Specification Book - Janaki Sent

Specification
Book
Bulletin No. AX 1001506 Cummins Diesel Sales and Service (India) Limited
Printed APRIL 2002
35 A/1/2, Erandawana, Pune 411 038
Page-1 Name _______________________________________
FOREWORD
Office Address ________________________________
This manual provides certain specifications of N, V, K, QSK
S, B, C, and CWC series of Cummins Diesel, Natural gas and Dual
fuel engines. Maintenance practices and minor details of trouble
shooting and repairs, parts information have also been included. ____________________________________________
For detailed operation / maintenance / troubleshooting procedures

and information, refer the respective engine (operation & Residential Address ____________________________
maintenance, shop and alternative repair) manuals. These additional
manuals can be procured from our Parts Department.
____________________________________________
The data compiled in this bulletin is subject to change without notice
and any obligation.
Specification
Telephone No. Res. ____________________________
The latest technology and the highest quality components are used
to manufacture Cummins engines. When replacement parts are Book
needed, we recommend using only genuine Cummins or Recon
exchange parts. Office ______________________________________
Driving Licence No. ____________________________
Renew ______________________________________
Cummins
Customer Assistance Cell
Permanent Income Tax A/c No. __________________
Tel. : (020) 5436680 Call Toll Free
Fax : (020) 5445916 Passport No. _________________________________
1 - 600 - 332000
Contact for On line Help....
E-mail : powermaster@kcl.cummins.com Renew ______________________________________
Visit our Website : cummins-india.com
Cummins Diesel Sales and Service (India) Limited
LIC Policies No. _______________________________
35/A/1/2, Erandwana, Pune 411 038.

Blood Group _________________________________ Phones : (020) 020-5430066, 5431234, 5431703
Fax : (91) - 020 – 5449490
Bankers ____________________________________ Web : www.cummins-india.com
Bulletin No. AX 1001506

Dealer Phone Nos. ___________________________ Printed APRIL 2002
Our Goal : Zero Engine Down Nearest Area Office Phone Nos. _________________
Compiled and published by Cummins “Service Training School”
Page-1 Name _______________________________________
FOREWORD
Office Address ________________________________

____________________________________________
and any obligation.
Specification
Telephone No. Res. ____________________________
Renew ______________________________________
Cummins
Fax : (020) 5445916 Passport No. _________________________________
1 - 600 - 332000
LIC Policies No. _______________________________

Fax : (91) - 020 – 5449490

Page-1 Name _______________________________________
FOREWORD
Office Address ________________________________

____________________________________________
and any obligation.
Specification
Telephone No. Res. ____________________________
Renew ______________________________________
Cummins
Fax : (020) 5445916 Passport No. _________________________________
1 - 600 - 332000
LIC Policies No. _______________________________

Fax : (91) - 020 – 5449490

Section - i Page i Section - i Page i-1
Page 2
GENERAL TABLE OF CONTENTS INTRODUCTION GENERAL SAFETY INSTRUCTIONS
Contents Section IMPORTANT SAFETY NOTICE
Contents Page
Introduction ……………………………………………………….. i
General Safety Instructions WARNING
Engine Data -N, V, K, QSK ……………………………………… 0 Important Safety Notice i-1
Engine Data - Genset Applications ………………………………1 Improper practices or carelessness can cause burns, cuts,
Acronyms and Abbreviations i-3 mutilation, asphyxiation or other bodily injury or death.
Gas & Dual Fuel Engine Data ……………………………………. 2
Engine Data - B Series …………………………………………… 3 Read and understand all of the safety precautions and warnings
Engine Data - C Series .………………………………………….. 3A before performing any repair. This list contains the general safety
precautions that MUST be followed to provide personal safety.
Engine Data - S Series ……….……………………………… 3B
• Make sure the work area surrounding the product is dry, well lit,
Engine Data - CWC Series ……………………………………… 3C
ventilated, free from clutter, loose tools, parts, ignition sources
Parts Information …………………………………………………. 4 and hazardous substances. Be aware of hazardous conditions
that can exist.
General Information ………………………………………………. 5
• Always wear protective glasses and shoes when working.
Trouble Shooting Charts …………………………………………. 6
Index ……………………………………………………………….. IN-01 • Rotating parts can cause cuts, mutilation or strangulation.
• Do not wear loose-fitting or torn clothing. Remove all jewellery

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

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

rotating the crankshaft. Do not attempt to rotate the crankshaft
by pulling or prying on the fan. This practice can cause serious
personal injury, property damage, or damage to the fan blade(s)
causing premature fan failure.
• If an engine has been operating and the coolant is hot, allow the
engine to cool before you slowly loosen the pressure cap and
relieve the pressure from the cooling system.
• Do not work on anything that is supported ONLY by lifting jacks

or a hoist. Always use blocks or proper stands to support the
product before performing any service work.
• Relieve all pressure in the air, oil, fuel and the cooling systems
before any lines, fittings, or related items are removed or
disconnected. Be alert for possible pressure when disconnecting
any device from a system that utilizes pressure. Do not check
for pressure leaks with your hand. High pressure oil or fuel can
cause personal injury.
Page 2
Contents Page
Introduction ……………………………………………………….. i
that can exist.

when working.

controls.


Page 2
Contents Page
Introduction ……………………………………………………….. i
that can exist.

when working.

controls.


Section - i INTRODUCTION ACRONYMS AND ABBREVIATIONS Page i-4
Kg Kilogram O/M Owner-Operator Manual
Km/l Kilometers per Liter OEM Original Equipment Manufacturer
KPa Kilopascal OPS Oil Pressure Sensor
KW Kilowatt OS Over Speed
Ib Pound PC Personal Computer
LCWL Low Coolant – Water Level P-P Peak to Peak
LED Light-Emitting Diode P/N Part Number
LLOP Low Lube Oil Pressure ppm Parts Per Million
LNG Liquid Natural Gas psi Pounds Per Square Inch
LTA Low Temperature Aftercooling PTO Power Takeoff
mA Milli-Ampere PWM Pulse Width Modulator
mW Milli-Watts Rpm(RPM) Revolutions Per Minute
mm Millimeter SAE Society of Automotive Engineers
MIP Mixer Inlet Pressure SCA Supplemental Coolant Additive
Mpa Megapascal STC Step Timing Control
mph Miles Per Hour VS Variable Speed
mpq Miles Per Quart VSS Vehicle Speed Sensor
MPU Magnetic Pickup V Volts
N-m Newton-meter
NG Natural Gas
A Ampere ECS Emission Control System
AC Alternating Current EMC Electro-Magnetic Compatibility
AFC Air Fuel Control EMF Electro-Motive Force
API American Petroleum Institute EMI Electro-Magnetic Interference
AMPS Amperes EPA Environmental Protection Agency
ASA Air Signal Attenuator EPROM Erasable Programmable Read Only Memory
ASTM American Society of Testing and Materials EPS Engine Position Sensor
AWG American Wire Gage E-STOP Emergency Stop
O
B+ Battery Positive F Fahrenheit
O
C Celsius FSOV Fuel Shutoff Valve
CARB California Air Resources Board Ft (FT) Foot
C.I.D. Cubic Inch Displacement GND Ground
CNG Compressed Natural Gas GOEM G-Drive Original Equipment Manufacturer
COM Communication GVW Gross Vehicle Weight
CPL Control Part List HCT High Coolant Temperature
cSt Centistokes Hg Mercury
CTS Coolant Temperature Sensor Hp Horsepower
CW Clockwise H2O Water
CCW Counterclockwise Hz Hertz
DC Direct Current ICM Ignition Control Module
DSR Data Set Ready IP53 Ingress Protection – Dust-Protected & Spraying Water
DTR Data Terminal Ready IP54 Ingress Protection – Dust-Protected & Splashing Water
ECM Electronic Control Module In Inch
ECP Electronic Control Panel I/O Input / Output
lifting components that weigh 23 kg [50 lb.] or more. Make sure
To avoid burns, be alert for hot parts on product that have been
Do not perform any repair when fatigued or after consuming

Corrosion inhibitor and lubricating oil, contain alkali. Do not get
IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH
Disconnect the positive (+) & negative (-) cables of battery and
To prevent suffocation and frostbite, wear protective clothing and
the substance in your eyes. In case of contact, immediately flood
OF CHILDREN. Avoid prolonged or repeated contact with

positioned correctly. Always use a spreader bar when
To avoid personal injury, use a hoist or get assistance when
condition and are of the correct capacity. Make sure hooks are
ONLY disconnect fuel and liquid refrigerant (freon) lines in a
all lifting devices such as chains, hooks or slings are in good
understand how to use them before performing any service
replacing fasteners. Do not use a fastener of poor quality if

Always use tools that are in good condition. Make sure you
Always use the same fastener part number ( or equivalent) when

eyes with large amounts of water for a minimum of 15 minutes.
skin. Do not swallow internally. In case of contact, immediately

Page i-2
turned off, and hot fluids in lines, tubes, and compartments.
disconnect all electrical/electronic controls before welding.

necessary. The lifting hooks must not be side-loaded.
alcohol or drugs that can impair your functioning.

wash skin with soap and water.
replacements are necessary.

Section – I Introduction
work.
well.
•
•
N-m Newton-meter
NG Natural Gas

O
O





Page i-2



work.
well.
•
•
N-m Newton-meter
NG Natural Gas

O
O





Page i-2



work.
well.
•
•
Section - 0 Page 0
ENGINE DATA (N, V, K, QSK SERIES)
CONTENTS Page No.
Cummins Engine nomenclature .......................................................... 0-1

Engine Data Plate .............................................................................. 0-2
Fuel Pump Data Plate ........................................................................... 0-2
Engine Specification
Ratings Other than Genset & Fire Pump Applications ................. 0-3
Ratings of Fire Pump Engine Models by Respective rpm ........... 0-7
Rail Engine Specifications .......................................................... 0-9
Engine Firing Order .................................................................... 0-12
Air Intake System .................................................................... 0-13
Air Exhaust System .................................................................... 0-13
Blow by Limits and Measurements ............................................ 0-15
Cooling System ......................................................................... 0-20
Fuel System ............................................................................... 0-29
Lubricating Oil System .............................................................. 0-30
Recommended Battery Capacity for Cummins Engines ......... 0-30
Overhead Setting Adjustments .................................................. 0-31
Maintenance Schedule for Industrial Fire pump Engines ......... 0-40
Maintenance Schedule for Starter and Alternator ..................... 0-43
Component measure Limits ........................................................ 0-44
Important Clearance Values ........................................................ 0-47
Viscous Vibration Damper Specifications ................................. 0-48
Important Torque Values ............................................................. 0-49
Section – 0 Page 0-3
Engine Specifications
RATINGS OTHER THAN GENSET & FIRE PUMP APPLICATIONS
Displace- Peak R.P.M.
No. of Bore & Stroke Engine Maximum
Engine Model* ment C.I.D. R.P.M. Torque Peak
Cyl. Inch (mm) Breathing H.P.
(Liter) Ft. Lb. Torque
6BT-5.9 C 6 (102 X 120) (5.9) T 137 2000 532 1400
6BTA-5.9-C 6 (102 X 120) (5.9) T.A. 155 2150 662 1500
5 1/8 x 6 495
N-495-C 4 N. A 125 2000 387 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NT-495-C 4 T 180 2100 495 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NTA-495-C 4 T.A. 212 2100 583 1500
(130 X 152) (8.1)
5 1/8 X 6 743
N-743-C 6 N.A. 212 2100 583 1500
(130 X 152) (12.2)
5 1/8 X 6 743
NT-743-C 6 T 295 2100 811 1500
(130 X 152) (12.2)
5 1/8 X 6 743
N-743-T-C 6 T 240 2100 655 1500
(130 x 152) (12.2)
5 1/8 X 6 743
NTA-743-C 6 T.A. 335 2100 963 1500
(130 X 152) (12.2)
6CTA-8.3-C 6 (114 X 135) (8.3) T.A. 230 2000 990 1500
5½X6 855
NT-855-C 6 T 335 2100 921 1500
(140 X 152) (14.00)
ENGINE DATAPLATE FUEL PUMP DATA PLATE

(Prior to July, 1988)
The engine dataplate shows specific
information about the engine. The Engine Model Ê É Fuel Pump Serial Number
(1) Engine Serial Number (E.S.N.)
N 495 KCL 73363
identifies the original engine parts list
or major assembly parts. The engine GR. KA 361 S 1500
history and warranty data are recorded
using the E.S.N. (2) The Control Parts Type of Governor È Ç Engine Speed
List (CPL) identifies and helps in
locating the most current parts that Ç Fuel Pump Code Number
determine performance and emission st
standards for engine certification. The July 1 , 1988 onwards
CPL can be considered as a guide to
up-to-date a Cummins engine with the
latest technology and design
ÉFuel Pump Code Number
improvements. (3) Engine Model tells CPL Number Ê É Fuel Pump Serial Number
you the engine series, displacement
and application. X 113 KA 361 A 78363
BM 70486
Fuel Pump AR/BM È

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

The model name provides the following data
K T A 3067 - ____ Q S K 19 - C
= Application Code = Application Codes

no alphabets = Automotive C = Construction
= Displacement in (cubic inches)
Bl = Off Highway
= Aftercooled C = Construction = Displacement in Litres
or F = Fire Pump
= Turbocharged Litres G = Genset = Engine Series
= Series Equivalent L = Locomotive
(Family of engines) Cubic Inches Litres M = Marine = System
495 8 P = Power Unit
743 12 R = Railcar (Horizontal engine) = Quantum Family
855 14
1150 19
1710 28
2300 38
3067 50
6BT-5.9 C 6 (102 X 120) (5.9) T 137 2000 532 1400
6BTA-5.9-C 6 (102 X 120) (5.9) T.A. 155 2150 662 1500
5 1/8 x 6 495
N-495-C 4 N. A 125 2000 387 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NT-495-C 4 T 180 2100 495 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NTA-495-C 4 T.A. 212 2100 583 1500
(130 X 152) (8.1)
5 1/8 X 6 743
N-743-C 6 N.A. 212 2100 583 1500
(130 X 152) (12.2)
5 1/8 X 6 743
NT-743-C 6 T 295 2100 811 1500
(130 X 152) (12.2)
5 1/8 X 6 743
N-743-T-C 6 T 240 2100 655 1500
(130 x 152) (12.2)
5 1/8 X 6 743
NTA-743-C 6 T.A. 335 2100 963 1500
(130 X 152) (12.2)
6CTA-8.3-C 6 (114 X 135) (8.3) T.A. 230 2000 990 1500
5½X6 855
NT-855-C 6 T 335 2100 921 1500
(140 X 152) (14.00)

N 495 KCL 73363
BM 70486
Fuel Pump AR/BM È

Number

K T A 3067 - ____ Q S K 19 - C

Bl = Off Highway
or F = Fire Pump
855 14
1150 19
1710 28
2300 38
3067 50
6BT-5.9 C 6 (102 X 120) (5.9) T 137 2000 532 1400
6BTA-5.9-C 6 (102 X 120) (5.9) T.A. 155 2150 662 1500
5 1/8 x 6 495
N-495-C 4 N. A 125 2000 387 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NT-495-C 4 T 180 2100 495 1500
(130 X 152) (8.1)
5 1/8 X 6 495
NTA-495-C 4 T.A. 212 2100 583 1500
(130 X 152) (8.1)
5 1/8 X 6 743
N-743-C 6 N.A. 212 2100 583 1500
(130 X 152) (12.2)
5 1/8 X 6 743
NT-743-C 6 T 295 2100 811 1500
(130 X 152) (12.2)
5 1/8 X 6 743
N-743-T-C 6 T 240 2100 655 1500
(130 x 152) (12.2)
5 1/8 X 6 743
NTA-743-C 6 T.A. 335 2100 963 1500
(130 X 152) (12.2)
6CTA-8.3-C 6 (114 X 135) (8.3) T.A. 230 2000 990 1500
5½X6 855
NT-855-C 6 T 335 2100 921 1500
(140 X 152) (14.00)

N 495 KCL 73363
BM 70486
Fuel Pump AR/BM È

Number

K T A 3067 - ____ Q S K 19 - C

Bl = Off Highway
or F = Fire Pump
855 14
1150 19
1710 28
2300 38
3067 50
Displace- Peak
Engine Model ment C.I.D. R.P.M. Torque R.P.M.
(Liter) Ft. Lb.
NT-855-C240 5½X6 855
6 T 240 2100 693 1500
(Big Cam III) (140 X 152) (14.00)
NT-855-C295 (Big 5½X6 855

6 T 295 2100 880 1500
Cam III) (140 X 152) (14.00)
NT-855-C335 (Big 5½X6 855

6 T 335 2100 997 1400
Cam III) (140 X 152) (14.00)
NTA-855-C360 5½ X6 855
6 T.A. 360 2100 1076 1350
(Big Cam III) (140 X 152) (14.00)
NTA-855-C400 5½X6 855

6 T.A. 400 2100 1196 1400
(Big Cam Ill) (140 X 152) (14.00)
0 0
NA. - Naturally Aspirated NOTE : Above Performance Ratings are for 300 ft (90m) 77 F (25 C)
T - Turbocharged
T. A. - Turbocharged
Aftercooled.

Engine Model ment CID. R.P.M. Torque Peak
6¼ X6¼ 2300
KTA-38-C 12 T.A. 1200 2100 3300 1500
(159 X 159) (37.8)
6¼ X6¼ 3067
KTA-50-C 16 T.A. 1600 2100 4400 1500
(159 X 159) (50.3)
6¼ X6¼ 3067
KTA 3067-S-C 16 T.A. 1200 1500 - -
(159 X 159) (50.3)
6.25 X 7.48
QSK-60 16 60 T.A. 2700 2100 10625 1500
(159 X 190)
* Following are the Equivalent Engine Models (based on units of displacement in C.I.D or liters.)
KT/KTA 1150 ... KT/KTA 19 N.A. – Naturally Aspirated
V/VT/VTA171O ... V/VT/VTA 28 T -- Turbocharged
KT/KTA 2300 ... KT/KTA 38 T.A. – Turbocharged Aftercooled
KTA 3067 ... KTA 50
Section –0 Page 0-4

Engine Model ment CLD. R.P.M. Torque Peak
5½ X6 855
NTA-855-C 6 T.A. 400 2100 1150 1500
(140 X 152) (14.00)
6¼ X6¼ 1150
KT-1150-C 6 T 450 2100 1350 1500
(159 X159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 525 2100 1575 1500
(159X 159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 600 2100 1650 1500
(159 X 159) (18.9)
6¼X6¼ 1150
KTTA-19-C 6 T.A. 700 2100 2014 1400
(159 X 159) (18.9)
5½X6 1710
VTA-28-C 12 T.A. 900 2100 2200 1500
(140 X 152) (28.0)
6¼ X6¼ 2300
KT-2300-C 12 T 900 2100 2700 1500
(159 X 159) (37.8)
6¼ X6¼ 2300
KTA-38-C 12 T.A. 1050 2100 3020 1500
(159 X 159) (37.8)
Displace- Peak
(Liter) Ft. Lb.
NT-855-C240 5½X6 855
6 T 240 2100 693 1500
(Big Cam III) (140 X 152) (14.00)
NT-855-C295 (Big 5½X6 855

6 T 295 2100 880 1500
Cam III) (140 X 152) (14.00)
NT-855-C335 (Big 5½X6 855

6 T 335 2100 997 1400
Cam III) (140 X 152) (14.00)
NTA-855-C360 5½ X6 855
6 T.A. 360 2100 1076 1350
(Big Cam III) (140 X 152) (14.00)
NTA-855-C400 5½X6 855

6 T.A. 400 2100 1196 1400
(Big Cam Ill) (140 X 152) (14.00)
0 0
T - Turbocharged
Aftercooled.

6¼ X6¼ 2300
KTA-38-C 12 T.A. 1200 2100 3300 1500
(159 X 159) (37.8)
6¼ X6¼ 3067
KTA-50-C 16 T.A. 1600 2100 4400 1500
(159 X 159) (50.3)
6¼ X6¼ 3067
KTA 3067-S-C 16 T.A. 1200 1500 - -
(159 X 159) (50.3)
6.25 X 7.48
QSK-60 16 60 T.A. 2700 2100 10625 1500
(159 X 190)
KTA 3067 ... KTA 50

5½ X6 855
NTA-855-C 6 T.A. 400 2100 1150 1500
(140 X 152) (14.00)
6¼ X6¼ 1150
KT-1150-C 6 T 450 2100 1350 1500
(159 X159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 525 2100 1575 1500
(159X 159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 600 2100 1650 1500
(159 X 159) (18.9)
6¼X6¼ 1150
KTTA-19-C 6 T.A. 700 2100 2014 1400
(159 X 159) (18.9)
5½X6 1710
VTA-28-C 12 T.A. 900 2100 2200 1500
(140 X 152) (28.0)
6¼ X6¼ 2300
KT-2300-C 12 T 900 2100 2700 1500
(159 X 159) (37.8)
6¼ X6¼ 2300
KTA-38-C 12 T.A. 1050 2100 3020 1500
(159 X 159) (37.8)
Displace- Peak
(Liter) Ft. Lb.
NT-855-C240 5½X6 855
6 T 240 2100 693 1500
(Big Cam III) (140 X 152) (14.00)
NT-855-C295 (Big 5½X6 855

6 T 295 2100 880 1500
Cam III) (140 X 152) (14.00)
NT-855-C335 (Big 5½X6 855

6 T 335 2100 997 1400
Cam III) (140 X 152) (14.00)
NTA-855-C360 5½ X6 855
6 T.A. 360 2100 1076 1350
(Big Cam III) (140 X 152) (14.00)
NTA-855-C400 5½X6 855

6 T.A. 400 2100 1196 1400
(Big Cam Ill) (140 X 152) (14.00)
0 0
T - Turbocharged
Aftercooled.

6¼ X6¼ 2300
KTA-38-C 12 T.A. 1200 2100 3300 1500
(159 X 159) (37.8)
6¼ X6¼ 3067
KTA-50-C 16 T.A. 1600 2100 4400 1500
(159 X 159) (50.3)
6¼ X6¼ 3067
KTA 3067-S-C 16 T.A. 1200 1500 - -
(159 X 159) (50.3)
6.25 X 7.48
QSK-60 16 60 T.A. 2700 2100 10625 1500
(159 X 190)
KTA 3067 ... KTA 50

5½ X6 855
NTA-855-C 6 T.A. 400 2100 1150 1500
(140 X 152) (14.00)
6¼ X6¼ 1150
KT-1150-C 6 T 450 2100 1350 1500
(159 X159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 525 2100 1575 1500
(159X 159) (18.9)
6¼ X6¼ 1150
KTA-1150-C 6 T.A. 600 2100 1650 1500
(159 X 159) (18.9)
6¼X6¼ 1150
KTTA-19-C 6 T.A. 700 2100 2014 1400
(159 X 159) (18.9)
5½X6 1710
VTA-28-C 12 T.A. 900 2100 2200 1500
(140 X 152) (28.0)
6¼ X6¼ 2300
KT-2300-C 12 T 900 2100 2700 1500
(159 X 159) (37.8)
6¼ X6¼ 2300
KTA-38-C 12 T.A. 1050 2100 3020 1500
(159 X 159) (37.8)
Page 0-9
24 V/NC type
1450 Ft/Min
1750 RPM
55 Deg. C
95 Deg. C
POINT & CROSS
30 Sq. Ft.
120 litres
1050 Kg
UNIMAT COPM
BALLAST CLN.
7 PSI
SMR
APPLICATION
8-W OHE-CAR
TIE-TAMPING
DETC/DEMU
DHMU/ARTV
1
2
Roof Mounted Radiator (RMR) & Side Mounted Radiator (SMR)
RAIL STAB.
OHE-CAR
DEMU
24 V/NC type
1850 Ft/Min
2450 RPM
55 Deg. C
95 Deg. C
24 Sq. Ft.
RAIL ENGINE SPECIFICATIONS
1250 Kg
80 litres
7 PSI
RMR
Technical Specifications:
2
4
HP-RATING
473 @ 2100
473 @ 2100
473 @ 2100
400 @ 2100
705 @ 1800
705 @ 1800
520 @ 2100
1400@1500
345 @ 1900
285 @2100
RAIL APPLICATION
RAIL EQUIPMENT
Special Feature in DEMU Value Package:
Limiting Ambient Temperature

Maximum Water outlet temp.
Air Velocity across the core
Float Switch Specifications

Radiator core area (total)
Total weight of radiators
2X NTA-855-R
Total radiator capacity
Maximum Fan Speed

2X NT-855-R
VTA-1710-L
KTA1150-R
KTA1150-L
KTA1150-L
KTA1150-L
VTA1710-L
No of radiator fans
NTA855-L
KTA-50-L
System Pressure
MODEL
No of radiators
Description
(unchoked)
OEM/MAKE
Section – 0
PLASSER
PLASSER
PLASSER
PLASSER
PLASSER
ICF/BHEL
Sr.No.
BEML
BHEL
10
11
1
2
3
4
5
6
7
8
9
SAN
KPC
ENGINE MODEL R.P.M. 2100 200 1900 1600 1700 1600 1500
KT-1150-F H.P. 400 397 391 383 373 361 -
KT-1150-F1 H.P. - - - - 380
KTA-1150-F H.P. 534 526 512 495 465 450 -
KTA-1150-F1 H.P. - - - - 450
V-1710-F H.P. 415 413 407 396 382 364 342
VT-1710-F H.P. 548 532 515 499 479 458 -
VT-1710-F1 H.P. - - - - 530
VTA-1710-F H.P. 691 670 651 626 605 573 -
VTA-1710-F1 H.P. - - - - - 614
KT-2300-F H.P. 801 800 792 780 755 723 -
KT-2300-F1 H.P. - - - - - - 750
KTA-2300-F H.P. 1069 1047 1016 982 941 890 -
KTA-2300-F1 H.P. . - - - 890
KTA-3067-F H.P. 1425 1390 1356 1306 1254 1194 1150
KTA-3067-F1 H.P. - - - - - - 1180

RATINGS OF FIRE PUMP ENGINE MODELS PER RESPECTIVE RPM
Engine Model R.P.M. 2100 2000 1900 1800 1700 1600 1500
N-495-F H.P. - 107 104 103 101 96 92
NT-495-F H.P. 155 150 145 140 134 127 119
NT-495-F1 H.P. - - - - - - 127
NTA-495-F H.P. 183 179 173 166 159 151 143
NTA-495-F1 H.P. - - - - - - 173
N-743-F H.P. 182 179 174 168 161 153 144
N-743-TF H.P. 207 203 198 191 182 173 162
NT-743-F H.P. 255 250 244 237 229 219 207
NT-743-F1 H.P. - - - - - - 231
NTA-743-F H.P. 285 278 269 268 248 235 -
NTA-743-F1 H.P. - - - - - - 255
NT-855-F H.P. 289 284 283 267 256 244 -
NTA-855-F (FFC) H.P. 345 343 337 327 315 301 268
NTA-855-F1 H.P. - - - - - - 306
NTA-855-F2 H.P. 352 - - - - - -
Page 0-9
24 V/NC type
1450 Ft/Min
1750 RPM
55 Deg. C
95 Deg. C
POINT & CROSS
30 Sq. Ft.
120 litres
1050 Kg
UNIMAT COPM
BALLAST CLN.
7 PSI
SMR
APPLICATION
8-W OHE-CAR
TIE-TAMPING
DETC/DEMU
DHMU/ARTV
1
2
RAIL STAB.
OHE-CAR
DEMU
24 V/NC type
1850 Ft/Min
2450 RPM
55 Deg. C
95 Deg. C
24 Sq. Ft.
1250 Kg
80 litres
7 PSI
RMR
2
4
HP-RATING
473 @ 2100
473 @ 2100
473 @ 2100
400 @ 2100
705 @ 1800
705 @ 1800
520 @ 2100
1400@1500
345 @ 1900
285 @2100
RAIL APPLICATION
RAIL EQUIPMENT


2X NTA-855-R
Maximum Fan Speed

2X NT-855-R
VTA-1710-L
KTA1150-R
KTA1150-L
KTA1150-L
KTA1150-L
VTA1710-L
No of radiator fans
NTA855-L
KTA-50-L
System Pressure
MODEL
No of radiators
Description
(unchoked)
OEM/MAKE
Section – 0
PLASSER
PLASSER
PLASSER
PLASSER
PLASSER
ICF/BHEL
Sr.No.
BEML
BHEL
10
11
1
2
3
4
5
6
7
8
9
SAN
KPC
ENGINE MODEL R.P.M. 2100 200 1900 1600 1700 1600 1500
KT-1150-F H.P. 400 397 391 383 373 361 -
KT-1150-F1 H.P. - - - - 380
KTA-1150-F H.P. 534 526 512 495 465 450 -
KTA-1150-F1 H.P. - - - - 450
V-1710-F H.P. 415 413 407 396 382 364 342
VT-1710-F H.P. 548 532 515 499 479 458 -
VT-1710-F1 H.P. - - - - 530
VTA-1710-F H.P. 691 670 651 626 605 573 -
VTA-1710-F1 H.P. - - - - - 614
KT-2300-F H.P. 801 800 792 780 755 723 -
KT-2300-F1 H.P. - - - - - - 750
KTA-2300-F H.P. 1069 1047 1016 982 941 890 -
KTA-2300-F1 H.P. . - - - 890
KTA-3067-F H.P. 1425 1390 1356 1306 1254 1194 1150
KTA-3067-F1 H.P. - - - - - - 1180

Engine Model R.P.M. 2100 2000 1900 1800 1700 1600 1500
N-495-F H.P. - 107 104 103 101 96 92
NT-495-F H.P. 155 150 145 140 134 127 119
NT-495-F1 H.P. - - - - - - 127
NTA-495-F H.P. 183 179 173 166 159 151 143
NTA-495-F1 H.P. - - - - - - 173
N-743-F H.P. 182 179 174 168 161 153 144
N-743-TF H.P. 207 203 198 191 182 173 162
NT-743-F H.P. 255 250 244 237 229 219 207
NT-743-F1 H.P. - - - - - - 231
NTA-743-F H.P. 285 278 269 268 248 235 -
NTA-743-F1 H.P. - - - - - - 255
NT-855-F H.P. 289 284 283 267 256 244 -
NTA-855-F (FFC) H.P. 345 343 337 327 315 301 268
NTA-855-F1 H.P. - - - - - - 306
NTA-855-F2 H.P. 352 - - - - - -
Page 0-9
24 V/NC type
1450 Ft/Min
1750 RPM
55 Deg. C
95 Deg. C
POINT & CROSS
30 Sq. Ft.
120 litres
1050 Kg
UNIMAT COPM
BALLAST CLN.
7 PSI
SMR
APPLICATION
8-W OHE-CAR
TIE-TAMPING
DETC/DEMU
DHMU/ARTV
1
2
RAIL STAB.
OHE-CAR
DEMU
24 V/NC type
1850 Ft/Min
2450 RPM
55 Deg. C
95 Deg. C
24 Sq. Ft.
1250 Kg
80 litres
7 PSI
RMR
2
4
HP-RATING
473 @ 2100
473 @ 2100
473 @ 2100
400 @ 2100
705 @ 1800
705 @ 1800
520 @ 2100
1400@1500
345 @ 1900
285 @2100
RAIL APPLICATION
RAIL EQUIPMENT


2X NTA-855-R
Maximum Fan Speed

2X NT-855-R
VTA-1710-L
KTA1150-R
KTA1150-L
KTA1150-L
KTA1150-L
VTA1710-L
No of radiator fans
NTA855-L
KTA-50-L
System Pressure
MODEL
No of radiators
Description
(unchoked)
OEM/MAKE
Section – 0
PLASSER
PLASSER
PLASSER
PLASSER
PLASSER
ICF/BHEL
Sr.No.
BEML
BHEL
10
11
1
2
3
4
5
6
7
8
9
SAN
KPC

ENGINE MODEL R.P.M. 2100 200 1900 1600 1700 1600 1500
KT-1150-F H.P. 400 397 391 383 373 361 -
KT-1150-F1 H.P. - - - - 380
KTA-1150-F H.P. 534 526 512 495 465 450 -
KTA-1150-F1 H.P. - - - - 450
V-1710-F H.P. 415 413 407 396 382 364 342
VT-1710-F H.P. 548 532 515 499 479 458 -
VT-1710-F1 H.P. - - - - 530
VTA-1710-F H.P. 691 670 651 626 605 573 -
VTA-1710-F1 H.P. - - - - - 614
KT-2300-F H.P. 801 800 792 780 755 723 -
KT-2300-F1 H.P. - - - - - - 750
KTA-2300-F H.P. 1069 1047 1016 982 941 890 -
KTA-2300-F1 H.P. . - - - 890
KTA-3067-F H.P. 1425 1390 1356 1306 1254 1194 1150
KTA-3067-F1 H.P. - - - - - - 1180
Engine Model R.P.M. 2100 2000 1900 1800 1700 1600 1500
N-495-F H.P. - 107 104 103 101 96 92
NT-495-F H.P. 155 150 145 140 134 127 119
NT-495-F1 H.P. - - - - - - 127
NTA-495-F H.P. 183 179 173 166 159 151 143
NTA-495-F1 H.P. - - - - - - 173
N-743-F H.P. 182 179 174 168 161 153 144
N-743-TF H.P. 207 203 198 191 182 173 162
NT-743-F H.P. 255 250 244 237 229 219 207
NT-743-F1 H.P. - - - - - - 231
NTA-743-F H.P. 285 278 269 268 248 235 -
NTA-743-F1 H.P. - - - - - - 255
NT-855-F H.P. 289 284 283 267 256 244 -
NTA-855-F (FFC) H.P. 345 343 337 327 315 301 268
NTA-855-F1 H.P. - - - - - - 306
NTA-855-F2 H.P. 352 - - - - - -
Page 0-12
8R-8L-6R-6L-7R-7L-4R-5L 1 2 3 4 5 6 7 8 FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL
CYLINDER COUNTING
12345678
12345678
123456
123456
123456
123456
123456
ENGINE FIRING ORDER
1234
RB
1R-1L-3R-3L-7R-7L-5R-5L RB
K50/QSK60 1R-1L-3R-3L-2R-2L-5R-4L RB
RB
LB
LB
LB
LB
1 R-6L-5R-2L-3R-4L
1L-6R-2L-5R-4L-3R
6L-1R-5L-2R-3L-4R
6R-IL-2R-5L-4R-3L
FIRING ORDER
1-5-3-6-2-4
1-2-4-3
RB - Right Bank
NOTE: LB - Left Bank
K1150/19/QSK19
o
o
o
Bank angle 60
Bank angle 60
Bank angle 40
Bank angle 60
N 743/855/14
Section - 0
V1710/V28
K 2300/38/
N495 / N-8
MODEL
QSK45
K 3067

CONTD....
Sr.
Equipment Type DEMU(BHEL) DEMU(NGEF) DETC(BHEL)
No.
17. Lighting Generator Model KELA16122FM KELA16122FM KELA16122FM
18. Net Weight:
Tare Weight 60 Tons 60 Tons 64.9 Tons
Pay Load 9.49 Tons 9.49 Tons 1.06 Tons

19. Maximum Passengers : Seats Stand Seats Stand
DPC 79 79 79 79 N.A. N.A.

TC 108 216 108 216
DTC 108 216 108 216

RAIL EQUIPMENT SPECIFICATIONS
Sr.No. Equipment Type DEMU(BHEL) DEMU(NGEF) DETC(BHEL)
1. Manufacturer of Equipment ICF ICF ICF
2. Engine Make CIL CIL CIL
3. Engine Model VTA-1710-L VTA-1710-L VTA-1710-L
4. Transmission Diesel Electric Diesel Electric Diesel Electric
5. Brake Air Air Air
6. Cooling System Hydrostatic Fan Drives Hydrostatic Fan Drives Hydrostatic Fan Drives
7. Installed Power (as per UlC 623-OR) 705 @ 1800RPM 705 @ 1800RPM 705 @ 1800RPM
8. Net Input to Traction 630 HP 630 HP 610 HP
9. Traction Motor Make BHEL NGEF BHEL
10. Traction Motor Rating 167W 167 W
11. Max. cruising speed (Kmph) 110 110 100
12. Compressor Make ELGI ELGI ELGI
13. Compressor Model TRC 1000 TRC 1000 TRC 1000
14. Exhauster Make N.A. N.A. KPC
15. Exhauster Model N.A. N.A. KRE 30 B
16. Lighting Generator Make KEL KEL KEL
Page 0-12
FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL
CYLINDER COUNTING
12345678
12345678
123456
123456
123456
123456
123456
ENGINE FIRING ORDER
1234
RB
1R-1L-3R-3L-7R-7L-5R-5L RB
K50/QSK60 1R-1L-3R-3L-2R-2L-5R-4L RB
RB
LB
LB
LB
LB
1 R-6L-5R-2L-3R-4L
1L-6R-2L-5R-4L-3R
6L-1R-5L-2R-3L-4R
6R-IL-2R-5L-4R-3L
FIRING ORDER
1-5-3-6-2-4
1-2-4-3
RB - Right Bank
K1150/19/QSK19
o
o
o
Bank angle 60
Bank angle 60
Bank angle 40
Bank angle 60
N 743/855/14
Section - 0
V1710/V28
K 2300/38/
N495 / N-8
MODEL
QSK45
K 3067

CONTD....
Sr.
No.
18. Net Weight:

DPC 79 79 79 79 N.A. N.A.

