Battery and circuit gravity. reservoir with Molybdenum Sulphide grease
connections Multi grade 20W40 over CE bearing pin.
(API-CD) oil.
Check visually Clean the brush dust inside

battery electrolyte the starter and secure CE
level. cover properly. Apply Elcoprine
sealing compound around cover.
Check the tightening torque

of all fasteners.
SM130 PE Starter Same as BS5 starter Same as BS5 starter Top up DE and CE Lubricate pinion on shaft
Shield with Multi with MOS2 grease OKS-410
grade 20W40 (API-CD)
oil.
Check tightening
torque of all fasteners.
AC5 Alternator Check belt tension. —— Check battery terminal Check tightening torque
voltage while charging. of all fasteners.
Check the smoothness of

ball bearings.
Check tightness of Clean and apply

output and WL terminal petroleum jelly
connections. for battery terminals.
Ensure the correct wattage of Warning Lamp. The wattage of the

bulb to be 2.2 Watt.
GENERAL INSTRUCTIONS:
Ensure the panel switch is not stickily.

Do not crank the starter more than 20 seconds.
If the clutch slip noise is heard, do not try to start the engine.
Check whether Warning Lamp ‘goes off’ when the engine is started.
Before starting the engine, check warning Lamp glows when the engine is started.
5. Daily Engine Log Book (Only For Genset Engines)
ENGINE STARTED AT HRS. HRS. HRS. HOURS RUN TILL YESTERDAY GENSET ROOM
ENGINE STOPPED AT HRS. HRS. HRS. HOURS RUN TODAY TEMPERATURE
TOTAL HRS HRS. HRS. TOTAL HOURS DATE :
ENGINE ALTERNATOR
(HEAT EXCHANGER RAW WATER)
TIME
(HRS.) L.O.P. L.O.T. W.T. TEMP. - IN TEMP. - OUT PRESS VOLTAGE CURRENT HZ PF KW KWh
Maintenance Operation
DIESEL FILLED LTS. HRS. LTS. HRS.
LUB OIL TOP UP LTS. HRS. LTS. HRS.
OBSERVATION REGARDING SMOKE CONDITION, LEAKAGES IF ANY, ENGINE SOUND ETC. SAMPLE FOR
REFERENCE ONLY
3-5
Maintenance due after Hrs. Carried out detail.
6. MAINTENANCE SCHEDULE c. Cummins Standby Generator Sets
a. Schedule Cummins standby generator sets may be required to

start and come on line in 10 seconds or less.
The maintenance schedules should be used to establish
maintenance practices for Cummins standby or These engines must be equipped with engine coolant
continuous duty generator sets. heaters capable of maintaining coolant temperature at
a minimum of 100° F (38°C).
Standby rated generator sets are for supplying electric
power in the event of normal utility power failure. No Engines subject to ambient temperatures 0° C and
overload capability is available for this rating. This below must also be equipped with a lubricating oil
rating may be used for continuous service for as heater. When using a lubricating oil heater Immersed in
long as the emergency may last. This rating conforms oil, the maximum temperature of heater surface in
with the BS 5514 / ISO 3046 1987 overload rating and contact with oil, should be less than 300° F (149°C) to
DIN “B” 6270. minimize formation of hard carbon on the heating
element.
Continuous duty rated generator sets are for supplying
electric power in lieu of commercially purchased power. Standby units should be operated once a week
Intermittent overloads up to the standby rating are under a minimum of 25% of rated KW load for at
allowable. This rating may be used for continuous least thirty minutes. During this test, the engine
service in commercial applications and it conforms with must reach normal operating temperature.
BS 5514 / ISO 3046 1987 and DIN “A” 6270 for
generator set applications. d. Cummins Continuous Duty Generator Sets
b. Using the Suggested Schedule Check Sheet Continuous duty generator sets may be equipped with
a cold starting aid. Maintenance procedure for these
Actual operating environment of the engine governs the devices can be found in the seasonal maintenance
maintenance schedule. The suggested check sheet section.
indicates some checks have to be performed more often
under heavy dust or other special conditions.
The maintenance schedule check sheet is designed

as a guide until adequate experience is obtained to
establish a schedule to meet a specific operation.
A detailed list of component checks is provided through

several check periods; also a suggested schedule basis
is given for hours of operation, or calendar of time.
A maintenance schedule should be established using

the check sheet as a guide; the result will be a
maintenance program to fit a specific operation.
Section 4 - “A” Maintenance Checks - Daily

Section Contents
Page
Daily Report .......................................................................................................................................................... 4-1
Check Engine Oil Level ....................................................................................................................................... 4-1
Drain Sediments ................................................................................................................................................... 4-1
Fill Marine Gear ................................................................................................................................................... 4-2
Check Air Cleaner ................................................................................................................................................ 4-3
Clean or Replace of Air Cleaner Element ........................................................................................................... 4-3
Air Cleaner Service Tips ...................................................................................................................................... 4-4
Check Engine Coolant Level ................................................................................................................................ 4-6
Check for Damage ............................................................................................................................................... 4-6
Drain Air Tank ...................................................................................................................................................... 4-6
Section 4
This Section gives details of operation to be

“A” Maintenance performing daily. These are very simple and just to
be checked to get good performance.
Checks
Daily Checks
1. DAILY REPORT should not be checked for approximately 15 minutes
Make a Daily Report of Engine Operation to the after engine shut-down. Keep dipstick with the oil
Maintenance Department pan with which it was originally shipped. Keep oil
level as near “H” (high) mark as possible.
The engine must be maintained in top mechanical
condition if the operator is to get optimum satisfaction CAUTION
from its use. The maintenance department needs daily Never operate the engine with oil level below the “L”
running reports from the operator to make necessary (low) mark or above the “H” (high) mark.
adjustments in the time allotted and to make provisions
for more extensive maintenance work as the reports b. If necessary, add oil of the same quality and brand
indicate the necessity.
as already in the engine. See Section 11.
Comparison and intelligent interpretation of the daily
report along with a practical follow-up action will 3. DRAIN SEDIMENT FROM FUEL TANKS / FUEL
eliminate practically all failures and emergency repairs. FILTER / WATER SEPARATOR
Report to the Maintenance Department any of the Loosen the fuel tank drain cock or plug, if used, and
following conditions: drain approximately 1 cup of fuel to remove water and
sediment. Close the drain cock or plug.
1. Low lubricating oil pressure.
2. Low power. If more moisture than usual is present when checking
3. Abnormal water or oil temperature. the fuel tanks, it may be advisable to install a water
4. Unusual engine noise. separator.
5. Excessive smoke.
6 Excessive use of coolant, fuel or lubricating oil. Contact the nearest Cummins Dealer for a water
7. Any fuel, coolant or lubricating oil leaks. separator that meets requirements.
2. CHECK ENGINE OIL LEVEL Drain plugs are located in the bottom of some fuel
a. Check oil level with dipstick oil gauge located on the filter cases and in the sump of some fuel supply tanks.
engine. Fig. 4-1. For accurate readings, oil level More condensation of water vapor occurs in a partially
filled fuel tank than in a full one. Therefore, fuel supply
tanks should be kept as nearly full as possible. Warm
returning fuel from the injectors heats the fuel in supply
tank. If the fuel level is low in cold weather, the fact, that
upper portion of the tank is not being heated by
returning fuel, tends to increase condensation. In warm
weather both the supply tank and the fuel are warm. In
the night, however, cool air lowers the temperature of
the tank much more rapidly than the temperature of the
fuel. Again this tends to increase condensation.
The general construction of the fuel and water separator
is as shown in Fig 4-2. It uses centrifuging principle for
separating out the water or sludge from diesel. The
water or sludge is collected in the bottom of the
Ref. Fig. 4-1. Checking engine oil level.
CMYK
polycarbonate plastic can and is drained out manually When vacuum drop is 8.00 inches (203.2 mm) of
by operating the drain valve provided at the bottom of mercury column replace the filter assembly.
the can. For this operation, the engine should be shut
Cummins India Limited has also developed a water
down and upper handle is required to be unscrewed so
separator which can be used with the existing fuel
as to induct atmospheric pressure on the can. After
filter assembly. This water separator should be
draining out water/sludge, close the drain valve and
connected in between fuel tank and fuel filter with
tighten the top ‘T’ handle.
suitable hoses. For construction of this water separator
refer Fig. No. 4-2. The instructions to drain water/
sludge are given on its Decal. These decals are
applied on the filter container/plastic can. The
Fuel Out Fuel In
instructions should be read and followed precisely to get
the satisfactory performance from this filter and w at er
separat or unit . Cummins I ndia Limited recommends
that fuel filter & water separators be checked and
drained daily (more often if extreme conditions exist
until the precise condition of the fuel is known). Only
after this evaluation you can determine the service
interval that can safely be used for your particular
application without exceeding the water reservoir
capacity. A typical layout for water separator,
fuel filter and fuel tank is shown in Ref. Fig. 4-3.
Water separator
Ref. Description Ref. Description
No. No.
01 Bowl 05 Float
02 Seal O ring 06 Seal (ball check)
03 Valve drain 07 Seal ring
08 Ball check
Fuel Tank
Fuel Filter
Water Seperaor Hose
Typical Layout for Water Separator & Fuel Filter on Engine
CMYK
Maintenance Operation 4-
4. FILL MARINE GEAR c. Clean or Replace Air Cleaner Elements

Many air filter manufacturers discourage the practice of
The marine gear is a separate unit and carries its own
cleaning air cleaner elements. The paper of filter
lubrication. Fill housing according to manufacturer’s
element gets weakened as a result of cleaning and can
recommendations.
lead to rupture / microscopic damages. Also inspection
CAUTION of the filter element after cleaning is difficult.
Never operate marine gear with oil level below “L” Hence, it is suggested to replace the filter element for
mark or above “H” mark on dipstick. longer engine life before first overhaul. However, if you
decide to clean your filter element following are the
Check Raw Water Pump Oil Level (If oil sump is
suggestions -
provided) (For Marine Engines only)
1. Clean only outer element. Never remove inner
Check oil level in raw water pump if pump has an oil element for cleaning. Inner element should be
sump. removed only for the replacement.
1. Remove pipe plug from side of pump. 2. Outer element should be removed for the cleaning
2. Fill housing with hypoid SAE 90 oil; replace plug. only when red band appears on the vacuum indicator.
It is observed that elements are cleaned frequently
5. CHECK AIR CLEANER to keep the system clean. But this practice leads
to damage to the paper element as well as problems
a. Clean Pre-Cleaner and Dust Pan
associated with handling and too frequent opening
Under extremely dirty conditions an air pre-cleaner may and closing the air intake system.
be used. Clean pre-cleaner jar and dry-type air cleaner
d. Suggested procedure to clean the outer element
dust pans daily or more often, as necessary, depending
on operating conditions. Always use clean, dry air on a dry filter element. The air
pressure should not exceed 60 PSI. Direct the
b. Check Inlet Air Restriction compressed air through the filter element from the clean
side i.e. inside to outside, running the nozzle up and
Vacuum Indicator down the filter element.
A mechanical restriction indicator is available to indicate Don’t bring the nozzle in contact with the paper of filter
excessive air restriction through a dry type air cleaner. element, as damage is likely to occur.
This unit can be mounted in air cleaner outlet or on
Do not direct the air jet from outside to inside. This will
vehicle instrument panel. The red flag (1, Fig. 4-4) in
make the dirt to penetrate the paper, allowing the dirt to
window gradually rises as cartridge loads with dirt. After
go into the clean side, damaging the engine.
changing or replacing cartridge, reset indicator by
Penetration of dirt will make tiny holes, reducing the
pushing reset button (2).
efficiency.
Handle the element carefully. Do not strike the element
against hard surface to loosen the accumulated
contaminants.
Cleaning will reduce the dust holding capacity of the
filter element. Replace the outer element after 4/5
cleanings or as soon as the red band appears even
after cleaning.
e. Inspection of the element after cleaning.
(Ref. Fig 4-5)
If small holes or parts are found on element when it is
checked with an electric bulb after cleaning and drying,
replace the element.
Do not use element whose folds or gasket or seal is
striction indicator damaged.
Air restriction on turbocharged / aftercooled engines CAUTION

must not exceed 25 inches of water column.
Holes, loose end seals, dented sealing surfaces and
Air restriction for naturally aspirated engines must not other forms of damage render cleaner in-operative
exceed 20 inches of water column. and require immediate element replacement.
CMYK
Never leave an air cleaner open longer than necessary.

Your open air cleaner is a direct entry
to the engine! Keep it protected during
Filter changes. If the housing is not
going to be reassembled immediately,
cover the opening. The only way to be
sure nothing got in, is to make sure
nothing can get in.
Don’t ignore a worn or damaged gasket in the housing.

Ref. Fig. 4-5 Element checking with electric bulb
If your air cleaner has a cover
gasket, replace it with a new one.
6. AIR CLEANER SERVICE TIPS Always check to be sure that no
Don’t remove element for inspection. piece of the old gasket remains in
the housing and that the gasket is
Such a check will always do more not worn. If your filter model calls for a new gasket with
harm than good. Ridges of dirt on the each use, never reuse the old one.
gasket sealing surface can drop on
the clean filter side when the gasket Don’t use a damaged or bunched filter.
is released. Stick with the regular
maintenance schedule, or, if you Never install a dented or punctured filter
service by restriction, believe the because it cannot protect properly against
gauge or restriction indicator. Get a new indicator if you contamination. A dent can make a firm seal
don’t trust your current one. impossible or can indicate damaged media. A
filter with bunched pleats saps engine power
and fuel dollars.
Never rap a filter to clean it.
Rapping hard enough to knock off dust Never use a warped cover on a housing.
damages the filter and destroys your engine
protection. Deeply embedded dirt is never Replace it with a new cover as
released by tapping. It is always safer to soon as possible. A warped or
keep operating until you can change to a damaged cover cannot make a
fresh Filter. proper seal. Also check to
ensure that there is no damage
to the air cleaner housing that
Never judge the filter’s life by looking at it......
could cause a leak.
Measure the airflow restriction.
A dirty-looking filter may still have Never substitute an incorrect element model number.
plenty of life left, while carbon
contamination is not visible to the Filters may look almost identical, but
eye. You can’t see the dirt that’s even a fraction of an inch difference in
embedded deep within the filter size can prevent a good seal or affect
paper. Your best bet for lowest filter cfm delivery. It’s always better to use the
maintenance costs and best engine dirty filter until you can get the correct
performance is to follow a restriction gauge. It’s a smart, one.
low-cost investment.
7-Step Filter Element Replacement 6. Make sure the gash seats evenly
1. Remove the old element gently ‘Baby’ If you don’t feel the gasket seating
that dirty filter, until you get ii clear of evenly for a perfect seal, you
the housing. Accidentally bumping it don’t have protection. Re-check
while still inside means dropped dirt to see if the sealing surface in the
and dust that will contaminate the housing is clean, and ensure that
clean side of your filter housing, before the filter is the correct model. It
the new filter element has a chance to may be too short for the housing.
do its job.
7. Ensure air-tight fit on all connections and ducts
2. Always clean the inside of the housing
carefully Dirt left in the air cleaner Check that all clamps and
housing spells death for your engine. flange joint are tight, as
Use a clean, damp cloth to wipe every well as the air cleaner
surface clean. Check it visually to
mounting bolts. Seal any
make sure it’s clean before putting in a
leaks irnmediately —
new filter.
leaks mean dirt is directly
entering your engine
3. Always clean the gasket sealing surfaces of the
housing
Proper Servicing is Essential

An improper gasket seal is one of the
most common causes of engine
contamination. Make sure that all Proper air cleaner servicing results in maximum engine
hardened dirt ridges are completely protection against the ravages of dust. Proper servicing
removed, both on the bottom and top can also save you time and money by maximizing filter
of the air cleaner. life and air cleaning efficiency.
4. Check for uneven dirt patterns Two of the most common problems are:
Your old filter has valuable clues A) Over Servicing. New filters increase in dust cleaning
to dust leakage or gasket efficiency as dust builds up on the media. Don’t be
sealing problems. A pattern on fooled by filter appearance! The filter should look
the element clean side is a sign dirty. By using proper filter measurement tools, you
that the old filter element was will use the full life of the filter at maximum efficiency.
not firmly sealed or that a dust
leak exists. Identify the cause B) Improper Servicing. Your engine is vulnerable to
of that leak and rectify it before abrasive dust contaminants during the servicing
installing a new filter. process. The most common cause of engine damage
is careless servicing procedures.
5. Press your fresh gasket to see that it springs back
By following the steps listed above, you can avoid
Make sure your new filter is made
unnecessary risk to the engine.
with a highly compressible gasket
that springs back (promptly) when
finger pressure is released. A high
quality gasket is one of the most
important parts of the filter.
Cleaning and Inspection of precleaner (Heavy duty)
1. Clean pre-cleaner openings of all soot, oil film and

any other objects that may have become lodged in
openings. Remove any dust or dirt in lower portion
of pre-cleaner and aspirator tubing. Inspect inside of
air cleaner housing for foreign material.
2. Inspect dirty precleaner for soot or oil. If there is

soot inside cyclone tubes, check for leaks in engine
exhaust system, exhaust “blow-back” into air intake
and exhaust from other equipment. If precleaner
appears “oily”, check for fumes escaping from
Air cleaner (light duty) crankcase breather. Excessive oil mist shortens life of
any dry-type precleaner.
To change element:
1. Loosen clamp assembly which holds cup assembly 3. Inspect clamps and flexible hose or tubing to be
to body air cleaner. sure all fittings are airtight on cleaners with exhaust
2. Remove cup assembly. aspirators.
3. Loosen wing nut of outer element and remove it.
4. Loosen wing nut of inner element and remove it.
Check Engine
Check Engine Coolant Level
Keep the cooling system filled to the operating level.

Check the coolant level daily or at each fuel fill point.
Investigate for causes of coolant loss. Check the
coolant level only when the system is cool.
Drain Air Tanks
In cold weather, condensed moisture in air tanks and

lines may freeze and make controls useless.
Drain air tanks to keep all water out of the compressed

air system.
Removing elements.
Check for Damage
Heavy duty air cleaners have pre-cleaners with cyclone
tube in addition to elements.
Visually check fuel system, etc., including AFC fuel
pump, for mis-adjustment or tampering; check all
connections for leaks or damage. Check engine for
damage; correct as necessary.
Other Mainenance
• Drain Air Tank.
• Drain Fuel Filter.
Air cleaner (heavy duty)

Section 5 - “A” Maintenance Checks - Weekly

Section Contents
Page
Fuel – Water Separator ......................................................................................................................................... 5-1
Lubricating Oil Level... ........................................................................................................................................... 5-1
Air Intake Restriction ............................................................................................................................................. 5-2
Water Pump and Drive Belts ................................................................................................................................... 5-2
Coolant Level ………………..................................................................................................................................... 5-3
Air Tank and Reservoirs..…..................................................................................................................................... 5-3

Section 5 Maintenance Operation 5-1
This Section gives details of operation to be

“A” Maintenance performing daily. These are very simple and just to
be checked to get good performance.
Checks
Daily Checks
Fuel – Water Separator
Cummins requires a fuel-water separator or fuel filter be Wait at least 15 minutes after shutting off the engine to
installed in the fuel supply system. check the oil level. This allows time for the oil to drain
into the oil pan.
Drain the water and sediment from the separator daily.
For additional lubricating oil recommendations and oil
Shut off the engine. Use your hand to open the drain pan capacity information, refer to Maintenance
valve. Turn the valve counterclockwise approximately Specifications (Section V).
3½ turns until the valve drops down 25.4mm [1 in] and
draining occurs.
Drain the filter sump until clear fuel is visible.
To close the valve, lift the valve and turn clockwise until
it is hand-tight.
Air Intake Restriction
Lubricating Oil Level Mechanical Indicator: A mechanical restriction indicator

is available to indicate excessive air restriction through
The engine must be level when checking the oil level to
a dry-type air cleaner.
make sure the measurement is correct.
Shut off the engine for an accurate reading.

This instrument can be mounted in the air cleaner outlet Refer to Section A for belt adjustment and replacement
or on the instrument panel. The red flag (1) in the window procedures. Belt damage can be caused by:
gradually rises as the cartridge loads with dirt. After
changing or replacing the cartridge, reset the indicator • Incorrect tension
by pushing the reset button (2). • Incorrect size or length
• Pulley misalignment
Restriction or vacuum indicators need to be installed as
• Incorrect installation
close as possible to the turbocharger air inlet in order to
• Severe operating environment
obtain a true indication of restrictions.
• Oil or grease on the side of belts.
Cogged Belt
Vacuum Indicator
Vacuum switches actuate a warning light on the Inspect the belts daily. Replace the belts if they are
instrument panel when the air restriction becomes cracked, frayed, or have chunks of material missing.
excessive. Small cracks are acceptable.
Adjust the belts that have a glazed or shiny surface,

which indicates belt slippage. Correctly installed and
tensioned belts will show even pulley and belt wear.
Refer to Section A for belt adjustment and replacement
procedures.
Belt damage can be caused by:
• Incorrect tension
• Incorrect size or length
• Pulley misalignment
Water pump and alternator drive belts
• Incorrect installation
Poly-Vee Belt • Severe operating environment
• Oil or grease on the belts
Inspect the belts daily. Check the belt for intersecting
cracks. Traverse (across the belt width) cracks are
acceptable. Longitudinal (direction of belt length) cracks
that intersect with transverse cracks are not acceptable.
Replace the belt if it is frayed or has pieces of material
missing.
Coolant Level
Measure the belt tension in the center span of the
pulleys. The coolant level must be checked daily.
Refer to the Belt Tension Chart for the correct gauge

and tension value for the belt width used.
An alternate method (deflection method) can be used to

check belt tension by applying 110 N [25 lbf] force
between the pulleys on v-belts. If the deflection is more
than one belt thickness per foot of pulley center
distance, the belt tension must be adjusted.
Refer to Section A for adjustment procedures.
For cogged belts, make sure that the belt tension gauge Coolant added to the engine must be mixed with the
is positioned so that the centre tensioning leg is placed correct proportions of antifreeze, supplemental coolant
directly over the high point (hump) of a cog. Other
additive, and water to avoid engine damage.
positioning will result in incorrect measurement.
Coolant recommendations and specification details on
correct mixing of coolant can be found in Maintenance
Specifications Section V.
Fill the cooling system with coolant. Refer to the

markings on the radiator or expansion tank for coolant
levels or refer to the OEM manual.
Note: Some radiators have two fill necks, both of which

must be filled when the cooling system is drained.
Final belt tension was not obtained by adjustment
alone. The water pump body was pulled straight by
snugging the capscrews in the order described, thus
increasing belt tension to final value.
Air Tanks and Reservoirs
If automatic purging or spitter valves are used, confirm

the valves are operating correctly. If a manual drain
valve is used on the wet tank, open the draincock on
the wet tank to drain any moisture accumulated in the
air system. If oil is present, the air compressor system
must be checked. Contact your Cummins Authorized
Repair Location.
CMYK
Section 6 - “B” Maintenance Checks -

300 hrs. / 6 months
Section Contents
Page
Lubricating oil change
interval… … … … … … . .......................................................................................................................................... 6-1
Engine Mounts ………………….............................................................................................................................. 6-2
Water Pump …………….......................................................................................................................................... 6-3
Coolant Concentration............................................................................................................................................. 6-4
Section 6 Maintenance Operations 6-1
At each “B” Maintenance Check, perform all the “A”