TC 108 216 108 216
DTC 108 216 108 216

Page 0-12
FLYWHEEL
FLYWHEEL
FLYWHEEL
FLYWHEEL
CYLINDER COUNTING
12345678
12345678
123456
123456
123456
123456
123456
ENGINE FIRING ORDER
1234
RB
1R-1L-3R-3L-7R-7L-5R-5L RB
K50/QSK60 1R-1L-3R-3L-2R-2L-5R-4L RB
RB
LB
LB
LB
LB
1 R-6L-5R-2L-3R-4L
1L-6R-2L-5R-4L-3R
6L-1R-5L-2R-3L-4R
6R-IL-2R-5L-4R-3L
FIRING ORDER
1-5-3-6-2-4
1-2-4-3
RB - Right Bank
K1150/19/QSK19
o
o
o
Bank angle 60
Bank angle 60
Bank angle 40
Bank angle 60
N 743/855/14
Section - 0
V1710/V28
K 2300/38/
N495 / N-8
MODEL
QSK45
K 3067

CONTD....
Sr.
No.
18. Net Weight:
DPC 79 79 79 79 N.A. N.A.
TC 108 216 108 216
DTC 108 216 108 216
5.
4.
3.
2.
1.
General Instructions for Measurement of blow-by :

Normal Power cylinder wear results in a gradual increase in blow-by reading over time. Sudden increase in blow-by reading indicates other problem.
Section- 0
Section - 0 Page 0-13 Section - 0 Page 0-14
Engine Performance Check Parameters
variable load / speed applications, note down the maximum blow-by pressure reading for a complete load cycle.
remaining breathers. Remove the plugs after checking the reading.
the reading, remove the plugs from rocker housings to permit venting of crankcase.
While checking the blow-by, ensure that engine coolant & oil temperatures are stabilized and maximum load is applied to the engine. In case of
While checking blow-by on 6 cylinder engines fitted with more than one breathers, connect the blow-by tool to one of the breathers & plug
In case of Naturally Aspirated engines, remove rocker cover & plug the vent holes in rocker housings before checking blow-by After checking
Ensure that the correct blow-by tool for particular engine model is being used.
Sketches showing set up of blow-by tools on various engine models are illustrated in this bulletin.
AIR INTAKE SYSTEM b) Where it is impossible to locate the point of measurement in a
Maximum Allowable Intake Restriction (at rated speed and load) straight section, it is permissible to measure on the side of a bend
• With Clean Filter Element 380mm H2O [15 in H2O] where flow is uniform and equivalent to flow along the centreline. DO
• With Dirty Filter Element 635 mm H2O [25 in H2O] NOT MEASURE ON INSIDE OR OUTSIDE RADIUS OF BEND AS
FLOW IS NOT UNIFORM AT THESE POINTS.
Method of checking air Intake restriction
I) Naturally aspirated Engines. c) At the point selected, weld a 1/8 inch (3.17mm) diameter pipe
(a) Minimum 30” water manometer to be connected to the INTAKE coupling to the exhaust tubing. Drill through tubing with a 1/8 inch drill.
MANIFOLD adjacent to the mounting flange. Remove all burrs. Mount 90 degree Weatherhead fitting to coupling.
(b) Run the Engine at maximum speed and record the manometer
Then use 3 feet (0.91m) of 1/8 inch inside diameter copper tubing, plug
reading.
10 feet (3.05m) of 3/16 inch (4.76mm) inside diameter soft rubberhose
Note: to manometer. The manometer may be mercury filled or water filled.
(1) Mercury manometer cannot be sensitive enough for reading
accurately.
(2) lf an engine is equipped with air compressor, do not connect NOTE: It is important that line to manometer be as specified to
BLOW-BY LIMITS & MEASUREMENTS

manometer adjacent to the air compressor connection of the minimise variation in reading due to standing wave phenomenon which
manifold. occurs in manometer line. A change in length or material of this line
can significantly change reading obtained.
II) Turbocharged Engine
(a) Connect a 30” water manometer to the air inlet pipe to the
Turbocharger. d) Start engine and operate until oil temperature reaches 140 degrees
(b) The connection should be located in a straight section of air intake Farenheit (60 Degrees Centigrade).
pipe to avoid of possible dynamic effect of the air stream.
(c) Run the Engine at rated speed under full load and record the
manometer reading. e) Take backpressure readings when engine is developing its
maximum horsepower at maximum engine speed.
AIR EXHAUST SYSTEM.
The exhaust back pressure should not be more than 75 mm (3”) Hg for f) Note difference in mercury level in both columns.
engines except S-3.8, KTA-50-G8 and QSK-60. However for new
installation it should be below 63 mm (2.5”) Hg. For S-3.8, KTA-50-G8
& QSK-60 engines the limit is 51 mm (2”) Hg. and the recommendation
for new installation is 38 mm (1.5”) Hg.. It is recommended to use
‘Schedule B’ MS pipes & long bend elbows.
If number of bends are more than 4 or pipe length is more than 10
meters then contact OEM/Cummins.
(A) System Restrictions (Back Pressure)

a) When engine pistons act against a back pressure in exhaust
system to expel exhaust gases, usable output of the engine is
lowered.
b) High back pressures indicates restrictions caused by foreign

objects/excessive bends/small sizes of piping.
(B) Measuring Exhaust Back Pressure
Page 0-15
a) The point of measurement of exhaust back pressure must be as
close as possible to the exhaust manifold or turbocharger outlet flange
area of uniform flow such as a straight section of pipe at least one pipe
diameter from any changes in flow area or flow direction.
5.
4.
3.
2.
1.

Section- 0
reading.
accurately.

AIR EXHAUST SYSTEM.

lowered.

Page 0-15
5.
4.
3.
2.
1.
Section- 0
reading.
accurately.

AIR EXHAUST SYSTEM.




lowered.



Page 0-15

Page 0-18
(BLOW-BY TOOL P/N 38722566 - ORIFICE SIZE : 0.302”)

SET UP FOR V-12/V-28 ENGINES
BLOW-BY CHECKING :
Section - 0
Page 0-17
P/N 3822570 (ORIFICE SIZE : 0.354”)

P/N 3822571 (ORIFICE SIZE : 0.406”)
P/N 3822566 (ORIFICE SIZE : 0.302”)
TO GAUGE OR WATER MANOMETER
SET UP FOR C/NH/NT/K-6 ENGINES
BLOW-BY CHECKING :
BLOW-BY TOOL
BLOW-BY TOOLS :
KT/KTA-1150 :
:
:
Section - 0
C/NH/NT
KTTA

BLOW-BY LIMITS (IN INCHES OF H2O)
Engine Model Orifice Size Blow-by Limits (Inches of water)
New/Rebuild Used engine
N-495 0.302” 5 8
NT/NTC/NTA-495 0.302” 8 12
N-743/N-855 0.302” 8 12
NT/A-743 & NT/A-855 0.302” 12 18
V/VT/VTA-1710 0.302” 12 25
KT-1150:
1500-1900 RPM Rating 0.354” 5 16
2000 & above RPM Rating 0.354” 6 17
KTA-1150:
1500-1900 RPM Rating 0.354” 7 19
QSK 19 0.406” 5 13
KTTA-19 0.406” 5 12
KT/A-2300 0.406” 5 16
KTA-3067/KTA-50 0.406” 7 19
Page 0-18

BLOW-BY CHECKING :
Section - 0
Page 0-17
P/N 3822570 (ORIFICE SIZE : 0.354”)

P/N 3822571 (ORIFICE SIZE : 0.406”)
P/N 3822566 (ORIFICE SIZE : 0.302”)
BLOW-BY CHECKING :
BLOW-BY TOOL
BLOW-BY TOOLS :
KT/KTA-1150 :
:
:
Section - 0
C/NH/NT
KTTA
N-495 0.302” 5 8
NT/NTC/NTA-495 0.302” 8 12
N-743/N-855 0.302” 8 12
NT/A-743 & NT/A-855 0.302” 12 18
V/VT/VTA-1710 0.302” 12 25
KT-1150:
1500-1900 RPM Rating 0.354” 5 16
KTA-1150:
1500-1900 RPM Rating 0.354” 7 19
QSK 19 0.406” 5 13
KTTA-19 0.406” 5 12
KT/A-2300 0.406” 5 16
KTA-3067/KTA-50 0.406” 7 19
Page 0-18

BLOW-BY CHECKING :
Section - 0
Page 0-17
P/N 3822570 (ORIFICE SIZE : 0.354”)

P/N 3822571 (ORIFICE SIZE : 0.406”)
P/N 3822566 (ORIFICE SIZE : 0.302”)
BLOW-BY CHECKING :
BLOW-BY TOOL
BLOW-BY TOOLS :
KT/KTA-1150 :
:
:
Section - 0
C/NH/NT
KTTA
N-495 0.302” 5 8
NT/NTC/NTA-495 0.302” 8 12
N-743/N-855 0.302” 8 12
NT/A-743 & NT/A-855 0.302” 12 18
V/VT/VTA-1710 0.302” 12 25
KT-1150:
1500-1900 RPM Rating 0.354” 5 16
KTA-1150:
1500-1900 RPM Rating 0.354” 7 19
QSK 19 0.406” 5 13
KTTA-19 0.406” 5 12
KT/A-2300 0.406” 5 16
KTA-3067/KTA-50 0.406” 7 19
Section - 0 Page 0-19 Section – 0 Page 0-20 Section - 0 Page 0-21
COOLING SYSTEM
CORROSION INHIBITOR
BLOW-BY CHECKING : ENGINE COOLANT PROPERTIES
SET UP FOR KV-12/KV-16/KTA-50 ENGINES Minimum Allowable Pressure cap 50 kPa [7 psi] A. Coolant Additive Concentrate
0 0 0 0
(BLOW-BY TOOL P/N 3822571 - ORIFICE SIZE : 0.406”) Coolant Operating Range 167 F (75 C) to 203 F (95 C) Part Number Description Qty.
Raw Water Recommendations 3167214 Coolant Additive Concentrate 0.5 It.
Use distilled, deionised or equivalent clean water. If distilled or 3167215 Coolant Additive Concentrate 1 lt.
deionised water cannot be used, the quality of water must meet 3167216 Coolant Additive Concentrate 2 It.
requirements listed below. 3167217 Coolant Additive Concentrate 5 It.
Parameter Limits Effects Coolant Additive Concentrate
3167218 10 It.
PH 5–9 Higher levels will Coolant Additive Concentrate
3167219 20 It.
corrode aluminium,
lead & promote scaling. It is supplied in plastic red colour containers having different part nos.
Calcium/ Less than 170 PPM Excessive hardness for different volumes. The colour of the coolant additive concentrate
Magnesium (as CaCO3+Mg C03) will cause scaling is deep purple.
hardness problems
Chlorides Less than 40 PPM Excessive levels of B. Premixed Coolant
(as Cl). chloride / sulphates It is supplied in plastic white colour containers having different part
Sulfates Less than 100 PPM cause corrosion of nos. for different volume. The colour of the coolant is pink.
cooling system
components. Part Number Description Qty.
TDS (Total Less than 400 PPM High TDS increases 3167221 Premixed Coolant 5 It.
Dissolved conductivity of water 3167222 Premixed Coolant 10 It.
Solids) and accelerates
3167223 Premixed Coolant 20 It.
corrosion
Raw water meeting above specifications can be mixed with Cummins
Corrosion resistor/ coolant additive, which can effectively safeguard
the engine against scaling and corrosion. C. Test Strip
Test stirp are required to check inhibitor concentration. These are
SPECIFICATIONS FOR TREATED COOLANT packed individually in a foil pack.
Parameter Limits Effects Part Number Description

3167225 Test Strip
pH 8.5 to 10 Higher levels will
3167226 Test Kit
corrode aluminium
lead & promote scaling
Important Note :
Chromate 3500 to 5000 PPM Lower concentration Shelf life for Coolant Additive Concentrate & Premixed Coolant
levels will corrode is 5 years & that of test strip/kit. is 18 months.
cooling system
components & higher
concentrations will form 4. Coolant Checking -
sludge, blocking of In normal operating condition with system maintained as per above,
coolant passages & the COOLANT will be maintained to the required specifications & no
water pump seal leaks checking is required. However coolant checking is suggested as
OR audit check or to take care of non use of recommendations for
service treatment and top up at 1500hrs/6 months.
New Coolant 0.6 to 1.0 units/ltr. Similar effects as above
Checking is also suggested at the following events,
Additive
concentrate - At the time of commissioning the engine,
- When coolant is totally replaced / excessive coolant loss occurs
Water Temperature - When concentration levels are unknown / doubtful.
Keep thermostats always in the engine, avoid long periods of idling, Coolant checking is very easy with the use of ‘TEST STRIP’.
and take necessary steps to keep water temperature up to a minimum
0 0
of 167 F (75 C). ‘TEST KIT’, is designed and supplied with the engine to facilitate
Check Thermostats and Seals coolant checking.
Remove the thermostats from the thermostat housings and check for Following two coolant properties need checking.
proper opening and closing temperature. Most Cummins Engines are a. Concentrating
0 0 0 0 0
equipped with either medium 170 to 185 F (77 to 85 C) or low 160 to This can be checked by ‘TEST KIT’.
0 0 0 0 0
175 F (71 to 79 C) and in a few cases high-range 180 to 195 F
0 0
(82 to 91 C) thermostats, depending on engine application.
COOLING SYSTEM
CORROSION INHIBITOR
0 0 0 0
3167218 10 It.
3167219 20 It.
corrode aluminium,
hardness problems
cooling system
corrosion

3167225 Test Strip
3167226 Test Kit
corrode aluminium
Important Note :
cooling system
components & higher
Additive
0 0
0 0 0 0 0
0 0 0 0 0
0 0
COOLING SYSTEM
CORROSION INHIBITOR
0 0 0 0
3167218 10 It.
3167219 20 It.
corrode aluminium,
hardness problems
cooling system
corrosion

3167225 Test Strip
3167226 Test Kit
corrode aluminium
Important Note :
cooling system
components & higher
Additive
0 0
0 0 0 0 0
0 0 0 0 0
0 0
Section-0
Section - 0 Page 0-22 Section –0 Page 0-23
ANNEXURE
Method
CONTROLLER & REPEAT THE PROCEDURE

PPM IS BELOW 3500. ADD PPM
GREEN/COLOURLESS
a. Remove the top tank cap of radiator/heat exchanger, use Requirements of COOLANT ADDITIVE CONCENTRATE
STEP4-ADD AMPOULE-C
GREEN/COLOURLESS
dropper or open vent cocks in the cooling system & collect
coolant sample in the beaker. System Present Genset Precharge - ‘B’ check
STEP3-ADD AMPOULE-B
b. Allow the coolant temperature to reach room temperature.
STEP BY STEP PROCEDURE FOR CHECKING CHROMATE CONCENTRATION USING COOLANT CHECKING KIT
Capacity Engine Model (first fill) requirement
GREEN/COLOURLESS
c. Remove ‘TEST STRIP’ from the pack. Dip the pad on the (it.) requirements (lt.)*
strip in coolant for 3 seconds. (lt.)*
d. Remove strip & shake briskly to remove excess coolant.
40-60 495-H/E & Radiator 4(2 + 2) 0.5
e. Wait for 45 seconds. Compare the colour of the pad with
the colour chart within next 30 seconds. 61-80 743-H/E & Radiator 5 1
f. Take action as shown in the colour chart. 855-H/E cooled
81-120 855 Rad-Cooled 7(5+2) 1
Following action is required after checking COOLANT & K6 Red / H/E
ADDITIVE CONCENTRATE concentration 121-175 No genset model at 10 1.5(1 + 0.5)
Below 0.4 units/It Add precharge quantity. i.e. quantity of present
ENGINES FITTED WITH CORROSION RESISTOR FILTERS

COOLANT ADDITIVE CONCENTRATE 176-225 1710-H/E 15(10 + 5) 2
STEP 1 -TAKE 25 ML. COOLANT IN BEAKER (YELLOW)

liquid as required for initial commissioning. 226-300 V1710-Radiator 20 3(2 + 1)
Below 0.4 to 0.6 units/It. Continue adding COOLANT ADDITIVE KV12 & 16/
STEP 2- ADD AMPOULE-A TO THE COOLANT

CONCENTRATE as per service 1 MW-H/E
treatment chart at B check. 301-400 KV12 & 16 Radiator 25(20 + 5) 4(2 + 2)
Above 0.6 units/It. OK, No action required. Cooled
401-500 1MW — Radiator 30(20 + 10) 5
b. pH of coolant Cooled
PROCEDURE
DILUTE COOLANT & REPEAT THE
PPM IS IN BETWEEN 5000 & 10,000
No special checking kit is required for this property. Special indicator
has bean added In the new corrosion inhibitor whose colour changes * Figures in bracket indicate combination of can sizes.
with pH. This is only visual check. When colour of the coolant is pink
the pH is within limit.(8.5 to 10.0 pH)
If colour of corrosion inhibitor is colourless then it indicates, Gross

undertreatment — Add precharge quantity, i.e. quantity of COOLANT
PINK
ADDITIVE CONCENTRATE liquid as required for initial
NO FURTHER ACTION IS REQUIRED

PPM IS IN BETWEEN 3500 & 5000
commissioning.
Conversion of field engines:

Chromate and new liquid corrosion inhibitor are compatible. If engines
having corrosion resistor are to be converted, use following method.

OF ITS CONCENTRATION.
DILUTE COOLANT TO 1/3
PPM IS ABOVE 10000.
Cummins India Ltd. encourages field conversions.
1. Drain coolant and remove corrosion resistor housing.
PINK
2. Disconnect and remove corrosion connections. Plug the
connections in block/water pump inlet.(Use following plugs as
required, 1/4” NPTF-S910B, 1/2” NPTF-S915A, 3/4” NPTF-S995
YELLOW
and 1” NPTF-S962).
3. Flush the coolant system with plain water twice to remove
chromate from cooling system. This is required as chromate has
yellow colour & new coolant has pink colour.
4. Precharge and maintain the coolant system as per instructions in
operation and maintenance manual.
Page 0-24
Section-0
ANNEXURE
Method

GREEN/COLOURLESS
STEP4-ADD AMPOULE-C
GREEN/COLOURLESS
STEP3-ADD AMPOULE-B
b. Allow the coolant temperature to reach room temperature.
Capacity Engine Model (first fill) requirement
GREEN/COLOURLESS
40-60 495-H/E & Radiator 4(2 + 2) 0.5
f. Take action as shown in the colour chart. 855-H/E cooled
81-120 855 Rad-Cooled 7(5+2) 1



401-500 1MW — Radiator 30(20 + 10) 5
PROCEDURE

PINK

commissioning.


PPM IS ABOVE 10000.
PINK
YELLOW
Page 0-24
ANNEXURE
Method
Section-0
b. Allow the coolant temperature to reach room temperature. Capacity Engine Model (first fill) requirement
40-60 495-H/E & Radiator 4(2 + 2) 0.5
GREEN/COLOURLESS
855-H/E cooled
GREEN/COLOURLESS
f. Take action as shown in the colour chart.
STEP4-ADD AMPOULE-C
81-120 855 Rad-Cooled 7(5+2) 1
GREEN/COLOURLESS

STEP3-ADD AMPOULE-B


401-500 1MW — Radiator 30(20 + 10) 5
PROCEDURE

PINK
commissioning.




PINK


PPM IS ABOVE 10000.
YELLOW



Page 0-24
Section - 0 Page 0-26
Coolant Recommendations and Specifications-SCA
WF2077
WF2076
WF2075
WF2074
WF2073
WF2072
WF2071
WF2070
Part No.
Part No.
Section –0
Section- 0
DCA80L
DCA75L
DCA70L
DCA65L
DCA60L
Notes:
0-16000
Kilometers
A. Consult the equipment manufacturer’s maintenance information
16001-24000
24001-32000
32001-40000
40001-48000
48001-56000
56001-64000
64001-72000
72001-80000
208
18.9
3.78
1.89
0.47
for total cooling system capacity.
B. When draining and replacing the Coolant, always pre-charge the
Cooling system to a SCA level of 1.5 units per gallon. This
Size
concentration level Must never be allowed to go below 1.2 units and
Service Interval
must be controlled when the level is greater than 3 units. Action
[2 U.S. qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[50 U.S. gal]

needed when the level goes below 1.2 is a filter and liquid pre-charge;
from 1.2 to 3.0 units, filter only; above 3.0, test at every oil change until
[Miles]
DCA4 Service Filters:

level falls to 3.0 or below.
[0-10000]
DCA4 liquid
8
6
4
2
[10001-15000]
[20001-25000]
[25001-30000]
[30001-35000]
[35001-40000]
[40001-45000]
[45001-50000]
[15001-20000]
23
15
12
SCA Units
NOTE : When performing service which requires draining the cooling
40
20
system, take special precautions to collect it in a clean container, seal
200
2200
it to prevent contamination, and save for reuse.
SCA Units
(blank filter without SCAs)
C. Change coolant filters at each oil change to protect the cooling
Fleetguard® DCA4 Service Filters and Liquid Precharge

system. Consult the coolant capacity chart to determine the correct
0-250
coolant filter for a given cooling system capacity and oil drain interval.
[Hours]
251-375
376-500
501-625
626-750
751-875
876-1000
1001-1125
1126-1250
Supplemental Coolant Additive (SCA)
DCA45L
DCA40L
DCA50L
DCA35L
DCA30L
Part No.
Fully formulated products contain SCAs and are required to protect the
WF2055
WF2054
WF2053
WF2052
WF2051
WF2077
WF2050
Part No.
cooling system from fouling, solder blooming, and general corrosion.
The coolant filter is required to protect the cooling system from
2
2
2
2
4
4
4
4
8
Maintenance Interval
Not Available
abrasive materials, debris, and precipitated coolant additives.
4-19
[1-5]
Supplemental coolant additives, or equivalent, are used to prevent liner
208
18.9
3.78
1.89
0.47
ENGINES FITTED WITH DCA FILTERS
pitting, corrosion, and scale deposits in the cooling system.
2
4
4
6
6
6
8
12
12
Size
Use the correct Fleetguard® coolant filter to maintain the
[6-10]
19-38
recommended SCA Concentration in the system.
[2 U.S qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[55 U.S. gal]

Maintain the correct concentration by changing the service filter at
4
6
6
8
each oil drain interval.

10
12
12
15
23
Maintenance Intervals for Cooling Systems up to 76 Liters [20 U.S. Gallons]
42-57
[11-15]
System Size in Liters [U.S. Gallons]
8
6
4
2
Note : The correct filter is determined by the total cooling system
23
15
12
40
DCA (Fleetcool) liquid
20
capacity and oil drain interval. Refer to the coolant Capacity Charts.
200
DCA (Fleetcool) Service Filters:
2200
SCA Units
SCA Units
The SCA concentration must not fall below 1.2 units or exceed 3 units
6
8
12
15
18
20
23
26
30
per gallon of cooling system capacity.

60-76

[16-20]
Install service filter(s) and/or liquid containing number of SCA units below
Page 0-27
Page 0-25
WF2077
WF2076
WF2075
WF2074
WF2073
WF2072
WF2071
WF2070
Part No.
Part No.
Section –0
Section- 0
DCA80L
DCA75L
DCA70L
DCA65L
DCA60L
Notes:
0-16000
Kilometers
16001-24000
24001-32000
32001-40000
40001-48000
48001-56000
56001-64000
64001-72000
72001-80000
208
18.9
3.78
1.89
0.47
Size
Service Interval
[2 U.S. qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[50 U.S. gal]

[Miles]

[0-10000]
DCA4 liquid
8
6
4
2
[10001-15000]
[20001-25000]
[25001-30000]
[30001-35000]
[35001-40000]
[40001-45000]
[45001-50000]
[15001-20000]
23
15
12
SCA Units
40
20
200
2200
SCA Units

0-250
[Hours]
251-375
376-500
501-625
626-750
751-875
876-1000
1001-1125
1126-1250
DCA45L
DCA40L
DCA50L
DCA35L
DCA30L
Part No.
WF2055
WF2054
WF2053
WF2052
WF2051
WF2077
WF2050
Part No.
2
2
2
2
4
4
4
4
8
Not Available
4-19
[1-5]
208
18.9
3.78
1.89
0.47
2
4
4
6
6
6
8
12
12
Size
[6-10]
19-38
[2 U.S qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[55 U.S. gal]

4
6
6
8

10
12
12
15
23
42-57
[11-15]
8
6
4
2
23
15
12
40
20
200
2200
SCA Units
SCA Units
6
8
12
15
18
20
23
26
30

60-76

[16-20]
Page 0-27
Page 0-25
Section - 0
Section –0
Page 0-26
Part No.
WF2077
WF2076
WF2075
WF2074
WF2073
WF2072
WF2071
WF2070
Part No.
Section- 0
DCA80L
DCA75L
DCA70L
DCA65L
DCA60L
16001-24000
24001-32000
32001-40000
40001-48000
48001-56000
56001-64000
64001-72000
72001-80000
Kilometers
0-16000
Notes:
Service Interval
208
18.9
3.78
1.89
0.47

[5 U.S. gal]
[1 U.S. gal]
[2 U.S. qt.]
[1 U.S. pt.]

[50 U.S. gal]
Size


[10001-15000]
[20001-25000]
[25001-30000]
[30001-35000]
[35001-40000]
[40001-45000]
[45001-50000]
[15001-20000]
DCA4 liquid
[Miles]
[0-10000]
SCA Units
23
15
12
8
6
4
2
SCA Units

200
40
2200
20

5

[Hours]
0-250
251-375
376-500
501-625
626-750
751-875
876-1000
1001-1125
1126-1250
Maintenance Interval system. Consult the coolant capacity chart to determine the correct
DCA50L
DCA45L
DCA40L
DCA35L
DCA30L
Part No.

WF2077
WF2055
WF2054
Not Available
WF2053
WF2052
WF2051
WF2050
Part No.

[1-5]
4-19
2
2
2
2
4
4
4
4
8
18.9
3.78
208
1.89
0.47

[5 U.S. gal]
[1 U.S. gal]
[2 U.S qt.]
[1 U.S. pt.]
[55 U.S. gal]
Size
[6-10]
19-38
2
4
4
6
6
6
8
12
12
[11-15]
42-57
4
6
6
8
10
12
12
15
23
SCA Units
SCA Units

23
15
12
8
6
4
2
200
40
20
2200
[16-20]
60-76
6
8
12
15
18
20
23
26
30
Page 0-27
Page 0-25
WF2077
WF2076
WF2075
WF2074
WF2073
WF2072
WF2071
WF2070
Part No.
Part No.
Section –0
Section- 0
DCA80L
DCA75L
DCA70L
DCA65L
DCA60L
Notes:
0-16000
Kilometers
16001-24000
24001-32000
32001-40000
40001-48000
48001-56000
56001-64000
64001-72000
72001-80000
208
18.9
3.78
1.89
0.47
Size
Service Interval
[2 U.S. qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[50 U.S. gal]

[Miles]

[0-10000]
DCA4 liquid
8
6
4
2
[10001-15000]
[20001-25000]
[25001-30000]
[30001-35000]
[35001-40000]
[40001-45000]
[45001-50000]
[15001-20000]
23
15
12
SCA Units
40
20
200
2200
SCA Units

0-250
[Hours]
251-375
376-500
501-625
626-750
751-875
876-1000
1001-1125
1126-1250
DCA45L
DCA40L
DCA50L
DCA35L
DCA30L
Part No.
WF2055
WF2054
WF2053
WF2052
WF2051
WF2077
WF2050
Part No.
2
2
2
2
4
4
4
4
8
Not Available
4-19
[1-5]
208
18.9
3.78
1.89
0.47
2
4
4
6
6
6
8
12
12
Size
[6-10]
19-38
[2 U.S qt.]
[1 U.S. pt.]
[5 U.S. gal]
[1 U.S. gal]
[55 U.S. gal]

4
6
6
8

10
12
12
15
23
42-57
[11-15]
8
6
4
2
23
15
12
40
20
200
2200
SCA Units
SCA Units
6
8
12
15
18
20
23
26
30

60-76

[16-20]
Page 0-27
Page 0-25
Section - 0 Page 0-29 Section – 0 Page 0-30
FUEL SYSTEM LUBRICATING OIL SYSTEM
Hours
Interval
0 0
Section- 0
Service
Fuel Inlet Maximum Restriction
0-250
251-500
501-750
• Typical Engine Oil Pressure [with 15W-40 Oil at 221 F (105 C)]
751-1000
2
• Clean Fuel Filter 100 mm Hg [4.0 in-Hg] • At idle (Minimum Allowable) 1 to 2 kg/cm
2
• Choked Fuel Filter 203 mm Hg [8.0 in-Hg] • At Rated speed 3 to 7 kg/cm
Shutoff Valve Solenoid Coil Resistance
Engines Provided With Demand Flow Cooling System {DFC}
10
15
20
25
on Ohms 24 VDC 28 to 32 Ohms 0 0
[with 15W-40 Oil at 221 F (105 C)]
[21-30]
79-144
Fuel supply & return line restriction for PT fuel system is max. 100 mm 2
• At idle (Minimum Allowable) 0.7kg/cm
Hg. For AME Critical Start engines, minimum 0.45 m (18”) of gravity 2
• At Rated speed 2.4 to 3.1 kg/cm
fuel feed needs to be provided to fuel pump at inlet connection.
System Size in Liters [US. Gallons]
15
25
35
50
Fuel Tank Design Requirements/Location DFC SYSTEM REGULATES OIL FLOW AND OIL COOLING ONLY
[31-50]
117-189
ON DEMAND, RATHER than continuously at maximum capacity.
• Size to suit atleast one shift operation or maximum 990 ltrs. 0 0 0 0
Oil Temperature Range 167 F (75 C) to 221 F (105 C)
(Material MS for fuel tank and piping)
0 0
• Drain fittings to bleed water condensate at lowest point of tank. Under full load conditions, an oil temperature of 240 F (116 C) for a
20
40
80
60
short.
[51-75]
• Fill neck to be provided to allow min. 5% expansion space.
193-284
Engine oil pressure must be indicated on the gauge within 15
• Breather is mandatory. seconds after starting. If oil pressure is not registered within 15
seconds, shut off the engine immediately to avoid engine damage.
• Use pipe sealant loctite type 577 for all connections, for sealing. Confirm the correct oil level in the oil pan.
50
75
25
100
No teflon tape to be used.
288-378
[76-100]
• Suction Line and return line to be separated by at least 300 mm. RECOMMENDED BATTERY CAPACITY
• Galvanizing not recommended, inside fuel tank. FOR CUMMINS ENGINES.
Battery 2
• Hand hole, Wire mesh filter screen at filling point. Model Cable Size mm
75
110
40
150
Capacity AH
Install service filter(s) and/or liquid containing number of SCA units below :
• Fuel return line should on top of fuel level for PT fuel system. For S-3.8 120 50
S/B engines with high Pressure fuel system fuel return should be B-5.9/495 150 50
dipped in fuel. N8/885 180 50
K19 180 70
50
200
100
150
70
382-568 572-757
V28 180
[101-150] [151-200]
KV & above 360 70
FUEL SYSTEM FUEL TANK LOCATION
NOTE : The number of plates within a given battery size determines
The objectives in locating a fuel tank are to make sure that the
reserve capacity. Reserve capacity is the length of time sustained
supply and return restrictions are within the limitations and at the
65
250
125
190
cranking can occur.
761-946
same time to avoid hydraulic lock after the engine shut down.
[201-250]
Battery Specifications :
A) When the tank can be located 8 to 20 inches below the fuel return
The Batteries listed in table are the minimum capacity which must
connection, the method meets the above requirements. In case of
fuel tank mounted above engine fuel connections special be provided to crank the engines at the minimum engine
temperatures expected. Battery capacities are given in cold
75
300
150
225
arrangements are required.
cranking amperes and for reference in ampere-hours. Minimum
Maintenance intervals for Cooling System up to 1514 Liters [400 US. Gallons]
950-1135
[251-300]
1) In case of fuel return line connection is less than 8 feet above the
engine fuel connections, then use of one check valve (P/No. battery capacities based on engines with no externally connected
178079) is recommended in injector line. And the other check parasitic loads.
valve (P/No. 185505) is fitted at the fuel pump outlet to prevent
90
350
175
260
hydraulic lock due to gravity flow when engine is shut down. Battery (Specific Gravity)
o o
[301-350]
2) In case return line cannot be restricted to less than 8 feet a float
1139-1325
Battery State of Charge Specific Gravity @ 27 C[80 F]
tank arrangement should be provided. 100% 1.260-1.280
B) In case of fuel tank below the fuel pump care should be taken to 75% 1.230-1.250
keep a tank outlet connection not more than six feet from pump
50% 1.220-1.220
100
200
300
400
inlet pipe. If this cannot be maintained it will be necessary to
25% 1.170-1.190
[351-400]
employ a transfer pump and an auxiliary tank.
1329-1574
Discharged 1.110-1.130
Page 0-28

Section- 0
Interval
251-500
501-750
751-1000
Service
Hours
FUEL SYSTEM
0-250
LUBRICATING OIL SYSTEM
Fuel Inlet Maximum Restriction • Typical Engine Oil Pressure [with 15W-40 Oil at 221 F (105 C)]
0 0
2
• Choked Fuel Filter • At Rated speed

2
203 mm Hg [8.0 in-Hg] 3 to 7 kg/cm
[21-30]
79-144
10
15
20
25
[with 15W-40 Oil at 221 F (105 C)]
Fuel supply & return line restriction for PT fuel system is max. 100 mm • At idle (Minimum Allowable) 0.7kg/cm
2
Hg. For AME Critical Start engines, minimum 0.45 m (18”) of gravity • At Rated speed 2.4 to 3.1 kg/cm
2
[31-50]
117-189
15
25
35
50
• Size to suit atleast one shift operation or maximum 990 ltrs. Oil Temperature Range
0 0 0 0
167 F (75 C) to 221 F (105 C)
193-284
[51-75]
0 0
20
40
80
60
short.
• Fill neck to be provided to allow min. 5% expansion space. Engine oil pressure must be indicated on the gauge within 15
288-378
[76-100]
• Use pipe sealant loctite type 577 for all connections, for sealing.
100
Confirm the correct oil level in the oil pan.

50
75
25

382-568 572-757
[101-150] [151-200]
Battery
110
150
2
75
40
Capacity AH
200
100
150
70
50
K19 180
V28 180 70
KV & above 360 70
761-946
[201-250]
250

125
190
65
same time to avoid hydraulic lock after the engine shut down. cranking can occur.
950-1135
[251-300]
300
150
225
75
arrangements are required. temperatures expected. Battery capacities are given in cold
parasitic loads.
1139-1325
[301-350]
178079) is recommended in injector line. And the other check

350
175
260

90
o o
2) In case return line cannot be restricted to less than 8 feet a float Battery State of Charge Specific Gravity @ 27 C[80 F]
1329-1574
B) In case of fuel tank below the fuel pump care should be taken to
[351-400]
75% 1.230-1.250
100
200
300
400
50% 1.220-1.220
Page 0-28

employ a transfer pump and an auxiliary tank. 25% 1.170-1.190

Section- 0
Interval
251-500
501-750
751-1000
Service
Hours
FUEL SYSTEM
0-250
LUBRICATING OIL SYSTEM
Fuel Inlet Maximum Restriction • Typical Engine Oil Pressure [with 15W-40 Oil at 221 F (105 C)]
0 0
2
• Choked Fuel Filter • At Rated speed

2
203 mm Hg [8.0 in-Hg] 3 to 7 kg/cm
[21-30]
79-144
10
15
20
25
[with 15W-40 Oil at 221 F (105 C)]
Fuel supply & return line restriction for PT fuel system is max. 100 mm • At idle (Minimum Allowable) 0.7kg/cm
2
Hg. For AME Critical Start engines, minimum 0.45 m (18”) of gravity • At Rated speed 2.4 to 3.1 kg/cm
2
[31-50]
117-189
15
25
35
50
• Size to suit atleast one shift operation or maximum 990 ltrs. Oil Temperature Range
0 0 0 0
167 F (75 C) to 221 F (105 C)
193-284
[51-75]
0 0
20
40
80
60
short.
• Fill neck to be provided to allow min. 5% expansion space. Engine oil pressure must be indicated on the gauge within 15
288-378
[76-100]
• Use pipe sealant loctite type 577 for all connections, for sealing.
100
Confirm the correct oil level in the oil pan.