“B” Maintenance Checks in addition to the following. This check
should be carried out at every 300 hour of operation
Checks or at every six month.
300 hrs / 6 months Checks

1. Lubricating Oil Change Intervals
Note: If the lubricating oil is drained from the oil Clean the area around the lubricating oil filter head.
pan to make an engine repair, new oil must be used. Remove the filter. Clean the gasket surface of the filter
Do not use oil after it has been drained from the oil
pan. head.
Note: The o-ring can stick on the filter head. Make sure
Note: Drain the engine oil when the temperature is the o-ring is removed.
approximately 60°C [140°F].
Note: See the Lubricating Oil Filter Specifications Chart
Remove the oil drain plug and copper washers from the
in this procedure.
bottom of the oil sump and the oil pan adapter cover
plate and drain the oil.
Install the oil drain plugs and new copper washers into
the oil sump and oil pan adapter cover plate.
Use the correct oil filter for your engine.
Tighten the oil drain plugs.
Combination Full Flow/Bypass Lubricating Filter:
Torque Value: 100 n•m [ 74 ft-lb ]
• Cummins® Part Number 3401544.
Fill the engine with clean 15W-40 oil CH4.
• Fleetguard® Part Number LF9009.
Apply a light film of lubricating oil to the gasket sealing

surface before installing the new filter. Use a high quality
CH-4 15W-40 multiviscosity oil, such as Cummins®
Premium Blue, or equivalent, in Cummins® engines.
Choose the correct oil for your operating climate as
outlined.
Shut off the engine. Wait approximately 5 minutes to let
the oil drain from the upper parts of the engine. Check
the oil level again.
Add oil, as necessary, to bring the oil level to the "H"

(high) mark on the dipstick.
Check the oil level on the dipstick. The level must be to

the “H” (high) mark on the dipstick.
2. Engine Mounts
Note: Engine mounts that act as isolators are not

supplied by Cummins Inc. Refer to the OEM service
Operate the engine to normal operating temperature
manual.
and check for oil leaks.
Check the torque on the nuts and bolts. Tighten any
that are loose. Inspect the rubber for deterioration and
age hardening. Replace any broken or lost bolts,
capscrews, or damaged rubber.
Capscrew size and grade vary with the flywheel

housing and mounting arrangement. Determine the
size and grade of the mounting bolts.
Shut the engine off and wait five to seven minutes to

allow the oil to drain back into the oil pan.
Check the oil level. Add oil as necessary to bring the

level up to the “H” (high) mark on the dipstick.
Use high performance, industrial-type grease (NLGI

Grade Number 2) fortified with extreme pressure (EP)
additives, such as BP Energrease™ FPG or Castrol
Spheerol™ EPL 2 grease, or its equivalent.
If the above greases are not available locally, contact a

Cummins® Distributor for advice on other Cummins®
approved equivalents.
a Cummins® Authorized Repair Location for
replacement.
Note: Engines with a weep hole filter (2) installed may

experience an occasional drip and minor chemical
buildup at the filter. This is normal and does not indicate
a leaking pump. Do not replace the water pump unless
an actual leak is confirmed.
These engines have two pumping elements on a

Lubricate the support until grease appears on the common shaft. There is only one weep hole.
outside of the support.
Inspect the water pump and bypass for coolant or oil
leakage. Check the water pump weep hole for excessive
3. Water Pump
leakage.
Jacket
A minor chemical buildup or streaking at the water pump

weep hole (1) is normal. Do not repair or replace the
water pump (2) unless an actual leak is confirmed.
Contact a Cummins® Authorized Repair Location for
replacement of the water pump.
Inspect the water pump and bypass for coolant or oil

leakage. Check the water pump weep hole for excessive
leakage.
Check that the water pump weep hole filter is clean and
These engines can have a two-pump, two-loop cooling free from any debris or chemical build-up.
system. The low temperature aftercooler pump will be
Check the filter for cuts and tears.
located near the front gear train on the left bank, if
equipped. Check both pumps for leakage. The
procedure for both pumps is similar.
Note: A minor chemical build up or streaking at the

water pump weep hole is normal. Do not repair or
replace the water pump unless an actual leak is
confirmed. Contact a Cummins® Authorized Repair
Location.
Dual Impeller
Every 6000 hours or 24 months inspect the water pump
A minor chemical buildup or streaking at the water pump for coolant or oil leakage at the water pump weep hole.
weep hole (1) is normal. Do not repair or replace the
water pump unless an actual leak is confirmed. Contact
any obstruction at each scheduled maintenance interval.
The recommended interval is 250 hours or 6 months of
operation.
The water seal was changed from a two-piece to a

unitized, one-piece design. The seal and seat are
fastened together in this design. This aids the prevention
of failures caused from dirt or oil contacting the seal and
seat surfaces during installation. A special tool must be
used to install the one-piece seal so that the seat is
installed at the correct dimension from the body of the
The new style water pump is a completely redesigned water pump. Correct installation results in proper spring
water pump with few major components common with tension.
the old water pump design. The major difference in the
new style water pump is the incorporation of an idler
assembly. This idler assembly is a spring loaded, inside 4. Coolant Concentration
mounted idler that maintains the proper tension on the
water pump drive belts. Periodic adjustment of the water
pump drive belts is no longer necessary. Excessive belt Check the SCA concentration level
and accessory drive pulley wear due to slippage caused
by improperly adjusted belts is reduced. • At least twice a year
• At every subsequent oil drain interval if the
A new, smaller diameter accessory drive pulley is also
concentration is above 3 units
used with the new style water pump. The smaller
• Whenever coolant is added to the cooling
diameter accessory drive pulley reduces the water pump
system between filter changes.
speed, resulting in less wear of the water pump
components. Water pump drive belts were changed
Use Fleetguard® coolant test kit, Part No. CC2602, to
from a width of 22.23 mm [7/8 in] to a width of 19.05 mm
check the SCA concentration level. Instructions are
[3/4 in].
included with the test kit. Use the Coolant
The water pump on the V28 Series Engines is the Recommendations and Specifications in Maintenance
centifugal-type with a cast iron impeller. The water pump Specifications (Section V) for the correct SCA and
is belt-driven from the accessory drive pulley. The water antifreeze level.
pump bearings are lubricated when assembled and do
not require additional grease during the service life of the
water pump.
The water pump idler bearing are lubricated during

assembly and do not require additional grease during
the service life of the idler assembly. A grease fitting has
been included in the idler pivot. Service the grease fitting
weekly with common lithium, based grease.
The old style water pump belt tension was controlled by

an adjustable sleeve. The water pump covers are
interchangeable between the old and the new style
water pumps.
Check the antifreeze concentration. Use a mixture of 50-
The water pump contains an oil seal and water pump
percent water and 50-percent ethylene glycol or
seal. The cavity between these seals has a vent. The
propylene glycol-based antifreeze to protect the engine
vent prevents contamination of the lubricant or coolant if
to -32°
C [-26°
F] year-around.
a seal leaks. Oil and coolant seeping from the vent will
not harm the operation of the pump. Check the vent for
The Fleetguard® refractometer, Part Number C2800,
provides a reliable, easy-to-read, and accurate
measurement of freezing point protection and glycol
(antifreeze) concentration.
Antifreeze is essential in every climate.
Antifreeze broadens the operating temperature range by

lowering the coolant freezing point and by raising its
boiling point.
The corrosion inhibitors also protect the cooling system

components from corrosion and prolong component life.
.
Maintenance Operation 6-
NOTES
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Section 7 - 1500 Hrs. Maintenance Checks

Section Contents
Page
Crankcase Breather Element................................................................................................................................. 7-1
Air Cleaner Element…............................................................................................................................................ 7-1
Zinc Anode Plug………………………………………………………………………………………………………………...7-2

Maintenance Operations 7-1
Section 7
At each “C” Maintenance Check, first perform all
“C” “A”, and “B” Checks in addition to the following :
Maintenance Checks
1500 Hrs. / 12 Months Checks
At first 1500 hrs. Check, first perform all “A” and

“B” Checks and the following -
Crankcase Breather Element
Disassemble the breather as illustrated.
Note: The present production style crankcase

breather used on industrial engines cannot be
removed from the rocker housing cover. Damage Check the breather element (1), the vapor barrier
to the cover or breather assembly will result. (2), the rubber gasket (3), the body (4), and the
cover (5) for cracks or other damage. Replace the
part if necessary.
Use solvent to clean the wire mesh breather

element and the vapor barrier.
Dry with compressed air. Apply a 3/8-in wide and a 0.010-in thick coat of
Note: Foam-type breather elements and vapor Cummins® sealant, Part Number 3801048, to the
barriers must be replaced. inside diameter of the breather mounting hole in
the rocker housing cover.
engine intake air filter air compressor air element
will not be present.
Place the rocker housing cover in an arbor press.
Place a support in the area below the breather

mounting hole, in the rocker housing cover.
Install the lower breather body in the mounting

hole. Use a suitable arbor and press the breather
into the rocker housing cover until it seats against Zinc Anode Plug
the ledge in the mounting. Assemble the breather Shut off the sea water inlet valve on the vessel
as illustrated. Use a new or cleaned breather hull. Remove the zinc plug(s).
element and a vapor barrier. Measure the length of the zinc plug(s) removed
from the heat exchanger. Replace any zinc plug if
it is 50 percent or more eroded.
Note : The frequency of change depends on the

chemical reaction of the sea water circulated
through the heat exchanger.
Assemble the breather, as shown, using a new or

cleaned breather element and vapor barrier.
Install the vent tube, hose, hose clamps, brackets, Zinc Plug Erosion Limits
and capscrews on the engine.
Tighten the capscrews mm in
Torque Value: 25 n•m [ 221 in-lb ] A 19.0 MIN 0.750
New 51.0 MAX 2.000
Air Cleaner Element

B 6.4 MIN 0.250
If the air compressor inlet is plumbed to the
New 16.0 MAX 0.630
engine intake air system downstream of the
Note: If any zinc plug does not meet specification,

replace it with a new zinc plug.
Install and tighten the zinc plug(s).
Note: Do not use Teflon™ tape or pipe sealant on

the threads of the sacrificial zinc plugs. Use of any
type of sealant will insulate the zinc anode and
prevent a good ground.
Torque Value:
1/4-inch Plug 12 n•m [ 106 in-lb ]
Torque Value:
3/8-inch Plug 22 n•m [ 195 in-lb ]
Torque Value:
1/2-inch Plug 30 n•m [ 22 ft-lb ]
Open the sea water valve on the vessel hull.
Operate the engine and check for leaks.
.
NOTES
Section 8 - “D” Maintenance Checks

Section Contents
Page
Fuel Pump ………………….................................................................................................................................. 8-1
Cooling System ………………............................................................................................................................... 8-2
Vibration Damper ………….................................................................................................................................... 8-3
Water Pump …………........................................................................................................................................... 8-4
Turbocharger ………………………………............................................................................................................. 8-5
8-b O p e r at i o n an d M ai n t e na n c e

M ai nte nance O per ati on 8-1
Section 8
At each “D” Maintenance Check, perform all “A”,

“D” “B” and “C” checks in addition to those following.
Most of these checks should be performed by a
Maintenance Checks Cummins Distributor or Dealer and where Cummins

Shop Manuals are available for complete
instructions.
6000 Hrs. / 24
Months
Fuel Pump
Disconnect the battery cables. See equipment

manufacturer service information. Clean the
fuel pump and the surrounding area before
removing it from the engine. Remove the wire
to the fuel shutoff valve. Remove the linkage
from the throttle lever.
Remove the four fuel pump mounting capscrews

and the fuel pump.
Remove the drive coupling (23).
Remove and discard the gasket.
Remove the fuel tubing and air tube:
1. Fuel drain line from the cylinder head

2. Gear pump cooling drain
3. Gear pump suction line
4. Air fuel control fuel drain
5. Fuel supply to the injectors
6. Air fuel control air supply hose
7. Tachometer cable, if used.
Clean the gasket surfaces of the fuel pump or

accessory drive mounting surfaces.
CMYK
8-b O p e r at i o n an d M ai n t e na n c e
Install the air fuel control air tube and fuel tubing:
1. Fuel drain from the cylinder head

2. Gear pump cooling drain
3. Gear pump suction line
4. Air fuel control air supply hose
5. Fuel supply to the injectors
6. Air fuel control fuel drain
7. Tachometer cable, if used.
Inspect the mounting surfaces for damage.
Take the fuel pump to a Cummins® Authorized

Repair Location for calibration.
Inspect the coupling spider for damage or wear.
Connect the electric wire to the fuel shutoff valve.