50
75
25

382-568 572-757
[101-150] [151-200]
Battery
110
150
2
75
40
Capacity AH
200
100
150
70
50
K19 180
V28 180 70
KV & above 360 70
761-946
[201-250]
250

125
190
65
same time to avoid hydraulic lock after the engine shut down. cranking can occur.
950-1135
[251-300]
300
150
225
75
arrangements are required. temperatures expected. Battery capacities are given in cold
parasitic loads.
1139-1325
[301-350]
178079) is recommended in injector line. And the other check

350
175
260

90
o o
2) In case return line cannot be restricted to less than 8 feet a float Battery State of Charge Specific Gravity @ 27 C[80 F]
1329-1574
B) In case of fuel tank below the fuel pump care should be taken to
[351-400]
75% 1.230-1.250
100
200
300
400
50% 1.220-1.220
Page 0-28

employ a transfer pump and an auxiliary tank. 25% 1.170-1.190
Section - 0 Page 0-31 Section - 0 Page 0-32 Section –0 Page 0-33
OVERHEAD SETTING ADJUSTMENTS VALUES -
VALUES -
Temperature Settings
Cold setting : The engine must have reached a stabilized oil temperature Cold setting Cold Setting
0 0
of 140 F (60 C) or below Injector Plunger Intake Exhaust Injector Plunger Travel Intake Valve Exhaust Valve
It is recommended that valve and injector plunger adjustments be made travel inch (mm) Valve Valve Inch (mm) Inch Inch
when engine is cold. Inch (mm) Inch (mm)
Adj. Recheck Adj. Recheck
NOTE / CAUTION Value Limit Value Limit
1. Outer Base Circle procedure, is MANDATORY for engines fitted with Aluminium 0.170 0.169 to 0.171 0.011 0.023 Aluminium 0.170 0.169 to 0.171 0.011 0.023
STC or HVT injectors. Rocker housing (4.32) (4.29 to 4.34) (0.28) (0.58) Rocker housing (4.32) (4.29 to 4.34) (0.28) (0.58)
2. Before doing STC Injector Setting drain the lube oil from Injectors &
manifold by idle running the engine for 5 minutes with disconnected Cast Iron 0.175 0.174 to 0.176 0.013 0.025 Cast iron 0.175 0.174 to 0.176 0.013 0.025
lube oil connection to Injectors Rocker housing (4.45) (4.42 to 4.47) (0.33) (0.63) Rocker housing (4.45) (4.42 to 4.47) (0.33) (0.63)
Hold the torque wrench in a position that allows you to look in a direct
line at the dial. This is to make sure the dial will be read accurately. NT-855 (Big Cam only - Non Top Stop)
Make sure the parts are aligned, and squeeze the oil out of the valve Torque Method - NH/NT-743/855 0.228 0.227 to 0.229 0.011 0.023
and injector train by tightening the adjusting screw. Bar in Pulley Set Cylinder (5.79) (5.76 to 5.82) (0.28) (0.58)
3. Two crankshaft revolutions are required to adjust all of the valves and Direction Position Injector Valve
injectors. Start A OR 1-6 VS 1 1 INJECTION / VALVE Adjustment – Top Stop Zero Lash (IBC) Method
4. Do not use a click-type torque wrench for STC Injectors. Advance to B OR 2-5 VS 5 5 (for NT-855-G5 Big Cam Ill NON STC Engines.)
5. The feeler gauge must slide backward and forward with only a slight Advance to C OR 3-4 VS 3 3 Bar in Pulley Set Cylinder
drag. Advance A OR 1-6 VS 6 6 Direction Position Injector Valve
6. The adjusting screw must not turn when the locknut is tightened. Advance to B OR 2-5 VS 2 2 Start A OR 1-6 VS 3 5
Advance to C OR 3-4 VS 4 4 Advance to B OR 2-5 VS 6 3
INJECTOR/VALVE SETTING VALUES Advance to C OR 3-4 VS 2 6
Advance A OR 1-6 VS 4 2
Torque Method-NH/NT-495/N-8 VALUES - Advance to B OR 2-5 VS 1 4
Bar in Pulley Set Cylinder Advance to C OR 3-4 VS 5 1
Direction Position Injector Valve Cold setting
Start A OR 1-4 VS 1 1 Injector Intake Valve Exhaust Valve VALUES
Advance to B OR 2-3 VS 2 2 In. Lbs. Inch Inch
Advance to A OR 1-4 VS 4 4 (N.m.) (mm) (mm)
Advance to B OR 2-3 VS 3 3 Aluminium 72 0.014 0.027 Cold setting Injector Intake valve Exhaust valve
Rocker housing (8.1) (0.36) (0.69) in-lb Inch Inch
VALUES – (N.m) (mm) (mm)
Cold setting Cast Iron 48 0.016 0.029 5 to 6 0.011 0.023
Injector Intake Valve Exhaust Valve Rocker housing (5.4) (0.41) (0.74) (0.6 to 0.7) (0.28) (0.58)
Aluminium In. Lbs. Inch Inch
Rocker housing (N.m.) (mm) (mm) NTA-855/N14 WITH STC INJECTORS – OBC Overhead Setting
72 0.014 0.027 Dial Indicator Method – NH/NT-743/855 Procedure
(8.1) (0.36) (0.69) Bar in Pulley Set Cylinder
Cast Iron 48 0.016 0.029 Direction Position Injector Valve Bar in Pulley Set Cylinder
Rocker housing (5.4) (0.41) (0.74) Start A OR 1-6 VS 3 5 Direction Position Injector Valve
Advance to B OR 2-5 VS 6 3
N-8G1, G2 follow (N-495 procedure/Sequence) Advance to C OR 3-4 VS 2 6 Start A OR 1-6 VS 1 1
Valve and Injector adjustment limits Advance A OR 1-6 VS 4 2 Advance to B OR 2-5 VS 5 5
Injector 6 lb-ft (70 lb-in) OBC Method Advance to B OR 2-5 VS 1 4 Advance to C OR 3-4 VS 3 3
Intake Valve 0.016” Advance C OR 3-4 VS 5 1 Advance A OR 1-6 VS 6 6
Exhaust Valve 0.029” Advance to B OR 2-5 VS 2 2
Advance to C OR 3-4 VS 4 4
Dial Indicator Method – NH/NT-495
Bar in Pulley Set Cylinder
Direction Position Injector Valve
Start A OR 1-4 VS 2 2
Advance to A OR 1-4 VS 3 3
VALUES -
0 0
VALUES -
0 0
Section - 0 Page 0-34 Section - 0 Page 0-35 Section - 0 Page 0-36
VALUES
VALUES VALUES Cold setting
Cold setting Injector Intake valve Exhaust valve
Cold setting in-lb Inch Inch
Injector Intake valve Exhaust valve Injector Plunger travel Intake valve Exhaust valve (N.m) (mm) (mm)
inch-lb Inch Inch inch (mm) Inch Inch 250 0.014 0.032
(N.m) (mm) (mm) (mm) (mm) (28) (0.36) (0.81)
125 0.014 0.027 Adj Recheck Loosen adjusting screw
(14) (0.36) (0.69) Value Limit by one turn
N-14 125 0.014 0.027 0.304 0.303 to 0.305 0.014 0.027 165
NTA-855 100 0.014 0.027 (7.72) (7.69 to 7.75) (0.36) (0.69) (19)
Injector for QSK 19
The torque wrench must be calibrated, have a resolution of 0.28 N-m
Torque Method-V-1710/28 K 19 With STC or HVT Injectors - OBC Overhead Setting [2.5 in-lb], and have a range of 17 to 23 N-m [150 to 200 in-lb].
Bar in Pulley Set Cylinder Procedure
Direction Position Injector Valve Be sure the parts are in alignment and squeeze the oil out of the valve
Bar in Pulley Valves Set Cylinder and injector train while tightening the adjusting screw.
Start 1-6L VS 1L 1L Direction Position Closed on Injector Valve Torque Value: 28 N-m [250 in-lb]
Advance to 1-6R VS 6R 6R
Loosen the adjusting screw at least one revolution.
Advance to 2-5L VS 2L 2L Start A OR 1-6 VS 1 4 5 Tighten the adjusting screw again.
Advance 2-5R VS 5R 5R Advance to B OR 2-5 VS 5 1 3
Advance to 3-4L VS 4L 4L Torque Value: 19 N-m [165 in-lb]
Advance to C OR 3-4 VS 3 5 6
Advance to 3-4R VS 3R 3R Advance A OR 1-6 VS 6 3 2
Advance to 1-6L VS 6L 6L Dial Indicator Method- KT/KTA 2300
Advance to B OR 2-5 VS 2 6 4
Advance 1-6R VS 1R 1R Bar in Pulley Set Cylinder
Advance to 2-5L VS 5L 5L Direction Position Injector Valve
Advance to 2-5R VS 2R 2R Start 1 R-6 R VS 1R 1R
Advance 3-4L VS 3L 3L Advance to 1 L-6 L VS 6L 6L
Values
Advance to 3-4R VS 4R 4R Advance to 2 R-5 R VS 5R 5R
Advance 2 L-5 L VS 2L 2L
Cold setting
Advance to 3 R-4 R VS 3R 3R
Injector Intake Valve Exhaust valve
VALUES - Advance to 3 L-4 L VS 4L 4L
in-lb Inch Inch
(N.m.) (mm) (mm)
Cold setting Advance 1 L-6 L VS 1L 1L
Injector Intake Valve Exhaust valve Advance to 2 R-5 R VS 2R 2R
100 0.014 0.027
in-lbs Inch Inch Advance to 2 L-5 L VS 5L 5L
(11) (0.36) (0.69) Advance 3 R-4 R VS 4R 4R
(N.m.) (mm) (mm)
Loosen adjusting screw Advance to 3 L-4 L VS 3L 3L
70 0.014 0.027
by one turn
(8) (0.36) (0.69)
90 Dial Indicator Method – KTA 3067
(10) Bar in Pulley Set Cylinder
Dial Indicator Method – KT/KTA - 1150 Direction Position Injector Valve
Start 1 R-8 R VS 1R 1R
QSK 19- OBC Overhead Setting Procedure Advance to 1 L-8 L VS 1L 1L
Direction Position Injector Valve Advance to 3 R-6 R VS 3R 3R
Bar in Pulley Valves Set Cylinder Advance 3 L-6 L VS 3L 3L
Direction Position Closed on Injector Valve Advance to 2 R-7 R VS 7R 7R
Advance to B OR 2-5 VS 6 3 Advance to 2 L-7 L VS 7L 7L
Advance to C OR 3-4 VS 2 6 Start A OR 1-6 VS 1 4 5 Advance to 4 R-5 R VS 5R 5R
Advance A OR 1-6 VS 4 2 Advance to B OR 2-5 VS 5 1 3 Advance 4 L-5 L VS 5L 5L
Advance to B OR 2-5 VS 1 4 Advance to C OR 3-4 VS 3 5 6 Advance to 1 R-8 R VS 8R 8R
Advance to C OR 3-4 VS 5 1 Advance A OR 1-6 VS 6 3 2 Advance to 1 L-8 L VS 8L 8L
Advance to B OR 2-5 VS 2 6 4 Advance 3 R-6 R VS 6R 6R
Advance to C OR 3-4 VS 4 2 1 Advance to 3 L-6 L VS 6L 6L
Advance to 2 L-7 L VS 2L 2L
Advance 4 R-5 R VS 4R 4R
VALUES
(N.m) (mm) (mm) (mm) (mm) (28) (0.36) (0.81)
N-14 125 0.014 0.027 0.304 0.303 to 0.305 0.014 0.027 165
NTA-855 100 0.014 0.027 (7.72) (7.69 to 7.75) (0.36) (0.69) (19)
Injector for QSK 19
Values
Cold setting
in-lb Inch Inch
(N.m.) (mm) (mm)
100 0.014 0.027
(11) (0.36) (0.69) Advance 3 R-4 R VS 4R 4R
(N.m.) (mm) (mm)
70 0.014 0.027
by one turn
(8) (0.36) (0.69)
VALUES
(N.m) (mm) (mm) (mm) (mm) (28) (0.36) (0.81)
N-14 125 0.014 0.027 0.304 0.303 to 0.305 0.014 0.027 165
NTA-855 100 0.014 0.027 (7.72) (7.69 to 7.75) (0.36) (0.69) (19)
Injector for QSK 19
Values
Cold setting
in-lb Inch Inch
(N.m.) (mm) (mm)
100 0.014 0.027
(11) (0.36) (0.69) Advance 3 R-4 R VS 4R 4R
(N.m.) (mm) (mm)
70 0.014 0.027
by one turn
(8) (0.36) (0.69)
Section -0 Page 0-37 Section – 0 Page 0-38 Section – 0 Page 0-39
VALUES - FOR KT/KTA-2300 & KTA-3067 KTA-50 (G3/G8) & QSK 60 (with STC Injectors) Outer Base Circle Set Tighten the injector adjusting screw locknut:
Procedure – Revised Firing Order Torque Value:
Cold setting With Adapter 47.5 N•m [35 ft-lb]
Injector Plunger travel Intake valve Exhaust valve Without Adapter 60 N•m [44 ft-lb]
Bar in Pulley Valves Closed Set Cylinder
inch (mm) Inch Inch Direction Position on Cylinder Valve Injector There are two different methods use to set valve lash clearance: Torque
(mm) (mm) Number wrench method and feeler gauge method; both are described below.
Adj. Recheck Start 1 R-8 R VS 1R 1R 6R Either method can be used; however, the torque wrench method has
Value Limit Advance to 1 L-8 L VS 1L 1L 6L proven to be the most consistent.
0.308 0.307 to 0.309 0.014 0.027 Advance to 3 R-6 R VS 3R 3R 7R
(7.82) (7.79 to 7.85) (0.36) (0.69) Advance to 3 L-6 L VS 3L 3L 7L Method
Advance to 2 R-7 R VS 2R 2R 4R Make sure the parts are aligned, and squeeze the oil out of the valve
Advance to 2 L-7 L VS 2L 2L 5L and the injector train by tightening the adjusting screw.
Advance to 4 R-5 R VS 5R 5R 1R Loosen the adjusting screw at least one revolution.
Advance to 4 L-5 L VS 4L 4L 1L Insert the feeler gauge between the rocker lever socket and the
Advance to 1 R-8 R VS 8R 8R 3R crosshead.
Advance to 1 L-8 L VS 8L 8L 3L Use torque wrench, Part No. 3376592, and tighten the adjusting screw.
K-38/QSK 45 Outer Base Circle Set Procedure (with STC Injectors) Advance to 3 R-6 R VS 6R 6R 2R Torque Value:
Advance to 3 L-6 L VS 6L 6L 2L 0.68 N•m [6 in-lb]
Advance to 2 R-7R VS 7R 7R 5R Remove the feeler gauge.
Bar in Pulley Valves Closed Set Cylinder Advance to 2 L-7 L VS 7L 7L 4L
Direction Position on Cylinder Valve Injector Advance to 4 R-5 R VS 4R 4R 8R NOTE: The adjusting screw must not turn when the locknut is tightened.
Number Advance to 4 L-5 L VS 5L 5L 8L Locknut torque can be applied with or without torque wrench adapter,
Start 1 R-6 R VS 1R 1R 2R Part No. ST-669.
Advance to 1 L-6 L VS 6L 6L 5L VALUES Tighten the locknut.
Advance to 2 R-5 R VS 5R 5R 4R Torque Value:
Cold setting KTA-50 With Adapter 47.5 N•m [35 ft-lb]
Advance 2 L-5 L VS 2L 2L 3L Injector Intake valve Exhaust valve Without Adapter 60 N•m [44 ft-lb]
Advance to 3 R-4 R VS 3R 3R 1R in-lb Inch Inch Attempt to insert a feeler gauge that is 0.03-mm [0.001-in] thicker. The
Advance to 3 L-4L VS 4L 4L 6L (N.m) (mm) (mm) valve lash is not correct if the thicker feeler gauge will fit.
Advance to 1 R-6 R VS 6R 6R 5R 100 0.014 0.027 Repeat the adjustment process until the proper lash is obtained.
Advance 1 L-6 L VS 1L 1L 2L (11) (0.36) (0.69)
Advance to 2 R-5 R VS 2R 2R 3R Injector Adjustment
Loosen adjusting Screw Use a dial-type torque wrench, Part No. 3824783, with 0.28 N•m [2.5 in-
Advance to 2 L-5 L VS 5L 5L 4L
by one turn lb] resolution and a range of 17 to 34 N•m [12.5 to 25 ft-lb] to tighten the
Advance 3 R-4 R VS 4R 4R 6R injector rocker lever adjusting screw. If the screw chatters during setting,
90
Advance to 3 L-4 L VS 3L 3L 1L (10) repair the screw and lever as required.
VALUES QSK 45 / 60 Torque Value:

with Torque Wrench Adapter,
45 N•m [35 ft-lb]
Cold setting Injector Intake valve Exhaust valve Valve Clearances - Initial Set Part No. ST-669 (1)
K-38 in-lb Inch Inch mm in without Adapter 60 N•m [45 ft-lb]
(N.m) (mm) (mm) Exhaust Valves (A) 0.81 MAX 0.032
100 0.014 0.027 Intake Valves (B) 0.36 MAX 0.014
(11) (0.36) (0.69)
Loosen adjusting screw
Tighten the injector adjusting screw.
by one turn
Torque Value:
90
28 N•m [248 in-lb]
(10)
Tighten the adjusting screw again.
Torque Value:
19 N•m [168 in-lb]
Advance 1 L-6 L VS 1L 1L 2L (11) (0.36) (0.69)
90

45 N•m [35 ft-lb]
(11) (0.36) (0.69)
by one turn
Torque Value:
90
28 N•m [248 in-lb]
(10)
Torque Value:
19 N•m [168 in-lb]
Advance 1 L-6 L VS 1L 1L 2L (11) (0.36) (0.69)
90

45 N•m [35 ft-lb]
(11) (0.36) (0.69)
by one turn
Torque Value:
90
28 N•m [248 in-lb]
(10)
Torque Value:
19 N•m [168 in-lb]
A-CHECK B-CHECK FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS. AFTER
CHECK EVERY ‘D’ CHECK
Check Starting Check coolant Check Crankshaft
Batteries inhibitor. Add End Clearance
coolant
concentrate, if
Check belts, required. Check Vibration
adjust if required Damper
Record Water Check Air
Temp. Compressor
Check Safety
Record RPM Controls
Engine Interval B C D
Series
All Hours Every 300 hours To be done at first Every 1500 Every 6000 hours To be done at 1500
Calendar Every 6 months 1500 hours only hours Every 1 Every 2 years hours after every
year D Check
Notes: 1. Perform checks on operating basis of interval that occurs first.

2. Any time cooling system is completely drained and/or flushed, check coolant using coolant checking kit.
3. It is suggested to operate the engine at operating temperatures once in a week.

Fuel System
Check Fuel Check Throttle
Supply Linkage Air System
Tighten Manifold
Air System Clean Fuel Tank Check air Cleaner Nuts or Capscrews
Check Air Cleaner Breather Evacuator valve.
Change if Check Turbocharger
Cooling System Change Fuel required. Compressor and
Check Coolant Filters Turbine wheel.
Level
Air System Check Turbocharger
Other Maintenance Clean / Change bearing clearance
Check leaks and Crankcase
Correct Breather Other Maintenance
Steam Clean
Check Engine Check Air Engine
Lubricating Oil Cleaner
and Water Heater Restriction Tighten Mounting
Bolts and Nuts
Check Raw Cooling System (As Required)
Water Change Water
Strainer Filter/Water
2
Softner
Section –0 MAINTENANCE SCHEDULE Page 0-40

FOR INDUSTRIAL FIRE PUMP ENGINES ONLY
EQUIPMENT NO.________________________________________________ ENGINE SERIAL NO.
MECHANIC ____________________________________________________ HOURS, CALENDAR
TIME SPENT ___________________________________________________ CHECK PERFORMED
PARTS ORDER NO. DATE
(Section 4, 5) (Section 6) CHECK (Section 7) (Section 8) EVERY ‘D’ CHECK
Daily Repeat “A” ALL STEPS OF Repeat “A” and “B” Repeat “A, B ALL STEPS OF
C-CHECK AND and C” C-CHECK AND
Lubrication Lubrication ADDITIONAL Cooling System ADDITIONAL
Check Engine Oil Change Engine STEPS Check Heat Fuel System STEPS
Level Oil Exchanger Core Clean and
Adjust Injectors Calibrate injectors Adjust Injectors
Fuel System Change Engine and Valves Check Water Pump if required. and Valves
Drain Sediment Full-Flow Oil Replace rocker
from Fuel Tanks Filter Replace rocker Fuel System cover gaskets Replace rocker
cover gaskets Clean Fuel Tank from cover gaskets
Drain Water Record Oil inside Replace Fuel
from the Water Pressure Pump Filter
Separator Other Maintenance Screen and
Inspect following Magnet
items and replace
as reqd. (Alternator/
Starter etc.)
coolant
concentrate, if
Temp. Compressor
Check Safety
Record RPM Controls
Series
year D Check


Fuel System
Tighten Manifold
Level
Steam Clean
Bolts and Nuts
Water Change Water
2
Softner

items and replace
Starter etc.)
coolant
concentrate, if
Temp. Compressor
Check Safety
Record RPM Controls
Series
year D Check


Fuel System
Tighten Manifold
Level
Steam Clean
Bolts and Nuts
Water Change Water
2
Softner

items and replace
Starter etc.)
Section -0 Page 0-45
W 2.1295 2.2555 6.0965 2.000
(54.089) (57.290) (154.851) (50.80)
1710 Min 2.1245 2.2535 6.095 6.5615 6.1240 1.9985 1.9978 2.122
(53.962) (57.239) (154.81) (166.662) (155.554) (50.762) (50.774) (53.85)
Max 2.1283 2.2545 6.096 6.5635 6.1260 1.9989 1.999 2.123
(54.059) (57.264) (154.84) (166.713) (155.600) (50.772) (50.77) (53.92)
W 3.0035 5.8465 2.3990 2.398 2.995
(76.276) (149.50) (60.935) (60.91) (76.07)
1150/19 Min 3.000 3.2535 5.845 7.4915 6.9820 2.3985 2.3988 2.995
(76.200) (82.638) (148.46) (190.284) (177.343) (60.922) (60.929) (76.07)
Max 3.002 3.2545 5.846 7.4935 6.9840 2.3989 2.399 2.997
(76.250) (82.664) (148.49) (190.335) (177.394) (60.932) (60.94) (76.12)
W 3.0025 3.1895 6.8465 2.3990 2.398 2.995
(76.264) (81.013) (173.876) (60.935) (60.91) (76.07)
2300/ Min 3.000 3.1875 6.845 7.4915 6.9820 2.3985 2.3988 2.996
3067 (76.200) (80.962) (173.863) (190.284) (177.343) (60.922) (60.929) (76.09)
38/50 Max 3.0015 3.1885 6.846 7.4935 6.984 2.3989 2.399 2.997
(76.238) (80.988) (173.884) (190.335) (177.39) (60.932) (60.94) (76.12)
W - Wear limit
Section- 0 Page 0-44

COMPONENT MEASUREMENT LIMITS
CYLINDER BLOCK SPECIFICATION Inch (mm)
Engine Camshaft Camshaft Main Cylinder Liner Cylinder Block Piston Pin Piston Pin Camshaft
Model bushing bushing brg counter Bore Lower Liner Bore O.D Journal
I.D. Bore Bore I.D. Inside Dia. Bore I.D. O.D
Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm) Inch (mm)
W 2.0015 2.1305 4.7505 2.0000 1.9978 1.996
(50.838) (54.115) (120.663) (50.800) (50.754) (50.70)
495/743 Min 1.9990 2.1285 4.7485 6.124 5.7490 1.9987 1.9988 1.997
(50.775) (54.064) (120.612) (155.554) (146.025) (50.767) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.126 5.7510 1.9990 1.9990 1.998
(50.813) (54.089) (120.65) (155.600) (146.075) (50.775) (50.775) (50.75)
W 2.0015 2.1305 4.7505 1.999 1.9985 1.996
(50.838) (54.115) (120.663) (50.775) (50.762) (50.70)
855 Min 1.999 2.1285 4.7485 6.5615 6.1240 1.9985 1.9988 1.997
(50.775) (54.064) (120.612) (166.662) (155.554) (50.762) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.5635 6.1260 1.9989 1.9990 1.998
(50.813) (54.089) (120.650) (166.713) (155.600) (50.772) (50.775) (50.75)
W- Wear limit
Section- 0 MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR Page 0-43

PRODUCT DAILY MAINTENANCE WEEKLY MAINTENANCE MONTHLY MAINTENANCE QUARTERLY MAINTENANCE
BS5 Starter Check tightness of battery Check battery specific Top up *DE Shield reservoir with Remove **CE cover and smear
and circuit connections gravity multi grade 20W40 (API-CD) oil. Molybdenum Sulphide grease over CE
bearing pin.
Check visually battery Clean the brush dust inside the starter and
electrolyte level. secure CE cover properly. Apply Elcoprine
sealing compound around cover.
Check the tightening torque of all fasteners
SM130 PE Same as BS5 starter Same as BS5 starter Top up DE and CE Shield with Lubricate pinion on shaft with MOS2 grease
Starter Multi grade 20W40(API-CD) oil OKS-410
Check tightening torque of all
fasteners.
AC5 Alternator Check belt tension ------ Check battery terminal voltage Check tightening torque of all fasteners
while charging.
Check tightness of output Clean and apply petroleum jelly Check the smoothness of ball bearings.
and WL terminal for battery terminals.
connections.
General Instructions : * DE- Drive end
Ensure the panel switch is not sticky. ** CE – Commutator end
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.
Ensure the correct wattage of Warning Lamp. The wattage of the bulb to be 2.2 Watt.
W 2.1295 2.2555 6.0965 2.000
(54.089) (57.290) (154.851) (50.80)
1710 Min 2.1245 2.2535 6.095 6.5615 6.1240 1.9985 1.9978 2.122
(53.962) (57.239) (154.81) (166.662) (155.554) (50.762) (50.774) (53.85)
Max 2.1283 2.2545 6.096 6.5635 6.1260 1.9989 1.999 2.123
(54.059) (57.264) (154.84) (166.713) (155.600) (50.772) (50.77) (53.92)
W 3.0035 5.8465 2.3990 2.398 2.995
(76.276) (149.50) (60.935) (60.91) (76.07)
1150/19 Min 3.000 3.2535 5.845 7.4915 6.9820 2.3985 2.3988 2.995
(76.200) (82.638) (148.46) (190.284) (177.343) (60.922) (60.929) (76.07)
Max 3.002 3.2545 5.846 7.4935 6.9840 2.3989 2.399 2.997
(76.250) (82.664) (148.49) (190.335) (177.394) (60.932) (60.94) (76.12)
W 3.0025 3.1895 6.8465 2.3990 2.398 2.995
(76.264) (81.013) (173.876) (60.935) (60.91) (76.07)
2300/ Min 3.000 3.1875 6.845 7.4915 6.9820 2.3985 2.3988 2.996
3067 (76.200) (80.962) (173.863) (190.284) (177.343) (60.922) (60.929) (76.09)
38/50 Max 3.0015 3.1885 6.846 7.4935 6.984 2.3989 2.399 2.997
(76.238) (80.988) (173.884) (190.335) (177.39) (60.932) (60.94) (76.12)
W - Wear limit

W 2.0015 2.1305 4.7505 2.0000 1.9978 1.996
(50.838) (54.115) (120.663) (50.800) (50.754) (50.70)
495/743 Min 1.9990 2.1285 4.7485 6.124 5.7490 1.9987 1.9988 1.997
(50.775) (54.064) (120.612) (155.554) (146.025) (50.767) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.126 5.7510 1.9990 1.9990 1.998
(50.813) (54.089) (120.65) (155.600) (146.075) (50.775) (50.775) (50.75)
W 2.0015 2.1305 4.7505 1.999 1.9985 1.996
(50.838) (54.115) (120.663) (50.775) (50.762) (50.70)
855 Min 1.999 2.1285 4.7485 6.5615 6.1240 1.9985 1.9988 1.997
(50.775) (54.064) (120.612) (166.662) (155.554) (50.762) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.5635 6.1260 1.9989 1.9990 1.998
(50.813) (54.089) (120.650) (166.713) (155.600) (50.772) (50.775) (50.75)
W- Wear limit

bearing pin.
fasteners.
while charging.
connections.
W 2.1295 2.2555 6.0965 2.000
(54.089) (57.290) (154.851) (50.80)
1710 Min 2.1245 2.2535 6.095 6.5615 6.1240 1.9985 1.9978 2.122
(53.962) (57.239) (154.81) (166.662) (155.554) (50.762) (50.774) (53.85)
Max 2.1283 2.2545 6.096 6.5635 6.1260 1.9989 1.999 2.123
(54.059) (57.264) (154.84) (166.713) (155.600) (50.772) (50.77) (53.92)
W 3.0035 5.8465 2.3990 2.398 2.995
(76.276) (149.50) (60.935) (60.91) (76.07)
1150/19 Min 3.000 3.2535 5.845 7.4915 6.9820 2.3985 2.3988 2.995
(76.200) (82.638) (148.46) (190.284) (177.343) (60.922) (60.929) (76.07)
Max 3.002 3.2545 5.846 7.4935 6.9840 2.3989 2.399 2.997
(76.250) (82.664) (148.49) (190.335) (177.394) (60.932) (60.94) (76.12)
W 3.0025 3.1895 6.8465 2.3990 2.398 2.995
(76.264) (81.013) (173.876) (60.935) (60.91) (76.07)
2300/ Min 3.000 3.1875 6.845 7.4915 6.9820 2.3985 2.3988 2.996
3067 (76.200) (80.962) (173.863) (190.284) (177.343) (60.922) (60.929) (76.09)
38/50 Max 3.0015 3.1885 6.846 7.4935 6.984 2.3989 2.399 2.997
(76.238) (80.988) (173.884) (190.335) (177.39) (60.932) (60.94) (76.12)
W - Wear limit

W 2.0015 2.1305 4.7505 2.0000 1.9978 1.996
(50.838) (54.115) (120.663) (50.800) (50.754) (50.70)
495/743 Min 1.9990 2.1285 4.7485 6.124 5.7490 1.9987 1.9988 1.997
(50.775) (54.064) (120.612) (155.554) (146.025) (50.767) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.126 5.7510 1.9990 1.9990 1.998
(50.813) (54.089) (120.65) (155.600) (146.075) (50.775) (50.775) (50.75)
W 2.0015 2.1305 4.7505 1.999 1.9985 1.996
(50.838) (54.115) (120.663) (50.775) (50.762) (50.70)
855 Min 1.999 2.1285 4.7485 6.5615 6.1240 1.9985 1.9988 1.997
(50.775) (54.064) (120.612) (166.662) (155.554) (50.762) (50.770) (50.72)
Max 2.0005 2.1295 4.750 6.5635 6.1260 1.9989 1.9990 1.998
(50.813) (54.089) (120.650) (166.713) (155.600) (50.772) (50.775) (50.75)
W- Wear limit

bearing pin.
fasteners.
while charging.
connections.
IMPORTANT TURBOCHARGER
SPECIFICATIONS For Tapered Roller Bearings - End Clearance
743
2300
1150
1710
N/NT/
Turbocharger Axial Play Radial Play at Engine Model End Clearance
Model
KT/KTA
KT/KTA
VT/VTA
Model Compressor End
NTA/495
NTA/855
Section - 0
V-28 0.003”-0.010”
KTA3067
H2A/H1E* 0.004” to 0.0125” to K-19 0.003”-0.016”
0.006” 0.0185” KV-38 0.001”-0.008”
MIN
MIN
MIN
MIN
N/NT/495/ MIN
MAX
MAX
MAX
MAX
MAX
HC3/4LGK 0.001” to 0.0074” to
0.004” 0.0208” FLYWHEEL HOUSING
HC-5A/HX80/ 0.002” to 0.0191” to
FLYWHEEL HOUSINGS ARE MANUFACTURED AS
HX82 0.005” 0.0294” PER S.A.E. STANDARDS GIVEN BELOW. WHILE
CONFIRMING THE SAE NO., BORE DIAMETER AND
6.5000
5.5000
5.7500
4.5000
4.5000
6.4980
5.4985
5.7485
4.4985
4.4985
T-50/VT-50 0.006” to 0.003” to
Journal
PITCH CIRCLE DIAMETER (PCD) SHOULD BE
Dia (Inch)
ST-50 0.018” 0.033” MEASURED.
T-18A 0.004” to 0.003”
0.009” 0.007” SAE NO. BORE PCD
4.000
4.2500
3.7500
3.1250
3.1250
4.2470
3.9985
3.7485
3.1235
3.1235
H1C 0.001” to 0.012” 0 25.5” 26.750”
1 20.125” 20.875”
0.003 0.018”
Dia (Inch)
Crank Pin
2 17.625” 18.375”
HX40 0.0037 0.0128 3 16.125’ 16.875”
0.0015 0.0195
* H1E - Watercooled bearing housing turbo.
VISCOUS VIBRATION DAMPER
4.802
2.751
4.051
2.128
2.378
4.798
2.748
4.049
2.125
2.375
IMPORTANT CLEARANCE VALUES
THICKNESS SPECIFICATIONS - INCH (MM)
Crank Pin
Engine Crank Liner Conrod Camshaft ACC Drive
Width (Inch)
Model Endplay Protusion Side Endplay Endplay Damper Maximum Recommended
Clearance Part No. Allowable Change interval
Thickness - Hours
N/NT/NTA 0.007” to 0.004” to 0.0045” to *0.008” to 0.003” to
Fillet
0.270
0.270
0.195
0.195
0.195
0.230
0.230
0.172
0.172
0.172
(Inch)
3037156 1.635 (41.53) 15000
Radius
495/743 0.017” 0.006” 0.013” 0.013” 0.013”
**0.001” to 207531 2.574(65.38) 15000
0.005” 211915 1.550(39.37) 15000
CRANKSHAFT DIMENSIONS
52
52
52
52
52
45
45
45
45
45
N/NT/NTA 0.007” to 0.004” to 0.0045” to 0.008” to 0.003” to 217321 1.663 (42.24) 15000
RC
/855 0.017” 0.006” 0.013” 0.013” 0.013”
217322 1.663(42.24) 15000
V/VT/VTA 0.006” to 0.004” to 0.007” to 0.010” to 0.002” to
Hardness
217323 1.663 (42.24) 15000
1710 0.013” 0.006” 0.022” 0.015” 0.013”
KT/KTA 0.004” to 0.003” to 0.008” to 0.006” to 0.002” to 3873899 2.574 (65.38) 24000
1150 0.016” 0.006” 0.014” 0.013” 0.012” 3015464 2.574(65.38) 24000
0.001
0.001
0.001
0.001
0.001
Nose
2300 0.015” 0.007” 0.020” 0.013” 0.013” 3628649 2.574 (65.38) 24000
& KTA 3067
3628650 2.574 (65.38) 24000
N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.018” 0.007” 0.013” 0.011” 0.012”
0.001
0.001
0.001
0.001
0.001
Rear
At any time the engine experiences the following problems, check
(Inch)
QSK 19 0.004” to 0.005” to 0.008” to 0.006” to 0.002” to
Flange
Vibration Damper. Replace if necessary
0.016” 0.007” 0.014” 0.013” 0.012”
a. Gear train failure
QSK 45/60 0.005”to 0.006” to 0.012” to 0.006” to 0.005” to b. Accessory drive shaft failure
0.020” 0.008” 0.020” 0.013” 0.011” c. Crankshaft failure
Alignment (TIR)
d. Damper mounting capscrew failure
Full
NOTE : e. Flywheel mounting capscrew failure
0.003
0.008
0.008
0.015
0.012
0.0035
* Indicates with support
Length
** Indicates with plate
KTA3067
For genset-app- “Acc drive endplay is 0 to 0.001”
Page 0-46
KT/KTA-2300
N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.018” 0.007” 0.013” 0.011” 0.012”
Section - 0
KTA3067
2300
KT/KTA
1150
KT/KTA
1710
VT/VTA
NTA/495
NTA/855
N/NT/
743
N/NT/495/ MIN
Model
Model Compressor End V-28 0.003”-0.010”
H2A/H1E* 0.004” to 0.0125” to K-19 0.003”-0.016”
MAX
MAX
MAX
MAX
MAX
MIN
MIN
MIN
MIN
0.006” 0.0185” KV-38 0.001”-0.008”
HC3/4LGK 0.001” to 0.0074” to

HC-5A/HX80/ 0.002” to 0.0191” to
Journal
Dia (Inch)
6.5000
5.5000
5.7500
4.5000
4.5000
6.4980
5.4985
5.7485
4.4985
4.4985
T-50/VT-50 0.006” to 0.003” to CONFIRMING THE SAE NO., BORE DIAMETER AND
ST-50 0.018” 0.033” MEASURED.
T-18A 0.004” to 0.003”
4.2500
4.000
3.7500
3.1250
3.1250
4.2470
3.9985
3.7485
3.1235
3.1235
SAE NO. BORE PCD
Crank Pin
Dia (Inch)
0.009” 0.007”
H1C 0.001” to 0.012” 0 25.5” 26.750”
1 20.125” 20.875”
0.003 0.018”
2 17.625” 18.375”
HX40 0.0037 0.0128 3 16.125’ 16.875”
0.0015 0.0195
Crank Pin
4.802
2.751
4.051
2.128
2.378
Width (Inch)
4.798
2.748
4.049
2.125
2.375
Fillet
(Inch)
Radius
0.270
0.270
0.195
0.195
0.195
0.230
0.230
0.172
0.172
0.172
Thickness - Hours
495/743 0.017” 0.006” 0.013” 0.013” 0.013” 3037156 1.635 (41.53) 15000
**0.001” to 207531 2.574(65.38) 15000
0.005” 211915 1.550(39.37) 15000
52
52
52
52
52
45
45
45
45
45
Hardness
RC
/855 0.017” 0.006” 0.013” 0.013” 0.013”
217322 1.663(42.24) 15000
217323 1.663 (42.24) 15000
1710 0.013” 0.006” 0.022” 0.015” 0.013”
0.001
0.001
0.001
0.001
0.001
Nose
1150 0.016” 0.006” 0.014” 0.013” 0.012” 3015464 2.574(65.38) 24000

2300 0.015” 0.007” 0.020” 0.013” 0.013” 3628649 2.574 (65.38) 24000
& KTA 3067
3628650 2.574 (65.38) 24000
N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.001
0.001
0.001
0.001
0.001
Flange
Alignment (TIR)
(Inch)
Rear
0.018” 0.007” 0.013” 0.011” 0.012”

QSK 19 0.004” to 0.005” to 0.008” to 0.006” to 0.002” to At any time the engine experiences the following problems, check
0.016” 0.007” 0.014” 0.013” 0.012”
0.003
0.0035
0.008
0.008
Length
Full

0.015
KTA3067
0.012
KT/KTA-2300

Page 0-46

N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.018” 0.007” 0.013” 0.011” 0.012”
Section - 0
KTA3067
2300
KT/KTA
1150
KT/KTA
1710
VT/VTA
NTA/495
NTA/855
N/NT/
743
N/NT/495/ MIN
Model
Model Compressor End V-28 0.003”-0.010”
H2A/H1E* 0.004” to 0.0125” to K-19 0.003”-0.016”
MAX
MAX
MAX
MAX
MAX
MIN
MIN
MIN
MIN
0.006” 0.0185” KV-38 0.001”-0.008”
HC3/4LGK 0.001” to 0.0074” to

HC-5A/HX80/ 0.002” to 0.0191” to
Journal
Dia (Inch)
6.5000
5.5000
5.7500
4.5000
4.5000
6.4980
5.4985
5.7485
4.4985
4.4985
T-50/VT-50 0.006” to 0.003” to CONFIRMING THE SAE NO., BORE DIAMETER AND
ST-50 0.018” 0.033” MEASURED.
T-18A 0.004” to 0.003”
4.2500
4.000
3.7500
3.1250
3.1250
4.2470
3.9985
3.7485
3.1235
3.1235
SAE NO. BORE PCD
Crank Pin
Dia (Inch)
0.009” 0.007”
H1C 0.001” to 0.012” 0 25.5” 26.750”
1 20.125” 20.875”
0.003 0.018”
2 17.625” 18.375”
HX40 0.0037 0.0128 3 16.125’ 16.875”
0.0015 0.0195
Crank Pin
4.802
2.751
4.051
2.128
2.378
Width (Inch)
4.798
2.748
4.049
2.125
2.375
Fillet
(Inch)
Radius
0.270
0.270
0.195
0.195
0.195
0.230
0.230
0.172
0.172
0.172
Thickness - Hours
495/743 0.017” 0.006” 0.013” 0.013” 0.013” 3037156 1.635 (41.53) 15000
**0.001” to 207531 2.574(65.38) 15000
0.005” 211915 1.550(39.37) 15000
52
52
52
52
52
45
45
45
45
45
Hardness
RC
/855 0.017” 0.006” 0.013” 0.013” 0.013”
217322 1.663(42.24) 15000
217323 1.663 (42.24) 15000
1710 0.013” 0.006” 0.022” 0.015” 0.013”
0.001
0.001
0.001
0.001
0.001
Nose
1150 0.016” 0.006” 0.014” 0.013” 0.012” 3015464 2.574(65.38) 24000

2300 0.015” 0.007” 0.020” 0.013” 0.013” 3628649 2.574 (65.38) 24000
& KTA 3067
3628650 2.574 (65.38) 24000
N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.001
0.001
0.001
0.001
0.001
Flange
Alignment (TIR)
(Inch)
Rear
0.018” 0.007” 0.013” 0.011” 0.012”

QSK 19 0.004” to 0.005” to 0.008” to 0.006” to 0.002” to At any time the engine experiences the following problems, check
0.016” 0.007” 0.014” 0.013” 0.012”
0.003
0.0035
0.008
0.008
Length
Full

0.015
KTA3067
0.012
KT/KTA-2300

Page 0-46

N8 0.007” to 0.004” to 0.0045” to 0.006” to 0.002” to
0.018” 0.007” 0.013” 0.011” 0.012”
Section - 0 Page 0
N8
855
ENGINE
495/743
ENGINE
K38/50
QSK19
Section - 0
Section -0
VT 1710
N/NT/NTA
N/NT/NTA
CONTENTS Page No.
QSK45/60
KT/A 2300
KT/A 3067
KT/A-1150
MODEL/SERIES
MODEL/SERIES
90
0
0
CAPS
TPA - Torque Plus Angle
CAPS
Loosen
Loosen
Loosen
Loosen
150/300
230/260
150/300
230/260
230/260
150/300
230/260
230/260
150/300
loosen
Flat cap
Flat cap
Loosen
Loosen
Loosen
Loosen
MAIN BRG
210/450
195/445
200/450
200/450
144/310
195/445
200/450
420-460
200-210/
MAIN BRG
144/310+
OLD TYPE
OLD TYPE
for cylinder
90 advance
210/420-460
SN. with first