The wire connection nut must be clean and tight.
Note : The wire connection nut and the ground

post nut must be clean and tight.
Install the linkage to the throttle lever.
Note : All NT engines use a white nylon or light

green fuel pump drive coupling. Install the drive
coupling (23), gasket, fuel pump, and four
capscrews. Tighten the capscrews. Torque
Value: 47 n•m [ 35 ft-lb ]
• Connect the battery cables. See equipment

manufacturer service information.
• Operate the engine to normal operating
temperature and check for leaks.
8-2 O p e r at i o n an d M ai n t e na n c e
Flow test Install the plug into the top of the housing.
Loosen the fuel line at the shutoff valve while Torque Value: 30 n•m [ 22 ft-lb ]. If the priming
the engine is cranking. If fuel does not come plug is hard to remove or the fuel pump is a
out of the connection, the pump must be variable speed (VS) type, remove the fuel supply
primed. hose to the gear pump.
Fill the hose and gear pump with clean fuel.
Install the fuel supply hose to the filter head.
Rotation Check
Remove the tachometer drive cable from the fuel

pump.
Prime
To reduce engine cranking time, prime the fuel
supply pump.
Note : If the fuel supply pump is dirty, clean the

outside of the pump.
Crank the engine and make sure the

tachometer drive shaft is turning.
Remove the plug from the top of the housing. Fill

the housing with clean fuel oil.
If the tachometer drive shaft rotates, check the gear

pump for rotation. Remove the fuel supply hose at
the gear pump. Look into the gear pump and crank
the engine. The gear pump gears must turn. If the
gear pump gears do not turn, replace the fuel
pump. If the tachometer drive shaft does not turn,
remove the fuel pump.
Crank the engine and check the air compressor

crankshaft or the accessory drive shaft for rotation.
M a i n te n a nc e O p e r at i o n 8-3
If the air compressor or accessory drive shaft does

The performance of RESTORE™ is dependent on
not turn, see equipment manufacturer service
time, temperature, and concentration levels. An
information.
extremely scaled or flow-restricted system, for
If the shaft turns, the fuel pump is damaged and example, can require higher concentrations of
must be replaced. cleaners, higher temperatures, longer cleaning
times, or the use of RESTORE Plus™ (cooling
system cleaner). Up to twice the recommended
Cooling System concentration levels of RESTORE™ can be used
safely. RESTORE Plus™ must be used only at its
recommended concentration level. Extremely
Remove the radiator cap after the engine is cool.
scaled or fouled systems can require more than
Open the petcocks on each turbocharger. Open the
draincock at the bottom of the radiator. Remove the one cleaning.
lower radiator hose. Open the aftercooler core

drain valves. Drain the cooling system. Do not
allow the cooling system to dry out.
Do not remove the coolant filters. Be sure the

petcocks are open to avoid air entrapment in the
cooling system. Immediately add 3.8 liters [1 gal]
of Fleetguard® Restore™, or equivalent, for each
38 to 57 liters [10 to 15 gal] of cooling system
Check for damaged hoses and loose or damaged
capacity, and fill the system with plain water. Turn
hose clamps. Replace as required. Check the
the heater temperature switch to HIGH to allow
radiator for leaks, damage, and buildup of dirt.
maximum coolant flow through the heater core.
Clean and replace as required.
The blower does not have to be on. For correct
filling instructions, see the Fill section below.
Operate the engine at a coolant temperature of at
least 85°
C [185°
F] for 1 to 1 ½ hours. Shut the
engine OFF. Allow it to cool to 50°
C [120°
F]. Drain
the cooling system. Fill the cooling system with
clean water. Operate the engine at high idle for
5 minutes with the coolant temperature above
85°
C [185°
F].
Shut the engine OFF. Allow it to cool to 50°

C
RESTORE™ (cooling system cleaner) is a heavy- [120°
F]. Drain the cooling system.
duty cooling system cleaner that removes If the water drained is still dirty, the system must
corrosion products, silica gel, and other deposits.
be flushed again until the water is clean.
Install a new coolant filter. Fill the cooling system
with fully formulated coolant. Use additional SCA to
bring the coolant to the correct SCA concentration
level. Install the pressure cap. Operate the engine
until the coolant reaches a temperature of 70°
C
[158°
F] and check for coolant leaks. Make sure the
radiator draincocks and aftercooler core drain
valves are closed. Open the cooling system venting
petcocks. Install the lower radiator hose(s). Use
fully formulated coolant to fill the cooling system.
Use the correct units of SCA to obtain the correct
cooling system protection. Begin filling the cooling
system with coolant. Fill until a continuous stream
of coolant begins to flow from each opened petcock
in the coolant system. Close each petcock as the
continuous stream of coolant begins to flow from
that petcock. Fill the system with the coolant to the
bottom of the radiator fill neck.
Vibration Damper, Rubber
Disconnect the batteries. Refer to the OEM

service manual. Remove the fan and fan shroud, if
necessary. Remove the drive belt. Remove the
crankshaft pulley. Note : The use of a guide bolt
will aid in the disassembly procedure.
Install the cooling system pressure cap. Operate
Remove the SAE Grade 8 capscrews, the
the engine until the coolant reaches a temperature
hardened washers, and the vibration damper.
of 85°
C [185°
F]. Check for leaks. Shut the engine
off, and allow it to cool. Check the coolant level.
Use a mild detergent to clean the vibration

damper.
Vibration Damper Eccentricity - TIR
Check the mating surfaces of the damper and the

adapter to make sure they are clean, dry, and free
of nicks or burrs.
Install the guide pins. Position the damper on the

adapter.
Check the flat surface of the inertia member for
alignment with the fan hub.
Replace the damper if the inertia member and the

hub are more than 0.08 mm [0.030 in] out-of-planar
alignment. Inspect the vibration damper hub for
cracks. Replace the damper if the hub is cracked.
Note : Cummins Inc. recommends the vibration

damper always be replaced after 24,000 hours of
operation. Inspect the elastic member for
deterioration. Replace the damper if chunks of Use clean engine oil to lubricate the capscrews and
rubber are missing, or if the elastic member is more washers. Install the washers and capscrews.
than 3.18 mm [0.125 in] below the metal surface. Tighten the capscrews in the sequence illustrated.
Check the index lines on the vibration damper.
Torque Value: 160 n•m [ 118 ft-lb ].
Replace the damper if these lines are more than
1.60 mm [0.063 in] out of alignment. Note : The
alignment of the damper face and eccentricity are
easiest to measure after installation on the
crankshaft during engine assembly.
Check the face alignment of the vibration damper

between the inertia member and the fan hub.
Position an indicator on the inertia member as

shown.
Remove the crankshaft pulley. Install the drive
Vibration Damper Face Alignment
belt. Install the fan and fan shroud, if removed.
Connect the batteries. Start the engine and check
for proper operation.
Measure the vibration damper eccentricity between Vibration Damper, Viscous

the mounting pilot and the outside of the inertia Disconnect the batteries. See equipment
member. manufacturer service information. Remove the fan
and fan shroud, if necessary. See equipment
manufacturer service information. Remove the fan
belt.
Note: The use of a guide bolt will aid the

disassembly procedure. Remove the Society of
Automotive Engineers (SAE) Grade 8 capscrews,
the hardened washers, and the vibration damper.
Steam clean and dry with compressed air. Check

If the measurement is not within specifications,
the mounting web for cracks. Check the housing for
make sure that the damper pilot is aligned correctly.
dents or raised surfaces. Remove and replace the
damper if any of these conditions are observed. If the damper is still not within specifications,
Measure the thickness in four places, 90 degrees reference the Clean and Inspect for Reuse section
apart, approximately 3.18 mm [0.125 in] from the of this procedure.
outside diameter, as illustrated. The difference
Place the indicator on the machined surface of the
between any two of the four measurements must
hub to measure the damper wobble. Turn the
not exceed 0.25 mm [0.010 in]. Apply a spray of
crankshaft 360 degrees.
spot check developer, type SKD-S2, or equivalent,
to the damper. Inspect for oil leaks. Check the Record the total indicator runout.
mating surfaces of the damper and the adapter to
make sure they are clean, dry, and free of nicks or
burrs. Install the guide pins. Position the damper on
the adapter. Use clean engine oil to lubricate the
capscrews and washers. Install the washers and
capscrews.
Tighten the capscrews in the sequence illustrated.
Install the fan belt. Install the fan and fan

shroud, if removed. See equipment
manufacturer service information. Connect
the batteries. See equipment manufacturer
Use a dial indicator.
service information. Operate the engine
Adjust the indicator as shown to measure the radial and check for proper operation.
alignment of the vibration damper. Turn the
crankshaft 360 degrees. Record the total indicator
runout.
Air Compressor
Install the splined coupling onto the accessory drive
shaft.
Disconnect the batteries. See equipment
manufacturer service information. Steam clean the Make sure the gasket surfaces of the accessory
air compressor and dry with compressed air. Drain drive and the air compressor are clean and not
the engine coolant. Remove the fuel pump. damaged. Use a new gasket and install the air
Remove the air compressor coolant lines. compressor and four capscrews to the accessory
drive. Torque Value: 68 n•m [ 50 ft-lb ]
Remove the air connections from the air
compressor. Remove the air compressor support Install the air compressor support bracket.
bracket and capscrews. Remove the four
Tighten the capscrews. Torque Value: 47 n•m [
capscrews, the air compressor, and splined
35 ft-lb ]
coupling.
Install the air lines to the air compressor and