*TPA method
250 +
blocks having
‘D’- KV16 250

letter ‘C’ KV12
150
150
CAPS
/240
CAPS
75/175
Torque
214950
63+60
loosen
All torque values listed below are in lbs.ft

70/140
70/150
Loosen 200- 70/150
CONROD
Loosen
Loosen
threaded
CONROD
70-75/140
70-75/140
capscrews
to 165-175
70-75/140-
70-75/140-
63 loosen
& brgs P.N.

with conrod
150 Loosen
150 Loosen
75/150/250
70/140/220
70/140/220
75/150/250
P.N. 3013930
480
350
CYL.
140-
HEAD
CYL.
HEAD
70/170
221+90
220+90
275, 310
160/290-
310/460-
100/200
100/200
52/148/0
50/150/0
100, 200,
/275/310
/250/355
/300/410
Cooling System ......................................................................... 0-20
Fuel System ............................................................................... 0-29
55
lb-in
10-12
11-12
11-13
11-13
10-13
133-140
INJECTOR
INJECTOR
/410
/410
50-55
FLANGE
180-200
180-200
FLANGE
160/290
160/290
crank with
screw 475
single cap-
Taper nose
100/200/320
148/280/505
CRANK FRONT
CRANK FRONT
IMPORTANT TORQUE VALUES

-
155
120
155
105
55-60
55-60
92/122
DAMPER
DAMPER
VIBRATION
VIBRATION
505
/380
/380
holes
85/ 215
190-200
200-220
190-200
110/210
110/210
148/280/
with hard
FLYWHEEL
FLYWHEEL
with safety
Capscrews
Capscrews
flat washers
288
-
35/145/340 70-135
-
-
-
325-335
SIDE CAPS
SIDE CAPS
MAIN BRGS
MAIN BRGS
75
-
110
215
185
180
-
-
-
Cam
head
IDLER
IDLER
SHAFT
SHAFT
without
W. Pump
Capscrew
Capscrew
with flange
59/122/207
flange head
Hyd. Pump 180

Page 0-50
Page 0-49
Section - 0 Page 0
N8
855
ENGINE
495/743
ENGINE
K38/50
QSK19
Section - 0
Section -0
VT 1710
N/NT/NTA
N/NT/NTA
CONTENTS Page No.
QSK45/60
KT/A 2300
KT/A 3067
KT/A-1150
MODEL/SERIES
MODEL/SERIES
90
0
0
CAPS
TPA - Torque Plus Angle
CAPS
Loosen
Loosen
Loosen
Loosen
150/300
230/260
150/300
230/260
230/260
150/300
230/260
230/260
150/300
loosen
Flat cap
Flat cap
Loosen
Loosen
Loosen
Loosen
MAIN BRG
210/450
195/445
200/450
200/450
144/310
195/445
200/450
420-460
200-210/
MAIN BRG
144/310+
OLD TYPE
OLD TYPE
for cylinder
90 advance
210/420-460
SN. with first

*TPA method
250 +
blocks having
‘D’- KV16 250

letter ‘C’ KV12
150
150
CAPS
/240
CAPS
75/175
Torque
214950
63+60
loosen
All torque values listed below are in lbs.ft

70/140
70/150
Loosen 200- 70/150
CONROD
Loosen
Loosen
threaded
CONROD
70-75/140
70-75/140
capscrews
to 165-175
70-75/140-
70-75/140-
63 loosen
& brgs P.N.

with conrod
150 Loosen
150 Loosen
75/150/250
70/140/220
70/140/220
75/150/250
P.N. 3013930
480
350
CYL.
140-
HEAD
CYL.
HEAD
70/170
221+90
220+90
275, 310
160/290-
310/460-
100/200
100/200
52/148/0
50/150/0
100, 200,
/275/310
/250/355
/300/410
Cooling System ......................................................................... 0-20
Fuel System ............................................................................... 0-29
55
lb-in
10-12
11-12
11-13
11-13
10-13
133-140
INJECTOR
INJECTOR
/410
/410
50-55
FLANGE
180-200
180-200
FLANGE
160/290
160/290
crank with
screw 475
single cap-
Taper nose
100/200/320
148/280/505
CRANK FRONT
CRANK FRONT
IMPORTANT TORQUE VALUES

-
155
120
155
105
55-60
55-60
92/122
DAMPER
DAMPER
VIBRATION
VIBRATION
505
/380
/380
holes
85/ 215
190-200
200-220
190-200
110/210
110/210
148/280/
with hard
FLYWHEEL
FLYWHEEL
with safety
Capscrews
Capscrews
flat washers
288
-
35/145/340 70-135
-
-
-
325-335
SIDE CAPS
SIDE CAPS
MAIN BRGS
MAIN BRGS
75
-
110
215
185
180
-
-
-
Cam
head
IDLER
IDLER
SHAFT
SHAFT
without
W. Pump
Capscrew
Capscrew
with flange
59/122/207
flange head
Hyd. Pump 180

Page 0-50
Page 0-49
NTA-855-G2
NTA-855-G
NTA-855-G1
NTA-743-G
NT-743-G
NT-743-G1
N8 G2
N8 G1
NTA-495-G
NTC-495-G
NT-495-G
Engine Model
Section -1
Section - 1 Page 1
CAC – Charge Air Cooler

T.A. – Turbocharged Aftercooled
T- Turbocharged
N.A – Naturally Aspirated
QSK-60-G4
QTA-60-G3
KTA-50-G8
KTA-50-G3
KTA-3067-G
KTA-38-G5
KTA-2300-G
KT-2300-G
VTA-28-G5
VTA-28-G3
VTA-28-G
VT-1710-G
KTA-19-G4
KTA-1150-G
KT-1150-G
Engine Model
Section –1
GENSET ENGINE & APPLICATION DATA
Contents Page
Engine specifications generator set application……………………………1-1
Modelwise recommendations – genset ……………………………………1-3
Recommendations for Genset Installation ………………………………...1-6
Genset AVM Location & Weight …………………………………………….1-7
Acoustic Enclosures – Range ……………………………………………….1-8
Cummins genset size details ……………………………………………….1-9
No. of
No. of
Cyl.
Load acceptance data……………………………………………………….1-10
Cyl.
16
16
16
16
16
12
12
12
12
12
12
12
6
6
6
6
6
6
4
4
4
4
4
6
6
6
Cable sizes for D. G. sets …………………………………………………..1-11
Exhaust gas temperatures – Genset application ………………………...1-12
Holset coupling details for Cummins engines …………………………….1-13
Torque Specifications for Holset Coupling ………………………………..1-13
6.25 x 7.48 (159 x 190)

6.25 x 7.48 (159 x 190)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
5 1/2 x 6 (140 x 152)
5 1/2 x 6 (140 x 152)
5 1/2 x 6 (140 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
Electronic engine controls information
Bore & Stroke
Bore & Stroke

How to use a digital volt / ohm meter………………………………..1-14
ENGINE SPECIFICATIONS OF GENERATOR SET APPLICATION
ENGINE SPECIFICATIONS OF GENERATOR SET APPLICATION – CONTD…..

Note : 1. * This is conversion of engine Horsepower to KW and not electrical output of alternator.
How to measure current, voltage, resistance,
(mm)
Inch
(mm)
Inch
internal resistance of meter, test for continuity,
Performance Ratings are for 300 Ft. (90 m) 77 F (25 C)

Connector checking …………………………………………1-14 to 1-15
2. All the above ratings of engines for generator set conform to ISO 3046.
EFC governor
EFC governor description …………………………………………….1-16
Introduction to parts …………………………………………………..1-17
EFC controller Specification & Operation …………………………1-18
Troubleshooting-EFC …………………………………………………1-19
Displacement
Displacement
Wiring diagram for
855 (14.00)
855 (14.00)
855 (14.00)
3067 (50.3)
3067 (50.3)
2300 (37.8)
2300 (37.8)
2300 (37.8)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1150 (18.9)
1150 (18.9)
1150 (18.9)
743 (12.2)
743 (12.2)
743 (12.2)
Cub. Inch
Cub. Inch
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
3660 (60)
3660 (60)
3067 (50)
Lucas SM130PE/DELCO REMY starter & Lucas
(liter)
(liter)
alternator model N, V, K6…………………………………………….1-21
Dual Delco Remy Starter & lucas alternator KV 12/16 ……………1-22
Engines with air starters ………………………………………………1-23
Detail wiring diagram for EFC governor……………………………..1-24
Solid state potentiometer ……………………………………………1-25
Rating BHP (kW)* Rating BHP (kW)*

Electronic instruments panel …………………………………………1-26

at 1500 R.P.M.
at 1500 R.P.M.
Prime Power
Prime Power
EIP Internal wiring Diagram ………………………………………….1-27
2319 (1730)
2117 (1579)
1933 (1441)
1470 (1097)
1180 (880)
1180 (880)
340 (253)
306 (228)
280 (208)
255 (190)
231 (172)
205 (150)
173 (129)
154 (115)
225(168)
202(151)
890 (664)
750 (560)
600 (448)
450 (336)
380 (283)
750 (560)
710 (530)
614 (458)
530 (395)
127 (95)
ECP without EFC governor & one starter 4054713………………..1-28
ECP with EFC governor & one starter : 4054714 ……….…………1-29
0
ECP with EFC governor & two starter : 4054715…………………..1-30
ECPG with two starters ………………………………………………1-31
0
Power command genset system architecture………………………1-32
Air Starter
Connection of Pilot Valve & Kit air starter …………………………..1-33
at 1800 R.P.M.
at 1800 R.P.M.
Prime Power
Prime Power
Air requirement for air starter ………………………………………...1-35
1635 (1220)
1350 (1007)
1085 (809)
360 (268)
257 (191)
200 (149)
139 (104)
910 (679)
525 (391)
420 (313)
750 (560)
620 (462)
Air Starting piping arrangement (Inertia engagement-N, K-1150)..1-36
--
--
--
--
--
--
--
Air Starting Piping arrangement
--
--
--
--
--
--
--
(Preengagement type starter-V, KV) ………………………………1-37
Maintenance Schedule other than Firepump engines …………………..1-38
Stand-By Duty Generator Set Maintenance ………………………………1-41
Continuous Duty Generator Set Maintenance ……………………………1-42
Effective utilization of DG set ………………………………………………1-43
Engine performance inspection report Genset ………………………….1-44
Breathing
Breathing
Engine
T-CAC
T-CAC
Engine
Alternate fuels
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T
T
T
T
T
T
LDO Operation ………………………………………………………1-46
Page 1-1
Page 1-2
SKO Operation ………………………………………………………1-47
Special LDO Operation …………………………………………….1-48
Heat Recovery system ………………………………….……………….1-49
Section - 1 Page 1
N8 G2
N8 G1
Contents Page
NT-743-G
NT-495-G
VTA-28-G
Section -1
NT-743-G1
NTA-855-G
NTA-743-G
NTA-495-G
NTC-495-G
KT-2300-G
VT-1710-G
KT-1150-G
Section –1
KTA-50-G8
KTA-50-G3
KTA-38-G5
VTA-28-G5
VTA-28-G3
KTA-19-G4
QTA-60-G3
QSK-60-G4
NTA-855-G2
NTA-855-G1
KTA-3067-G
KTA-2300-G
KTA-1150-G
Engine Model
Engine Model
T- Turbocharged

6
6
6
6
6
6
4
4
4
4
4
6
6
6
16
16
16
16
16
12
12
12
12
12
12
12
Cyl.
Cyl.
No. of
No. of

Inch
(mm)
Inch
(mm)

EFC governor
Bore & Stroke

Bore & Stroke

5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 1/2 x 6 (140 x 152)

5 1/2 x 6 (140 x 152)
5 1/2 x 6 (140 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6.25 x 7.48 (159 x 190)

6.25 x 7.48 (159 x 190)
Wiring diagram for
(liter)
(liter)
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
Cub. Inch
743 (12.2)
743 (12.2)
743 (12.2)
3660 (60)
3660 (60)
3067 (50)
Cub. Inch
855 (14.00)
855 (14.00)
855 (14.00)
3067 (50.3)
3067 (50.3)
2300 (37.8)
2300 (37.8)
2300 (37.8)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1150 (18.9)
1150 (18.9)
1150 (18.9)
Displacement
Displacement

0
0
127 (95)
225(168)
202(151)
340 (253)
306 (228)
280 (208)
255 (190)
231 (172)
205 (150)
173 (129)
154 (115)
890 (664)
750 (560)
600 (448)
450 (336)
380 (283)
750 (560)
710 (530)
614 (458)
530 (395)
1180 (880)
1180 (880)
2319 (1730)
2117 (1579)
1933 (1441)
1470 (1097)
Prime Power
Prime Power
at 1500 R.P.M.
0
at 1500 R.P.M.

Air Starter
--
--
--
--
--
--
--
--
--
--
--
--
--
--

360 (268)
257 (191)
200 (149)
139 (104)
910 (679)
525 (391)
420 (313)
750 (560)
620 (462)
1085 (809)
1635 (1220)
1350 (1007)
Prime Power

Prime Power
at 1800 R.P.M.
at 1800 R.P.M.


Alternate fuels
T
T
T
T
T
T
LDO Operation ………………………………………………………1-46

T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T-CAC
T-CAC
Engine
Engine
SKO Operation ………………………………………………………1-47

Breathing
Breathing

Page 1-1

Page 1-2
Section - 1 Page 1
N8 G2
N8 G1
Contents Page
NT-743-G
NT-495-G
VTA-28-G
Section -1
NT-743-G1
NTA-855-G
NTA-743-G
NTA-495-G
NTC-495-G
KT-2300-G
VT-1710-G
KT-1150-G
Section –1
KTA-50-G8
KTA-50-G3
KTA-38-G5
VTA-28-G5
VTA-28-G3
KTA-19-G4
QTA-60-G3
QSK-60-G4
NTA-855-G2
NTA-855-G1
KTA-3067-G
KTA-2300-G
KTA-1150-G
Engine Model
Engine Model
T- Turbocharged

6
6
6
6
6
6
4
4
4
4
4
6
6
6
16
16
16
16
16
12
12
12
12
12
12
12
Cyl.
Cyl.
No. of
No. of

Inch
(mm)
Inch
(mm)

EFC governor
Bore & Stroke

Bore & Stroke

5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 ½ x 6 (140 x 152)
5 1/2 x 6 (140 x 152)

5 1/2 x 6 (140 x 152)
5 1/2 x 6 (140 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
5 1/8 x 6 (130 x 152)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6 ¼ x 6 ¼ (159 x 159)
6.25 x 7.48 (159 x 190)

6.25 x 7.48 (159 x 190)
Wiring diagram for
(liter)
(liter)
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
495 (8.1)
Cub. Inch
743 (12.2)
743 (12.2)
743 (12.2)
3660 (60)
3660 (60)
3067 (50)
Cub. Inch
855 (14.00)
855 (14.00)
855 (14.00)
3067 (50.3)
3067 (50.3)
2300 (37.8)
2300 (37.8)
2300 (37.8)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1710 (28.0)
1150 (18.9)
1150 (18.9)
1150 (18.9)
Displacement
Displacement

0
0
127 (95)
225(168)
202(151)
340 (253)
306 (228)
280 (208)
255 (190)
231 (172)
205 (150)
173 (129)
154 (115)
890 (664)
750 (560)
600 (448)
450 (336)
380 (283)
750 (560)
710 (530)
614 (458)
530 (395)
1180 (880)
1180 (880)
2319 (1730)
2117 (1579)
1933 (1441)
1470 (1097)
Prime Power
Prime Power
at 1500 R.P.M.
0
at 1500 R.P.M.

Air Starter
--
--
--
--
--
--
--
--
--
--
--
--
--
--

360 (268)
257 (191)
200 (149)
139 (104)
910 (679)
525 (391)
420 (313)
750 (560)
620 (462)
1085 (809)
1635 (1220)
1350 (1007)
Prime Power

Prime Power
at 1800 R.P.M.
at 1800 R.P.M.


Alternate fuels
T
T
T
T
T
T
LDO Operation ………………………………………………………1-46

T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T.A.
T-CAC
T-CAC
Engine
Engine
SKO Operation ………………………………………………………1-47

Breathing
Breathing

Page 1-1

Page 1-2
NOTES
1. All the ratings of engines for generator sets are for continuous duty.
2. The PH value of the engine coolant should be kept within 8.5 to 10.0
3. Lubricating oil recommended - Multiviscosity 15W40
4. Diesel fuel recommended as per IS 1460 1974 Grade ‘a’.
5. All engines have counter-clockwise rotation as viewed from the principal output end.
6. Total air requirement for radiator cooled engines would be addition of fan flow and forced ventilation air volumes.
7. For the details of cooling tower please Contact nearest Cummins Office.
Performance Guarantee -
Engine output figures in this booklet conform with ES 5514/ISO 3074 for generator set applications. Turbocharged engine may be operated without any
loss in power up to 1500 m. elevation and 38 deg. C ambient temperature. Turbocharged engines require no deration in power output for humidity.
Cummins has always been a pioneer in product improvement. This specifications may change without notice.
Section – 1 MODEL – WISE RECOMMENDATIONS – GENSET – CONTD….. Page 1-4

Total Air (ventilation +
Fuel supply /return Pipes
Lub Oil System Capacity

Exhaust pipe size max. 4
breathing)
banks x flow per bank)
Exh. Gas flow (No. of
Heat Exchanger
Radiator Fan flow in

upto 10 mtrs.Min ID
Bends Max. Length
Radiator Core Area

Typical Room Size
requirement for
Coolant Capacity
10 mtrs. Min. ID
R for Radiator)
Rating (0.8 pf)
Genset room
Genset
(H for HE,
LxWxH
HxW
Max. amb. Above
Max. amb. below

40 C (rise 5 C)
40 C (rise 5 C)
cooling tower
Engine Model
Capacity (wbt
pipe Size (ID)

water flow at
o
engine HE
Raw water
o
Min. raw
Typical
26 C)
o
o
KVA m x m x m No. x mm No.xItr/sec mm ltr Itr Itr/sec Itr/sec Itr/sec mxm Itr/min TR mm
NTA 855 G2BC 320 7.5 x 5.0 x 5.0 1 x 125 1 x 1055 20 39 - 10325 5350 - 1.25 x 1.1 **275+125 35 65+40
NTA 855 G2 285 7.5 x 5.0 x 5.0 1 x 125 1 x 980 15 36 55 (H) 95 (R) 9775 5065 10070 1.3 x 1.1 275 30 65
NTA 855 G 250 7.5 x 5.0 x 5.0 1 x 125 1 x 950 15 36 55 (H) 80 (R) 8730 4530 10070 1.3 x 1.1 240 25 50
NTA 855 G1 225 7.5 x 5.0 x 5.0 1 x 125 1 x 850 15 36 55 (H) 80 (R) 7965 4135 10070 1.3 x 1.1 240 25 50
NTA 743 G 200 7.5 x 5.0 x 5.0 1 x 125 1 x 695 15 36 52 (H) 75 (R) 7430 3845 8025 1.1 x 1.1 175 20 40
NT 743 G 180 7.0 x 5.0 x 5.0 1 x 125 1 x 660 15 36 50 (H) 70 (R) 6780 3510 8025 1.1 x 0.9 175 20 40
N8 G2 180 7.0 x 5.0 x 5.0 1 x 100 1 x 600 15 33 75 (R) 5850 3030 5710 1.0 x 0.95 NA NA NA
NT 743 G1 160 7.0 x 5.0 x 5.0 1 x 125 1 x 545 15 36 50 (H) 70 (R) 6050 3140 8025 1.1 x 0.9 175 20 40
N8 G1 160 7.0 x 5.0 x 5.0 1 x 100 1 x 560 15 33 75 (R) 5250 2725 5710 1.0 x 0.95 NA NA NA
NTA 495 G 140 6.5 x 5.0 x 4.0 1 x 100 1 x 485 15 27 43 (H) 62 (R) 5115 2640 3775 0.9 x 0.8 151 15 40
NTC 495 G 125 6.5 x 5.0 x 4.0 1 x 100 1 x 440 15 27 40 (H) 55 (R) 4575 2370 3775 0.8 x 0.9 151 15 40
NT 495 G 100 6.5 x 5.0 x 4.0 1 x 100 1 x 410 15 27 40 (H) 55 (R) 3760 1950 3775 0.8 x 0.9 151 15 40
6BT5.9 G1 82.5 6.0 x 4.0 x 3.5 1 x 75 1 x 225 15 14.3 20 (R) 3495 1790 3590 0.7 x 0.7 NA NA NA
S3.8 G7 625 6.0 x 3.5 x 3.0 1 x 75 1 x 190 10 10 16.5 (R) 2325 1595 2000 0.6 x 0.6 NA NA NA
S3.8 G6 50 5.0 x 3.5 x 3.0 1 x 75 1 x 150 10 10 11 (R) 2060 1055 1890 0.5 x 0.5 NA NA NA
S3.8 G3 35 5.0 x 3.5 x 3.0 1 x 65 1 x 115 10 10 11 (R) 1295 670 1180 0.5 x 0.5 NA NA NA
* Typical Sizes, actual specifications may change as per site condition. ** Separate raw water connections for LTA & main circuit. NA=Not Applicable
Section – 1 MODEL – WISE RECOMMENDATIONS - GENSET Page 1-3

Exh. Gas flow (No. of banks x
Radiator Fan flow in Genset

Bends Max. Length 10 mtrs.
breathing)
Heat Exchanger
requirement for
upto 10 mtrs.Min ID
Radiator Core Area

Typical Room Size
Coolant Capacity
Genset
R for Radiator)
flow per bank)
Rating (0.8 pf)
(H for HE,
LxWxH
Min. ID
HxW
room
Max. amb. below
Typical cooling
40 C (rise 5 C)
Raw water pipe

tower Capacity
Engine Model
Min. raw water
flow at engine
Above 40 C
(wbt 26 C)
Max. amb.
(rise 5 C)
o
Size (ID)
o
o
HE
o
KVA mxmxm No. x mm No.xItr/sec mm Ltr Itr Itr/sec Itr/sec Itr/sec mxm Itr/min TR mm
QSK60-G4 2000 12.5 x 7.5 x 6.5 2 x 325 2 x 2880 50 400 550 (H) 51655 26960 - - 1560 200 125
QSK60-G3 1875 12.5 x 7.5 x 6.5 2 x 325 2 x 2620 50 400 550 (H) 47400 24680 - - 1560 200 125
K15000EG/50G8 1500 12.0 x 7.0 x 6.5 2 x 250 2 x 2175 25 177 320 (H) 40890 21235 - - 1300 150 125
KTA 50G3 1250 12.0 x 7.0 x 6.5 2 x 250 2 x 1820 25 177 310 (H) 440 (R) 32680 17040 27375 2.1 x 2.0 **1100+416 125 100+75
KTA 38 G5 1000 11.0 x 7.0 x 6.5 2 x 250 2 x 1650 25 145 260 (H) 27135 14140 23855 1.9 x 1.8 900 100 100
KTA 2300 G 750 9.0 x 6.0 x 5.0 2 x 200 2 x 1225 25 118 230 (H) 300 (R) 22990 11960 22655 1.9 x 1.65 625 70 100
VTA 28 G5 625 8.5 x 6.0 x 5.0 2 x 125 2 x 1025 20 95 212 (H) 250 (R) 19940 10385 22655 1.9 x 1.65 540 60 75
VTA 28 G3 600 8.5 x 6.0 x 5.0 2 x 125 2 x 920 20 95 210 (H) 240 (R) 18960 9835 18880 1.9 x 1.6 480 60 75
KTA 19 G4 500 8.5 x 5.5 x 5.0 1 x 200 1 x 1600 20 55 125 (H) 175 (R) 14210 7375 20280 1.6 x 1.5 **383+148 60 75+40
VT 1710 G 450 8.5 x 6.0 x 5.0 2 x 125 2 x 800 20 95 210 (H) 14615 7595 11800 1.4 x 1.4 450 50 75
KTA 1150 G 380 8.5 x 5.5 x 5.0 1 x 125 1 x 1225 20 55 80 (H) 115 (R) 12070 6255 10385 1.25 x 1.15 300 35 65
KT 1150 G 320 8.0 x 5.5 x 5.0 1 x 125 1 x 1100 20 55 75 (H) 110 (R) 10345 5370 10385 1.25 x 1.15 275 30 65
NOTES


breathing)
Heat Exchanger

upto 10 mtrs.Min ID
Bends Max. Length
Radiator Core Area

Typical Room Size
requirement for
Coolant Capacity
10 mtrs. Min. ID
R for Radiator)
Rating (0.8 pf)
Genset room
Genset
(H for HE,
LxWxH
HxW
Max. amb. Above
Max. amb. below

40 C (rise 5 C)
40 C (rise 5 C)
cooling tower
Engine Model
Capacity (wbt
pipe Size (ID)

water flow at
o
engine HE
Raw water
o
Min. raw
Typical
26 C)
o
o
NTA 855 G2BC 320 7.5 x 5.0 x 5.0 1 x 125 1 x 1055 20 39 - 10325 5350 - 1.25 x 1.1 **275+125 35 65+40
NTA 855 G2 285 7.5 x 5.0 x 5.0 1 x 125 1 x 980 15 36 55 (H) 95 (R) 9775 5065 10070 1.3 x 1.1 275 30 65
NTA 855 G 250 7.5 x 5.0 x 5.0 1 x 125 1 x 950 15 36 55 (H) 80 (R) 8730 4530 10070 1.3 x 1.1 240 25 50
NTA 855 G1 225 7.5 x 5.0 x 5.0 1 x 125 1 x 850 15 36 55 (H) 80 (R) 7965 4135 10070 1.3 x 1.1 240 25 50
NTA 743 G 200 7.5 x 5.0 x 5.0 1 x 125 1 x 695 15 36 52 (H) 75 (R) 7430 3845 8025 1.1 x 1.1 175 20 40
NT 743 G 180 7.0 x 5.0 x 5.0 1 x 125 1 x 660 15 36 50 (H) 70 (R) 6780 3510 8025 1.1 x 0.9 175 20 40
N8 G2 180 7.0 x 5.0 x 5.0 1 x 100 1 x 600 15 33 75 (R) 5850 3030 5710 1.0 x 0.95 NA NA NA
NT 743 G1 160 7.0 x 5.0 x 5.0 1 x 125 1 x 545 15 36 50 (H) 70 (R) 6050 3140 8025 1.1 x 0.9 175 20 40
N8 G1 160 7.0 x 5.0 x 5.0 1 x 100 1 x 560 15 33 75 (R) 5250 2725 5710 1.0 x 0.95 NA NA NA
NTA 495 G 140 6.5 x 5.0 x 4.0 1 x 100 1 x 485 15 27 43 (H) 62 (R) 5115 2640 3775 0.9 x 0.8 151 15 40
NTC 495 G 125 6.5 x 5.0 x 4.0 1 x 100 1 x 440 15 27 40 (H) 55 (R) 4575 2370 3775 0.8 x 0.9 151 15 40
NT 495 G 100 6.5 x 5.0 x 4.0 1 x 100 1 x 410 15 27 40 (H) 55 (R) 3760 1950 3775 0.8 x 0.9 151 15 40
S3.8 G7 625 6.0 x 3.5 x 3.0 1 x 75 1 x 190 10 10 16.5 (R) 2325 1595 2000 0.6 x 0.6 NA NA NA
S3.8 G6 50 5.0 x 3.5 x 3.0 1 x 75 1 x 150 10 10 11 (R) 2060 1055 1890 0.5 x 0.5 NA NA NA
S3.8 G3 35 5.0 x 3.5 x 3.0 1 x 65 1 x 115 10 10 11 (R) 1295 670 1180 0.5 x 0.5 NA NA NA


breathing)
Heat Exchanger
requirement for
upto 10 mtrs.Min ID
Radiator Core Area

Typical Room Size
Coolant Capacity
Genset
R for Radiator)
flow per bank)
Rating (0.8 pf)
(H for HE,
LxWxH
Min. ID
HxW
room
Max. amb. below
Typical cooling
40 C (rise 5 C)
Raw water pipe

tower Capacity
Engine Model
Min. raw water
flow at engine
Above 40 C
(wbt 26 C)
Max. amb.
(rise 5 C)
o
Size (ID)
o
o
HE
o
QSK60-G4 2000 12.5 x 7.5 x 6.5 2 x 325 2 x 2880 50 400 550 (H) 51655 26960 - - 1560 200 125
QSK60-G3 1875 12.5 x 7.5 x 6.5 2 x 325 2 x 2620 50 400 550 (H) 47400 24680 - - 1560 200 125
K15000EG/50G8 1500 12.0 x 7.0 x 6.5 2 x 250 2 x 2175 25 177 320 (H) 40890 21235 - - 1300 150 125
KTA 50G3 1250 12.0 x 7.0 x 6.5 2 x 250 2 x 1820 25 177 310 (H) 440 (R) 32680 17040 27375 2.1 x 2.0 **1100+416 125 100+75
KTA 38 G5 1000 11.0 x 7.0 x 6.5 2 x 250 2 x 1650 25 145 260 (H) 27135 14140 23855 1.9 x 1.8 900 100 100
KTA 2300 G 750 9.0 x 6.0 x 5.0 2 x 200 2 x 1225 25 118 230 (H) 300 (R) 22990 11960 22655 1.9 x 1.65 625 70 100
VTA 28 G5 625 8.5 x 6.0 x 5.0 2 x 125 2 x 1025 20 95 212 (H) 250 (R) 19940 10385 22655 1.9 x 1.65 540 60 75
VTA 28 G3 600 8.5 x 6.0 x 5.0 2 x 125 2 x 920 20 95 210 (H) 240 (R) 18960 9835 18880 1.9 x 1.6 480 60 75
KTA 19 G4 500 8.5 x 5.5 x 5.0 1 x 200 1 x 1600 20 55 125 (H) 175 (R) 14210 7375 20280 1.6 x 1.5 **383+148 60 75+40
VT 1710 G 450 8.5 x 6.0 x 5.0 2 x 125 2 x 800 20 95 210 (H) 14615 7595 11800 1.4 x 1.4 450 50 75
KTA 1150 G 380 8.5 x 5.5 x 5.0 1 x 125 1 x 1225 20 55 80 (H) 115 (R) 12070 6255 10385 1.25 x 1.15 300 35 65
KT 1150 G 320 8.0 x 5.5 x 5.0 1 x 125 1 x 1100 20 55 75 (H) 110 (R) 10345 5370 10385 1.25 x 1.15 275 30 65
NOTES


breathing)
Heat Exchanger

upto 10 mtrs.Min ID
Bends Max. Length
Radiator Core Area

Typical Room Size
requirement for
Coolant Capacity
10 mtrs. Min. ID
R for Radiator)
Rating (0.8 pf)
Genset room
Genset
(H for HE,
LxWxH
HxW
Max. amb. Above
Max. amb. below

40 C (rise 5 C)
40 C (rise 5 C)
cooling tower
Engine Model
Capacity (wbt
pipe Size (ID)

water flow at
o
engine HE
Raw water
o
Min. raw
Typical
26 C)
o
o
NTA 855 G2BC 320 7.5 x 5.0 x 5.0 1 x 125 1 x 1055 20 39 - 10325 5350 - 1.25 x 1.1 **275+125 35 65+40
NTA 855 G2 285 7.5 x 5.0 x 5.0 1 x 125 1 x 980 15 36 55 (H) 95 (R) 9775 5065 10070 1.3 x 1.1 275 30 65
NTA 855 G 250 7.5 x 5.0 x 5.0 1 x 125 1 x 950 15 36 55 (H) 80 (R) 8730 4530 10070 1.3 x 1.1 240 25 50
NTA 855 G1 225 7.5 x 5.0 x 5.0 1 x 125 1 x 850 15 36 55 (H) 80 (R) 7965 4135 10070 1.3 x 1.1 240 25 50
NTA 743 G 200 7.5 x 5.0 x 5.0 1 x 125 1 x 695 15 36 52 (H) 75 (R) 7430 3845 8025 1.1 x 1.1 175 20 40
NT 743 G 180 7.0 x 5.0 x 5.0 1 x 125 1 x 660 15 36 50 (H) 70 (R) 6780 3510 8025 1.1 x 0.9 175 20 40
N8 G2 180 7.0 x 5.0 x 5.0 1 x 100 1 x 600 15 33 75 (R) 5850 3030 5710 1.0 x 0.95 NA NA NA
NT 743 G1 160 7.0 x 5.0 x 5.0 1 x 125 1 x 545 15 36 50 (H) 70 (R) 6050 3140 8025 1.1 x 0.9 175 20 40
N8 G1 160 7.0 x 5.0 x 5.0 1 x 100 1 x 560 15 33 75 (R) 5250 2725 5710 1.0 x 0.95 NA NA NA
NTA 495 G 140 6.5 x 5.0 x 4.0 1 x 100 1 x 485 15 27 43 (H) 62 (R) 5115 2640 3775 0.9 x 0.8 151 15 40
NTC 495 G 125 6.5 x 5.0 x 4.0 1 x 100 1 x 440 15 27 40 (H) 55 (R) 4575 2370 3775 0.8 x 0.9 151 15 40
NT 495 G 100 6.5 x 5.0 x 4.0 1 x 100 1 x 410 15 27 40 (H) 55 (R) 3760 1950 3775 0.8 x 0.9 151 15 40
S3.8 G7 625 6.0 x 3.5 x 3.0 1 x 75 1 x 190 10 10 16.5 (R) 2325 1595 2000 0.6 x 0.6 NA NA NA
S3.8 G6 50 5.0 x 3.5 x 3.0 1 x 75 1 x 150 10 10 11 (R) 2060 1055 1890 0.5 x 0.5 NA NA NA
S3.8 G3 35 5.0 x 3.5 x 3.0 1 x 65 1 x 115 10 10 11 (R) 1295 670 1180 0.5 x 0.5 NA NA NA


breathing)
Heat Exchanger
requirement for
upto 10 mtrs.Min ID
Radiator Core Area

Typical Room Size
Coolant Capacity
Genset
R for Radiator)
flow per bank)
Rating (0.8 pf)
(H for HE,
LxWxH
Min. ID
HxW
room
Max. amb. below
Typical cooling
40 C (rise 5 C)
Raw water pipe

tower Capacity
Engine Model
Min. raw water
flow at engine
Above 40 C
(wbt 26 C)
Max. amb.
(rise 5 C)
o
Size (ID)
o
o
HE
o
QSK60-G4 2000 12.5 x 7.5 x 6.5 2 x 325 2 x 2880 50 400 550 (H) 51655 26960 - - 1560 200 125
QSK60-G3 1875 12.5 x 7.5 x 6.5 2 x 325 2 x 2620 50 400 550 (H) 47400 24680 - - 1560 200 125
K15000EG/50G8 1500 12.0 x 7.0 x 6.5 2 x 250 2 x 2175 25 177 320 (H) 40890 21235 - - 1300 150 125
KTA 50G3 1250 12.0 x 7.0 x 6.5 2 x 250 2 x 1820 25 177 310 (H) 440 (R) 32680 17040 27375 2.1 x 2.0 **1100+416 125 100+75
KTA 38 G5 1000 11.0 x 7.0 x 6.5 2 x 250 2 x 1650 25 145 260 (H) 27135 14140 23855 1.9 x 1.8 900 100 100
KTA 2300 G 750 9.0 x 6.0 x 5.0 2 x 200 2 x 1225 25 118 230 (H) 300 (R) 22990 11960 22655 1.9 x 1.65 625 70 100
VTA 28 G5 625 8.5 x 6.0 x 5.0 2 x 125 2 x 1025 20 95 212 (H) 250 (R) 19940 10385 22655 1.9 x 1.65 540 60 75
VTA 28 G3 600 8.5 x 6.0 x 5.0 2 x 125 2 x 920 20 95 210 (H) 240 (R) 18960 9835 18880 1.9 x 1.6 480 60 75
KTA 19 G4 500 8.5 x 5.5 x 5.0 1 x 200 1 x 1600 20 55 125 (H) 175 (R) 14210 7375 20280 1.6 x 1.5 **383+148 60 75+40
VT 1710 G 450 8.5 x 6.0 x 5.0 2 x 125 2 x 800 20 95 210 (H) 14615 7595 11800 1.4 x 1.4 450 50 75
KTA 1150 G 380 8.5 x 5.5 x 5.0 1 x 125 1 x 1225 20 55 80 (H) 115 (R) 12070 6255 10385 1.25 x 1.15 300 35 65
KT 1150 G 320 8.0 x 5.5 x 5.0 1 x 125 1 x 1100 20 55 75 (H) 110 (R) 10345 5370 10385 1.25 x 1.15 275 30 65
Rear Overhang Rad (m)

Rear Overhang HE (m)
Front overhang Rad (m)
Front overhang HE (m)
9 & 10
8 &9
7 &8
6 &7
5 &6
3 &4
2 &3
1 &2
Distance between foundation holes / AVM’s in meters
Base rail length Rad (m)

Base rail length HE (m)
Quantity
AVM Model (Gerb)
Weight (kg)
Genset
Weight (kg)
Engine only
Alternator Model
Engine Model
Genset rating – KVA
Location selection criterion

Section – 1
Section – 1
th
th
th
th
th
rd
nd
st
RECOMMENDATIONS GENSET INSTALLATION
KV 16 G4
KV 16
KV 12
VTA 1710
K6 G4
K6
NTA 855
NT/A 743
N 4.8
NT/C/A 495
S / 6BT 5.9
S 3.8
Model
th
th
th
th
th
nd
rd
th
Room Layout :-
Typical 2-meter free space around genset is recommended for
proper heat dissipation and ease of service.
Radiator
H.E.
Radiator
H.E
However, to avoid hot air recirculation radiator cooled engines may
have less space in front. Minimum 1.5 meter free space is a must for
100 KVA and bigger gensets, for smaller gensets it should be 1
meter.
Room Ventilation
1250
1000
625/750
500/590
500
320/380
250/285
KVA Rating
160/180/200
160/180
30/40/50
100/125/140
62.5/75/82.5
KS-FS1300
1425/1500
KTA50G8
12,135
11,100
For radiator cooled engines opening in front of radiator should be 1.5
- Max overhang of 350 mm for HE cooled sets

- Max distance between two AVM’s 1.2 m
0.275
5690
5690
HC7
0.38
0.25
5.96
5.75
0.2
0.5
0.5
0.7
0.7
0.9
16
1
1
times radiator core & at back 2.25 to 3 times radiator core. Ducting in
GENSET WEIGHT AVM LOCATION (GERB MAKE) – SUMMARY

front of radiator is recommended, however it is not mandatory. If
THE RANGE OF CUMMINS ACOUSTIC ENCLOSURES

opening exactly in the front of radiator is not possible then ducting
should be done to take out hot air. If opening in the back side of
KS-FS1300
genset is not possible then opening on both sides of genset at the
KTA50G3
10,600
10,000
HC6Z
5662
5662
1250
rear of the alternator may be acceptable. In this case total openings
0.35
0.20
5.80
5.65
0.95
0.3
0.3
0.6
0.6
14
1
1
1
in two side walls should be atleast 3 times radiator core.
Additional ventilation arrangement may be required for radiator
9200
8600
7000
7600
7300
6900
6200
Length (mm)
5200
5400
3500
4900
4000
cooled engines installed in acoustic rooms enclosures. Radiator
KS-FS1300
KTA38G5
cooled engines may create slight negative pressure inside the genset
0.975
0.525
9500
8600
4600
4600
1000
HC6
0.40
0.20
5.30
4.90
0.4
0.2
12
1
1
1
room/enclosure. Maximum static restriction should not increase 6-
mm water column.
Foundation.
KS-FS1300
KTA2300G
Do not install Genset on loose sand or clay. Foundation should be
0.325
0.950
0.625
0.700
1.000
1.000
7900
7400
4136
4196
0.33
0.20
KC6
4.80
4.80
designed considering safe bearing capacity of soil. Vibration isolators
750
0.2
- Same foundation drawing for HE & Radiator cooled se ts.