Inspect the compressor housing for cracks or other
tighten.
damage. Inspect the splined coupling for cracks or
other damage.
Position the timing mark on the air compressor Install the air compressor coolant lines. Install the
crankshaft at the 12-o'clock position. fuel pump. Fill the engine cooling system. Connect
Position the accessory driveshaft dowel pin at the the batteries. See equipment manufacturer service
2-o'clock position as view from the front of the information.
engine.
Water Pump
The new style water pump is a completely of the pump. Check the vent for any obstruction at
redesigned water pump with few major components each scheduled maintenance interval. The
common with the old water pump design. The major recommended interval is 300 hours or 6 months of
difference in the new style water pump is the operation.
incorporation of an idler assembly. This idler
The water seal was changed from a two-piece to a
assembly is a spring loaded, inside mounted idler
unitized, one-piece design. The seal and seat are
that maintains the proper tension on the water
fastened together in this design. This aids the
pump drive belts. Periodic adjustment of the water
prevention of failures caused from dirt or oil
pump drive belts is no longer necessary. Excessive
contacting the seal and seat surfaces during
belt and accessory drive pulley wear due to
installation. A special tool must be used to install
slippage caused by improperly adjusted belts is
the one-piece seal so that the seat is installed at
reduced.
the correct dimension from the body of the water
A new, smaller diameter accessory drive pulley is pump. Correct installation results in proper spring
also used with the new style water pump. The tension.
smaller diameter accessory drive pulley reduces the
Note: Additional information regarding other parts
water pump speed, resulting in less wear of the
of the cooling system can be located within this
water pump components. Water pump drive belts
group.
were changed from a width of 22.23 mm [7/8 in] to
a width of 19.05 mm [3/4 in]. Disconnect the batteries. Refer to the OEM service
manual. Drain the cooling system. Remove the
The water pump on the V28 Series Engines is the
coolant bypass tube. Remove the water pump drive
centifugal-type with a cast iron impeller. The water
pulley. Remove the mounting capscrews and the
pump is belt-driven from the accessory drive pulley.
water pump assembly. Remove the water tube to
The water pump bearings are lubricated when
the oil cooler and discard the o-rings.
assembled and do not require additional grease
during the service life of the water pump.
The water pump idler bearing are lubricated during

assembly and do not require additional grease
during the service life of the idler assembly. A
grease fitting has been included in the idler pivot.
Service the grease fitting weekly with common
lithium, based grease.
The old style water pump belt tension was

controlled by an adjustable sleeve. The water
pump covers are interchangeable between the old Use Scotch-Brite® 7447 to clean the inside
and the new style water pumps. diameter of the coolant transfer tube bore (1).
The water pump contains an oil seal and water Visually inspect the water pump weep hole (2) for
pump seal. The cavity between these seals has a indications of leakage.
vent. The vent prevents contamination of the
lubricant or coolant if a seal leaks. Oil and coolant
seeping from the vent will not harm the operation
Note: New retaining rings are supplied with the

new bearings. Use a gasket scraper to remove the
gasket material from the gasket sealing surfaces.
Use Scotch-Brite® 7447 to clean the following

components:
• Bearing and oil seal bores in the water pump

body
• Inside diameter of coolant transfer tube in the
Use solvent or steam to clean the exterior of the water pump
water pump. Dry with compressed air. Inspect the • Shaft of the water pump.
body of the water pump for cracks or other damage.
Use solvent to clean the water pump components.
Inspect the water pump pulley for worn or damaged
Dry with compressed air. Visually inspect the water
grooves. Turn the water pump shaft by hand.
pump body for cracks, porosity, or excessive
Inspect the bushings and impeller for freedom of corrosion.
rotation. Note: If damaged parts are found or the
Note: If the part being inspected is not within the
shaft does not rotate freely in the body or the water
specifications, or is damaged, the part must be
pump, the water pump must be replaced or rebuilt.
replaced.
Remove the water pump cover.
Measure the inside diameter of the bearing bores
of the water pump body.
Water Pump Bearing Bore Inside Diameter with

Idler.
Use water pump pulley and impeller puller, Part

Number ST-647, to remove the water pump pulley
Measure the inside diameter of the bearing bores
and impeller. Remove the front oil seal from the
of the water pump body. Seal and Seat Assembly
body of the water pump. Discard the seal. Support
Bore Inside Diameter with Idler
the impeller side of the water pump body in an
arbor press. Push the shaft from the pulley end to
remove the bearings and the shaft from the body.
Discard the bearings. Use disassembly fixture,
Part Number 3375326, and an arbor press. Press
the bushing and water pump seal assembly from
Visually inspect the water pump impeller for cracks
the shaft. Use a suitable pulley, or a punch and
or other damage.
hammer, to remove the outer bearing races from
the body of the water pump. Discard the races.
Remove the retaining ring from inside the front of
the water pump.
8- O p e r at i o n an d M ai n t e na n c e
Measure the inside diameter of the water pump

From the impeller end of the pump, install the water
impeller bore.
pump shaft and bearing assembly into the water
Impeller Bore Inside Diameter pump body. Position the water pump with the pulley
end up. Install the inner bearing spacer over the
water pump shaft. Use Chevron® SRI grease, or
equivalent. Fill the water pump with 0.026 liter to
0.060 liter [0.97 oz to 1.15 oz]. Note : The water
pump must be lubricated at this time. No grease
fittings are provided on the new style water pumps.
Visually inspect the water pump drive pulley for Cummins Inc, recommends the use of grease
cracks or other damage. Visually inspect the meeting the specifications of MIL-G-3545,
grooves of the pulley for wear or other damage. excluding those of sodium containing soda soap
thickeners. Apply Chevron® SRI, or equivalent, to
Measure the inside diameter of the bore of the
the bearing and cone. Use a mandrel, Part Number
water pump drive pulley.
3375772, or equivalent. Support the water pump on
Drive Pulley Bore Inside Diameter with Idler the impeller end of the shaft. Install the remaining
inner race.
Measure the end play of the water pump.
Water Pump Assembly - End Play
Visually inspect the water pump shaft for grooves,

nicks, or other damage. Install the retaining ring
from the new bearing assembly in the retaining
Note: If the end play of the water pump assembly
groove inside of the front of the water pump body.
is not within the tolerance specifications, check to
Use a mandrel, Part Number 3375771, or
make sure the bearing inner and outer races are
equivalent.
properly seated against the inner and outer
Install one new bearing race in the front of the water spacers.
pump body. Make sure to seat the bearing race on
Use installation tool, Part Number 3375768.
the retaining ring. Install the outer bearing race
Support the water pump body. Install the oil seal in
spacer from the impeller end of the water pump.
the front of the water pump. Press the oil seal in
Use a mandrel, Part Number 3375771, or
position with the installation tool. Note: The oil seal
equivalent.
must be installed between 0.00 mm and 0.51 mm
Note: Be careful not to move the previously [0.000 in to 0.020 in] below the chamfer in the body
installed bearing race when installing the second of the water pump.
race. Install a new bearing race in the rear of the
Support the pulley end of the water pump body.
water pump body. Make sure the bearing race is
seated on the spacer. Apply water pump grease, Use oil seal installation tool, Part Number
Chevron® SRI, or equivalent, to one of the 3375769, to install the rear oil seal.
bearings and cone. Use a mandrel, Part Number
3375772, or equivalent. Install the inner race on the
water pump shaft. Make sure the bearing cone is
seated on the shoulder of the shaft.
M a i n te n a nc e O p e r at i o n 8-
Note: The oil seal must be installed between 0.00 Install the water pump idler spring retainer bracket.
mm and 0.51 mm [0.000 in to 0.020 in ] below the
chamfer in the water pump body. Use oil seal and
bushing installation tool, Part Number 3375769. Position the water pump assembly on the mounting
Install the gasket and bushing from the rear of the pad. Install the valve set pointer.
water pump. Apply a film of pipe sealant, Part
Number 3375066, or equivalent, to the outside Note: An engine stamped with CPL 1595, with
diameter of the new water pump seal. Support the timing of 0.052, requires an offset valve set pointer.
pulley side of the water pump in an arbor press. Install the lock washers and the capscrews.
Use water pump seal mandrel, Part Number
Tighten the capscrews.
3377260, to push the water pump seal into the
body of the water pump. Install the water pump seal Torque Value: 75 n•m [ 55 ft-lb ]
over the shaft. Apply one drop of Loctite® 290, or
equivalent, to the joint between the water pump
shaft and the water pump seal. Apply a light film of
Loctite® 609 in the bore of the drive pulley. Support
the water pump pulley in an arbor press. Push the
water pump shaft into the pulley bore until the pulley
touches the inner bearing race. Apply a light film of
Loctite® 609 in the bore of the impeller.
Support the pulley end of the water pump shaft in

an arbor press. Push the impeller on the shaft to
Install the water pump drive pulley. Fill the cooling
the specified clearance between the vanes of the
system. Connect the battery cables. Refer to the
impeller and the body.
OEM service manual. Operate the engine to 70°
C
Install the water pump cover and the new gasket. F] coolant temperature and check for leaks.
[160°
Tighten the capscrews.
Torque Value: 45 n•m [ 33 ft-lb ] Jacket
Rotate the pulley by hand. Inspect the bearing for A minor chemical buildup or streaking at the water
freedom of rotation. pump weep hole (1) is normal. Do not repair or
replace the water pump (2) unless an actual leak is
Note : If the water pump pulley does not rotate
confirmed. Contact a Cummins® Authorized
freely in the body of the water pump, the water
Repair Location for replacement of the water pump.
pump must be disassembled, inspected, and
assembled again. Inspect the water pump and bypass for coolant or
oil leakage. Check the water pump weep hole for
excessive leakage.
These engines can have a two-pump, two-loop

cooling system. The low temperature aftercooler
pump will be located near the front gear train on the
left bank, if equipped. Check both pumps for
leakage. The procedure for both pumps is similar.
Check that the water pump weep hole filter is clean

and free from any debris or chemical build-up.
Check the filter for cuts and tears.
Dual Impeller
Turbocharger
A minor chemical buildup or streaking at the water
pump weep hole (1) is normal. Do not repair or
Remove the oil supply tube from the
replace the water pump unless an actual leak is
turbocharger. See equipment manufacturer
confirmed. Contact a Cummins® Authorized
service information. Remove the oil drain tube
Repair Location for replacement.
from the turbocharger. See equipment
Note: Engines with a weep hole filter (2) installed manufacturer service information. Remove
may experience an occasional drip and minor the air crossover. See equipment
chemical buildup at the filter. This is normal and manufacturer service information. Remove
does not indicate a leaking pump. Do not replace the intake and the exhaust pipes from the
the water pump unless an actual leak is confirmed. turbocharger. See equipment manufacturer
service information.
These engines have two pumping elements on a
common shaft. There is only one weep hole. Loosen the clamp on the air crossover hose
Inspect the water pump and bypass for coolant or connection. Remove the four turbocharger
oil leakage. Check the water pump weep hole for mounting nuts. Remove the turbocharger and
excessive leakage. gasket. Discard the gasket. Clean the
turbocharger and the exhaust manifold gasket
surfaces.
M a i n te n a nc e O p e r at i o n 8-
Cracks on the turbocharger mounting flange longer

than 15 mm [0.6 in] are not acceptable. Cracks on
the turbocharger mounting flange must not reach
the mounting holes. Two cracks on the
turbocharger mounting flange must be separated
by 6.4 mm [0.25 in]. Inspect the exhaust manifold
gasket surfaces and the mounting studs for cracks
or any other damage.
Replace any cracked manifolds or damaged

Install the oil supply tube from the turbocharger.
mounting studs.
See equipment manufacturer service information.
Install the intake and the exhaust pipes from the

turbocharger. See equipment manufacturer
service information. Operate the engine and check
for leaks.
Turbocharger Radial Bearing Clearance
Apply a film of high-temperature anti-seize Remove the air intake and the exhaust piping from
compound, Part Number 3823097, or equivalent, the turbocharger. See equipment manufacturer
onto the turbocharger mounting studs. Install a new service information.
mounting gasket, the turbocharger, and the four
mounting nuts. Do not tighten the mounting nuts
until the aftercooler air inlet hose is installed on the
turbocharger. Install a new gasket, air crossover,
and the four capscrews.
Tighten the turbocharger mounting nuts.

Tighten the air crossover hose clamps and
mounting capscrews. Use a narrow width feeler gauge to measure the
radial clearance (side-to-side).
TorqueValue:
Air Crossover Hose Clampa 8 n•m [ 71 in-lb ] Note: Hold the shaft toward the feeler gauge to
Torque Value: check this dimension.
Air Crossover to Intake Manifold Mounting Rebuild or replace the turbocharger if the radial
Capscrews 35 n•m [ 26 ft-lb ] clearance is greater than specified.
Install the oil drain tube from the turbocharger. See
equipment manufacturer service information.
Remove the air intake and the exhaust piping. See

equipment manufacturer service information.
Note: Hold the shaft toward the feeler gauge to

check this dimension.
Use a narrow width feeler gauge to measure the

radial clearance (side-to-side).
Rebuild or replace the turbocharger if the radial

clearance is greater than specified. Contact a
Cummins® Authorized Repair Location for
assistance.
Turbocharger Axial Clearance
Remove the intake and the exhaust piping from the

turbocharger. Measure the axial clearance (end-
to-end). Rebuild or replace the turbocharger if the

axial clearance is greater than specified.
Axial Clearance (end-to-end)

NOTES
Section 9 - Seasonal Maintenance Checks

Section Contents
Page
Replace hose ....................................................................................................................................................... 9-1
Check pre-heater cold starting air ........................................................................................................................ 9-1
Check thermostats and seals .............................................................................................................................. 9-1
Steam clean engine ............................................................................................................................................. 9-1
Checking mountings ............................................................................................................................................. 9-1
Check fan & drive pulley mounting ..................................................................................................................... 9-1
Check crankshaft end clearance ......................................................................................................................... 9-1
Check raw (sea) water pump ............................................................................................................................... 9-2
Section 9 There are some maintenance checks which may or

may not fall exactly into suggested maintenance
schedule due to hours of operation but are
performed once or twice each year.
Seasonal Maintenance Checks

Replace Hose (As Required) replace any broken or lost bolts or capscrews.
Inspect the oil filter and cooling system hose and Torque Turbocharger Mounting Nuts (As Required)
hose connections for leaks and/or deterioration.
Torque all turbocharger mounting capscrews and
Particles of deteriorated hose can be carried
nuts to be sure that they are holding securely.
through the cooling system or lubricating system
Torque the mounting bolts and supports so that
and restrict or clog small passages, especially
vibration will be at a minimum.
radiator core and lubricating oil cooler, and
partially stop circulation. Replace as necessary. Check Fan and Drive Pulley Mounting
Check the fan to be sure it is securely

Check Pre-heater Cold-Starting Aid mounted; tighten the capscrews as necessary.
Check the fan for wobble or bent blades. Check
Remove the 1/8 inch pipe plug from the manifold,
the fan hub and crankshaft drive pulley to be sure
near the glow plug and check the operation of the
they are securely mounted. Check the fan hub
Pre-heater as described in Section 1.
pulley for looseness or wobble; if necessary,
Check Thermostats and Seals remove the fan pilot hub and tighten the shaft nut.
Tighten the fan bracket capscrews.
Remove the thermostats from the thermostat
housings and check for proper opening and Check Crankshaft End Clearance
closing temperature. Most Cummins Engines are
The crankshaft of a new or newly rebuilt engine
equipped with either medium 170°to 185°
F (77°to
must have end clearance as listed in Table 9-1. A
85°
C) or low 160°to 175°
F (71°to 79°
C) and in a
worn engine must not be operated with more than
few cases high-range 180°to 195°
F (82°to 91°
C)
the worn limit end clearance shown in the same
thermostats, depending on engine application.
table. If the engine is disassembled for repair,
rapidly. Tighten all mounting bolts or nuts and
install new thrust rings.
Engine New New Worn

Checking Mountings Series Minimum Maximum Limit
NTA-855 0.007 0.018 0.022

Tighten Mounting Bolts and Nuts (As Required)
(0.18) (0.45) (0.56)
V28 0.006 0.013 0.018
Engine mounting bolts will occasionally work (0.15) (0.33) (0.46)
loose and cause the engine supports and KTA-19 0.004 0.016 0.022
brackets to wear (0.10) (0.40) (0.56)
KTA-38 0.005 0.015 0.022
KTA-50 (0.13) (0.38) (0.56)
The check can be made by attaching an indicator 1. Check all pipes and fittings for leaks. Tighten
to rest against the damper or pulley, while prying as necessary.
against the front cover and inner part of the pulley
2. Remove cover plate to drain
or damper. End clearance must be present with
pump.
the engine mounted in the unit and assembled to
the transmission or converter. 3. Lift out impeller and check for cracks, breaks
or damage. Replace impeller if necessary.
Check Raw (Sea) Water Pump
Note: If impeller is subjected to extreme
Maintenance and service periods for raw water temperatures, either hot or cold, impeller life is
shortened and inspection periods must be adjusted
pump must be adjusted to agree with the type of
accordingly.
application to which it is subjected. If coolant being
pumped through the raw water pump is relatively 4. Clean out all
free of sediment, corrosive chemicals, foreign sediment.
material and abrasives such as sand or mud,
5. Install new cover plate gasket and install
normal maintenance periods are sufficient.
cover on pump.
Accelerated maintenance periods are necessary
to compensate for undesirable operating Note: A 0.015 inch (0.38 mm) gasket should be used
conditions. to maintain proper impeller-to-cover clearance.
6. No lubrication is necessary when sealed

bearings are used.
Section 10 Maintenance Operation 10-1
In-Frame Overhaul / Major Engine Overhaul

In-Frame Overhaul/Major Engine Overhaul
Operating conditions of the engine, normally

dictate when the engine is in need of an in-Frame
overhaul or a major overhaul. Oil consumption,
excessive drop of oil pressure at idling, oil dilution,
excessive blow-by, unusual noise, vibrations and
exhaust smoke should be analyzed in determining
the next course of action.
At this time, perform all previous checks and

inspect the following:
Accessory Drive Bearings Cylinder Head Cylinder

Liners
Front Gear Train Rear Gear Train Lubricating Oil
Pump Pistons
Connecting Rods Piston Rings Crankshaft
Journals Camshafts
Cam Followers
Accessory Drive Seal
Front and Rear Crankshaft Seals
Oil Cooler
Rebuild instructions, new parts or exchange parts

are available from any Cummins Distributors or
Dealers.
NOTES
Section 11 - Specifications and Torque

Section Contents
Page
Lubricating oil ..................................................................................................................................................... 11-1
Fuel Oil………………………................................................................................................................................ 11-2
Cooling System………......................................................................................................................................... 11-3
Test Strip............................................................................................................................................................... 11-4
Test Kit .............................................................................................................................................................. 11-5
Coolant Top Up .................................................................................................................................................. 11-7
Coolant Checking ............................................................................................................................................... 11-7
Coolant Replacement ......................................................................................................................................... 11-7
Conversion of field engines ............................................................................................................................... 11-7
Coolant capacities .............................................................................................................................................. 11-8

Section 11 Specifications and Torque 11-1
Providing and maintaining an adequate supply of

Specifications clean high quality fuel, lubricating oil, grease and
coolant in an engine is one way of insuring long life
and Torque and satisfactory performance.
Lubricant, Fuel and Coolant

The Functions of Lubricating Oil The oil must have an additive package to combat
these contaminants. The package generally consists of :
The Lubricating oil used in a Cummins engine must
be multifunctional. It must perform the primary Detergents/Dispersants which keep insoluble matter
functions of:
in suspension until they are filtered from the oil or are
removed with the oil change. This prevents sludge
Lubrication by providing a film between the moving
parts to reduce wear and friction. and carbon deposits from forming in the engine.
Cooling by serving as a heat transfer media to Inhibitors to maintain the stability of the oil, prevent
carry heat away from critical areas. acids from attacking metal surfaces and prevent
rust during the periods the engine is not operating.
Sealing by filling in the uneven surfaces in the
cylinder wall, valve stems and turbocharger oil seals. Other Additives that enable the oil to lubricate highly
Cleaning by holding contaminants in suspension loaded areas, prevent scuffing and seizing, control
to prevent a build up of deposits on the engine foaming and prevent air retention in the oil.
surfaces.
In addition, it must also provide:

Oil Performance Classification System
Dampening and cushioning of components that
operate under high stress, such as gears and push The American Petroleum Institute (API), The American
tubes. Society of Testing and Materials (ASTM) and the
Society of Automotive Engineers (SAE) have jointly
Protection from oxidation and corrosion. developed and maintained a system for classifying
lubricating oil by performance categories. The following
Engine lubricating oil must be changed when it can no is brief description of the APl’ categories used in the
longer perform its functions within an engine. Oil does
Cummins Lubricating oil recommendations.
not wear out, but it becomes contaminated to the point
that it can no longer satisfactorily protect the engine.
Contamination of the oil is a normal result of engine SAE 15W40 Lub oil with API CH-4, CES 20071 & CES
operation. During engine operation a wide variety of 20076 classification oils are formulated for service of
contaminants are introduced into the oil. Some of these high speed, four stroke cycle diesel engines. This is the
are: best oil available in India now. Hence, we recommend
to use this oil only.
By-products of Engine Combustion—asphaltenes,
soot and acids from partially burned fuel.
Break-in Oils
Acids, varnish and sludge which are formed as a
result of the oxidation of the oil as it breaks down
or decomposes. Special “break-in” lubricating oils are not recommended
for new or rebuilt Cummins engines. Use the same
Dirt entering the engine through the combustion air, lubricating oils used in normal engine operation.
fuel, while adding or changing lubricating oil.
Viscosity Recommendations various ambient temperatures. The only viscosity grades

recommended are those shown in this table.
The viscosity of an oil is a measure of its resistance
to flow. The Society of Automotive Engineers has Cummins has found that the use of multigraded
classified engine oils in viscosity grades: Oils that lubricating oil improves oil consumption control, improved
meet the low temperature [0° F (–18° C)] requirement engine cranking in cold conditions while maintaining
carry a grade designation with a “W” suffix. Oils that lubrication at high operating temperatures and may
meet both the low and high temperature requirements contribute to improved fuel consumption. Cummins
are referred to as multigrade or multiviscosity grade oils. does not recommend the use of single grade lubricating
oils.
Multigraded oils are generally produced by adding
viscosity index improver additives to retard the thinning The primary criterion for selecting an oil viscosity
effects, a low viscosity base oil will experience at engine grade is the lowest temperature the oil will experience
operating temperatures. Multigraded oils that meet the while in the engine oil sump. Bearing problems can be
requirements of the API classifications, are caused by the lack of lubricating during the cranking
recommended for use in Cummins engines. and start up of a cold engine when the oil being used
is too viscous to flow properly. Change to a lower
Cummins recommends the use of multigraded lubricating viscosity grade of oil as the temperature of the oil in the
oil with the viscosity grades shown in Table 11-1 which engine oil sump reaches the lower end of the ranges
shows Cummins Viscosity grade recommendations at shown in Table 11-1.
Cummins Recommended SAE Oil Viscosity Grades vs Ambient Temperatures
Note : For temperature consistently below -25°

C (-13°
F) refer to lub oil manufacturer for recommendations.
Engine Oil Recommendations for Cummins weight ratio etc. for meeting customer expectations of
Engines engine performance, durability and cost of operation.
Quality of Lubricating oil is one of the key drive factors to
L u b r i ca t in g o i l ha ve a l so u n d e r g on e va r i o u s
decide the performance, Durability and total cost of
improvements to meet the requirements of these
operation of diesel engine. Hence we have always been
changes in diesel engine technology. With this, SAE
recommending the best available / suitable engine oil to
15W40 grade Lubricating oil with API CH-4 classification
be used in our engine.
is now available in India from most of oil companies.
Cummins India Limited has been continuously This is the best engine oil currently available in India
upgrading the products to incorporate latest technology suitable for Cummins engines. However we recommend
such as low temp. aftercooling, two stage turbocharging, to use Valvoline Cummins Premium Blue for Cummins
electronics, air to air charge air cooling, high power to engine.
Specifications and Torque 11-3
This provides several advantages such as, CAUTION