12
- Max tilt 0.2 mm / meter of length of base rail

(AVMs) reduce generator set vibration and noise transmission to the
surrounding structure, hence they are recommended, however they
3000
3000
2200
2500
2500
2000
1800
Width (mm)
1600
1800
1200
1600
1400
are not mandatory. The length and breadth of foundation should be
at least 150-300 mm (6-12”) more than base rail length and breadth
KS-FS1300
VTA28G5
respectively.
0.275
6400
6100
3050
3150
0.35
0.28
1.05
4.20
4.20
1.05
1.05
625
0.2
0.5
10
Cooling System
Raw water inlet temperature should be 32 deg C with typical
temperature rise of 7-11 deg C. Cooling tower should be selected
based on this temperature difference and wet bulb temp. of site.
(HE length?)
KTA19G4
It is mandatory to install raw water temperature & pressure gauges at
KS 84
0.200
0.350
0.500
0.900
0.900
0.900
4700
4400
1927
1927
0.35
0.20
3.90
3.60
500
10
inlet and outlet connections to H.E.
3500
3500
2600
3500
3200
2600
2400
2400
Height (mm)
2400
1750
2200
1750
Recommended raw water pressure at inlet of heat exchanger should
2
be 3.5 kg/cm (50 psi) max.
There should be positive pressure on suction of raw water pump.
4000
3900
1886
2142
KTA
380/320
KT/A 1150
Strainer, non-return valve should be used in cooling tower circuit
KS 84
0.175
1.125
0.725
1.125
Page 1-8
0.33
0.17
3.70
3.32
Typical raw water Pump size, (20 m total head on Pump)
0.4
Page 1-7
8
Upto 380 KVA 2.2 kW (3 HP)
3700
3600
1700
2000
KT
400 to 625 KVA 3.7 kW (5 HP)
750 to 1500 KVA 5.5 kW (7.5 HP)
1875 to 2000 KVA 7.5 kW (10 HP)
st
th
th
th
th
th
rd
nd
8 &9
7 &8
6 &7
5 &6
3 &4
1 &2
2 &3
Genset
th
th
th
th
th
9 & 10
rd
nd
Quantity
th
K6
S 3.8
N 4.8
Weight (kg)
Weight (kg)
Section – 1
Engine only
KV 16
KV 12
K6 G4
Model
Section – 1
Room Layout :-
Engine Model
NTA 855
NT/A 743
KV 16 G4
VTA 1710
Alternator Model
S / 6BT 5.9
NT/C/A 495
AVM Model (Gerb)

H.E
H.E.


Radiator
Radiator
meter.
Room Ventilation
500
1250
1000
1
1
16
0.2
0.5
0.5
0.7
0.7
0.9
0.38
0.25
5.96
5.75
HC7
625/750
500/590
320/380
250/285
160/180
5690
5690
0.275
30/40/50
12,135
11,100
KTA50G8
1425/1500
KS-FS1300
KVA Rating
160/180/200
100/125/140
62.5/75/82.5

1
1
1
14
0.3
0.3
0.6
0.6
0.35
0.20
5.80
5.65
0.95
5662
5662
1250
HC6Z
10,600
10,000
KTA50G3
KS-FS1300
9200
8600
7000
7600
7300
6900
6200
5200
5400
3500
4900
4000
1
1
1
12
0.4
0.2
0.40
0.20
HC6
5.30
4.90
9500
8600
4600
4600
1000
0.975
0.525
mm water column.
KTA38G5
Length (mm)
KS-FS1300
Foundation.
12
0.2
750
0.33
0.20
KC6
4.80
4.80
7900
7400
4136
4196
0.325
0.950
0.625
0.700
1.000
1.000
KTA2300G
KS-FS1300
3000
3000
2200
2500
2500
2000
1800
1600
1800
1200
1600
1400
respectively.
Width (mm)
10
0.2
0.5
625
0.35
0.28
1.05
4.20
4.20
1.05
1.05
6400
6100
3050
3150
0.275
Cooling System
VTA28G5
KS-FS1300
inlet and outlet connections to H.E. 10
500
0.35
0.20
3.90
3.60
4700
4400
1927
1927
0.200
0.350
0.500
0.900
0.900
0.900
KS 84

KTA19G4
(HE length?)
3500
3500
2600
3500
3200
2600
2400
2400
2400
1750
2200
1750

KTA
Height (mm)
4000
3900
1886
2142

8
380/320
0.4
0.33
0.17
3.70
3.32
0.175
1.125
0.725
1.125
KS 84

KT/A 1150
KT
400 to 625 KVA 3.7 kW (5 HP)

3700
3600
1700
2000
Page 1-8
Page 1-7
750 to 1500 KVA 5.5 kW (7.5 HP)

1875 to 2000 KVA 7.5 kW (10 HP)
st
th
th
th
th
th
rd
nd
8 &9
7 &8
6 &7
5 &6
3 &4
1 &2
2 &3
Genset
th
th
th
th
th
9 & 10
rd
nd
Quantity
th
K6
S 3.8
N 4.8
Weight (kg)
Weight (kg)
Section – 1
Engine only
KV 16
KV 12
K6 G4
Model
Section – 1
Room Layout :-
Engine Model
NTA 855
NT/A 743
KV 16 G4
VTA 1710
Alternator Model
S / 6BT 5.9
NT/C/A 495
AVM Model (Gerb)

H.E
H.E.


Radiator
Radiator
meter.
Room Ventilation
500
1250
1000
1
1
16
0.2
0.5
0.5
0.7
0.7
0.9
0.38
0.25
5.96
5.75
HC7
625/750
500/590
320/380
250/285
160/180
5690
5690
0.275
30/40/50
12,135
11,100
KTA50G8
1425/1500
KS-FS1300
KVA Rating
160/180/200
100/125/140
62.5/75/82.5

1
1
1
14
0.3
0.3
0.6
0.6
0.35
0.20
5.80
5.65
0.95
5662
5662
1250
HC6Z
10,600
10,000
KTA50G3
KS-FS1300
9200
8600
7000
7600
7300
6900
6200
5200
5400
3500
4900
4000
1
1
1
12
0.4
0.2
0.40
0.20
HC6
5.30
4.90
9500
8600
4600
4600
1000
0.975
0.525
mm water column.
KTA38G5
Length (mm)
KS-FS1300
Foundation.
12
0.2
750
0.33
0.20
KC6
4.80
4.80
7900
7400
4136
4196
0.325
0.950
0.625
0.700
1.000
1.000
KTA2300G
KS-FS1300
3000
3000
2200
2500
2500
2000
1800
1600
1800
1200
1600
1400
respectively.
Width (mm)
10
0.2
0.5
625
0.35
0.28
1.05
4.20
4.20
1.05
1.05
6400
6100
3050
3150
0.275
Cooling System
VTA28G5
KS-FS1300
inlet and outlet connections to H.E. 10
500
0.35
0.20
3.90
3.60
4700
4400
1927
1927
0.200
0.350
0.500
0.900
0.900
0.900
KS 84

KTA19G4
(HE length?)
3500
3500
2600
3500
3200
2600
2400
2400
2400
1750
2200
1750

KTA
Height (mm)
4000
3900
1886
2142

8
380/320
0.4
0.33
0.17
3.70
3.32
0.175
1.125
0.725
1.125
KS 84

KT/A 1150
KT
400 to 625 KVA 3.7 kW (5 HP)

3700
3600
1700
2000
Page 1-8
Page 1-7
750 to 1500 KVA 5.5 kW (7.5 HP)

1875 to 2000 KVA 7.5 kW (10 HP)
Section – 1 Page 1-10 Section - 1 Page 1-11
LOAD ACCEPTANCE DATA
TYPICAL CABLE SIZES FOR DG SETS
CUMMINS-GENSET ROOM SIZE DETAILS
% STAND BY Earthing
KVA Amp. Cable size
Approx. Dry FREQUENCY RECOVERY Strip/Wire
ENGINE MODEL LOAD IN ONE Rating Rating (sq. mm) x runs (m)
Engine Model Total Dimensions of Set Weight of DIP (HZ) TIME (SEC.) (Copper)
STEP
Engine (Kgs.) 30 42 16*1 8 SWG
N-495-G 100 1.5 3 50 70 25*1 8 SWG
L-mm H-mm W-mm
N-495-G 2585 1495 940 890 N-495-G 80 3 4 62.5 87 35*1 25 mm x 3 mm
NTC-495-G 70 4 4 75 104 50*1 25 mm x 3 mm
NT-495-G 2580 1740 940 940
82.5 115 70*1 25 mm x 3 mm
N-743-G 2950 1725 940 940 N-743-G 100 1.5 3
100 139 95*1 25 mm x 3 mm
NT-743-G/G1 3060 1880 1006 1140 NT-743-G 80 3 4
125 174 120*1 25 mm x 3 mm
NTA-743-G 3050 1880 1105 1190 NTA-743-G1 80 3 4 140 195 150*1 25 mm x 3 mm
N-855-G 2985 1880 1006 1220 N-855-G 100 1.5 3 160 223 185*1 25 mm x 3 mm
NTA-855-G/G2 1945 1105 1105 1176 NTA-855-G 70 4 4 180 250 240*1 25 mm x 3 mm
KT-1150-G 3580 1840 1290 1255 NTA-855-G2 65 5 5 200 278 300*1 25 mm x 3 mm
KTA-1150-G 3580 1840 1290 1255 225 313 400*1 150*2 25 mm x 6 mm

KT-1150-G 65 5 5
250 348 400*1 185*2 95*3 25 mm x 6 mm
VT-1710-G 4510 2052 1460 1634 KTA-1150~G 65 5 5
285 396 225*2 120*3 70*4 25 mm x 6 mm
VTA-1710-G 4510 2052 1460 1680 VT-1710-G 80 4.5 5 320 445 300*2 150*3 95*4 25 mm x 6 mm
KT-2300-G 5070 2770 1780 2447 VTA-1710-G 70 4 4 380 529 400*2 185*3 120*4 25 mm x 6 mm
KTA-2300-G 5070 2770 1780 2769 450 626 240*3 150*4 95*5 25 mm x 6 mm
KT-2300-G 80 4.5 6
KTA-3067-G 5635 2770 1894 3609 500 696 300*3 185*4 120*5 32 mm x 6 mm
KTA-2300-G 65 5 4
600 835 240*4 185*5 120*6 32 mm x 6 mm
KT-3067-G 60 4 4
625 870 300*4 185*5 120*6 32 mm x 6 mm
KTA-50G3 47 4 4 650 904 300*4 225*5 150*6 50 mm x 6 mm
750 1043 400*4 240*5 185*6 50 mm x 6 mm
The above specifications are for reference only and are subject to 1000 1391 300*6 225*7 50 mm x 6 mm
alteration without notice. 1250 1739 400*7 300*8 240*7 50 mm x 6 mm
1500 2087 400*8 300*9 240*10 50 mm x 6 mm
1800 2504 400*10 50 mm x 6 mm
2000 2782 500*10 50 mm x 6 mm
Notes :
1. Use 3-1/2 core armored power cables with aluminium conductor.
(AYFY)
2. Current rating of cables are taken based on operating temperature of
o
70 C.
3. For multiple runs of cables deration factor of 0.75 is considered i.e.
25% deration applied.
4. AYFY conductor, PVC insulation, Steel strip armour, PVC outer
sheath.
5. Cable sizes mentioned are in square mm.
6. For sets above 1000 kVA use of proper busbars in bus ducts is
recommended.
% STAND BY Earthing
KVA Amp. Cable size
STEP
N-495-G 100 1.5 3 50 70 25*1 8 SWG
L-mm H-mm W-mm
N-495-G 2585 1495 940 890 N-495-G 80 3 4 62.5 87 35*1 25 mm x 3 mm
NTC-495-G 70 4 4 75 104 50*1 25 mm x 3 mm
NT-495-G 2580 1740 940 940
82.5 115 70*1 25 mm x 3 mm
N-743-G 2950 1725 940 940 N-743-G 100 1.5 3
100 139 95*1 25 mm x 3 mm
NT-743-G/G1 3060 1880 1006 1140 NT-743-G 80 3 4
125 174 120*1 25 mm x 3 mm
NTA-743-G 3050 1880 1105 1190 NTA-743-G1 80 3 4 140 195 150*1 25 mm x 3 mm
N-855-G 2985 1880 1006 1220 N-855-G 100 1.5 3 160 223 185*1 25 mm x 3 mm
NTA-855-G/G2 1945 1105 1105 1176 NTA-855-G 70 4 4 180 250 240*1 25 mm x 3 mm
KT-1150-G 3580 1840 1290 1255 NTA-855-G2 65 5 5 200 278 300*1 25 mm x 3 mm
KTA-1150-G 3580 1840 1290 1255 225 313 400*1 150*2 25 mm x 6 mm

KT-1150-G 65 5 5
250 348 400*1 185*2 95*3 25 mm x 6 mm
VT-1710-G 4510 2052 1460 1634 KTA-1150~G 65 5 5
285 396 225*2 120*3 70*4 25 mm x 6 mm
VTA-1710-G 4510 2052 1460 1680 VT-1710-G 80 4.5 5 320 445 300*2 150*3 95*4 25 mm x 6 mm
KT-2300-G 5070 2770 1780 2447 VTA-1710-G 70 4 4 380 529 400*2 185*3 120*4 25 mm x 6 mm
KTA-2300-G 5070 2770 1780 2769 450 626 240*3 150*4 95*5 25 mm x 6 mm
KT-2300-G 80 4.5 6
KTA-3067-G 5635 2770 1894 3609 500 696 300*3 185*4 120*5 32 mm x 6 mm
KTA-2300-G 65 5 4
600 835 240*4 185*5 120*6 32 mm x 6 mm
KT-3067-G 60 4 4
625 870 300*4 185*5 120*6 32 mm x 6 mm
KTA-50G3 47 4 4 650 904 300*4 225*5 150*6 50 mm x 6 mm
750 1043 400*4 240*5 185*6 50 mm x 6 mm
1500 2087 400*8 300*9 240*10 50 mm x 6 mm
1800 2504 400*10 50 mm x 6 mm
2000 2782 500*10 50 mm x 6 mm
Notes :
(AYFY)
o
70 C.
sheath.
recommended.
% STAND BY Earthing
KVA Amp. Cable size
STEP
N-495-G 100 1.5 3 50 70 25*1 8 SWG
L-mm H-mm W-mm
N-495-G 2585 1495 940 890 N-495-G 80 3 4 62.5 87 35*1 25 mm x 3 mm
NTC-495-G 70 4 4 75 104 50*1 25 mm x 3 mm
NT-495-G 2580 1740 940 940
82.5 115 70*1 25 mm x 3 mm
N-743-G 2950 1725 940 940 N-743-G 100 1.5 3
100 139 95*1 25 mm x 3 mm
NT-743-G/G1 3060 1880 1006 1140 NT-743-G 80 3 4
125 174 120*1 25 mm x 3 mm
NTA-743-G 3050 1880 1105 1190 NTA-743-G1 80 3 4 140 195 150*1 25 mm x 3 mm
N-855-G 2985 1880 1006 1220 N-855-G 100 1.5 3 160 223 185*1 25 mm x 3 mm
NTA-855-G/G2 1945 1105 1105 1176 NTA-855-G 70 4 4 180 250 240*1 25 mm x 3 mm
KT-1150-G 3580 1840 1290 1255 NTA-855-G2 65 5 5 200 278 300*1 25 mm x 3 mm
KTA-1150-G 3580 1840 1290 1255 225 313 400*1 150*2 25 mm x 6 mm

KT-1150-G 65 5 5
250 348 400*1 185*2 95*3 25 mm x 6 mm
VT-1710-G 4510 2052 1460 1634 KTA-1150~G 65 5 5
285 396 225*2 120*3 70*4 25 mm x 6 mm
VTA-1710-G 4510 2052 1460 1680 VT-1710-G 80 4.5 5 320 445 300*2 150*3 95*4 25 mm x 6 mm
KT-2300-G 5070 2770 1780 2447 VTA-1710-G 70 4 4 380 529 400*2 185*3 120*4 25 mm x 6 mm
KTA-2300-G 5070 2770 1780 2769 450 626 240*3 150*4 95*5 25 mm x 6 mm
KT-2300-G 80 4.5 6
KTA-3067-G 5635 2770 1894 3609 500 696 300*3 185*4 120*5 32 mm x 6 mm
KTA-2300-G 65 5 4
600 835 240*4 185*5 120*6 32 mm x 6 mm
KT-3067-G 60 4 4
625 870 300*4 185*5 120*6 32 mm x 6 mm
KTA-50G3 47 4 4 650 904 300*4 225*5 150*6 50 mm x 6 mm
750 1043 400*4 240*5 185*6 50 mm x 6 mm
1500 2087 400*8 300*9 240*10 50 mm x 6 mm
1800 2504 400*10 50 mm x 6 mm
2000 2782 500*10 50 mm x 6 mm
Notes :
(AYFY)
o
70 C.
sheath.
recommended.
EXHAUST GAS TEMPERATURE
GENSET APPLICATION DETAILS OF HOLSET COUPLINGS FOR CUMMINS ENGINES ELECTRONIC ENGINE CONTROLS -INFORMATION
Exhaust Gas GENERAL INFORMATION
Engine Model Temperatures Engine Models Type of Flexible Coupling
Deg. F (Deg.C) How To Use A Digital Volt/Ohm Meter
All “B” Series On most meters, the negative (black) meter lead
KT 1150 G 1050 (566)
N/NT/NTA 495, NTC 495, 0.37 RB SAE 14 must be plugged in the “COM” position and the
KT2300 970 (521) positive (red) meter lead must be plugged into
N-743, N-743-T, N 855
KTA 1150 G 975 (524) one of the positions marked for current,
NT/NTA 743, NT/NTA 855, resistance, or voltage. Refer to the
KTA 2300 G 1005 (541)
NTA 855 G2 0.73 RB SAE 14 manufacturer’s instructions for more detail.
* KTA 50G3 878 (490)
N 743-TG 900 (482) KT/KTA 1150
NOTE: When measuring to a block ground, use
N 855-G 1000 (538) V/VT/VTA 1710 1.15 RB SAE 14 a clean unpainted metal surface to ensure a
N495 1155 (524) KT/KTA 2300 good measurement.
N8 G2 860 (460) KTA 3067 2.15 RB SAE 14
How To Measure Current
NT 495 G 955 (513)
Make an open circuit at the place where the
NT 743 945 (507)
current needs to be measured.
NT 743 G 945 (507) Torque Specifications for Holset Coupling Select the AC current (A~) or DC current (A -)
NT 743 G1 890 (477) function on the meter.
NTA 495 G 840 (449) Coupling Grade Flange Bolts Grade Cover Set Screws Turn on the power in the circuit being measured.
Type 8.8 Torque Tighten 8.8 Torque Tighten
NTA 743 G 890 (477) Put the leads of the meter across the open circuit
N-m (Ft.Lbs) N-m (Ft.Lbs)
NTA 855 G 895 (480) to measure the current. Read the displayed
0.37 M 10 37 (27.29) M 10 37 (27.29)
NTA 855 G2 940 (504) measurement.
0.73 M 12 64 (47.20) M 10 37 (27.29)
NTC 495 G 1040 (560)
1.15 M 12 64 (47.20) M 12 64 (47.20)
QSK60-G3 845 (450) How To Measure Voltage
2.15 M 12 64 (47.20) M 12 64 (47.20)
QSK60-G4 865 (463)
Select the AC voltage (V~) or DC voltage (V-)
VT 1710 G 1000 (538)
function on the meter.
VTA 28 G5 920 (493)
NOTE :- Turn on the power in the circuit being measured.
Data is based on operation under SAE standard J8 16b conditions of A flexible coupling operating in correctly assessed system requires Put the leads of the meter in parallel with the
500 feet (150m) altitude. (29.00 inch (736 mm) Hg. dry barometer) 85
no maintenance. It is recommended that the rubber blocks are component to measure the voltage potential
Deg. f (29 Deg C) intake air temperature and 0.38 in (9.6 mm) Hg
water vapour pressure, using no.2 diesel or a fuel corresponding to inspected for every 5000 hrs.
difference between the two points of the
ASTM D2.
A small amount of rubber dust is normal. In initial running large component.
* Data is based on operation under SAE standard J 1349 quantity of dust requires inspection on use of sufficient lubricants,
conditions of 300 feet (100 m) altitude. 29.61 inch Hg (100 kPa) damages during assembly and proper torques.
barometer, 77 Deg. F (25 Deg C) intake air temp; using No 2
diesel or a fuel corresponding to ASTM D2.
KT 1150 G 1050 (566)
N-743, N-743-T, N 855
KTA 2300 G 1005 (541)
* KTA 50G3 878 (490)
N 743-TG 900 (482) KT/KTA 1150
N8 G2 860 (460) KTA 3067 2.15 RB SAE 14
NT 495 G 955 (513)
NT 743 945 (507)
0.37 M 10 37 (27.29) M 10 37 (27.29)
0.73 M 12 64 (47.20) M 10 37 (27.29)
NTC 495 G 1040 (560)
1.15 M 12 64 (47.20) M 12 64 (47.20)
2.15 M 12 64 (47.20) M 12 64 (47.20)
QSK60-G4 865 (463)
VT 1710 G 1000 (538)
VTA 28 G5 920 (493)
ASTM D2.
KT 1150 G 1050 (566)
N-743, N-743-T, N 855
KTA 2300 G 1005 (541)
* KTA 50G3 878 (490)
N 743-TG 900 (482) KT/KTA 1150
N8 G2 860 (460) KTA 3067 2.15 RB SAE 14
NT 495 G 955 (513)
NT 743 945 (507)
0.37 M 10 37 (27.29) M 10 37 (27.29)
0.73 M 12 64 (47.20) M 10 37 (27.29)
NTC 495 G 1040 (560)
1.15 M 12 64 (47.20) M 12 64 (47.20)
2.15 M 12 64 (47.20) M 12 64 (47.20)
QSK60-G4 865 (463)
VT 1710 G 1000 (538)
VTA 28 G5 920 (493)
ASTM D2.
Electronic Engine Controls - EFC GOVERNOR INTRODUCTION TO PARTS
Engine Controls - 1) EFC Governor Description

How To Measure Resistance The Electric Fuel Controller (EFC) governor A change in current in the actuator coil will
in used on engine for controlling it’s speed make the actuator-shaft rotate. The fuel flow
Select the resistance function on the meter. either in an isochronous mode or with and the engine speed or power will change,
adjustable droop. EFC governor is used on
Verify that there is no power to the components when the actuator shaft rotates.
PT fuel system. The governor contains a
being tested.
magnetic pickup, actuator mounted in
Put the leads of the meter in parallel with the housing, called as a housing actuator, a
component to measure resistance. governor controller, mounting parts, and a
cable harness for interconnections.
How To Find The Internal Resistance of The 2) Introduction to Parts

Meter The magnetic pickup senses the engine
speed at the flywheel ring gear and The figure shows how various parts are
It is important to know the internal resistance of functionally connected. Following major parts
the meter when measuring small resistances. To generates an A C voltage with it’s frequency
are included in the EFC governor.
accurately measure small resistances, the proportional to the engine speed. The
internal resistance of the meter must be frequency also depends on number of gear
subtracted from the measured resistance. teeth on the flywheel. Signal from magnetic
pickup is sensed by a governor controller
Turn the meter “ON” and is used as a speed feedback.
Set the meter to the lowest ohm scale. Measure 2a) Magnetic Pickup:
the resistance across the meter test leads A magnetic pickup is an electro-magnetic
(including special test leads if they are being device. It is mounted on the flywheel housing
used). so that the ring gear teeth are sensed by a
The actuator mounted in the housing pickup. Sensing distance should be between
actuator is used to control the fuel flow from 0.028” - 0.042” from the flywheel gear tooth. A
“ZERO” the meter or subtract this value when
taking measurements. the fuel-pump to the injectors. Actuator pickup requires a hole with 5/8-18 UNF-2A
valve (When no current is flowing in size tap for mounting. Three pin power- lock
actuator coil) is normally closed. Actuator connector is provided to connect the magnetic
How To Test For Continuity valve opens depending on the amount of pickup to the engine harness.
Select the continuity function on the meter current through the actuator coil.
(usually marked with a diode symbol). Make sure
there is no power to the component being
measured. Put the leads of the meter in parallel
with the component to test continuity. 2b) Actuator and Housing Actuator:
The governor controller compares the
The actuator is an electromagnetic rotary
The meter will beep if the resistance is less than electrical signal from the magnetic pickup
solenoid valve. The actuator is housed in the
150 Ohms. If there is an open circuit, the meter with a preset speed reference point. If there
aluminium housing. This assembly is used as
will not beep. is a difference in the two signals, the
a valve for controlling the speed and horse
controller will change the current to the
power of an engine.
actuator.
Connector - Checking
When disconnecting connectors during
troubleshooting, the pins must always be
inspected to make sure they are not the cause of
a bad connection. The three things to look for are
bent, corroded and pushed back pins.

being tested.

power of an engine.
actuator.

being tested.

power of an engine.
actuator.
CONTROLLER SPECIFICATIONS TROUBLE-SHOOTING
SYMPTOM 2) Engine has rough performance or surge.
OPERATION A) Three lamps are provided for diagnostics on EFC controller.
CHECKS and CORRECTIONS:
Governor Mode 0% (ISOCHRONOUS) TO 6-8% 1) Power OK Lamp : This lamp glows only when the supply voltage i) Install sight glass and check for air in fuel.
Droop is within 18 to 30 Volts. If this lamp at any time does not glow,
check for battery voltage or connections. ii) Check whether controller is adjusted correctly.
Steady State Stability Less than + / – 1/ 2 %
iii) Check ac ripple voltage on 24 V dc supply by digital
Idle Speed Setting (Frequency Range) 1 KHz to 4 KHz 2) Mag. Pickup OK : This lamp glows when the engine runs at a multimeter / oscilloscope. If ripple is more than 1 volts
Run Speed Setting (Frequency Range) Idle Setting to 6 KHz speed above 200 rpm. If this lamp does not glow, it indicates that remove the cause or ripple. Connect battery charger
the pulses from pickup are not being received. Check the gap directly to battery terminals.
POWER between pickup and flywheel ring gear. If the gap is OK, check the
connections. If the connections are also OK, replace the pickup. iv) Check the system voltage. If it is below 19 V dc charge the
Operation Voltage 24 Volts dc + / -6 Volts.
batteries.
Power Consumption 60 Watt Max. Check Magnetic Pickup signal on the controller terminal no. 8 and
9 with digital multimeter on AC voltage range during cranking. If it v) Remove connections going to controller and apply 24 V to
Normal Operating Current 1.5 Amps is more than 1.5 V AC then magnetic pickup is OK. If magnetic the actuator terminals. If the actuator does not click, as if it
ENVIRONMENTAL pickup ok lamp still does not glow, replace the controller. is not operating, or operating slow, loosen all of the
capscrews used for actuator mounting and tighten them
Ambient Operating Temperature -10 to 55 degrees Centigrade again as per procedure.
3) Actuator OK : This lamp glows when actuator coil is taking
Relative humidity 0 to 90 % current in the range of 0.5 to 1.8 amps. approx. i.e. lamp is off
vi) Remove actuator and check ‘O’ rings, springs and gasket.
PHYSICAL when actuator is taking full current or zero current. This lamp is off Replace defective parts.
when the engine is at standstill. At the time of cranking, this lamp
Dimensions 12” x 8” x 3” turns on momentarily. Lamp remains on when the engine speed is vii) Check whether the actuator is sticky. If found sticky, clean
Weight 2.5 Kg (approx) governed. If this lamp is not glowing, it indicates that, either with isopropyl alcohol. Reinstall the actuator as per the
actuator is not properly connected or else the actuator is fully procedure.
PROTECTION
open but the sufficient fuel is not flowing. Check fuel input line or
High Voltage Protection 36 V DC fuel filters.
SYMPTOM 3) Engine operates at high idle
Reverse Supply Polarity 36 V DC
B) Following is the list of symptoms and checks to be performed. CHECKS and CORRECTIONS :
Vibration Protection Controller sealed with EPOXY
Carry out all the checks or corrections in sequence till the problem
Compound. is rectified. i) Check whether run speed is adjusted too high. If so adjust
the speed correctly.
SYMPTOM : 1) Engine cranks but will not start.
ii) Check ‘O’ rings in the actuator.
MAGNETIC PICKUP SPECIFICATIONS CHECKS and CORRECTIONS:
iii) Check Voltage at the actuator terminals, If it is more than
i) Check for fuel in tank and fuel valve.
Proximity to gear teeth 0.028 min. - 0.042 max (inches) 17 V, inspite of
ii) Check whether fuel is reaching injector while cranking
1) Putting run / idle switch on idle mode.
(1/2 to 3/4 turn) engine.
Or
Thread size 5/8- 18 UNF-2A iii) Check whether fuel shutoff valve opens when the engine is
cranked. 2) Decreasing Run speed in Run mode by rotating run pot.
Tap drill size 37/64 CCW. then check wiring, RUN/IDLE switch and it’s
iv) Check for the RUN and IDLE pot. settings. If these are
disturbed, set them properly as per the procedure. connections, If these are OK replace the controller.
Temp. range -10 to 55 degrees centigrade
v) Check ‘Diagnostic lamps’ and take action accordingly.
Output 2 V RMS minimum SYMPTOM 4) Engine operates at high idle
vi) Check the voltage on the actuator terminals during cranking
the engine (Magnetic Pickup OK lamp should glow). It CHECKS and CORRECTIONS :
should be more than 8 volts DC. If it is less then replace the i) Check battery voltage. It is below 20 V charge the battery.
OPERATION controller.
ii) Check voltage at actuator terminals. If it is less than 17 V,
1) ACTUATOR PART NOS.
change the controller.
Part No. Description iii) Calibrate the fuel pump along with the actuator and
housing actuator.
3085219 Actuator, 24 V, Normally Closed, LOW FLOW, for use on NT
iv) Check the fuel system.
- 855 and KTA- 19 engines.
3085220 Actuator, 24 V, Normally Closed, HIGH FLOW, for use on

VTA - 28, KT (A) 38 and KTA -50.
batteries.
PROTECTION
Or
housing actuator.

VTA - 28, KT (A) 38 and KTA -50.
batteries.
PROTECTION
Or
housing actuator.

VTA - 28, KT (A) 38 and KTA -50.
Section - 1 WIRING DIAGRAM Page 1-21






Section - 1 EIP INTERNAL WIRING DIAGRAM Page 1-27






Section - 1 Page 1-33 Section-1 Page 1-34 Section-1 Page 1-35
Kit Air Starter: AIR REQUIREMENT FOR AIR STARTER
AIR - STARTER
CONNECTIONS OF PILOT VALVE & KIT AIR STARTER.
1. Inertia Engagement type starter P/N 3022692 has been specified Air Requirement
Pilot Valve Connections: on NH/NT and K-6 engine models. Kit air starter P/N AR-2141259 Sr. Cft/Sec.
Model
includes manual pilot valve P/N 3233856 whereas Kit air starter AR- No. (Lit/Sec) for
Pilot valve P/N 3234239 (for both electrical & manual operation) or P/N 3241325 includes electrical pilot valve P/N 3234239. Remaining Air Starting
3233856 (only for manual operation) is used on all air starters. It parts in both these are listed below. 1. N-495-G 8(227)
activates the main air line and the air starter.
2. NT-495-G 8(227)
S/N Part No. Description Qty.
3. NTC-495-G 8(227)
1. 68705 Adapter 4. N-743-G 8(227)
2. 112105 Elbow 4 5. NT-743-G-1 8(227)
3. 3022697 Valve air relay 1 6. NT-743-G 8(227)
7. NTA-743-G 8(227)
4. 3026796 Elbow Plain Street 1
8. N-855-G 8(227)
5. 3235030 Lubricator Air 1
9. NTA-855-G 8(227)
6. 3235031 Filter Air 1
10. NTA-855-G-2 8(227)
7. 3875667 Adaptor 2 11. KT-1150-G 18.60(527)
Please refer above sketch. 8. 3237162 Adaptor 1 12. KTA-1150-G 18.60 (527)
1. The air inlet should be connected to hole no. 1. The outlet from
9. 3237163 Coupler 1 13. VT-1710-G 18.60 (527)
hole no. 2 should be connected to the air starter pinion connection
(in case of pre-engagement type starters) and to main air valve (in 10. 3237164 Adapter 1 14. VTA-1710-G 18.60(527)
case of inertia engagement type starters). Please refer schematic 11. S-906-C Elbow for air start 1 15. KT-2300-G 18.60 (527)
diagrams on later pages. 16. KTA-2300-G 18.60 (527)
12. S-911-C Elbow 1
13. S-913-C Nipple 1 17. KTA-3067-G 18.60 (527)
When the knob is operated either manually or electrically, hole no.
1 & 2 get connected to each other and subsequently the air flow is 14. S-910-B Plug pipe 1
received at the main valve.
2. Hole no. 4 should be plugged.
3. Hole no. 3 and 5 should be kept OPEN as shown. These holes
are provided to release the pressurized air when the engine 2. Per-engagement type starter P/N 3026797 has been specified on
starting operation is completed. V-12 and KV engine models. Kit air starter P/N AR-3240892
4. This lay-out is applicable ONLY WHEN the pilot valve is includes manual pilot valve P/N 3233856 whereas Kit air starter P/N
connected for the air starter. AR-3241304 includes electrical pilot valve P/N 3234239. Remaining
parts in both these ARs are listed below.
CAUTION:
All connections to and from the pilot valve should be made as 1. 68705 Adapter 1
stated. Wrong connections may lead to malfunctioning of the 2. 112105 Elbow 5
starting system causing damage to the air starter pinion. 3. 3022697 Valve air relay 1
6. 3235031 Filter Air 1
7. 3875667 Adaptor 3
8. 3237445 Coupling assembly 1
9. S-910-B Plug pipe 1
10. S-955 Bushing 1
11. S-1047-A Elbow male adapter 1
12. 3237170 Nipple 1
Please refer schematic diagram.