- Reduced wear and tear.
- Better high temp oxidation stability Do not intermix different brands of oil as two different
- Optimum Lub oil consumption. brands of oils may not be compatible with each other.
- Lesser crown land deposits on piston and valves. It is there fore recommended that the brand which is
- Better emission control used for initial fill / oil change, should only be used
- Better cleanliness of internal passages and components. for top-up. Different brand of oil may be used after
- Less sludge formation due to improved dispersancy. draining all the existing oil i.e., at the oil drain interval
- Increased control on acid formation resulting in less and after flushing the lub oil system with new brand
corrosion of bearings and other components. of oil.
Cummins India Limited strongly recommends the use of
SAE 15W40 Lub oil with API CH-4, CES 20071 & CES Note
20076 classification for all Cummins engines to get the The responsibility of meeting oil quality lies with
various advantages and optimum performance from the the oil manufacturer & Cummins will not be
engine. responsible for problems occurring on engines due
to poor quality of oil.
As a comparative advantage we strongly recommend
following brand of lube oil for Cummins engines. Grease Recommendations
Valvoline Cummins Premium Blue, API CH-4, CES Cummins India Limited Pune, recommends the use of
20071 & CES 20076. grease meeting the specifications of MIL-G-3545,
This oil have a minimum TBN of 10.5 to counteract the excluding those of sodium or soda soap thickeners.
higher sulphur content of high speed diesel available in Contact lubricant supplier for grease meeting these
specifications.
India.
TEST TEST PROCEDURE
High-Temperature Performance
Dropping point, °
F ASTM D 2265
350 min.
Bearing life, hours
at 300° F. *FTM 331
10,000 rpm 600 min.
Low-Temperature Properties
Torque, GCM ASTM D 1478
Start at 0°F. 15,000 max.
Run at 0° F. 5,000 max.
Rust Protection and Water Resistance
Rust test ASTM D 1743
Pass
Water resistance, % ASTM D 1264
20 max.
Stability
Oil separation, %
CAUTION 30 Hours @ 212° F. *FTM 321
Beware of the spurious oils in the market. Bad oil 5 max.
quality is detrimental to engine performance. Hence Penetration
oil should always be procured from the original Worked ASTM D 217
manufacturer or the authorised distributor. 250-300
Lubricating oil to be used in the engine must meet all Bomb Test, PSI Drop ASTM D 942
qualities as per manufacturer’s specifications. 100 Hours 10 max.
Cummins India recommends audit checks of fresh 500 Hours 25 max.
engine oil to ensure the quality of oil. Facility to check Copper, Corrosion *FTM 5309
suitability of oil for using it in the engine is available Pass
with Cummins service network. Dirt Count, Particles/cc *FTM 3005
25 Microns + 5,000 max.
If in doubt about the quality of lub oil, contact lub oil 75 Microns + 1,000 max.
manufacturing company / Cummins service network 125 Microns + None
and get oil analysed in laboratories. Rubber Swell *FTM 3606
10 max.
* Federal Test Method Std. No. 791a
CAUTION Active Sulfur Copper Strip Corrosion not

(ASTM D130) to exceed No. 2 rating after
Do not mix brands of grease as damage to bearings three hours at 122°
F (50°C).
may result. Excessive lubrication is as harmful as Water and Sediment Not to exceed 0.1 volume
inadequate lubrication. After lubricating fan hub, (ASTM D1796) percent.
replace both pipe plugs. Use of fittings will allow Carbon Residue Not to exceed 0.35 mass
lubricant to be thrown out, due to rotative speed. (Rams bottom, percent on 10 volume
Fuel Oil Recommendations ASTM D524 or percent residuum.
Conradson, ASTM D189)
Cummins Diesel Engines have been developed to take
the advantage of high energy content and generally Density (ASTM D287) 42 to 30°API gravity at
lower cost of No. 2 Diesel Fuels. Experience has shown 60° F (0.816 to 0.876 g/cc at
that a Cummins Diesel Engine will also operate 15° C).
satisfactorily on No. 1 fuels or other fuels within the Cloud Point 10° F (6°C) below lowest
following specifications . (ASTM D97) ambient temperature at
Table 11-3 : Recommended Fuel Oil Properties : which the fuel is expected
Property Recommended to operate
Specifications Ash Not to exceed 0.02 mass
Viscosity 1.3 to 5.8 centistokes (ASTM D482) percent (0.05 mass percent
(ASTM D445) (1.3 to 5.8 mm per second) with lubricating oil blending).
at 104° F (40°
C) Distillation The distillation curve must
Cetane Number 40 Minimum above 32° F. (ASTM D86) be smooth and continuous.
(ASTM D-613) 45 Minimum below 32° F. Acid Number Not to exceed 0.1 Mg KOA
Sulfur Content Not to exceed 0.25 % mass (ASTM D664) per 100 ML.
(ASTM D-129 or 1552) percent.
TABLE 11-4: REQUIREMENTS FOR HIGH SPEED DIESEL FUEL AS PER IS 1460 : 2005
Sr. Characteris tic s Requirement Method of test Ref. to
No. [P;] of IS 1448/ISo/ASTMD/
IP/EN/Annex of this Standard
Bharat Stage II Bharat Stage III
1 2 3 4 5
1 Acidity, Inorganic Nil Nil [ P : 2 ]
2 Acidity, total mg. of KOH/g Max. To report To report [ P : 2 ]
3 Ash, percent by mass Max. 0.01 0.01 [P : 4]/ISo 6245
4 Carbon residue (Ramsbottom) on 10 percent 0.30 0.30 [P : 8]/ISo 10370
residue1), percent by mass, Max
5 Cetane Number2), Min. 48 3) 513) [P : 9]/ISO 5165
6 Cetane index2), Min. 46 3) 463) D 4737/ISo 4264
7 . Pour point4), Max. [P : 10]/D 5949 or D 5950 or D 5985
a) Winter 3 °C 3 °C
b) Summer 15°C 15°C
8 Copper strip corrosion for 3 hours at 100°C Not worse than No. 1 Not worse than No. 1 [P : 15]/ISO 2160
9 Distillation percent v/v, recovered [P : 18]/ISO 3405
a) at 350°C, Min. 85 —
b) at 360°C, Min. — 95
c) at 370°C, Min. 95 —
10 Flash point : (a) Abel, °C Min. 35 35 [P : 20]
b) Pensky Martens closed cup5), °C, Min. 66 66 [P : 21]
11 Kinematic viscosity cSt at 40°C 2.0 to 5.0 2.0 to 4.5 [P : 25]ISO 3104
12 Sediment, percent by mass Max 0.05 — [P : 30]
13 Total contamination, mg / kg — 24 EN 12662
14 Density at 15 oC 6) ,kg/m 3 820-860 820-845 [P : 16]or [P:32]7)/D 4052
ISO 3675 or ISO 12185
15 Total sulphur8), mg / kg, Max 500 350 IP : 336 or D 4294 9)
ISO 14596orISO 8754/P :83/D
2785/D 5433/D2622/D3120
16 Water content, percent (v/v) 0.05 — [P : 40]/ISo 3733/ISO6296
Water content mg / kg, Max — 200 ISO 12937
17. Cold Filter Plugging Point (CFPP) 4), Max. [P : 110]/D6371
a) Winter 6 °C 6 °C
b) Summer 18°C 18°C
18 Total sediments10), mg. per 100 ml. Max. 1.5 — Annex A/ISO 11205/D2274 10)
19 Oxidation stability, g/m 3, Max — 25 ISO 12205 or D 2274
20 Polycyclic aromatic hydrocarbon (PAH), — 11 IP 391 or EN 12916
precent by mass, Max
21 Lubricity corrected wear scar diameter 460 460 ISO 12156-1
(wsd 1.4) at 600 C, microns, Max
22 Oxygen content11) percent by mass, Max 0.6 0.6 Annex B
Coolant Specifications
Cooling System
Part Description Qty.
Cummins engines are provided with fleetcool XB Coolant Number
Additive Concentrate - (CAC) and premix coolant. To
ensure adequate corrosion protection, checking coolant 3167214 Coolant additive concentrate 0.5 lt.
3167215 Coolant additive concentrate 1 lt.
at every B Check is essential. The checking procedures
3167216 Coolant additive concentrate 2 lt.
and the details of the Coolant Checking Kit are given 3167217 Coolant additive concentrate 5 lt.
below : 3167218 Coolant additive concentrate 10 lt.
Salient Features of CAC
B. Pre-mixed Coolant
- Safe / environmental & user friendly
- Easy operation, time saving at ‘B’ check. It is supplied in plastic white colour containers having
- To be filled in through Radiator / make up (auxiliary) different part nos. for different volumes. The colour of the
tank Cap coolant is pink.
Part Number Description Qty.
- Cost benefit to the customer at ‘B’ check.
Effective from Aug. 04
- Easy checking process. 3167221 Pre-mixed Coolant 5 lt.
CAC Availability form and Checking 3167222 Pre-mixed Coolant 10 lt.
CAC is available in two forms, 3167223 Pre-mixed Coolant 20 lt.
a) Coolant Additive Concentrate, which can be mixed with 3167224 Pre-mixed Coolant 205 lt.
water of 1:16 proportion and, C. Test strip
New Test strip is introduced. Test strip is required
b) Pre-mixed coolant, which can be directly added in to check coolant concentration and are packed
cooling system. To check the coolant concentration Test individually in a foil pack.
Strip and a Test Kit are available. Part Number Description
Make Up Coolant Specifications 4912590 Test strip
Where possible, it is recommended that a supply of D. Test Kit
make-up coolant be prepared to the following Test kits are supplied in cardboard boxes.
specifications, using soft water. Chromate treatment of Part Number Description
coolant assures constant level of concentration when
4912590 Test Kit
coolant is added. This consists of
2. Coolant Additive Concentrate (CAC) a) 2 test strips,
A. Coolant Additive Concentrate b) a clear plastic beaker
c) a dropper to collect the coolant.
It is supplied in plastic red colour containers having d) Fleetcool XB Concentration correction table
part no. 4912783.
different part nos. for different volumes. The colour of the
coolant additive concentrate is deep purple. IMPORTANT NOTE
Shelf life for Coolant Additive Concentrate & Pre-
mixed Coolant is 5 years & that of test strip is one year.
CMYK
coolant to avoid frequent checking with Coolant

Checking Strip.
Checking is recommended in case of following
conditions –
1. At the time of initial commissioning,
2. When coolant is totally replaced / excessive coolant
loss occurs
3. When concentration levels are unknown / doubtful.
Special Instructions :
For all old engines using fleetcool XB coolant, it is
strongly recommended that coolant concentration should
be checked and controlled within 0.4 to 0.6 units per
liter. In case it is excess of 0.6, immediate correction as
per tabulation Card Part No. 4912783 provided in
Coolant test kit Part No. 3167226 is required.
Front Page of concentration Back Page of CCT INSTRUCTIONS FOR USE
correction table
The Coolant Additive Concentrate and pre-mixed coolant
is supplied with each engine as,
• Required quantity of Coolant Additive Concentrate
as per engine model.
• Coolant test kit 3167226
• Pre-mixed coolant for top up.
Test Strip Pin 4912590
It is proven that high concentration of fleetcool XB 1) First fill at the time of engine commissioning
coolant causes gel effect leading to water pump seal Genset Applications
surface damage. Lower concentration of fleetcool XB a) Add Coolant Additive Concentrate supplied in kit
coolant cause liner pitting. Purpose of this note is to in radiator top tank / expansion tank
emphasize need to control fleetcool XB coolant
concentration within band of 0.4 to 0.6 units per liter.
b) Fill the remaining system by water till the system is
The Coolant Checking Strip Part number 3167225 is
completely filled.
superseded by new part number 4912590. The new test
strip is supplied with engine effective from August
2004.
For correct coolant concentration adjustment Tabulated
card Part no 4912783 is included in each Coolant
checking kit Part No. 3167226. This card tabulates
amount of coolant to be removed and to be topped up
with water for reducing excess concentration.
In case of lower concentration, tabulation gives amount
of coolant to be replaced with Coolant concentrate in
order to increase concentration.
Tabulation is done for different models and for different
measured concentrations. It is advisable to run the
engine for few minutes after coolant concentration
correction and recheck concentration in order to ensure
that it is within 0.4 to 0.6 units per liter.
The tabulation is aimed to attain coolant concentration
correction in one go and avoid iteration i.e no repeat
adjustment should be required.
It is advised that always top up radiator with pre mix
CMYK
a) Prepare coolant mixture by mixing 15 parts of water During coolant checking two coolant properties namely
with 1 part of Coolant Additive Concentrate supplied coolant concentration and pH value of coolant are to be
in kit and stir for thorough mixing. checked as follows:
b) Fill the system completely with this coolant. Measure Concentration
and note down the system capacity for further This can be checked by Test Kit, using following method:
reference purpose.
i. Remove the top tank cap of radiator/heat
2. Coolant Top Up exchanger, use dropper or open vent cocks in
the cooling system & collect coolant sample
If system is topped up by water it leads to dilution of the in the beaker.
coolant i.e. coolant concentration becomes lower. In
ii. Allow the coolant temperature to reach room
order to maintain the coolant concentration it is must to
temperature.
top up the system by pre-mixed coolant only and not by
water. iii. Remove ‘Test Strip’ from the pack. Dip the
strip in coolant for 3 seconds.
To facilitate top up, pre-mixed coolant is made available.
This Pre-mixed coolant is to be used as supplied. Do not iv. Remove strip and shake briskly to remove
dilute. excess coolant.
If pre-mixed coolant is not available, mix 15 parts of v. Wait for 45 seconds. Compare the colour of
water : 1 part of Coolant Additive Concentrate and use the strip with the colour chart within next 30
this coolant for top up. seconds.
Improper cooling system top-up is the primary reason vi. Take action as shown in the colour chart.
for low concentration levels in the coolants which in
term causes corrosion and liner pitting.
pH of coolant
3. Coolant Checking No special checking kit is required for this property. This
In normal operating condition with system maintained as is only visual check. Special colour indicator has been
per above, the coolant will be maintained to the required added in the new CAC whose colour changes with pH.
specifications and no checking is required. However When colour of the coolant is pink the pH is within limit.
coolant checking is suggested as audit check, at every (8.5 to 10.0 pH)
1500 hrs./6 months during operation. Checking is also If coolant becomes colourless, then it indicates very
suggested in case of following : low level of concentration. Hence add CAC as required
— At the time of commissioning the engine, to maintained the concentration level.
— When coolant is totally replaced / excessive coolant
4. Coolant Replacement
loss occurs
— When concentration levels are unknown / doubtful. At 6000 hrs. of operation or after two years, it is
Coolant checking is very easy with the use of Test necessary to replace the coolant.
Strip.
Important Note :
Use of good quality water along with CAC is important for
optimum cooling system performance. Water used in
cooling system must meet following specifications.
Hardness (as CaCO3) - 170 ppm max

Chlorides (as Cl) - 40 ppm max
Sulfate (as SO4) - 100 ppm max
pH - 5 to 9
TDS - Less than 400 ppm.
(Total Dissolved Solids)
It is suggested to get Water quality checked from
authorised laboratories if water quality is doubtful.
Details of Coolant Capacity with Radiator & H.E. Engines
Sr. KVA Engine Actual Coolant capacity with Radiator Actual Coolant capacity with HE
No Rating Model (Ltrs.) (Lt)
1 320 NTA 855 88 36

2 380 NTA 14 77 36
3 500 KTA 19 162 60
4 625 VTA 28 155 212
5 750 KTA 38 G2 305 225
6 1010 KTA 38 G5 255 200
7 1250 KTA 50 G3 415 290
8 1500 KTA 50 G8 480 300
To ensure adequate corrosion protection check engine

Coolant
coolant per procedure under Check Engine Coolant in
W ater coolant is important for cooling system section 6.
performance. Excessive levels of calcium and
magnesium contributes to scaling problems and Check magnesium plate for pitting or being eaten away,
excessive levels of chlorides and sulphates cause change if more than 50% of area is lost, where
cooling system corrosion. The quality of water must Corrosion Resistor is used.
meet the requirements listed below :
Water maximum levels
3
• Calcium Magnesium 170 PPM as (CaCO3 + MgCO )
(Hardness)
• Chloride 40 PPM as (Cl)
• Sulphur (Sulphates) 100 PPM as (SO 4)
Coolant Specifications for Aluminum Radiators:
Complete EG 50:50 Premix Engine Coolant's corroson inhibitor level needs to be inspected at least every 6 months
or every 500 Hrs. of operation, whichever is earlier using 3-Way Test strip analysis. DCA4 is a supplement coolant
additive (SCA), which is to be added in the cooling system in as in condition to maintain the required concentration
level of corrosion inhibitors (Molybdate & Nitrite) in Complete 50:50 Premix Engine Coolant based on 3 way test
strip analysis result.
3-Way Strip analysis chart: Test Procedure:
1. Stop the genset and ensure the coolant temperature reduces to less than 40 0C confirmed from monitoring
controller/guage.
2. Remove the radiator cap and collect the coolant sample on plastic bowl using filler, which are supplied along
with test kit. DO NOT collect the sample from the coolant recovery bottle or overflow system. Coolant must be
between 100C and 550C and when tested.
3. Remove one strip from one packet. DO NOT touch the pads on the end of the strip, discard strip if Nitrate test
pad has turned brown.
4. Dip strip in coolant sample for one second, remove and shake strip briskly to remove excess liquid.
5. 45 seconds after dripping strip compare and records results in the following order.
a) Compare Freezepoint (end pad) to color chart and record result.
b) Next compare Molyboate (middle pad) to color chart and record list.
c) Finally compare Nitrate test to color chart and record result.
6. All three readings must be completed no later than 75 seconds after dipping strip.
7. It is okay to estimate a value between color blocks, but if uncertain about the color match, pick the lower
numbered block.
8. Determine where the Molybdate level intersects the nitrate level on the chart. The amount of SCA units per litre
in the cooling system is given where the Molybdate row intersects the Nitrate column.
9. For best results follow test times carefully. Use a stopwatch or clock with a sweep second hand. Comparing
the test strip to the color chart too soon before, or too late after, the required test time will result incorrect readings
and improper treatment and could result in liner pitting and engine damage.
In case of any doubt or any additional information needed, please contact your local DFSE/ regional service support
team.
Operation and Maintenance
Verify the Strip colour with the below mentioned chart.
I
I
i
Section 12 Specifications and Torque 12-1
Capscrew Markings and Torque Values

Current Usage Much Used Much Used 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 Minimum Commercial Medium Commercial Best 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)
Capscrew Body Size Torque Torque Torque Torque

(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 :
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 originally supplied, adhere to torque specifications for that
placement.
12-2 Specifications and Torque
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)
Notes :
1. Do not use these values when the torque values are specified 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

Section 13 Troubleshooting 13-1
Troubleshooting is an organized study of the

Troubleshooting problem and a planned method of procedure for
investigation and correction of the difficulty. The
chart on the following page includes some of the
problems that an operator may encounter during
the service life of a Cummins diesel engine.
Cummins Diesel Engines

The chart does not give all the answers for correction but instead to a clogged air cleaner or possibly a
of the problems listed, but it is meant to stimulate a restricted exhaust passage, causing excessive back
train of thought and indicate a work procedure directed pressure. Too often, engines are c ompletely
toward the source of trouble. To use the troubleshooting disassembled in search of the cause of a certain
chart, find the complaint at the top of the chart; then complaint and all evidence is destroyed during
follow down that column until you come to a black dot. disassembly operations. Check again to be sure an
Refer to the left of the dot for the possible cause. easy solution to the problem has not be overlooked.
Think Before Acting

Study the problem thoroughly. Ask these questions : Find and Correct Basic Cause of the Trouble
1. What were the warning signs preceding the trouble? After a mechanical failure has been corrected, be sure to
locate and correct the cause of the trouble so the same
2. What previous repair and maintenance work has failure will not be repeated. A complaint of “sticking
injector plungers” is corrected by replacing the faulty
been done? injectors, but something caused the plungers to stick.
The cause may be improper injector adjustment or more
3. Has similar trouble occurred before? often, water in the fuel.
4. If the engine still runs, is it safe to continue running
Tools and Procedures to Correct a Complaint
it to make further checks?
Tools and procedure to correct the complaints found in

Do Easiest Things First this Troubleshooting section are available from Cummins
Most troubles are simple and easily corrected; examples Dealers. This list includes all engines model , shop and
are “low-power” complaints caused by loose throttle engines repair and rebuild manuals.
linkage or dirty fuel filters, “excessive lube oil
cons umption” caused by leaking gaskets or
connections, etc.
Always check the easiest and obvious things first.

Following this simple rule will save time and trouble .
Double-Check Before Beginning Disassembly

Operations
The source of most engine troubles can be traced not
to one part alone but to the relationship of one part
with another. For instance, excessive fuel consumption
may not be due to an incorrectly adjusted fuel pump,
NOTES
Cummlnalndla Umlted
C. ReglatenJd Ofl'lce:Kothrud, Puna 411038

Tel; +91 20-25385435, 25380240
Fax: +91-:20-25381591
VMW.cumminsindia..com
Bulletin No. 3243773-10 / October 2017

OM Manual 3243773 - 10

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Bulletin No.

• The best warranty policy in the industry

• Largest dealer network

• 24 hour customer assistance cell

• Various training program

We hope you will take advantage of all we offer.

NTA-855-C NTA-14 - C VTA-28 - G

KTAA - 19 - G10 KTA-50 - G

Engine Data Plate: Engine Model - N T A - 1 4 - C

Engine Data Plate: Engine Model - V T A - 2 8 - G

Engine Data Plate: Engine Model - K T A A - 1 9 – G 1 0

Engine Data Plate: Engine Model - K T A - 3 8 – G 1 4 & K T A - 5 0 – G

To the Owner and Operator ...................................... i-2

Section 2 - Industrial Fire Pump Engines

Engine Starting Procedure ..................................... 2-1

Crankcase Breather Element ................................... 7-1

Cummins Diesel Engines ................................... 13-1

Section 9 - Seasonal Maintenance Checks

Replace hose ......................................................... 9-1

Section 10 – Major Engine Overhaul

In-Frame overhaul / Major Engine Overhaul ........ 10-1

Section 11 – Specification and Torque

Lubricating Oil ....................................................... 11-1

We suggest the following points of contact: 3. Cummins PT Fuel System Course

If you still have problems please write to:

Cummins India Limited

W e do request that above steps be followed in order. Most of

Customer Assistance Cell Parts Assistance

Technical Information & Service Assistance

While asking for assistance please provide the

1. Your Name & Phone or Fax Number.

2. Engine Serial Number.

3. Name of the Customer.

5. General Description of Assistance

Cummins Indi a Ltd

1. KEEP DIRT OUT OF THE ENGINE.

2. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.

3. REGULATE THE ENGINE’S FUEL.

4. CONTROL OPERATING TEMPERATURE.

5. GUARD AGAINST CORROSION.

6. LET THE ENGINE BREATHE.

8. KNOW YOUR ENGINE’S CONDITION.

9. CORRECT PROBLEMS WHILE THEY ARE SIMPLE.

10. SCHEDULE & CONTROL YOUR ENGINE MAINTENANCE.

NTA-855 Engine Model

K50 Engine Model

To the Owner and Operator

About the Manual

How to Use the Manual

The illustrations are intended to show repair or replacement

General Safety Instructions

API American Petroleum Institute

Engine Operating Range

Section 1 - Operating Instructions

THIS PAGE LEFT INTENTIONALLY BLANK

The engine operator must assume responsibility

General - AII Applications

Correct care of your engine will result in longer life,

• Check the oil pressure indicators, temperature

safety devices are available, such as air intake

1.1 Starting the Engine

The engine requires clean air and fuel to be supplied to