AIR - STARTER
Model
2. NT-495-G 8(227)
3. NTC-495-G 8(227)
1. 68705 Adapter 4. N-743-G 8(227)
2. 112105 Elbow 4 5. NT-743-G-1 8(227)
7. NTA-743-G 8(227)
8. N-855-G 8(227)
9. NTA-855-G 8(227)
6. 3235031 Filter Air 1
10. NTA-855-G-2 8(227)
7. 3875667 Adaptor 2 11. KT-1150-G 18.60(527)
9. 3237163 Coupler 1 13. VT-1710-G 18.60 (527)
12. S-911-C Elbow 1
13. S-913-C Nipple 1 17. KTA-3067-G 18.60 (527)
CAUTION:
6. 3235031 Filter Air 1
7. 3875667 Adaptor 3
10. S-955 Bushing 1
12. 3237170 Nipple 1

AIR - STARTER
Model
2. NT-495-G 8(227)
3. NTC-495-G 8(227)
1. 68705 Adapter 4. N-743-G 8(227)
2. 112105 Elbow 4 5. NT-743-G-1 8(227)
7. NTA-743-G 8(227)
8. N-855-G 8(227)
9. NTA-855-G 8(227)
6. 3235031 Filter Air 1
10. NTA-855-G-2 8(227)
7. 3875667 Adaptor 2 11. KT-1150-G 18.60(527)
9. 3237163 Coupler 1 13. VT-1710-G 18.60 (527)
12. S-911-C Elbow 1
13. S-913-C Nipple 1 17. KTA-3067-G 18.60 (527)
CAUTION:
6. 3235031 Filter Air 1
7. 3875667 Adaptor 3
10. S-955 Bushing 1
12. 3237170 Nipple 1

Section-1 Page 1-40
A-CHECK B-CHECK FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS.
CHECK CHECK
Series
All(except Hours Every 300 hours To be done at first Every 1500 hours Every 6000 hours To be done at 1500
NT/NTC-495-G) Calendar Every 6 months 1500 hours only Every 1 year Every 2 years hours alter every D
& N-8-G Check
(Big Oil Sump) Every 500 hours To be done at first Every 1500 hours Every 6000 hours
1500 hours only To be done at 1500
NT-495-G Hours Every 6 months Every 1 year Every 2 years
hours after every D
NTC-495-G Calendar
Check
& N-8-G
(Big Oil Sump)
1. Any time cooling system is completely drained and/or flushed, check coolant using coolant checking kit. Refer “Check Engine Coolant” details
on Operation and Maintenance Manual Bulletin no. - 3243773
2. Under extremely dusty condition perform at more frequent intervals.
“Note : B Check Maintenance schedule of NTC 495 big sump, QSK 60 engines is 500hrs”

A-CHECK B-CHECK FIRST 1500 C-CHECK D-CHECK 1500 HRS. AFTER
HRS. EVERY ‘D’ CHECK
Check Air Cleaner Record Oil Pressure Replace Aneroid Check Fuel Pump
Restriction Clean/ Fuel System Breather Calibration
Change Air Check Aneroid Oil Replace Aneroid
Cleaner Element Clean Fuel Tank Belows & Calibrate
Check Hyd. Gov. Oil From inside
if required Air System
Check Throttle Linkage
Cooling System Cooling System Clean Turbocharger
Check / Coolant Lubricate ball Clean Radiator/ Compressor Wheel
Level joints of the throttle Change Air Cooler and Diffuser if required
Other Maintenance linkage of Hyd. governor. External Check Turbocharger
Drain Air Tank Change Fuel Filter Check Fan Hub/ Bearing Clearance
Check & Correct Clean Fuel Tank Breather idler and Water Tighten Manifold
Leaks *Air System Pump / idler Nuts or Capscrews
1
Clean / Change Other Maintenance
Drain Fuel Filter/ Cooling System
Crankcase Breather Inspect following
Water Separator Change coolant
Check Air Piping parts & Replace
Daily Descale cooling
Cooling System as Required
Check Oil level Change Water Filter/ system
(Alternator/
of marine gear & Water Softener Other Maintenance
Starter, etc.) Check Vibration
Raw Wtr pump Check coolant inhibitor.
Check belts, Damper
Add coolant concentrate, Check air Cleaner Check Air
adjust if required if required. Compressor
Evacuator valve,
Check Heat Exchanger Check Safety
Change if required
Zinc plugs Controls
Section - 1 Page 1 - 38
MAINTENANCE SCHEDULE
CUMMINS DIESEL ENGINES
(OTHER THAN INDUSTRIAL FIRE PUMP ENGINES)
Check each operation as performed
FIRST 1500 HRS. C-CHECK D-CHECK 1500 HRS. AFTER
A-CHECK B-CHECK
Daily / Weekly Repeat “A” All STEPS OF Repeat “A’ and Repeat “A” “B” & “C” All STEPS OF
C-CHECK AND “B” C-CHECK AND
Lubrication Lubrication ADDITIONAL Lubrication Lubrication ADDITIONAL
Check Engine Check Engine STEPS
STEPS (None) (None)
Oil Level Oil
Fuel System Fuel System
Fuel System Change Engine Adjust Injectors Change Hyd. Gov Clean and Calibrate Adjust Injectors
Drain Sediment Full-Flow Oil and Valves Oil Injectors if required. and Valves
from Fuel Tanks Filter Change Aneroid Replace rocker
Air System Change By-Pass Replace rocker Oil cover gaskets Replace rocker
Clean Pre-Cleaner Filter cover gaskets cover gaskets
Dust Pan Weekly Check Aneroid Replace Fuel Pump
Change Marine Adjustment Filter Screen & Magnet
Gear Oil
Section-1 Page 1-40
CHECK CHECK
Series
& N-8-G Check
hours after every D
NTC-495-G Calendar
Check
& N-8-G
(Big Oil Sump)

1
(Alternator/
Check belts, Damper
Evacuator valve,
Change if required
Zinc plugs Controls
A-CHECK B-CHECK
STEPS (None) (None)
Oil Level Oil
Gear Oil
Section-1 Page 1-40
CHECK CHECK
Series
& N-8-G Check
hours after every D
NTC-495-G Calendar
Check
& N-8-G
(Big Oil Sump)

1
(Alternator/
Check belts, Damper
Evacuator valve,
Change if required
Zinc plugs Controls
A-CHECK B-CHECK
STEPS (None) (None)
Oil Level Oil
Gear Oil
Section – 1 Page 1-41 Section – 1 Page 1-42
STAND-BY DUTY GENERATOR SET MAINTENANCE CONTINUOUS DUTY GENERATOR SET MAINTENANCE
Checks A B Checks A B C D
Load
Water
INPUT
Section - 1
1 Year/1500Hrs.
2 Yers/6000Hrs.
Fuel
6 Mos./300 Hrs.
6 Mos./300Hrs.
Oil
Air
Engine Engine Schedul
Schedule
Monthly
Systems e
Annual
Weekly
Annual
Systems
Daily
Daily
Check : For Leaks l l l l l Check :For Leaks l l l l l
Operation of Oil Heater l l l l l Operation of Oil Heater l
Engine Oil Level l l l l Engine Oil Level l l l l l
Hydraulic Governor Oil Level l l l l Hydraulic Governor Oil Level l l l l l
Lubricating Lubricating
Full Flow Filter l l Change : Full Flow Filter l l l l
By-Pass Filter l l By-Pass Filter l l l l
Engine Oil l l Engine Oil l l l l
Hydraulic Governor Oil l l Hydraulic Governor Oil l l l l
Check : For Leaks l l l ll Check : For Leaks l l l l l
For Radiator Air Restriction l ll For Radiator Air Restriction l l l l l
Operation of Coolant Heater l l l ll Operation of Coolant Heater l
Hose and Connection l ll Hose and Connection l l l l l
Coolant Level l l ll Coolant Level l l l l l
l l l l
EFFECTIVE UTILISATION OF D G SET

Anti-Freeze and Concentration of Coolant l ll Anti-Freeze and Concentration of Coolant
Cooling
Cooling Belt Condition and Tension l ll Belt Condition and Tension l l l l l
Fan Hub. Drive Pulley and Water Pump l Fan Hub. Drive Pulley and Water Pump l l l l
Heat Exchanger Zinc Anode Plugs l l Heat Exchanger Zic Anode Plugs l
Change: Water Filter l l l l
INSTALLED AS PER CUMMINS

Motor operated Louvers l l l
l l Clean : Water Separator l
Unit Measurement diesel/units

Change: Water Filter
l l Cooling System l
Preventive Breakdown
Clean : Water Separator
l Check : For Leaks l l l l l
RECOMMENDATIONS
Cooling System
kWH meter calibration

l l l Air Cleaner Restriction l l l l l
Check : For Leaks
l l l l Air Intake Piping and Connections l l l l
Maintenance
Air Cleaner Restriction
Clean : Crankcase Breather l l l l
l l
Load factor
OPERATE
Air Intake Piping and Connections
Or Change Air Cleaner Element l l l l
Clean : Crankcase Breather l l
DG Set
Or Change Air Cleaner Element l l Check : For Leaks l l l l l
l l l l l Governor Linkage l l l l
Check : For Leaks
Fuel lines and Connections l l l l
Fuel Level l l l
Drain : Sediment from Tanks l l l l l
Governor Linkage l l
Fuel Change : Fuel Filters l l l l
Fuel Fuel lines and Connections l l
Clean : Float Tank Breather l l l l l
Fuel Transfer Pump l l l
and calibrate injector l
Drain : Sediment from Tanks l l
and/or Calibrate Fuel Pump l
Change Float Tank Breather l
Adjust Injectors and Valves l
Check For Leaks l l l
Check For Leaks l l l l l
For Exhaust Restriction l l l
Exhaust Drain Condensate Trap l l l
Exhaust Clean Turbocharger Comp. Wheel and Diffuser l
Exhaust Manifold and Turbocharger
Torque l Check Turbocharger Bearing Clearances l
Capscrews
Torque Exhaust Manifold and Turbocharger Capscrews l l
Check Battery Charging System l l l l
Check For Unusual Vibration l l l l l
Electrical Battery Electrolyte level and Specific Gravity l l l
Vibration Damper l
Safety Controls and Alarms l l
Engine Crankshaft End Play l
Check For Unusual Vibration l l l l Related Tighten Mounting Hardware l
Engine Tighten Mounting Hardware l Clean : Engine l
Clean Engine l Grease : Fan Pillow Bloc Bearings l l l l
Check Air Inlet and Outlet for Restriction l l l Check : Battery Charging System l
Windings and Electrical Connections l Battery Electrolyte level and Specific Gravity l l l l
Operation of Generator Heater Strips l Engine Grow Plug l
Main
l
Generator Grease Bearing Ang Clean Magnetic Pickup Unit l l
Measure and Record Generator Winding Safety Control and Alarms l l
l
Resistance
Check : Air Inlet and Outlet for Restriction l l l l l
Check/Clean Generator l l
Windings and Electrical Connections l l l l l
Output
Check Start Switch in Automatic l l l l l Main Operation of Generator Heater Strips l
Instrumentation l Generator Grease : Bearing l l
Switchgear Power Distribution Wiring and Connections l l Check/
Power Circuit Breaker l l Generator l
Page 1-43
Clean:
Transfer Switch l l Check Power Distribution Wiring and Connections l l l l
Perform Operational Load Test l l l l Switchgear Power Circuit Breaker l l
Operational Generator Load Bank Test l Transfer Switch l l
Check Service Tool Availability l l l Operational
Perform Generator Load Bank Test l
Procedures
Load
Water
INPUT
Section - 1
1 Year/1500Hrs.
2 Yers/6000Hrs.
Fuel
6 Mos./300 Hrs.
6 Mos./300Hrs.
Oil
Air
Schedule
Monthly
Systems e
Annual
Weekly
Annual
Systems
Daily
Daily
l l l l

Anti-Freeze and Concentration of Coolant l ll Anti-Freeze and Concentration of Coolant
Cooling
Change: Water Filter l l l l

Motor operated Louvers l l l
l l Clean : Water Separator l

Change: Water Filter
l l Cooling System l
Clean : Water Separator
l Check : For Leaks l l l l l
RECOMMENDATIONS
Cooling System

l l l Air Cleaner Restriction l l l l l
Check : For Leaks
l l l l Air Intake Piping and Connections l l l l
Maintenance
Air Cleaner Restriction
Clean : Crankcase Breather l l l l
l l
Load factor
OPERATE
Air Intake Piping and Connections
DG Set
l l l l l Governor Linkage l l l l
Check : For Leaks
Fuel Level l l l
Capscrews
Vibration Damper l
Main
l
Generator Grease Bearing Ang Clean Magnetic Pickup Unit l l
l
Resistance
Output
Power Circuit Breaker l l Generator l
Page 1-43
Clean:
Procedures
Air
Oil
Load
Fuel
Water
Schedule
INPUT
Systems Systems e
Section - 1
Daily
6 Mos./300Hrs.
1 Year/1500Hrs.
2 Yers/6000Hrs.
Annual
Daily
Weekly
Monthly
6 Mos./300 Hrs.
Annual
Anti-Freeze and Concentration of Coolant l ll Anti-Freeze and Concentration of Coolant l l l l
Cooling
Motor operated Louvers l l l Change: Water Filter l l l l
Change: Water Filter l l Clean : Water Separator l
Clean : Water Separator l l Cooling System l
Cooling System l Check : For Leaks l l l l l
Check : For Leaks l l l Air Cleaner Restriction l l l l l
Air Intake Piping and Connections l l l l
Air Cleaner Restriction l l l l
Air Intake Clean : Crankcase Breather l l l l
Piping and Connections l l
Check : For Leaks l l l l l Governor Linkage l l l l
Fuel Level l l l
DG Set

Load factor
OPERATE

Maintenance


RECOMMENDATIONS


For Exhaust Restriction
l l l
Capscrews

Vibration Damper l
Main
Generator Grease Bearing l Ang Clean Magnetic Pickup Unit l l
l
Resistance
Generator
Output
Power Circuit Breaker l l l

Clean:
Page 1-43

Procedures
ESN:
KWH
LDO OPERATION
Model:
CT Ratio
Blow bye
Hours run
Section-1
Customer:
Frequency
LDO PROPERTIES - SUBSTITUTE
Section - 1
KW reading
Oil pressure
Power factor
Air restriction
Higher Sulphur content : Oil with Higher TBN value.
Fuel pressure
Ambient temp.
Coolant Quality
Oil temperature
Excessive suspended particles : Alongwith suitable Centrifuge.
Ammeter reading
Higher Wax Content : Heater/s & Thermostatic Switch to maintain
0
Coolant temperature
around 60 C Temp. of fuel
LDO with following properties can be used on “G” Drive Engines.
Temperature differential
Oil used (Brand & Grade)

Properties of LDO :
kWH meter last calibrated on

(√3 – V.I. Cos ∅)
Base coolant (Add Water/Premix)
Sr. Recommended
Parameter
No. Specifications
0 3
01 Density, @15 C Kg / m 880-900
0 0
KW (max.)
02 Flash Point (PMMC) C 66 C min.
t LTA = (T3 - T1)

0
03 Kinematic Viscosity, cSt @ 40 C 2.5 to 15.7
LTA HE Water outlet temp (Raw Water Circuit) (T3)

0
0 Winter : 12 C
Raw water inlet to HE temp/Radiator bottom tank (T1)

04 Pour point C 0
Units generated (Unit reading on kWH meter x CT ratio)

Summer : 21 C
LB =
Average load factor = (Units generated / Hours run) x 100

Outlet from HE temp/Radiator top tank (T2)
T MAIN = (T2 – T1)
05 Water content 2500 PPM Max.
06 Total Sulphur % wt. 1.8 % Max.
pH =
1. Additive -
“of H2O,
LDO is always with suspended, coagulated matter, which restricts
the flow. To disperse the coagulated matter an additive is
required to be added in LDO. This additive is added to the bulk
storage tank at the time of fill up in the ratio of 10000:1
RB =
(LDO:Additive). The additive will be supplied by CDS&S under
ppm =
the P/N –
or
“of H2O
Engine performance inspection report - Genset
ENGINE PERFORMANCE INSPECTION REPORT - GENSET

Units/Lt.
/
/
0
0
0
0
0
0
0
0
Kgs/cm
psi
“of H20
C
C
C
C
C
C
KWs
AMPS.
Hz.
C
C
2
%
Page 1-44
Page 1-45
ESN:
KWH
LDO OPERATION
Model:
CT Ratio
Blow bye
Hours run
Section-1
Customer:
Frequency
Section - 1
KW reading
Oil pressure
Power factor
Air restriction
Fuel pressure
Ambient temp.
Coolant Quality
Oil temperature
Ammeter reading
0
Coolant temperature

Properties of LDO :

(√3 – V.I. Cos ∅)
Sr. Recommended
Parameter
No. Specifications
0 3
01 Density, @15 C Kg / m 880-900
0 0
KW (max.)
t LTA = (T3 - T1)

0

0
0 Winter : 12 C

04 Pour point C 0

Summer : 21 C
LB =

T MAIN = (T2 – T1)
pH =
1. Additive -
“of H2O,
RB =
ppm =
the P/N –
or
“of H2O

Units/Lt.
/
/
0
0
0
0
0
0
0
0
Kgs/cm
psi
“of H20
C
C
C
C
C
C
KWs
AMPS.
Hz.
C
C
2
%
Page 1-44
Page 1-45
Oil pressure
Coolant temperature
Ambient temp.

Power factor
Frequency
KWH
KW reading
Ammeter reading
CT Ratio
Hours run
Customer:
Model:
ESN:
Section - 1

Fuel pressure
Blow bye
Coolant Quality
Air restriction

Oil temperature
Section-1
LDO OPERATION

(√3 – V.I. Cos ∅)
0
Properties of LDO :
Sr. Recommended
t LTA = (T3 - T1)

Parameter
KW (max.)
No. Specifications
0 3
01 Density, @15 C Kg / m 880-900
0 0
T MAIN = (T2 – T1)


0

0
LB =
0 Winter : 12 C
04 Pour point C 0
Summer : 21 C
pH =
“of H2O,
1. Additive -
ppm =
RB =
the P/N –
or
“of H2O
Units/Lt.
/
Page 1-44
Kgs/cm
Page 1-45
“of H20
AMPS.
/
KWs
Hz.
psi
0
0
C
C
C
C
C
C
%
C
C
2
Section – 1 Page 1-47 Section – 1 Page 1-48 Section – 1 Page 1-49
Details of Part Numbers (LDO Kit) SLDO OPERATION HEAT RECOVERY THROUGH EXHAUST GAS BOILERS
Properties We offer :
S/N Part Number Description • Exhaust Gas Steam Boiler
1 AX1001334 LDO Additive 1 litre Sr. Parameter Recommended • Exhaust Gas Hot Water Generator or
2 AX1001335 Additive 5 litre No. Specifications • Exhaust Gas Thermic Fluid Heater
0 3
3 AX1001332 Filtration Unit System 01 Density, @15 C Kg / m 880-900
4 AX1001331 LDO Filtration Kit Energy Balance
0 0
(LDO Filtration Unit System P/N 02 Flash Point (PMMC) C 66 C Min.
Without HRU
AX 1001332 + Duplex Fuel Filter 03 Kinamatic Viscosity, Cst @ 40 C
0
2.0 to 5.0 Electrical output - 34%
P/N AR3240256)
5 AX1001333 Service Kit for Filtration Unit 0 0 Radiation loss - 3%
04 Pour point C Winter : 3 C
6 AX1001336 Centrifuge Module Summer : 15 C
0 Coolant loss - 25%
7 AX1001337 Intermittent Kit – Centrifuge 05 Water Content 5000 PPM Max. Stack loss - 34%
8 AX1001338 Major Service Kit – Centrifuge Alternator loss - 4%
06 Total Sulfur % wt. 0.35 % Max.
9 3226055 Thermostatic Switch – Day Tank
10 3226053 Heater – Day Tank 07 Sediments % wt. 0.05 % Max. With HRU
11 AR3240256 Duplex filter Electrical output - 34%
08 Carbon Residue % wt. 1.5 % Max. Heat recovery - 20%
09 Ash % by Mass Max. 0.01 Radiation loss - 3%
SKO/ LOW SULPHUR FUELS (< 0.25%) OPERATION Coolant loss - 25%
To improve lubricity of SKO and to enhance Cetene number, 10 Cetane No. 34 to 35 Stack loss - 14%
suitable additive is selected with optimum dosage / ratio of 1:1000
(Additive : SKO). 11 Copper Strip Corrosion for 3 1b Alternator loss - 4%
SKO with following properties can be used on all genset engines. Hours at 100 Deg. Cent.
12 Net Calorific Value 10,500 Kcal/Kg Approx. Advantages :
• Improved Efficiency
Sr. Recommended • Reduced Energy cost
Parameter
No. Specifications • Recovery of heat upto 60% from the Waste Exhaust gases
01 Density, @15 C
0
0.785-0.825 The Special LDO Cetane number is very low i.e. 34 to 35. Hence • Low Maintenance Cost
0
suitable additive with optimum dosage of ratio 1000 litres of Special • Attractive Payback Period
02 Flash Point 35 C min. LDO to 1.5 litres of additive is needed to be blended. If the additive is • 100% Depreciation in first year
0 not used, engine power cylinder components will fail due to
03 Viscosity, Cst @ 38 C 1.0-1.4
detonation from poor combustion of fuel causing piston erosion.
Silencer
04 Aromatic Content 18% Hence it is mandatory to blend Special LDO with additive in bulk
storage tank.
05 Gross Calorific value 11,000 K cals / Kg DG Set Gas Exh. Gas Chimney
06 Cetane No. 38 min. CDS&S will supply additive as per details given below : Divertor Boiler
0 0
Damper
07 Pour point C <0 C Additive Volume Part No. Special LDO Volume
08 Water content 500ppm max. 15 Litre Container AX1002587 10 KL
Steam / Hot Water Generation at 75% load.
09 Total Sulphur 0.25% max.
It is preferred that the additive is added in to bulk storage tank while Sr. DG set Steam generation in Hot Water
2
unloading the Special LDO tanker which will ensure proper mixing. No. Capacity kg/hr @ 10.5 kg/cm generation in
0
It is necessary to use Centrifuge Kit to ensure the clean fuel supply (kVA) pressure(*) kg/hr @ 80 C(*)
Additive in containers of 10, 20, 50, 100 liters of volumes and part
number are stated below for SKO & Low sulphur fuels : to engine at usage point and blending the Special LDO fuel with 1 250 110 1556
additive to improve it’s combustibility. 2 320 148 2086
01. AR 323844100 SKO ADDITIVE 10 LTS. 3 380 164 2091
02. AR 323844500 SKO ADDITIVE 20 LTS. Note : Operating cummins diesel engines with alternate fuel other 4 500 180 2385
03. AR 323844300 SKO ADDITIVE 50 LTS. than diesel may cause to reduction in engine life / durability. 5 625 230 3253
04. AR 323844400 SKO ADDITIVE 100LTS. Engines may be operated considering the profit getting against break 6 750 271 3824
even point of fuel cost v/s engine repair cost. 7 1000 404 5696
1:1000 (Additive : Fuel) 8 1250 499 7046
* Steam and Hot water generation figures are indicative.

These may vary with DG set operational conditions.
0 3
0 0
Without HRU
0
P/N AR3240256)
Parameter
01 Density, @15 C
0
0
Silencer
storage tank.
0 0
Damper
2
0
1:1000 (Additive : Fuel) 8 1250 499 7046

0 3
0 0
Without HRU
0
P/N AR3240256)
Parameter
01 Density, @15 C
0
0
Silencer
storage tank.
0 0
Damper
2
0
1:1000 (Additive : Fuel) 8 1250 499 7046

Section-2 Page 2 Section –2 Page 2-2
DG T
Dual Fuel Engines
G T A 855
Gas Engines
Section -2
GAS & DUAL FUEL ENGINE DATA CUMMINS GAS ENGINES TECHNOLOGY
Contents Page
A
Key Components
Cummins Gas & Dual Fuel Engine Nomenclature ………….………..2-1
855
• Carburettor
Cummins Gas Engine Technology ………………………….…………2-2
Gas Engine Ratings & Specifications …………………….……………2-3 • Distributor / Altronic
--
--
Gas Engine Maintenance Schedule ……………………..…………….2-6
G
• Ignition transformer
Altronic III Data ……………………………………………..……………2-7
= Gas engine
= Turbocharged
= Aftercooled
= Displacement in Cu. in.
= Application Codes (G = Generating set)

= Natural Gas dual fuel engine (Diesel & Gas)
= Turbocharged
= Aftercooled

Cummins Dual Fuel Engines Technology ……………….……………2-8 • Spark plug
Dual Fuel Engine Ratings & Specifications ……………..…………….2-8
• Pressure regulators
Derating recommendations …………………………………………2-8
Gas adjustment of Engines running on gas • Gas shut off valves
with different heat value…………………………………….………...…2-9
• Separate water circuit for after cooling circuit in case of
Some Important values …………………………………….…………2-10
turbocharged aftercooled engines
L.O. recommendations for Natural gas engine ………….………….2-10
CUMMINS ENGINE NOMENCLATURE

Carburettor Models & Adjustments ……………………….………….2-11
Technology
Properties of Hydrocarbons & gas fuels ………………….…………2-11
Engine Wiring Diagrams …………………………………….………...2-13 A mixture of fuel and air enters the engine through a carburettor and
Conversion Kits for Various Dual Fuel Engines ……………………2-16 is spark-ignited(Sl). The fuel injector is replaced by a spark plug in
the cylinder head and a fuel pump by a carburetor and ignition
Modelwise Part Numbers ……………………………………………...2-17 distributor.
Some Part / Repair Kit Nos…………………………………………....2-18
The gas induction through the carburettor requires low pressure gas
at 500 mm maximum water column at engine point. Most of the
components (including load bearing components) used in gas
engines are the same as those in standard, proven diesel engines.
Hence, Cummins gas engines are structurally more robust than
conventional SI engines. The peak cylinder pressure of Cummins
gas engines is designed such that it will be lower than diesel
engines. Hence, because of lower stress level, longer service life,
high reliability and maintenance-free operation are achieved.
Cautions
• Remove amphenol connector on altronic unit while carrying out

welding other wise Altronic unit will get damaged.
• While installing the regulators ensure that the arrow is in the
direction of gas flow.
• After the gas drain pipe welding/fabrication is complete ensure
that the entire line is flushed by air / gas / tested for leaks.
• Room should have opening or exhaust fan from roof or top most
point of room for venting of natural gas as it is lighter than air.
Page 2-1
DG T
A
Contents Page
Section -2
Key Components
Gas Engines
• Carburettor
855
G T A 855
Dual Fuel Engines
--
--
G
G
= Aftercooled
= Gas engine
= Aftercooled
= Turbocharged
= Turbocharged

Technology




Cautions

Page 2-1
DG T
Dual Fuel Engines
G T A 855
Gas Engines
Section -2
Contents Page
A
Key Components
855
• Carburettor
--
--
G
= Gas engine
= Turbocharged
= Aftercooled

= Turbocharged
= Aftercooled


Technology
Cautions

Page 2-1
Section -2 Page 2-5
NOTES
* ABOVE DATA IS PRELIMINARY AND * INDUCED DRAFT TYPE COOLING TOWER * FOLLOWING STANDARD IGNITION
ESTIMATED. IS RECOMMENDED. SYSTEMS ARE SUPPLIED. 495, 743, 855
NA ENGINES:
H T LUCAS/MAGTRONIC OPTIONAL 1710
NA. ALL TA ENGINES EXCEPT 3067: L T
MAGTRONIC 3067 TA: LT ALTRONIC.
* RATING AND GAS CONSUMPTION * PLEASE SUPPLY RELIABLE GAS * PRESENTLY ALTRONIC IS USED IN
DEPENDS ON GAS COMPOSITION I PRESSURE GAUGES TO ENSURE PLACE OF MAGTRONIC
CALORIFIC VALUE. CORRECTNESS OF DESIRED
PRESSURES IN THE SYSTEM.
* GAS ENGINE RATING GUIDELINES ON * SELECTION OF GAS ENGINE
ACCOUNT OF GAS COMPOSITION ARE * NA ENGINES ARE AVAILABLE WITH BOTH COMPONENTS PARTICULARLY IGNITION
GIVEN SEPARATELY COOLING ARRANGEMENTS I.E. SYSTEM DEPEND ON AREA OF
RADIATOR OR HEAT EXCHANGER. TA OPERATION.
* PLEASE CONSIDER SUITABLE DERATING ENGINES ARE AVAILABLE WITH HE
AS PER THE SITE CONDITIONS. (2NOS.) OR RADIATOR. FOR ENGINE AND
DERATING RECOMMENDATIONS ARE HE EXCLUSIVELY FOR AFTERCOOLER EXHAUST AND AFTERCOOLER
SAME AS NA AND TA DIESEL ENGINES. CIRCUIT. * TEMPERATURES ARE CRITICAL AND
HENCE NEED TO BE MONITORED
* PLEASE SEND A QUESTIONNAIRE DULY * NA-NATURALLY ASPIRATED ENGINES CONSTANTLY FOR BETTER
FILLED ALONGWITH YOUR PURCHASE TA-TURBOCHARGED AFTERCOOLED PERFORMANCE AND INCREASED
ORDERS. ENGINES. DURABILITY
Section -2 Page 2-4
G-1710-G- GTA-855- GTA-1150- GTA-1710- GTA-2300- GTA-3067-

DESCRIPTION / PARAMETER G-495-G(NA) G-743-G(NA) G-855-G(NA)
(NA) G(TA) G(TA) G(TA) G(TA) G(TA)
ENGINE WATER FLOW USGPM (LT/MIN) 48(174) 58(212) 69(261) 175(662) 92(348) 122(464) 190(719) 245(936) 370(1413)
AFTER COOLER WATER FLOW NOT NOT NOT NOT
35(133) 30(114) 40(151) 70(266) 86(327)
USGPM (LT/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
RAW WATER FLOW FOR ENGINE HE
51(193) 83(314) 91(344) 192(727) 135(511) 200(757) 278(1052) 400(1552) 560(2120)
@92 DEG. F/32 DEG C USGPM (LT/MIN)
RAW WATER FLOW FOR AFTERCOOLER NOT NOT NOT NOT
40(151) 50(190) 80(333) 85(320) 120(454)
HE @ 92 DEG.F/32 DEG. C USGPM (LT/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
COOLING TOWER CAPACITY (TR)
ENGINE & AFTERCOOLER 20 30 30 75 60 80 100 150 200
AFTERCOOLER ALONE NOT APPL NOT APPL NOT APPL NOT APPL 10 10 15 15 20
MAIN GAS PIPELINE SIZE INCH (MM) 1(25) 1.5(40) 1.5(40) 2(50) 2(50) 2(50) 2(50) 2.5(65) 2.5(65)
MAIN LINE GAS PRE PSIG (KG/SQ.CM) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4) 20(1.4)
GAS PRESSURES
AFTER 1st REGULATOR PSIG (KG/SQ.CM) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5) 7(0.5)
AFTER 2nd REGULATOR INCH WC(CM.WC) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20) 6-8(15-20)
PLEASE CONTACT CDS&S FOR ANY SPECIAL REQUIREMENT
Section -2 Page 2-3

PRELIMINARY ENGINE DATA FOR CUMMINS GAS ENGINES
DESCRIPTION / PARAMETER G-495- G-743- G-855- G-1710- GTA-855- GTA-1150- GTA-1710- GTA-2300- GTA-3067-
G(NA) G(NA) G(NA) G-(NA) G(TA) G(TA) G(TA) G(TA) G(TA)
ENGINE RATING BHP @ 1500 RPM 92(12), 86(10) 137(12),129(10) 157(12),157(10) 333(12),313(10) 242(10) 333(8.5) 480(10) 600(8.5) 800(8.5)
(COMPRESSION RATIO)
81(8.5) 121(8.5) 147(8.5) 293(8.5) 227(8.5) 313(7.5) 451(8.5) 570(7.5) 750(7.5)
NATURAL GAS CONSUMPTION FOR
GAS CALORIFIC VALUE
12.2(21) 18.5(31) 21.7(37) 44.2(75) 31(52) 46(77) 61(103) 80(135) 111(187)
970 BTU/CFT OR 8730 KCAL/CUB M
STD. CUB FT/MIN (STD.CUB M/HR)
EXHAUST TEMPERATURE (STACK)
1200(649) 1200(649) 1220(660) 1200(649) 932(500) 1030(555) 970(521) 1060(571) 1180(638)
DEG.F(DEG.C)
HEAT REJECTION TO WATER
3723(938) 6119(1542) 6702(1689) 14165(3570) 9904(2495) 14813(3733) 20455(5155) 28557(7197) 40731(10265)
JACKET BTU/MIN(KCAL/MIN)
HEAT REJ. TO AFTER COOLER NOT NOT NOT NOT
1417(357) 1700(428) 2914(734) 3116(785) 3829(965)
WATER BTU/MIN(KCAL/MIN) APPLICABLE APPLICABLE APPLICABLE APPLICABLE
HEAT REJECTION TO EXHAUST
2732(689) 4521(1139) 4995(1259) 10305(2597) 6589(1661) 10679(2891) 13761(3468) 18897(4762) 25765(6745)
BTU/MIN(KCAL/MIN)
AIR FLOW SCFM 120 198 214 450 400 558 800 997 1207
EXHAUST FLOW CFM 360 602 661 1372 1007 1504 2068 2739 3549
Section -2 Page 2-5
NOTES
NA ENGINES:
Section -2 Page 2-4

35(133) 30(114) 40(151) 70(266) 86(327)
51(193) 83(314) 91(344) 192(727) 135(511) 200(757) 278(1052) 400(1552) 560(2120)
40(151) 50(190) 80(333) 85(320) 120(454)
GAS PRESSURES
Section -2 Page 2-3

(COMPRESSION RATIO)
81(8.5) 121(8.5) 147(8.5) 293(8.5) 227(8.5) 313(7.5) 451(8.5) 570(7.5) 750(7.5)
GAS CALORIFIC VALUE
12.2(21) 18.5(31) 21.7(37) 44.2(75) 31(52) 46(77) 61(103) 80(135) 111(187)
1200(649) 1200(649) 1220(660) 1200(649) 932(500) 1030(555) 970(521) 1060(571) 1180(638)
DEG.F(DEG.C)
3723(938) 6119(1542) 6702(1689) 14165(3570) 9904(2495) 14813(3733) 20455(5155) 28557(7197) 40731(10265)
1417(357) 1700(428) 2914(734) 3116(785) 3829(965)
2732(689) 4521(1139) 4995(1259) 10305(2597) 6589(1661) 10679(2891) 13761(3468) 18897(4762) 25765(6745)
BTU/MIN(KCAL/MIN)
AIR FLOW SCFM 120 198 214 450 400 558 800 997 1207
EXHAUST FLOW CFM 360 602 661 1372 1007 1504 2068 2739 3549
Section -2 Page 2-5
NOTES
NA ENGINES:
Section -2 Page 2-4

35(133) 30(114) 40(151) 70(266) 86(327)
51(193) 83(314) 91(344) 192(727) 135(511) 200(757) 278(1052) 400(1552) 560(2120)
40(151) 50(190) 80(333) 85(320) 120(454)
GAS PRESSURES
Section -2 Page 2-3

(COMPRESSION RATIO)
81(8.5) 121(8.5) 147(8.5) 293(8.5) 227(8.5) 313(7.5) 451(8.5) 570(7.5) 750(7.5)
GAS CALORIFIC VALUE
12.2(21) 18.5(31) 21.7(37) 44.2(75) 31(52) 46(77) 61(103) 80(135) 111(187)
1200(649) 1200(649) 1220(660) 1200(649) 932(500) 1030(555) 970(521) 1060(571) 1180(638)
DEG.F(DEG.C)
3723(938) 6119(1542) 6702(1689) 14165(3570) 9904(2495) 14813(3733) 20455(5155) 28557(7197) 40731(10265)
1417(357) 1700(428) 2914(734) 3116(785) 3829(965)
2732(689) 4521(1139) 4995(1259) 10305(2597) 6589(1661) 10679(2891) 13761(3468) 18897(4762) 25765(6745)
BTU/MIN(KCAL/MIN)
AIR FLOW SCFM 120 198 214 450 400 558 800 997 1207
EXHAUST FLOW CFM 360 602 661 1372 1007 1504 2068 2739 3549
cycle. Gaseous fuel is added to the air which is inducted at air intake
A dual fuel engine is basically a diesel engine with conversion kit to run
engine. At the end of compression, diesel is injected through a

conventional fuel system. This pilot injection acts as a source of ignition.
compressed in the cylinder just as air is compressed in normal I.C.
the engine with diesel and any suitable gas. This works on the diesel
Separate water circuit for aftercooler in case of turbo charged

The engine can run either on diesel or on diesel+gas. Adequate controls
manifold or before turbocharger. This mixture of air and gas is
Engine
(cont.)
Page 2-8
rating
0.001% Max.
1060
BHP
130
405
800
145
300
275
550
85
DUAL FUEL ENGINE MODELS AND THEIR SPECIFICATIONS
0.1 Max.
1. Above are continuous ratings for both NA and TA engines with
Carbon Dioxide (CO2) 0-12%

0-8%
Carbon Monoxide (CO) 0-1%
Engine
Speed
1500
1500
1500
1500
1500
1500
1500
1500
1500
RPM
Hydrogen Sulphate
CUMMINS DUAL FUEL ENGINES
Fuel pump throttle and gas control valve linkage
Sulphur Content
Selector switch for diesel and dual fuel modes
Two solenoid valves for diesel flow restriction
Aspira-
N.A.
N.A.
N.A.
N.A.
T.A.
T.A.
T.A.
T.A.
T.A.
tion
75-99% Nitrogen (N2)

following gas analysis (By Volume)
Disp
12.2
18.9
37.8
50.3
(Lit)
8.1
14
28
14
20
are provided for dual fuel operation.
Modified air intake manifold
0-15%
Stroke
0-2%
0-1%
0-2%
(mm)
152
152
152
152
152
159
152
159
159
Gas pressure regulators
aftercooled engines
Gas shut off valves
Gas control valve
(mm)
Bore
130
130
140
140
140
159
140
159
159
Propane (C3H8)
Methane (CH4)
Hydrogen (H2)
Key Components
Ethane (C2H6)
Ethane (C2H4)
DGTA-1150-G
DGTA-1710-G
DGTA-2300-G
DGTA-3067-G
Gas piping
DGTA-855-G
DG-1710-G
Technology
DG-495-G
DG-743-G
DG-855-G
Section - 2
Engine
NOTES:
Model
•
•
•
•
•
•
•
•
•
SECTION - 2 ALTRONIC III Page 2-7

NAME PLATE DETAILS
8 A 2 9 H T -BEL
MOUNTING A=VERTICAL
The Firing order of Altronic III is as Follows BEL= ADJUSTABLE BASE
No.of CCW Rotation CW Rotation D=FLANGE
Cyl. EL=BASE MOUNT
4 A-B-C-D A-D-C-B G=HORIZANTAL FLANGE
6 A-B-C-D-E-F A-F-E-D-C-B GL=HORIZ. FL-FLEX COUPLING
12 A-B-C-D-E-F-H-I-J-K-L-M A-M-L-K-J-I-H-F-E-D-C-B GN=HORIZ. FL-GEAR FLEX COUPLING
16 A-B-C-D-E-F-H-J-K-L-M-N-P-R-S-T A-T-S-R-P-N-M-L-K-J-H-F-E-D-C-B GV=HORIZ.FLANGE TWO SLOTS
J=ROUND FLANGE - 3 SLOTS
Wiring Color Code OPTIONS H=HIGH OUT PUT UNIT
G - Orange S= EXTRA OUT PUT UNIT
N - Black T=ELECTRONIC TIMING
Other - White
STATOR WINDING 0-9 NOS.
GEAR RATIO 1=1:1
2=2:1
3=3:1
4=4:1
5=2.5:1
6=1.5:1
FIRING PATTERN A=EVEN FIRING PATTERN
OTHER LETTERS=ODD FIRING PATTERN
NO OF CYLINDERS 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16
Section 2 MAINTENANCE SCHEDULE Page 2-6

CUMMINS GAS ENGINES
A- CHECK B-CHECK C-CHECK D-CHECK E-CHECK F-CHECK
DAILY 500 Hours / 3Months 1000 Hours / 6 Months 2000 Hours / Yearly 6000 Hours 15000 Hours
• Check Operators Report • Repeat ‘A’ Check • Repeat ‘A’ and ‘B’ Check • Repeat ‘A’ ‘B’ and ‘C’ • Repeat ‘A’ ‘B’ ‘C’ and • Repeat ‘A’ ‘B’ ‘C’ ‘D’
Check ‘D’ Check and ‘E’ Check
• Check Leaks and • Check Heat Exchanger • Change Engine Oil • Clean / Replace Spark • Check Thermostat • This Maintenance
Correct Zinc Plugs • Change Engine Oil Filter Plugs • Clean Auxiliary Coolant Check is often referred
• Check Engine Oil Level • Change and Adjust Belt • Record Oil Pressure • Change Fan Hub and Heater to as ‘In-Chassis
• Check Coolant Level Tension • Change Oil Bath Air Drive Pulley • Clean Engine Inspection’ where some
• Check Gas Leaks and • Check Engine Coolant Cleaner Oil • Clean Tray Screen • Tighten Mounting Bolts key parts, such as
Correct and Corrosion Resistor • Lubricate Electrical • Check Air Piping and and Nuts bearings are checked
• Check Air Cleaner • Check Generator for Equipment Vent Tube Connections • Check Crankshaft End for wear to determine if
Element Dust • Lubricate Water Pump/ • Clean or Replace Air Clearance the engine may be
• Check Pre-Cleaner Dust • Check Connection and Fan Hub Cleaner Element • Check Engine Blow-By operated for another
Pan Gauges • Adjust Throttle Linkage (Paper) • Clean Radiator Core service period.
• Check Hydraulic (GV-1710) • Check Vibration (externally) Likewise, oil
Governor Oil Level • Adjust Valve / Crossheads Damper Alignment • Change Vibration consumption, oil
• Lubricate PTO Bearing • Change Hydraulic • Check Oil Bath Air Damper pressure and other
Governor Oil Cleaner signs of wear should be
• Clean and Tighten • Check Cylinder analyzed during the
Electrical Connections Compression and check. Wear limits and
• Check Auxiliary Water Record other information is
Pump • Check Gas Pressure available from
• Clean Crankcase Breather To Carburetor Distributor/Dealers of
• Check Inlet Air Restriction Cummins India Limited.
Note : Maintenance Schedule of Dual fuel engine is same as Diesel engine.


Engine
(cont.)
Page 2-8
rating
0.001% Max.
1060
BHP
130
405
800
145
300
275
550
85
0.1 Max.

0-8%
Engine
Speed
1500
1500
1500
1500
1500
1500
1500
1500
1500
RPM
Hydrogen Sulphate
Sulphur Content
Aspira-
N.A.
N.A.
N.A.
N.A.
T.A.
T.A.
T.A.
T.A.
T.A.
tion

Disp
12.2
18.9
37.8
50.3
(Lit)
8.1
14
28
14
20
0-15%
Stroke
0-2%
0-1%
0-2%
(mm)
152
152
152
152
152
159
152
159
159
aftercooled engines
Gas shut off valves
Gas control valve
(mm)
Bore
130
130
140
140
140
159
140
159
159
Propane (C3H8)
Methane (CH4)
Hydrogen (H2)
Key Components
Ethane (C2H6)
Ethane (C2H4)
DGTA-1150-G
DGTA-1710-G
DGTA-2300-G
DGTA-3067-G
Gas piping
DGTA-855-G
DG-1710-G
Technology
DG-495-G
DG-743-G
DG-855-G
Section - 2
Engine
NOTES:
Model
•
•
•
•
•
•
•
•
•

NAME PLATE DETAILS
8 A 2 9 H T -BEL
MOUNTING A=VERTICAL
Cyl. EL=BASE MOUNT
Other - White
GEAR RATIO 1=1:1
2=2:1
3=3:1
4=4:1
5=2.5:1
6=1.5:1
NO OF CYLINDERS 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16

CUMMINS GAS ENGINES


Engine
(cont.)
Page 2-8
rating
0.001% Max.
1060
BHP
130
405
800
145
300
275
550
85
0.1 Max.

0-8%
Engine
Speed
1500
1500
1500
1500
1500
1500
1500
1500
1500
RPM
Hydrogen Sulphate
Sulphur Content
Aspira-
N.A.
N.A.
N.A.
N.A.
T.A.
T.A.
T.A.
T.A.
T.A.
tion

Disp
12.2
18.9
37.8
50.3
(Lit)
8.1
14
28
14
20
0-15%
Stroke
0-2%
0-1%
0-2%
(mm)
152
152
152
152
152
159
152
159
159
aftercooled engines
Gas shut off valves
Gas control valve
(mm)
Bore
130
130
140
140
140
159
140
159
159
Propane (C3H8)
Methane (CH4)
Hydrogen (H2)
Key Components
Ethane (C2H6)
Ethane (C2H4)
DGTA-1150-G
DGTA-1710-G
DGTA-2300-G
DGTA-3067-G
Gas piping
DGTA-855-G
DG-1710-G
Technology
DG-495-G
DG-743-G
DG-855-G
Section - 2
Engine
NOTES:
Model
•
•
•
•
•
•
•
•
•

NAME PLATE DETAILS
8 A 2 9 H T -BEL
MOUNTING A=VERTICAL
Cyl. EL=BASE MOUNT
Other - White
GEAR RATIO 1=1:1
2=2:1
3=3:1
4=4:1
5=2.5:1
6=1.5:1
NO OF CYLINDERS 2, 3, 4, 5, 6, 7, 8, 9, 10, 12, 16
CUMMINS GAS ENGINES
Section -2 Page 2-9 Section -2 Page 2-10 Section – 2 Page 2-11
The gas low heat value (LHV) limits are 850-970 BTU/CFT@ Final timing is made by attaching a timing light to No. 1 cylinder primary IMPCO CARBURETOR MODELS FOR DIFFERENT
0
60 F and 29.92 in Hg. Pressure Gas has to be a “dry gas” free lead. If a low voltage timing light is not available, it will be necessary to CUMMINS ENGINE MODELS
from liquid hydrocarbons, foreign particles, dust etc. connect an additional ignition transformer in parallel with the No. 1 ENGINE CARBURETOR
cylinder ignition transformer to allow use of a high voltage timing light. G/GTA-495 200
2. NA - Naturally Aspirated The timing light directed at the timing marks on the accessory drive N-743/855 225
Engine performance is based on operation at 500 feet altitude pulley will indicate the firing position of No. 1 cylinder. Rotating the GV-1710 2 X 225
0
and 29.4 C ambient temperature. Magtronic clockwise when viewed at timing window advances the timing GTA-855 200 T
on G 495/743/855 engines and retards timing on G 1710 engines. With GTA-1710 600-3
Derating recommendations: final timing adjusted. Secure the base mounting bolts. GTA-2300 2 X 200 T
a) 3.5% per 1000 feet above 500 feet altitude. GTA-3067 2 X 600 - 3
0 0
b) 2% per 5.5 C above 29.4 C ambient temp. SOME IMPORTANT VALUES CARBURETOR POSITION & ADJUSTMENTS
c) derating on account of humidity as per BS- 5514 Ignition transformer Naturally aspirated engines carburetor is mounted on intake manifold
1. Primary resistance - 0.2 to 0.3 OHMS. (after air cleaner), where as in turbocharged engines, carburetor
3. TA - Turbocharged Aftercooled 2. Secondary resistance - 4500 to 5500 OHMS. mixture unit is fitted in between air cleaner and the turbo, the throttle
Engine performance is based on operation at 5000 feet altitude unit is fitted between turbo and after cooler intake manifold.
0
and 38 C ambient temperature SPARK PLUG It is recommended to connect 2nd stage PRV as near as possible to
Derating recommendations Spark plug gap - 0.018 inch. carburetor.
a) 4% per 1000 feet rise above 5000 feet. Spark plug torque 28 to 30 ft-lb. The power mix adjustment valve is to be adjusted to middle position.
0 0
b) 2% per 11 C rise above 38 C. Check for centre electro continuity The idle screw is required to be adjusted (tight fully and loose for 2.5
c) No derating on account of humidity. Socket size – 13/16 inch. turns) when the engine speed is less than 650 rpm.
HPR is red in color
4. Engine rating and consumption figures depend on gas quality. Adaptor spark plug Correct the inlet pressure to HPR for 20 psi with another regulator (if
Hence, please furnish gas composition by volume, calorific value, 1. Use St - 890 wrench for removing Adaptor. reqd.) Adjust the outlet pressure of this regulator to 7psig by rotating
gas pressure and gas flow rate at engine point, and get 2. Torque - 70/80 ft-lb. counter.
confirmation from Cummins for engine rating. Clockwise to decrease the outlet pressure
NATURAL GAS ENGINE OIL RECOMMENDATIONS Check the HPR flow direction — arrowmark is in line with flow.
5. Presently all TA engines are Heat Exchanger cooled. The use of quality engine oils combined with appropriate oil and filter
change intervals are critical factors in maintaining engine performance LPR is blue in color
6. Standard engines are available with electric starting and durability Adjust the outlet pressure of this regulator to 3 - 8” of H2O by rotating
arrangement. However optional air/gas starting arrangement plug inside the top cap counter-clockwise to decrease the outlet
could be made available with extra cost. Cummins India Ltd. recommends the use of a high quality SAE 15W-40 pressure.
engine oil for natural gas engines. The specifications meeting Cummins Check the LPR flow direction arrow is in line with flow.
Specifications are subject to change without notice. recommended Volvoline GEO15W-40 oil blends for natural gas engines
are Note : exhaust gas temperatures of duel fuel engines are same as
GAS ADJUSTMENT OF ENGINES RUNNING ON GAS diesel engines.
WITH DIFFERENT HEAT VALUE API CD Quality Phosphorous - 250 - 350ppm PROPERTIES OF HYDORCARBONS / GAS FUELS
Higher Heat Value (H.C.V)-Total heat evolved by complete
• Run the engine at rated speed with 10-20% load. SAE 15W40 Viscosity Zinc - 250 – 350ppm
combustion of fuel when the products of combustion cooled down to
• Fix the throttle valve. Less than 0.5% Sulfated Ash Calcium - 1200 ppm 15 deg. C
TBN (ASTM D2896) - 5/5.5 Lower heat Value (L.C.V) - It is (HCV – Total heat absorbed by the
• Adjust the pressure regulator till the engine runs at its highest
TAN (ASTM D 664) - 0.5 - 0.7 combustion gases (steam etc.)) at the combustion temperatures.
speed
Octane value of Natural gas apx. 130, higher the octane value -
• Lower the pressure till the speed has dropped 3% better the anti knocking qualities.
• Run the engine at rated speed with 100% load. A sulfated ash limit of 0.5 percent mass has been placed on all engine Octane should not be more than 4%
lubricating oils recommended for use in Cummins natural gas engines. 1 Gallon =3.78litres=0.833 Gallons (UK)
• Adjust the carburettor power mixture valve till the CO percentage Higher ash oils can cause valve and/or piston damage, spark plug
is between 0.5 and 1.0% Boiling Pt. of Liquid @ NTP - Temperature at which liquid state of
fouling, and lead to excessive oil consumption and degradation of the matter converts to gaseous state.
When it is not possible to measure the CO percentage adjust till the catalyst. BTU / Cu. Ft. HHV (1 BTU = 252 cal)
highest vacuum in the inlet manifold is obtained. 9.5 Cu. Ft of Air to burn 1 Cu. Ft. Gas at STP
Initial timing of the Magtronic is made by turning the engine to place Lower / Upper limit Flammability - Minimum / Maximum air to gas
No.1 cylinder on magtronic side of engine on top dead centre of its ratio for better combustion.
compression stroke, rotating the drive coupling of the Magtronic by Self Ignition Temp – The temperature the gas ignites.
hand to locate the red painted timing finger visible in the timing Propane can be liquified by pressurizing it at 100 PSIG (LPG)
window and installing the Magtronic to the engine drive coupling. Proprane should not be more than 1.7%
0
0
0 0
0
0 0
HPR is red in color
speed
0
0
0 0
0
0 0
HPR is red in color
speed
Section - 2
Section – 2
Section - 2
Page 2-12
Methane Ethane Propane Butane

Formula C1 H4 C2 H6 C3 H8 C4 H10
Normal State
Gas Gas Gas Gas
@ NTP
Boiling Pt. of
-256OF -127OF -43OF 31OF
Liquid @ NTP
BTU/Cu.Ft. HHV 1,012 1,783 2,558 3,354
Cu. Ft. of Air to
9.53 16.67 23.82 30.97
burn 1 Cu. Ft. Gas
Lower / Upper limit
5/15 3/10 2.2/10 1.8/9
Flammability
Self Ignition Temp. 650OC 515OC 470OC 365OC
Max air + gas temp at the end of compression = 2400OF

Maximum temperature of exhaust = 1300OF
1. Natural Gas
ENGINE WIRING DIAGRAMS

Mixture of different hydrocarbon gases.
Methane rich gas with Ethane, Propane, Butane etc.
Minimum 70% Methane is required. More the methane content,
better the performance.
If Propane, Butane, Ethane percentage is higher than 2% by
volume, can cause detonation. Hence lower C.R. Pistons are to be
used .
Subsequent de-ration in power.
Available piston C.R. 12:1, 10:1, 8:5:1, 7:5:1
Available forms of Natural Gas
Piped Natural Gas
Compressed Natural Gas (CNG)
Liquified Natural Gas (LNG)
2. Bio-gas / Sewage
Methane 60-65%, Carbon Dioxide 25-30%.
Due to recent advance in Biotechnology, Digester gas is produced
02
02
by anaerobic bacteria from organic waste.
Sulfur/Hydrogen sulfide should be less than 0.1% by volume. If in
1. 24 VOLT NEGATIVE SYSTEM.
2. TURN THE STARTING KEY SWITCH TO START
3. RELEASE THE PUSH BUTTON AFTER ENGINE
4. WATCH THE LUB OIL PRESSURE GAUGE AND
5. TURN STARTING SWITCH TO ‘OFF’ POSITION
1. 24 VOLT NEGATIVE GROUND SYSTEM.
2. TO START THE ENGINE :-
5. TO STOP THE ENGINE :-
6. THIS DIAGRAM REFERS TO THE 12 VOLT H.T.

excess, can cause damage to the engine components.
DURING STARTING & RUNNING OF ENGINE.

MAGTRONIC ‘P’ TERMINAL FROM ‘EARTH’
SWITCH IN OFF POSITION TO DISCONNECT
PUSH BUTTON KEEP IGNITION TOGGLE
SIMULTANEOUSLY PRESS THE STARTER
POSITION TO CRANK THE ENGINE
FIRES.
INDICATES MORE THAN 1 Kg/cm 2

POSITION WHEN OIL PRESSURE GAUGE
SHIFT STARTING SWITCH KEY TO RUN
‘MAGTRONIC’.
THIS IS ESSENTIAL FOR DISCHARGING
EARTH ‘P’ CONNECTION FROM MAGTRONIC.
TOGGLE SWITCH’ TO ‘ON’ POSITION TO
TO SHUTDOWN THE ENGINE THEN TURN
- PRESS THE STARTER PUSH BUTTON.

12 V SUPPLY TO IGNITION COIL
- KEEP THE IGNITION SWITCH ON TO GIVE
POSITION
TURN THE STARTING KEY SWITCH TO START
FIRES.

IGNITION COIL DAMAGE

- THIS ESSENTIAL FOR PREVENTING
SWITCH) TO OFF POSITION.
- THEN TURN IGNITION SWITCH (TOGGLE
TO ‘OFF’ POSITION
- TURN STARTING SWITCH
SYSTEM USED ON GAS ENGINE.

DISTRIBUTOR TYPE LUCAS IGNITION
3. L.P.G. :
Liquified Petroleum Gas (LPG)
Mixture of Butane and Propane (3:2 by Volume)
Pistone C.R. 8.5 : 1.
Caloric Value
Natural Gas 850-970 BTU/CFT = 7562 - 8629 kcal/Cu.m
LPG 2769 BTU/CFT = 24635 kcal/Cu.m
Bio Gas 540 -600BTU/CFT = 4804-5338 kcal/Cu.m
Weight to Volume ratio (at 70deg F and 30” of mercury) is

0.458lbs./SCF=923.7BTU/SCF
Page 2-13
Page 2-14
140 SCF Natural gas = 1 gallon of diesel = 129,575 BTUs/Gallon
Specific gravity of Natural Gas = 0.695 (wrt. air as 1)

Section - 2
Section - 2
Normal State
Gas Gas Gas Gas
@ NTP
Boiling Pt. of
-256OF -127OF -43OF 31OF
Liquid @ NTP
BTU/Cu.Ft. HHV 1,012 1,783 2,558 3,354
Cu. Ft. of Air to
9.53 16.67 23.82 30.97
burn 1 Cu. Ft. Gas
Lower / Upper limit
5/15 3/10 2.2/10 1.8/9
Flammability

1. Natural Gas
used .
Piped Natural Gas

2. Bio-gas / Sewage
02
02
3. L.P.G. :
FIRES.
FIRES.

POSITION
Mixture of Butane and Propane (3:2 by Volume) ‘MAGTRONIC’.

Caloric Value












Page 2-13
Page 2-14

Section - 2
Section - 2
Normal State
Gas Gas Gas Gas
@ NTP
Boiling Pt. of
-256OF -127OF -43OF 31OF
Liquid @ NTP
BTU/Cu.Ft. HHV 1,012 1,783 2,558 3,354
Cu. Ft. of Air to
9.53 16.67 23.82 30.97
burn 1 Cu. Ft. Gas
Lower / Upper limit
5/15 3/10 2.2/10 1.8/9
Flammability

1. Natural Gas
used .
Piped Natural Gas

2. Bio-gas / Sewage
02
02
3. L.P.G. :
FIRES.
FIRES.

POSITION
Mixture of Butane and Propane (3:2 by Volume) ‘MAGTRONIC’.

Caloric Value












Page 2-13
Page 2-14
Section – 2 PART NUMBER DETAILS Page 2-17
I. Engines having Magtronic and Internal mounted ignition transformers :
Engine model Spark Plug Ignition coil Magtronic/ Pressure regulator Carburettor
Altronic Stage I Stage II
G-495 199148 166836 168175 3875040 3875043 179765
G-743 199148 166836 168144 3875040 3875043 191864
G-855 199148 166836 168144 3875040 3875043 191864
GTA-855 199148 166836 168144 3875040 3875043 3232503
G-1710 199148 166836 168145 3875041 3875043 (2) 191718(2)
GTA-1710 199148 166836 168145 3875041 3875044 3232502
II Engines having Magtronic/Altronic and External mounted Ignition transformers:
Spark Magtronic/ Pressure regulator Carburetor
Engine model Ignition Coil
Plug Altronic Stage I Stage. II
G-495 3873431 3873589 168175 3875040 3875043 179765
G-743 3873431 3873589 168144 3875040 3875043 191864
G-855 3873431 3873589 3392709 3875040 3875043 191864
GTA-855 / 1150 3873431 3873589 3392709 3875040 3875043 3232503
G-1710 3673431 3873589 3392710 3875041 3875043 (2) 191718(2)
GTA-1710 3873431 3673589 3392710 3875041 3875044 3232502
GTA-1150 3873431 3873589 3392709 3875041 3875044 3232503
GTA-2300 3873431 3873589 3876325 3875042 3875044(2) 3232503 (2)
GTA-3067 3873431 3873589 3392712 * 3875042 3875044(2) 3876533 (2)
* Altronic
Ill. Engines having High Tension Distributor drive system Pressure regulator
Carburettor
Engine model Spark Plug Ignition coil Distributor 1 Stage. I Stage II
G-495 3873431 3812217 3875380 3875040 3875043 179765
G-743 3873431 3812217 3812219 3875040 3875043 191864
G-855 3873431 3812217 3812219 3875040 3875043 191864
Refer SPT No 3242600-Dec. 2001 for new cyl head spare parts.

CONVERSION KITS FOR VARIOUS DUAL FUEL ENGINES
SR. CONVERSION KIT CONVERSION FROM RELEASE COOLINGTOWER RAW WATER
NO PART NO TONNAGE FOR CIRCULATING PUMP FLOW
DIESEL TO DUAL FUEL AFTERCOOLER
ENGINE ENGINE
1 AR 3879769 - 01 N-495-G DG-495-G ER 907102-000 -- --
ER 917234-000
2 AR 3880008 - 00 NTC-495-G DGTA-495-G SP-4019 5 TON 20 US GPM
3 AR 3879738 - 02 N-743-G DG-743-G
ER 907078-000 -- --
ER 917234-000
AR 3879766 - 01 NTA-855-G DGTA-855-G ER 907102-000 10 TON 40 US GPM
4
ER 917234-000
5 AR 3879755 - 01 KTA-1150-G DGTA-1150-G ER 907010-000 (WITH HC5) 20 TON 80 US GPM
ER 917234-000 (WITH 4LGK)
6 AR 3880190 - 00 VTA-1710-G DGTA-1710-G ER 928039-000 20 TON 80 US GPM
7 AR 3880084 - 00 KTA-2300-G DGTA-2300-G ER 927181-000 30 TON 120 US GPM
1 - THIS DIAGRAM REFERS TO THE

H.T. LUCAS DISTRIBUTOR TYPE
IGNITION SYSTEM ON 6 CYLINDER
GAS ENGINE
G-495 199148 166836 168175 3875040 3875043 179765
G-743 199148 166836 168144 3875040 3875043 191864
G-855 199148 166836 168144 3875040 3875043 191864
GTA-855 199148 166836 168144 3875040 3875043 3232503
G-1710 199148 166836 168145 3875041 3875043 (2) 191718(2)
GTA-1710 199148 166836 168145 3875041 3875044 3232502
G-495 3873431 3873589 168175 3875040 3875043 179765
G-743 3873431 3873589 168144 3875040 3875043 191864
G-855 3873431 3873589 3392709 3875040 3875043 191864
GTA-855 / 1150 3873431 3873589 3392709 3875040 3875043 3232503
G-1710 3673431 3873589 3392710 3875041 3875043 (2) 191718(2)
GTA-1710 3873431 3673589 3392710 3875041 3875044 3232502
GTA-1150 3873431 3873589 3392709 3875041 3875044 3232503
GTA-2300 3873431 3873589 3876325 3875042 3875044(2) 3232503 (2)
GTA-3067 3873431 3873589 3392712 * 3875042 3875044(2) 3876533 (2)
* Altronic
Carburettor
G-495 3873431 3812217 3875380 3875040 3875043 179765
G-743 3873431 3812217 3812219 3875040 3875043 191864
G-855 3873431 3812217 3812219 3875040 3875043 191864

ENGINE ENGINE
1 AR 3879769 - 01 N-495-G DG-495-G ER 907102-000 -- --
ER 917234-000
3 AR 3879738 - 02 N-743-G DG-743-G
ER 907078-000 -- --
ER 917234-000
4
ER 917234-000
ER 917234-000 (WITH 4LGK)

GAS ENGINE
G-495 199148 166836 168175 3875040 3875043 179765
G-743 199148 166836 168144 3875040 3875043 191864
G-855 199148 166836 168144 3875040 3875043 191864
GTA-855 199148 166836 168144 3875040 3875043 3232503
G-1710 199148 166836 168145 3875041 3875043 (2) 191718(2)
GTA-1710 199148 166836 168145 3875041 3875044 3232502
G-495 3873431 3873589 168175 3875040 3875043 179765
G-743 3873431 3873589 168144 3875040 3875043 191864
G-855 3873431 3873589 3392709 3875040 3875043 191864
GTA-855 / 1150 3873431 3873589 3392709 3875040 3875043 3232503
G-1710 3673431 3873589 3392710 3875041 3875043 (2) 191718(2)
GTA-1710 3873431 3673589 3392710 3875041 3875044 3232502
GTA-1150 3873431 3873589 3392709 3875041 3875044 3232503
GTA-2300 3873431 3873589 3876325 3875042 3875044(2) 3232503 (2)
GTA-3067 3873431 3873589 3392712 * 3875042 3875044(2) 3876533 (2)
* Altronic
Carburettor
G-495 3873431 3812217 3875380 3875040 3875043 179765
G-743 3873431 3812217 3812219 3875040 3875043 191864
G-855 3873431 3812217 3812219 3875040 3875043 191864

ENGINE ENGINE
1 AR 3879769 - 01 N-495-G DG-495-G ER 907102-000 -- --
ER 917234-000
3 AR 3879738 - 02 N-743-G DG-743-G
ER 907078-000 -- --
ER 917234-000
4
ER 917234-000
ER 917234-000 (WITH 4LGK)

GAS ENGINE
SOME AX PART / REPAIR KIT NUMBERS OF GAS ENGINES
Butterfly valve – G 855

Each AX1002313
Gas Engine
Butterfly Valve – GTA 1150
Each AX1002314
Gas Engine
Butterfly Valve – GTA 1710
Each AX1002315
Gas Engine
Repair Kit – Gas Pressure
R2301K Each AX1002316
Regulator P/No. 3875040
R2304K Each AX1002317
R2304KB Each AX1002318
R6102K Each AX1002319
R6106K Each AX1002320
Section - 3 Page 3 Section - 3 Page 3-2
Cummins Engine Nomenclature (B & C Series)
Section - 3
B SERIES SPECIFICATIONS
AIR INTAKE SYSTEM
B
Contents Page
1) Check air inlet service indicator for signs of choking. Air inlet
B & C Series Engine Identification……………………………………...3-1
T
restriction should not exceed 635 mm (25”) of water. Inspect/clean air
Air Intake System…………………………………………………………3-2 cleaner element every 250 hours of engine operation. Excessive
intake restriction will lead to
A
Exhaust System ………………………………………………………….3-2
Blow-By Readings………………………………………………………..3-3 a) Engine hard starting
5.9
Cooling System …………………………………………………………..3-4 b) Engine not taking load with black smoke.
-
Lubricating Oil System …………………………………………………..3-5 c) Excessive injector carboning leading to early injector failure.
G
Fuel System ………………………………………………………………3-6 d) Excessive blow-by.
Mechanical System …………………………………………………….3-8 e) Engine oil dilution.
ENGINE IDENTIFICATION (B & C SERIES)

= Number of cylinders
= Series (Family of engines)
= Turbocharged
= Aftercooled
= Displacement in Litres
= Application Codes (G-Genset)

Electrical System ………………………………………………………3-12
I) Engine over heating etc.
Important Clearances ………………………………………………3-14
g) Turbocharger failure / leakage
Important Torques ……………………………………………………..3-15
B Series Specifications ………………………………………………..3-16

EXHAUST SYSTEM
B Series Genset Specifications ………………………………………3-17
1) Check turbocharger end play and radial clearance at every 1000
Maintenance Schedule ………………………………………………3-18
hours, Permissible turbo end play is .10 to .16mm (.004” to .006”) and
radial clearance is .30 to .46mm (.012” to .018’) failure to check turbo
will lead to similar problems as mentioned above and premature turbo
failure.
2) In case of excessive lengths & bends in exhaust piping - check

exhaust back pressure during installation. It should not exceed 76.2
mm (3”) of mercury.
Page 3-1
6
AIR INTAKE SYSTEM
B
Contents Page
Section - 3
T
A
Exhaust System ………………………………………………………….3-2
5.9
-
G

= Aftercooled
= Turbocharged
EXHAUST SYSTEM


failure.

Page 3-1
Section - 3
AIR INTAKE SYSTEM
B
Contents Page
T
A
Exhaust System ………………………………………………………….3-2
5.9
-
G

= Turbocharged
= Aftercooled


EXHAUST SYSTEM
failure.

Page 3-1
COOLING SYSTEM LUBRICATING OIL SYSTEM
1) Ensure equipment is in level. Coolant radiator fill rate of a) The pressure regulating valve is designed to keep the oil
Section - 3
approximately 11.5 litres/minute (3 U. S. GPM) should be pressure from exceeding 414 kPa. (60 psi).
maintained during initial fill. This will ensure complete system b) The bypass valve is designed to open when the pressure drop
deaeration. Air in the system causes water pump impeller across the filter is more than 138 kPa. (20 psi). When a filter
B Series:
cavitation resulting in reduced coolant flow, hence overheating - becomes plugged, and oil pressure decrease of 69 kPa. (10 psi)
6B-5.9 upto 2200 RPM

4 B-3.9 up to 2500 RPM
Resulting in head gasket burning. or less from the normal operating pressure can be observed on
4 B-3.9 above 2500 RPM
6-B-5.9 above 2500 RPM
6BT/A5.9 upto 2200 RPM

4BT/A-3.9 up to 2200 RPM
4BT/A-3.9 :2200-2500 RPM

the vehicle oil pressure gauge. The pressure will return back to
6BT/A-5.9 above 2500 RPM

6B-5.9 upto 2200-2500 RPM

To ensure complete system deaeration run the engine for 05/10 normal when the filter bypass valve will open.
minutes at low idle with radiator cap removed - stop the engine,
c) Minimum oil pressure at low idle (625 to 725 RPM) is 69 kPa (10
check & top up the system.
psi). Minimum oil pressure at rated speed is 207 kPa. (30 psi)
2) Added coolant must be clean and treated as follows:
1) Check the engine oil level daily - and maintain the level upto ‘H’
7
7
1
4
1
5
1
4
3
1
Mixture of water : Ethylene glycol (1:1) = 50% + 50%. mark. Oil level above ‘H’ will cause hard starting & over heating a
level below ‘L’ mark may cause engine seizure. Make sure the
New/Rebuild
(Inches of H2O)
If the coolant is not clean it will lead to entry of foreign particles equipment is in level. A slight angle may give you a false reading
and rust formation. This may clog the coolant passages, on the dipstick.
resulting in overheating - subsequently leading to piston rings
2) Change engine oil and filter every 250 hours, replace with new
block damage and head gasket burning.
filter and use recommended engine oils only. Failure to do so will
cause severe engine damage.
6
3
3
4
2
28
17
21
13
10
3) Stop all cooling system external leaks and ensure that the
pressure cap is sealing and in good working condition. An 3) A loose suction tube, damaged gasket or crack in the suction
Used Engine
tube can cause a temporary loss of prime for the oil pump. The
(Inches of H2O)
engine operated with external leaks/pressure cap missing, leads
to system aeration and over heating. engine will have low oil pressure or no oil pressure at starting
followed by normal oil pressure. Under such a condition stop the
4) Never operate the engine without a thermostat. If done so engine immediately and rectify the fault.
engine will overheat. A missing or defective jiggle pin of the
4) Check the condition of oil.
thermostat can cause engine to run cold . Thermostat operating
BLOW-BY READINGS
0 0
a) Thin black oil is an indication of fuel in the oil.
range is 83 C to 88 C.
b) Milky discolouration is an indication of water in the oil.
5) Every 1000 hours or 32,000 Kms. (20,000 miles) check fan hub, a) Fuel in the oil can be caused by :
belt tension bearing and belt tension. This will ensure proper i) Injection pump shaft seal leaking/defective.
cooling system operation. If any of the three are defective, it will ii) Fuel leaking by the rings/Faulty injectors.
lead to engine over heating leading to other serious progressive iii) Defective lift pump.
damages. The belt tension is to be checked at the longest span iv) A crack in the cylinder head from the fuel filter location
of the belt. The maximum permissible deflection is 9.5 to to the air intake.
12.7mm (3/8” to 1/2”). With the belt tensioner checking tool ST - v) Restricted fuel drain line.
1293 the value is 36.32 to 49.94 Kgs. (80 to 110 Lbs).
a) Use the following logic to identify fuel in the lube oil.
6) To identify a head gasket blown condition, for engine not Power normal : Replace the fuel pump
(Orifice Size 0.221”)

starting. Check the compression of each of the cylinders. Normal Lower power - : Replace the
compression is 2068 kPa. (300 psi) at 150 cranking RPM. A increased white injectors
689.5 kPa (100 psi) difference between cylinders indicates a smoke during
compression seal problem. If the compression is found low on start up
adjacent cylinders and the pressure cannot be increased by Low power - : Verify the rings are
oiling the rings, the head gasket is probably leaking between the increased black sealing by
smoke performing a
cylinders.
compression
check.
Page 3-3
6B-5.9 upto 2200-2500 RPM
4BT/A-3.9 :2200-2500 RPM
4 B-3.9 up to 2500 RPM
Section - 3
B Series:
(Inches of H2O)
New/Rebuild
7
1
5
1
(Inches of H2O)
Used Engine
28
17
21
13
10
6
3
4
BLOW-BY READINGS
engine operated with external leaks/pressure cap missing, leads tube can cause a temporary loss of prime for the oil pump. The
0 0
lead to engine over heating leading to other serious progressive
iii) Defective lift pump.

Page 3-3
smoke performing a
cylinders.
compression
check.
6B-5.9 upto 2200-2500 RPM
4BT/A-3.9 :2200-2500 RPM
4 B-3.9 up to 2500 RPM
Section - 3
B Series:
(Inches of H2O)
New/Rebuild
7
1
5
1
(Inches of H2O)
Used Engine
28
17
21
13
10
6
3
4
BLOW-BY READINGS
engine operated with external leaks/pressure cap missing, leads tube can cause a temporary loss of prime for the oil pump. The
0 0
lead to engine over heating leading to other serious progressive
iii) Defective lift pump.

Page 3-3
smoke performing a
cylinders.
compression
check.
b) Water in oil can be caused by b) Loosen bleeding screw on top of the banjo nut of the fuel c) Spray pattern.
(i) Cup plugs leaking. filter head, prime by lift pump till a positive flow of fuel is d) For a used injector chatter test is not necessary.
(ii) Damaged cylinder head gasket observed - tighten the bleed screw.
In a running engine to check for satisfactory injector
(iii) Oil cooler element leaking c) Switch on the switch key to energise the coil & keep the oil operation - loosen the supply lines to each injector and
pressure By Pass switch button pressed (if provided) and
(iv) After cooler element leaking. notice drop in engine rpm. If on loosening supply, the
continue priming by lift pump. For a Robert Bosch VE
Pump do not loosen any screw on pump for bleeding. In engine rpm does not fall - this indicates that this injector
5) If the lube system is not maintained, it will also lead to case of Lucas CAV DPA Pumps-loosen the bleeding is defective.
excessive oil consumption. screw on top of the fuel pump housing.
CAUTION:
a) Worn or damaged seals in the turbocharger can allow d) Release the high pressure supply lines at the injectors and Do not bleed a hot engine as this could cause fuel to spill onto
the oil to leak into the air cross over pipe and burn in crank the engine till squirts of diesel is observed at all a hot exhaust manifold creating a danger of fire.
the combustion chamber, or leak past the engine injectors. Tighten the supply and start the engine.
exhaust casing and burn inside the exhaust piping.
9) To determine a worn or malfunctioning injection pump -
b) Inadequate sealing of the piston rings will result in oil 5) Tighten all suction lines regularly. This is done to prevent air visually check fuel delivery with an externally connected
being blown out of the breather tube and/or consumed entering the fuel system. Air in the system will cause engine tested injector to one of the pump outlets. Replace the pump if
by the engine. A blow by check / compression check hard / not starting problems. the fuel is not being delivered/sprayed.
can confirm the same.
For air, check at the following points.
c) Oil can also be lost through a worn or malfunctioning air a) Elbow connections and hose from tank to strainer. NOTE
compressor. Look for carbon build up and oil deposits b) Strainer ‘O’ ring. a) While checking for spray, do not put your hand under the
in the air line from the compressor to the air tank. nozzle spray. The fuel Injection pressure is high enough to
c) Elbow connections and hose from strainer to lift pump.
After lift pump the system is under pressure. penetrate your skin and blood vessels to cause blood
FUEL SYSTEM poisoning.
1) Drain water and sediments from fuel tank and fuel water 6) For a problem of engine not taking load or engine not starting, b) Do not attempt any adjustments on the fuel pump in the
separator filter daily. This will ensure trouble free service the lift pump can be one of the reasons. To check the lift pump field, as this may result in fuel pump malfunction.
from the fuel pump and injectors, as diesel alone acts as a for proper operation only after confirming that the system does
lubricant for the moving parts of the fuel system. not draw in air. Check for : MECHANICAL SYSTEM
a) Volume delivered by lift pump within 30 seconds of 1) If any of the cylinder head capscrews are loosened for
2) Replace fuel filter, clean strainer and replace ‘O’ ring every
500 hours. If not done - will lead to low power, engine not cranking should be 0.75 litres. any work- all the capscrews must be retorqued to the
b) Pressure should be 21 to 49 kPa (3 to 7 psi) specified value and in sequence. If not done this may
starting etc. The fuel suction restriction should not exceed
152.4 mm (6”) of mercury. lead to blown head gasket between consecutive
If the above two checks are not satisfied, this indicates that cylinders.
3) The fuel drain line restriction should not exceed 34.5 kPa. (5 a) Lift pump lever may be worn out.
psi), and the return line must be connected to the bottom of b) Lift pump inlet/outlet valves may be defective. 2) Valve setting must be carried out every 1000 hours or
the fuel tank, to prevent pump housing drain back by the c) Lift pump diaphragm may be ruptured. If so diesel will leak 32,000 Kms (20,000 miles) of engine operation. If not
process of syphoning. In case of a sudden unexplained shut out the weep hole in the housing. done it will lead to low power, black smoke, over heating,
down, engine restarts on cranking, check fuel return line for d) The camshaft lobe is worn out. hard starting etc.
restriction.
In case of stationary applications or wherever possible, it is NOTE : The procedure is as follows:
advisable to install the base of the diesel tank slightly above Frequent filter replacement to get full power from the engine indicates a) Remove the valve covers.
the top of the engine - a worn lift pump or a worn camshaft lobe. This occurs because even
a) Eliminate the problem of drain back. with a little flow restriction due to partially choked fuel filter, the b) Locate TDC for cylinder No. 1 by barring engine slowly
required quantity of fuel will not be delivered - resulting low power. while pressing the engine timing pin, till the pin engages
b) Eliminate the fitment of a lift pump.
in the slot of the camshaft gear. Disengage the timing
c) Eliminate air from the fuel system & priming will be very 7. Check solenoid coil for operation, an inoperative coil will lead to pin.
easy. engine not starting. To restart the engine - remove the valve,
d) Eliminate the problem of hard starting caused due to from the coil and refit the coil. In this condition the mechanical c) Check / set valves with engine cold - below 60 deg.
system aeration. shut off levers is to be operated to shut off the engine. Safety centigrade. (140 Deg. F). Oil temperature.
e) Maintain solid fuel in all lines at all times. controls will not be functioning.
Intake clearance to be set to : .254 mm (.010”).
4) Procedure for bleeding air from the fuel system 8. To determine whether the injector is operative, check the Exhaust clearance to be set to: .508 mm (.020”).
following
a) Check and tighten all connections from the diesel tank
a) Opening pressure. (Also called as pop pressure).
to the lift pump.
b) Leakage test.
CAUTION:
restriction.
following
to the lift pump.
b) Leakage test.
CAUTION:
restriction.
following
to the lift pump.
b) Leakage test.
Section-3 Page 3-9 Section -3 Page 3-10 Section-3 Page 3-11
ELECTRICAL SYSTEM
4 CYLINDER ENGINE 6 CYLINDER ENGINE d) Bar the engine in the direction of rotation until the dial
reads maximum and starts back. The maximum dial The electrical system consists of battery, starting motor; alternator,
reading should be equal to or above the following fuel shut off valve, low lubricating oil pressure safety control, high
1. Intake* Exhaust* 1. Intake* Exhaust*
specifications. water temperature safety control, starting switch, push button,
2. Intake* Exhaust$ 2. Intake* Exhaust$ indicating lamp, amp meter, toggle switch, air discharge temperature
3. Intake$ Exhaust* 3. Intake$ Exhaust* safety control in IR H P450, P600 and P450 compressor, etc.
4. Intake$ Exhaust$ 4. Intake* Exhaust$ Intake- 16.154 mm (0.636”) and exhaust- 11.532 mm
(0.454”) 1) Battery
5. Intake$ Exhaust*
6. Intake$ Exhaust$ Make sure the battery terminals are not loose or corroded.
* - Set the values. Voltage across the battery terminals should be 12 V or 24 V
NOTE: according the system.
$ - Do not set the values.
Any time a new camshaft is installed, new tappets should also be
installed. 2) Starting Motor
d) Mark the crankshaft pulley and gear case cover or
7) A rod knock occurs when the engine is not loaded. Verify (1) Engine does not Crank :
flywheel and flywheel housing. Rotate through 360
by first applying load and then unloading and listening for
degrees to realign the marks. * If the solenoid (magnetic switch) does not make an audible
the knock.
sound check for loose wiring connections.
e) Set the remaining cylinders. * Check the voltage at the solenoid.
8) A main bearing knock will be heard when the engine is
loaded. No voltage - check the condition of the battery. Check the
NOTE:
connections at the battery, engine and solenoid.
For a new / overhauled (with valves replaced) / recon engine or
9) For a problem of hard starting check engine blow by after •
reconditioned cylinder head the intake clearance is .30mm (.012”). If 12 V at the solenoid - Check the voltage at the S (switch)
confirming that air/exhaust system and fuel system are
These values are kept higher than normal to provide for initial terminal on the solenoid. The ignition switch must be at the
ok.
setting in. START position.
The solenoid is at fault if the check indicates 12V at the S
f) Install the valve covers and torque capscrews to 24 N.m
terminal.
(18 Ft. Lbs).
The trouble-shooting procedure is the same for 24V system.
3) Valve sealing : If the compression is low on one or more The values are 24V.
nonadjacent cylinder and the pressure cannot be
increased by oiling the rings, poor valve sealing is to be If no voltage is indicated at the S terminal of the ignition switch check:
suspected. Valve leakage is often audible from the intake
* Fuses
and exhaust manifold.
* Voltages to the ignition switch
4) Worn valve seals can be identified by excessive smoke * And if the vehicle is so equipped, voltage to clutch switch,
at idling or when the engine unloaded when the vehicle neutral safety switch and engine safety shut off system.
is going down the hill. Verify the condition by removing If the solenoid does make an audible sound turn the switch
the valve spring and inspecting the seals. off and attempt to bar the engine in both directions, as
follows.
5) If frequent valve setting is required - and if rocker lever, 1) Direction of engine rotation
valve stem, and push rods do not show excessive wear
2) Direction opposite engine rotation.
then the tappets and/or the camshaft lobes are worn out.
If the camshaft lobe is worn out, low power and unusual 3) Direction of engine rotation.
noise from the intake/exhaust manifold will be observed. If the engine will bar at step 3 - attempt to start the engine.
If the starter cranks the engine, check the starter pinion
To confirm whether the camlobes and tappets are worn gear & flywheel ring gear for damage.
out, check the valve lift as follows. 4) If engine does not rotate - check for internal malfunction of
a) Check the rocker levers, valve stems, push rods for Engine / Equipment.
wear. If the engine bars and the starting motor does not crank,
check the voltage between the solenoid and starting motor.
b) Adjust the valve lash to zero clearance with the engine in
The ignition switch must be in the start position.
the valve set position for the subject cylinder. An
approximation can be achieved by observing the No voltage - starter is at fault.
adjusting screw length out of the rocker lever. Normal voltage - The solenoid is at fault.
c) Set up a dial indicator on top of the valve spring retainer When troubleshooting a 24 V system, the value is 24 volts.
and adjust the dial indicator to zero.
ELECTRICAL SYSTEM
(0.454”) 1) Battery
5. Intake$ Exhaust*
the knock.
NOTE:
ok.
terminal.
(18 Ft. Lbs).
* Fuses
follows.
ELECTRICAL SYSTEM
(0.454”) 1) Battery
5. Intake$ Exhaust*
the knock.
NOTE:
ok.
terminal.
(18 Ft. Lbs).
* Fuses
follows.
Section-3 Page 3-12 Section - 3 Page 3-14
3) Engine Cranking Speed too Low IMPORTANT CLEARANCES
* Make sure the wiring connections are clean, tight and not A : Alternator “BAT” terminal to ground.
damaged. B : Alternator No.1 terminal to ground. CHECK POINT SPECIFIED
* Check the battery voltage. C : Alternator No.2 terminal to ground.
If the engine is free, check the voltage at the starter Crankshaft endplay 0.005” / 0.010”: Assly.
during cranking. If the voltage drops more than 2.4 volts A zero reading indicates a break between the voltmeter After test
check that all connections are tight. The limit for 24 volts connection and the battery. Locate and repair the open Free rotation with turn torque 0 to 15 N-m.
system is 4.8 volts. If the cables are correct and the circuit. Con. Rod side clearance 0.004”/0.012”
Voltage drop exceeds the limits, replace the starter.
Sr. No. on Exh. side
If the engine requires more than a normal effort to bar, With all accessories turned off, connect voltmeter across Piston protrusion 0.020”/0.027” (NA)
check for excessive load from the driven units and the battery. Operate engine at moderate speed. If W.R.T. Block Deck 0.012”/0.027” (TC)
accessories. voltage is 15.5 or more, replace the alternator or repair. Camshaft endplay 0.005”/0.0135”
The limit for 24 volts system is 25 volts.
4) Alternator
Trouble with the charging system may be indicated by the 6) Checking Fuel Shut Off Valve GEAR TRAIN BACKLASHES
indicator lamp or ammeter. Crank to Camgear 0.003” / 0.013”
Check all connections for loose or corroded connections and Crank to lub pump drive 0.004” / 0.010”
Check the indicator lamp for normal operation as shown
below: for broken wires. Remove the valve. Ground the valve and Lub pump gears 0.004” / 0.010”
connect 12 volts DC to the terminal and observe plunger Camgear to fuel pump gear 0.003” / 0.013”
Abnormal Indicator Lamp Operation movement. Use 24 volts for 24 V system (Hold the valve Alignment of timing mark A. 4BT 3.9 (CAV)
carefully while checking. The valve may fly off when supply
Engine Switch Lamp Ammeter reading between camgear and fuel B. 4B 3.9, 4BTA (BOSCH)
disconnected.)
STOPPED OFF OFF 0 pump gear C. 6BT 5.9, 6BTA (BOSCH)
STOPPED ON ON - Ve D. 6B 5.9, 6BT5.9, (CAV)
7) Low lub oil pressure Safety Control
RUNNING ON OFF + Ve
Check all connections for loose or corroded connections and RUNOUT
Switch OFF, Lamp ON. Engine STOPPED
for broken wires. Connect the wires to ‘N.O.’ contact.
* Disconnect the lamp lead at the ignition switch.
* If the lamp stays on there is a short to a positive wire on Rear cover seal bore 0.020”
When oil pressure reaches more than 10 PSI the micro switch
the ignition side of the lamp. within the safety control operates. It makes ‘N.O.’ contact. Flywheel housing face 0.008”
* If the lamp goes off there is a short in the switch. Bore 0.008”
Switch ON, lamp OFF, Engine STOPPED within the safety control operates. It makes ‘N.O.’ out side VALVE SETTING
This condition can be caused by a break in the circuit. To contact to “N.C.” internally. MANUFACTURING SERVICE
determine where a circuit break exists - Check for a
blown fuse, a burned out bulb, defective bulb socket, or Intake 0.012” 0.010”
If the engine does not start. Short the “N.O.” terminal & start
a break in lead circuit between alternator and ignition Exhaust 0.022” 0.020”
the engine. If the engine starts, the safety control is defective.
switch. Replace the safety control.
Switch ON, lamp ON. Engine RUNNING Engage timing pin
Check the drive belt and alternator pulley to be sure that B) High Water Temperature Safety Control 6 Cyl. - set 1,2,4 Intake
the alternator is rotating. 1,3,5 Exhaust
Disconnect the leads to Alternator – If the lamp stays on, Check for loose or corroded connections and for broken wires.
Connect the wires to “N.C.” contact. 4 Cyl. - set1,2 Intake
there is a short to ground on the alternator side of the
lamp. 1,3 Exhaust
0
If engine does not start, check continuity of “N.C.” contact with Remove pin, rotate by 360 and set all other valves
If the lamp goes off, replace the alternator.
the help of ohmmeter. If the continuity is not shown, the safety
5) Abnormal charging system operation control is defective, replace the safety control.
Check the battery and all wiring connections. Inspect the
wiring for defects. Check all connections for tightness and 9) Starting Switch and Push Button
cleanliness.
Check all connections for tightness and cleanliness.
With ignition switch ON and all wiring harness leads
connected, connect a voltmeter from :
4) Alternator
disconnected.)
RUNNING ON OFF + Ve
lamp. 1,3 Exhaust
0
cleanliness.
4) Alternator
disconnected.)
RUNNING ON OFF + Ve
lamp. 1,3 Exhaust
0
cleanliness.
Section - 3 Page 3-15 Section-3 Page 3-16
(L x B x H) in mm. With S. B. alternator

Approx. Dimensions of D. G. Set
150 mm exhaust manifold out flange
Exhaust gas back pressure max. at
Noise Level at 3 mts Distance (dB)
Coolant Capacity – with Radiator (ltrs)
Lubrication Oil Capacity
Fuel Consumption at 1500 RPM (gms/bhp-hr)
Alternator Insulation Class
Alternator Voltage Regulation
Alternator Size (Prime)
Battery Capacity
Compression Ratio
Bore & Stroke in mm
Aspiration & Cooling
Governor Class
Engine Configuration
No. of Cylinders
Prime Power Rating at 1500 RPM
Engine Model
Parameter
Section – 3
IMPORTANT TORQUES B SERIES SPECIFICATIONS
Important N-m Important N-m
MIN MAX
Torque Values S.S. Torque Values S.S. DATA
mm (Inch) mm (Inch)
Main bearing 60/120/ Lift pump mtg. 24, 12 mm
capscrews 160, 23mm capscrews CYL BORE 102.00 (4.0157) 102.116(4.0203)
Connecting 35/70/100, Fuel, Dual filter 32, 24 mm MAIN JRNL BORE 83.106 (2.2730)
Rod 12mm head nut torque
Cyl. Head Mtg. 40/85/126, Lub oil filter head, 80, 19 mm CAM BORE 54.164 (2.1324)
capscrews 18mm(also.refer.next.page) CAM BORE NO. 1 54.089 (2.1295) 54.139 (2.1314)
G.E. Hsg. Mtg. 24, 12 mm pressure regulator
Camshaft thrust 24, 13mm LO. Cooler mtg. 24, 12 mm CRANK MAIN JRNL DIA 82.962 (3.2662) 83.013 (3.2682)
plate mounting capscrews OUT OF ROUNDNESS 0.050 (0.002)
capscrews
TAPER 0.013 (0.0005)
Lub pump mtg. 24, 13mm Lub Oil filter head 24, 12 mm
BEARING CLEARANCE 0.119 (0.00475)
capscrews
Wtr pump mtg. 24, 13mm Alternator pulley nut 80, 22 PISTON PIN BORE 40.006 (1.5750) 40.025 (1.5758)
2175 x 807 x 2060
105 HP/60 kWe

Mechanical A2
Turbocharged,
capscrews
Water cooled
12 V 150 Ah
PISTON PIN DIA 39.990 (1.5744) 40.0032 (1.5749)
6BT 5.9 G1
102 x 120
14.3 ltrs.
+/- 1.5%
Rear cover plate 9, 10 mm Cover intake/ 24, 12, 13 mm
UC22W
17.5 : 1
75 kVA
3.0”Hg
In line
22.00
155
CRANK ROD JRNL DIA 68.962 (2.7150) 69.013 (2.7170)
90
Aftercooler
6
Suction tube and 24, 13mm Belt tensioner 43,15 mm OUT OF ROUNDNESS 0.050 (0.002)
Brace
B - SERIES - GENSET SPECIFICATIONS

mounting capscrews 14 mm TAPER 0.013 (0.0005)
Oil pan mounting 24, 10 mm Belt tension 24, 5 mm BEARING CLEARANCE 0.089 (0.0035)
bracket
PISTON RING CLEARANCE
2175 x 807 x 2060

capscrews 12 mm ALLEN
105 HP/66 kWe

Mechanical A2
Turbocharged,
Water cooled
12 V 150 Ah
Drain plug on oil 43, 17mm Fan hub mtg. 24, 13mm TOP (TURBOCHARGED) USE KEYSTONE GAUGE
6BT 5.9 G1
102 x 120
14.3 ltrs.
82.5 kVA
+/- 1.5%
17.5 : 1
UC22G
3.0”Hg
In line
pan
22.00
155
TOP (N. ASPIRATED) 0.075 (0.003) 0.150 (0.0059)
90
6
Rocker cover mtg. 24, 15 mm Crankshaft pulley 137, 15 mm
torque INTERMEDIATE 0.075 (0.003) 0.150 (0.0059)
Fuel pump drive 65, 22mm Vibration damper 137, 15mm OILCONTROL 0.040 (0.0016) 0.130 (0.0051)
shaft
Nut BOSCH/MICO PISTON RING GAPS
with spring 81, 22mm Exhaust mfd. mtg. 43, 14mm
cooled, Water cooled

TOP (TURBOCHARGED) 0.40 (0.0160) 0.70 (0.0275)
Turbocharged, After
1015 x 598 x 946
washer CAV capscrews
124 HP/80 kWe

Mechanical A2
6BTA 5.9 G1 I
Engine Only
12 V 150 Ah
Fuel pump mtg. 24, 12 mm Turbocharger nuts 32, 15 mm TOP (N. ASPIRATED) 0.25 (0.0100) 0.55 (0.0215)
102 x 120
100 kVA
+/- 1.5%
17.3 : 1
3.0”Hg
In line
nuts.
150
INTERMEDIATE 0.25 (0.0100) 0.55 (0.0215)
90
6
-
-
-
Fuel pump lock 30, 10mm Flywheel housing 60, 18mm
OIL CONTROL 0.25 (0.0100) 0.55 (0.0215)
screw with Hex mtg. C/s
special washer Bosch CAV
Gear cover mtg. 24, 13mm Flywheel mounting 137, 19mm
capscrews or 12 mm capscrews

Turbocharged, After
Injector nozzle 60, 24 mm Starter mtg. 43, 17mm
1015 x 598 x 946
154 HP/100kWe
Mechanical A2
6BTA 5.9 G2 I
nut Deep Well capscrews
Engine Only
12 V 150 Ah
102 x 120
125 kVA
+/- 1.5%
17.3 : 1
3.0”Hg
In line
REMARKS :-
149
90
6
-
-
-
Lifting Hook 24 Nm 12mm
Page 3-17
Front
Rear
* Socket Size
NOTES NOTES Im portant Note for
___________________________________________________________ ___________________________________________________________
B & C Series Cylinder Head Torque
___________________________________________________________ ___________________________________________________________
M anufactured after 1991.
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
B Series : Cylinder Head :
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Tighten all Capscrews 90N-m (66 ft-lb)

___________________________________________________________ ___________________________________________________________
Recheck to 90 N-m (66 ft-lb)
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Long Capscrews Rkr Assly only 120 N-m (89 ft-lb)
___________________________________________________________ ___________________________________________________________
Recheck Long Capscrews 120 N-m (89 ft-lb)
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Advance all 90 degrees

___________________________________________________________ ___________________________________________________________
For detailed procedures refer to Trouble
___________________________________________________________ ___________________________________________________________ shooting & Repair Manual B-Series engines
___________________________________________________________ ___________________________________________________________
Bulletin No : 3810486
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
C Series : Cylinder Head :
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Tighten all Capscrews 70 N-m (52 ft-lb)
___________________________________________________________ ___________________________________________________________
Recheck to 70 N-m (52 ft-lb)
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Long Capscrews only 145 N-m (105 ft-lb)

___________________________________________________________ ___________________________________________________________
Recheck Long Capscrews 145 N-m (105 ft-lb)
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________ Advance all 90 degrees

___________________________________________________________ ___________________________________________________________
For detailed procedures refer to Trouble
___________________________________________________________ ___________________________________________________________ shooting & Repair Manual C-Series engines
Bulletin No : 3666003
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________
___________________________________________________________ ___________________________________________________________

Fuel Consumption at 1500 RPM (gms/bhp-hr)
Battery Capacity
Compression Ratio
Bore & Stroke in mm
Governor Class
No. of Cylinders
Engine Model
Parameter
Section – 3
MIN MAX
mm (Inch) mm (Inch)
capscrews 160, 23mm capscrews CYL BORE 102.00 (4.0157) 102.116(4.0203)
Connecting 35/70/100, Fuel, Dual filter 32, 24 mm MAIN JRNL BORE 83.106 (2.2730)
capscrews 18mm CAM BORE NO. 1 54.089 (2.1295) 54.139 (2.1314)
capscrews
TAPER 0.013 (0.0005)
Lub pump mtg. 24, 13mm Lub Oil filter head 24, 12 mm
capscrews
2175 x 807 x 2060
105 HP/60 kWe

Mechanical A2
Turbocharged,
capscrews
Water cooled
12 V 150 Ah
PISTON PIN DIA 39.990 (1.5744) 40.0032 (1.5749)
6BT 5.9 G1
102 x 120
14.3 ltrs.
+/- 1.5%
UC22W
17.5 : 1
75 kVA
3.0”Hg
In line
22.00
155
90
Aftercooler
6
Suction tube and 24, 13mm Belt tensioner 43,15 mm OUT OF ROUNDNESS 0.050 (0.002)
Brace

mounting capscrews 14 mm TAPER 0.013 (0.0005)
bracket
PISTON RING CLEARANCE
2175 x 807 x 2060

capscrews 12 mm ALLEN
105 HP/66 kWe

Mechanical A2
Turbocharged,
Water cooled
12 V 150 Ah
6BT 5.9 G1
102 x 120
14.3 ltrs.
82.5 kVA
+/- 1.5%
17.5 : 1
UC22G
3.0”Hg
In line
pan
22.00
155
TOP (N. ASPIRATED) 0.075 (0.003) 0.150 (0.0059)
90
6
shaft
with spring 81, 22mm Exhaust mfd. mtg. 43, 14mm

TOP (TURBOCHARGED) 0.40 (0.0160) 0.70 (0.0275)
Turbocharged, After
1015 x 598 x 946
124 HP/80 kWe

Mechanical A2
6BTA 5.9 G1 I
Engine Only
12 V 150 Ah
102 x 120
100 kVA
+/- 1.5%
17.3 : 1
3.0”Hg
In line
nuts.
150
INTERMEDIATE 0.25 (0.0100) 0.55 (0.0215)
90
6
-
-
-
OIL CONTROL 0.25 (0.0100) 0.55 (0.0215)

Turbocharged, After
1015 x 598 x 946
154 HP/100kWe
Mechanical A2
6BTA 5.9 G2 I
Engine Only
12 V 150 Ah
102 x 120
125 kVA
+/- 1.5%
17.3 : 1
3.0”Hg
In line
REMARKS :-
149
90
6
-
-
-
Page 3-17
Front
Rear
* Socket Size
Parameter
MIN MAX
Section – 3

Engine Model
mm (Inch) mm (Inch)
Governor Class
No. of Cylinders
Battery Capacity
CYL BORE 102.00 (4.0157) 102.116(4.0203)
Compression Ratio
capscrews 160, 23mm capscrews
Bore & Stroke in mm

Connecting 35/70/100, Fuel, Dual filter 32, 24 mm

MAIN JRNL BORE 83.106 (2.2730)



capscrews 18mm CAM BORE NO. 1 54.089 (2.1295) 54.139 (2.1314)



capscrews
TAPER 0.013 (0.0005)
Lub pump mtg. 24, 13mm Lub Oil filter head 24, 12 mm Fuel Consumption at 1500 RPM (gms/bhp-hr)
capscrews
capscrews
PISTON PIN DIA 39.990 (1.5744) 40.0032 (1.5749)
6

H
Aftercooler
90
155
22.00
In line
3.0”Hg
17.5 : 1
75 kVA
UC22W
Suction tube and 24, 13mm Belt tensioner 43,15 mm

+/- 1.5%
14.3 ltrs.
OUT OF ROUNDNESS 0.050 (0.002)

102 x 120
6BT 5.9 G1
12 V 150 Ah
Water cooled
Brace
Turbocharged,
Mechanical A2
105 HP/60 kWe
TAPER 0.013 (0.0005)

2175 x 807 x 2060
mounting capscrews 14 mm
bracket
capscrews 12 mm ALLEN PISTON RING CLEARANCE
pan
TOP (N. ASPIRATED) 0.075 (0.003) 0.150 (0.0059)
6
90
155

22.00
In line
3.0”Hg
17.5 : 1
UC22G
+/- 1.5%
14.3 ltrs.
82.5 kVA

102 x 120
6BT 5.9 G1
12 V 150 Ah
Water cooled
Turbocharged,
Mechanical A2
105 HP/66 kWe
2175 x 807 x 2060
shaft
with spring 81, 22mm Exhaust mfd. mtg. 43, 14mm TOP (TURBOCHARGED) 0.40 (0.0160) 0.70 (0.0275)
nuts. INTERMEDIATE 0.25 (0.0100) 0.55 (0.0215)
-
-
-
6
90
150
In line

3.0”Hg
17.3 : 1
+/- 1.5%
100 kVA
OIL CONTROL 0.25 (0.0100) 0.55 (0.0215)

102 x 120

Engine Only
12 V 150 Ah
6BTA 5.9 G1 I
Mechanical A2
124 HP/80 kWe
1015 x 598 x 946

Turbocharged, After

REMARKS :-
-
-
-
6
90
149

In line
3.0”Hg
17.3 : 1
+/- 1.5%
125 kVA
Front
102 x 120
Engine Only
12 V 150 Ah
6BTA 5.9 G2 I

Mechanical A2
154 HP/100kWe
1015 x 598 x 946
Rear
Turbocharged, After
* Socket Size
Page 3-17
Section 3 Page 3-19
B SERIES ENGINE MAINTENANCE SCHEDULE – CONTD…..
Check/Inspect/Clean……..
Intake System Air Cleaner Air Cleaner Air Cleaner Air Cleaner
Intake System Intake System Intake System Intake System
Fuel Strainer Antifreeze Antifreeze
Fan Hub Fan Hub
Belt Tensioner Belt Tensioner
Bearing Bearing
Belt Condition Belt Condition
Damper
Note : For B-series (PSIL) genset applications refer respective operation & Maintenance Manuals for maintenance schedule.
*Drain the complete cooling system and flush the entire system. Add treated water during fill.

B SERIES ENGINE MAINTENANCE SCHEDULE
Daily or Every 3 Months, Every 6 Months, Every 12 Months, Every 2 years

Refuelling 250 Hours or 500 Hours or 1000 Hours or 2000 Hours or
8000 Kms 16,000 Kms 32,000 Kms 64,000 Kms
(5000 Miles) (10,000 Miles) (20,000 Miles) (40,000 Miles)
Check ………Change/replace………
Oil level Lube Oil Lube Oil Lube Oil Lube Oil
Coolant level Lube Filter Lube Filter Lube Filter Lube Filter
Fuel water trap Fuel Filter Fuel Filter Fuel Filter Fuel Filter
‘O’ Ring Antifreeze*/
Strainer Corrosion
resistor
Adjust…………….
Valve Lash Valve Lash
Clearance Clearance
Section 3 Page 3-19
B SERIES ENGINE MAINTENANCE SCHEDULE – CONTD…..
Check/Inspect/Clean……..
Intake System Air Cleaner Air Cleaner Air Cleaner Air Cleaner
Intake System Intake System Intake System Intake System
Fuel Strainer Antifreeze Antifreeze
Fan Hub Fan Hub
Belt Tensioner Belt Tensioner
Bearing Bearing
Belt Condition Belt Condition
Damper
Note : For B-series (PSIL) genset applications refer respective operation & Maintenance Manuals for maintenance schedule.
*Drain the complete cooling system and flush the entire system. Add treated water during fill.

B SERIES ENGINE MAINTENANCE SCHEDULE
Daily or Every 3 Months, Every 6 Months, Every 12 Months, Every 2 years

Refuelling 250 Hours or 500 Hours or 1000 Hours or 2000 Hours or
8000 Kms 16,000 Kms 32,000 Kms 64,000 Kms
(5000 Miles) (10,000 Miles) (20,000 Miles) (40,000 Miles)
Check ………Change/replace………
Oil level Lube Oil Lube Oil Lube Oil Lube Oil
Coolant level Lube Filter Lube Filter Lube Filter Lube Filter
Fuel water trap Fuel Filter Fuel Filter Fuel Filter Fuel Filter
‘O’ Ring Antifreeze*/
Strainer Corrosion
resistor
Adjust…………….
Valve Lash Valve Lash
Clearance Clearance
Section - 3A Page 3A-2
Section- 3A Page 3A Section - 3A Page 3A-1
C-SERIES SPECIFICATIONS BOSCH PE PUMP PRODUCT DESIGNATION
ENGINE SPECIFICATIONS
Contents Page
A typical inline pump will have the following name plate.
01 Specifications & Product Information………………………...…3A-1 ENGINE SERIES : C
02 ‘C’ Series Design Features ………………………………………3A-1 BORE : 114 MM
BOSCH
STROKE : 135 MM made in Germany
03 Parts Common To ‘B’ Series Engine……………………………3A-1
DISPLACEMENT : 8.3 LITERS 02256063 SERIAL
04 PE Bosch Pump Product Designation ………………………..3A-2 FIRING ORDER : 1-5-3-6-2-4 NUMBER
05 Governor Product Designation ………………………………….3A-3 ALPHA PES6A 100D 320/3
PRODUCT INFORMATION NUMERIC RS2697
06 Motorpal Pump Product Designation ………………………...…3A-3
CONSTRUCTION APPLICATION PRODUCT
07 ‘C’ Series Checkpoint Information …..………………………….3A-4 6CTA8.3C POWERING TELCO DESIGNA- 9 400 230 097
08 Important Basic Engine Design ……………………………….. 3A-5 HYDRAULIC TION __________________ TEN
EXCAVATOR DIGIT
09 Important Tips To Troubleshooting Systemwise .…………… 3A-7
RATED AT 230 HP @ 2000 RPM PART
10 Procedure For Installation of Fuel Pump ……………………3A-11 NUMBER
11 Procedure For Valve Setting …………………………………3A-12 GENSET APPLICATION
6CTA8.3G POWERING 160 KVA GENSET The product designation for the above name plate can be broken into
12 ‘C’ Series Engine Maintenance Schedule…………………….3A-13
sections as follows.
13 Important Clearances …………………………………………3A-15 RATED AT 205 HP @ 1500 RPM
14 Important Torque Values ………………………………………3A-16
PE - Inline Pump With Camshaft
THIS ENGINE IS LOW TEMPERATURE
AFTERCOOLED (INTAKE AIR) VERSION.
S - Flange Mounted
‘C’ SERIES ENGINE DESIGN FEATURES
• Single Piece Cylinder Head 6 - Number of High Pressure
• Replaceable Guides Outlet (Pumping Elements)
• Wet Cylinder Liners - Mid Stop Design
A - Pump Size; MW = Pump Size
• Short Water Jacket
• Gerotor Lube Pump
• Forged Steel Crankshaft 100 - Plunger Diameter (multiply times 1/10 mm)
• Steel Camshaft
• Two Valves Per Cylinder D - Execution; /=Original;
• High Swirl Combustion A = first change;
• Helical Intake Port B = second change;
C = third change; etc
• Inline Fuel Injection Pump
320/3 - Construction information
PARTS COMMON TO ‘B’ SERIES ENGINE
.. Crankshaft Seals (Rear)
R - Direction Of Rotation
.. Valve Tappets (R = Right; L = Left)
.. Engine Timing Pin Assembly
.. Fuel Pump Drive Access Cover S2697 - Application Information
.. Belt Tensioner
.. Fuel Filters
.. Camshaft Thrust Plate
Contents Page
BOSCH
EXCAVATOR DIGIT
S - Flange Mounted
• Steel Camshaft
.. Belt Tensioner
.. Fuel Filters
Contents Page
BOSCH
EXCAVATOR DIGIT
S - Flange Mounted
• Steel Camshaft
.. Belt Tensioner
.. Fuel Filters
Section - 3A Page 3A-4 Section- 3A Page 3A-5
‘C’ SERIES ENGINE
CHECKPOINT INFORMATION VIBRATION DAMPER
GOVERNOR PRODUCT DESIGNATIONS
- Check alignment marks at proper service checks
OIL TEMPERATURE AT OIL SUMP
‘RSV’
- Range -99 to 127 Degrees Centigrade
RS V 400-1100 A0C 2190 8R 8 RIB POLYVEE K SECTION BELT
OIL PRESSURE AT MAIN RIFLE
- min 10 psi idle - 30 psi rated - Proper belt tension – 80 to 140 lbs – ST – 1293 Gauge
R = Flyweight Governor
- Typical 30 psi idle - 60 psi rated
S = Swivel Lever Model TURBOCHARGER I AIR MANIFOLD PRESSURE CRANKCASE VENT
V = Variable Speed Governor (all speed) - Pressure 27-40 in. Hg at rated - Engine blow by
Note : Pressure subject to engine HP and design.
400 = Low Idle Pump Speed - New engine after break in 0.8 in. of water
FUEL INJECTION PUMP
- Used engine max. 18 in. of water
1100 = Full Load Pump Rated Speed - Fuel Gallery Pressure - 20 psi. min.
Note : Blow by reading at rated RPM with 0.302” orifice restriction
A = Fits On “A” Size Pump Note : Regulated by fuel drain connection
- Fuel Drain Restriction -20.4 in. Hg.
0 = Numerical Code For Percent of
FUEL SHUT OFF SOLENOID - TWO COILS – PULL AND HOLD COMPRESSION PRESSURE AT CRANKING SPEED OF
Regulation (flyweight and spring combination)
- min. Operating Voltage -24 V; Peak Amps-2 - New engine - 350 psi. min
C = Governor Model (version) Resistance Ohms Across Coil - 29.5 ± 2.5 ; Peak Amps – 1
- Used engine - 300 psi min
2190 = Application Number Dipstick litres
- Low Level - 15.3 Note : Difference between pressures of 2 adjacent cylinders
R = Located On Right End Of Pump - High Level - 18.9 indicates cylinder head gasket damaged.
Note: Level may change with oil pan option
MOTORPAL PUMP PRODUCT DESIGNATION IMPORTANT BASIC ENGINE DESIGN
OIL PRESSURE REGULATOR
- Regulator plunger starts to open at 60 psi 01. # 4 MAIN UPPER THRUST BEARING
A typical motorpal Mf injection pump details are as follows
pressure and returns oil back to sump. 02. PISTON COOLING NOZZLES IN # 1,2,4,5,6 & 7 MAIN
BEARING SADDLES.
PP6M 10K 1 f N10812 WATER TEMPERATURE 03 ALL UPPER MAIN BEARINGS SAME PART NUMBER
P = stands for fuel injection pump - Min 70 Degrees Centigrade EXCEPT #4, WHICH IS A THRUST.
P = stands for flange type mounting - Max 95 Degrees Centigrade 04. ALL LOWER MAIN BEARINGS SAME PART NUMBER.
6 = represents No. of injection units 05. CONNECTING RODS NOT PRESSURE LUBRICATED AT
TURBOCHARGER
UPPER PIN BORE. NOTE: OILED BY PISTON COOLING
Mf = Size of pump, depending on the plunger stroke - Turbocharger Outlet Restriction - 2.0 in Hg. (max. at rated load) NOZZLE.
- Turbocharger inlet Restriction
10 = Diameter of the plunger (mm) 06. CONNECTING ROD BEARING, UPPER & LOWER
6C8.3 - 20 in. of water BEARINGS SAME PART NUMBER.
K = Plunger head shape with constant beginning of injection 6CT8.3 / 6CTA8.3 - 25 in. of water
07. TAPPETS SAME PART NUMBER AS USED ON ‘B’ SERIES,
1 = Rotation of Camshaft (Clockwise from drive end) MUSHROOM TAPPET OR TOP HAT STYLE.
WATER MANIFOLD
08. CAM THRUST, METAL CONSTRUCTION. ACCESS TO
N10812 = Assembly document number - Upper manifold
CAPSCREWS, WHEN TIMING MARKS ARE ALIGNED.
- Cold side of system
09. CAM BUSHINGS IN ALL CAM BORES.
- Higher pressure side
- Upper manifold pressure - - PROPER ALIGNMENT IS WHEN OIL HOLE IN BUSHING
IS ALIGNED WITH OIL SUPPLY PASSAGE.
12 to 25 psi (rated) with 7 psi pressure cap
Note: Engine RPM and temperature, - OIL FEEDS OVERHEAD FROM #7 CAM BUSHING
pressure cap will cause pressure difference. - OIL FEEDS FUEL PUMP SUMP FROM # 1 CAM
- Lower manifold BUSHING
- Hot side of system 10. NO TIMING MARKS ON FUEL PUMP DRIVE GEAR.
- Lower pressure side 11. WATER PUMP CAN ONLY BE INSTALLED IN ONE
POSITION.
‘RSV’
FUEL INJECTION PUMP
BEARING SADDLES.
TURBOCHARGER
WATER MANIFOLD
POSITION.
‘RSV’
FUEL INJECTION PUMP
BEARING SADDLES.
TURBOCHARGER
WATER MANIFOLD
POSITION.
Section - 3A Page 3A-6 Section – 3A Page 3A-7 Section - 3A Page 3A-8
IMPORTANT TIPS ON TROUBLE
SHOOTING – SYSTEMWISE 9. Fuel injection pump timing with respect to engine is
12. ONE PIECE HEAD DESIGN extremely critical. Pump timing that is off by only a few
AIR SYSTEM crankshaft degrees will cause
NOTE : CAPSCREWS UNDER INJECTOR HOLD-ON 1. Poor performance - Starting and power
1. Air flow restriction will result in excess smoke and low
CAPSCREWS 2. Excessive smoke and emissions
power. 3. Poor fuel economy
2. Entry of non filtered air will result in damage to cylinders.
13. ROCKER LEVER OIL SUPPLYTUBE CAN ONLY BE 10. The length, internal size and rigidity of the high pressure
INSTALLED IN ONE POSITION AS REMOVED, AS TUBE 3. Excess smoke and low power can result if there are leaks
on the pressurised side and/or exhaust leaks. fuel lines is critical to smooth engine operation. DO NOT
WILL TAKE A SEATED POSITION, BECAUSE OF
WELD OR SUBSTITUTE LINES. USE ONLY THE
PRESSURE OF THE CLAMPING FORCE OF THE 4. A malfunctioning turbocharger can result in :
SPECIFIED PART NUMBER FOR THE ENGINE.
ROCKER LEVER SUPPORT.
- low power & black smoke
WARNING : THE PRESSURE OF THE FUEL IN THE LINE
14. LINERS MID STOP DESIGN 0.0005” TO 0.0045” LINER - High lubricating oil consumption and blue smoke IS SUFFICIENT TO PENETRATE THE SKIN
PROTUSION AND CAUSE SERIOUS BODY HARM.
- Unusual noise
15. HIGH PRESSURE INLINE PUMP WILL BE ROBERT 11. For removing air in high pressure line, bleed at the fitting
Engine Model Orifice size Blow by limits Inch of water
BOSCH ‘A’ OR ‘MW’ TYPE OR MOTORPAL PUMP. that connects the injector. Bleed one line at a time, until the
engine runs smooth.
16. A FUEL PUMP POSITIONER OR TIMING PIN IS 6 CT/A-8.3 0.302” 4 18
12. To ascertain a malfunctioning injector; operate the engine
PROVIDED FOR PUMP INSTALLATION. FUEL PUMP
FUEL SYSTEM and loosen the fuel line nut one at a time at injector end and
INSTALLATION WILL REQUIRE ENGINE TO BE
POSITIONED AT T.D.C. OF COMPRESSION STROKE 1. The lift pump should deliver a volume of 0.75 litres within listen for a change in engine speed. A drop in engine speed
FOR # 1 CYLINDER. 30 seconds of cranking. indicates the injector was delivering fuel to the cylinder and
vice versa.
17. TWO PISTION COOLING NOZZLES PER CYLINDER. CAUTION : Make sure the wire to the fuel solenoid is
disconnected before performing this check. LUBRICATING SYSTEM
Residue fuel in the injection pump may allow the
engine to start. 1. A pressure regulator, stuck in closed position will result in
high oil pressure.
2. Frequent fuel filter replacement to get full power from the
engine can indicate a worn lift pump. 2. Low oil pressure may be a result of
a. Oil pressure gauge faulty.
3. For a problem of low power, if the lift pump delivers the b. Low engine oil level
required volume, check for restrictions on supply leaks in c. Loose suction tube
the fuel circuit to the lift pump. d. Choked oil filter
a. Tank vent e. Pressure regulator stuck in open position
f. Oil dilution
b. Supply tank g. Excessive worn oil pump
c. Supply line h. Worn bearings
d. Pre filter
3. Coolant in the oil results from a crack or leak between the
e. Supply line coolant and oil circuits from following components.
4. Air in the fuel system will result in engine hard to start, run - oil cooler
- aftercooler
rough, misfire, produce low power.
- core plugs in cylinder head
5. Filtration and separation of water from the fuel is important - cylinder liner seal
for troublefree operation and long life of fuel system. - headgasket
- cylinder liner (crack)
6. A restricted travel of the fuel control lever (Throttle Lever) - cylinder head (cracked passage)
can cause low power. - cylinder block (cracked passage)
7. The high idle screw of the fuel injection pump is set at the 4. Fuel diluting oil is limited to four sources
factory and should not be adjusted in the field. - lift pump
- malfunctioning injector
8. Partial actuation of the mechanical shut down lever will - inadequate piston ring sealing
affect fuel flow and engine power. - a worn or damaged injection pump
- Unusual noise
engine runs smooth.
vice versa.
high oil pressure.
f. Oil dilution
d. Pre filter
- aftercooler
- Unusual noise
engine runs smooth.
vice versa.
high oil pressure.
f. Oil dilution
d. Pre filter
- aftercooler
Section - 3A Page 3A-9 Section - 3A Page 3A-10 Section - 3A Page 3A-11
NOTE : An increase in white smoke during the first start of the
2. Engine cranking speed too low may be due to PROCEDURE FOR INSTALLING FUEL PUMP
day is a symptom that an injector is leaking.
- low battery voltage
COOLING SYSTEM - starter faulty A typical PES6A Robert Bosch Pump
1. Overheating of the engine may result due to - excessive load from drive units
- internal engine malfunction 1. Bring cylinder no. 1 to TDC of compression stroke, by using
- water temperature gauge malfunction
engine timing pin.
- less coolant level
3. Trouble with the charging system may be indicated by 2. Remove access plug of fuel pump governor housing timing
- oil level more than “H” mark
indicator lamp or ammeter. pin.
- airin cooling system
In case ignition switch is off, lamp is on, when engine is 3. Remove the pump timing pin.
- restricted water pump suction line stopped, then the reason may be
- belttensioner malfunction - short to the positive wire of ignition side of lamp 4. Rotate fuel pump shaft, till timing tooth is in centre of
- choked radiator
access plug hole.
- short in the ignition switch
- damaged fan hub bearings 5. Reverse position of timing pin, so that timing pin engages in
In case of ignition switch on, lamp off, with engine stopped, tooth and locks the fuel pump shaft.
- thermostat malfunction
the reason may be 6. Fit access plug.
- overfueling
- blown fuse
- over loading 7. Make sure the “O” ring seals are correctly installed and are
- burned out bulb
- incorrect
fan shroud not damaged. Lubricate the mounting flange.
- defective bulb socket
- damaged fan 8. Slide the pump shaft through the drive gear and position the
- open circuit between alternator and ignition switch
pump flange on to the mounting studs.
COOLANT LOOP
OF CONVENTIONAL AFTERCOOLING In case of ignition switch on, lamp on, engine running, the 9. Install the mounting nuts. Torque value – 43 N.m. (32 ft. Ib).
reason may be 10. Install the retaining nut and washer. Torque value 10-15
- belt slippage N.m.
(7-11 ft.lb.)
- short circuit to ground, on the alternator side of lamp
- faulty alternator 11. Disengage the timing pin.
12. Remove the fuel pump timing pin plug. Reverse the position
4. Abnormal charging system operation may be due to of the pin and install the pin, plug and sealing washer.
- loose connections 13. Tighten the fuel pump drive nut.
- defective wiring Torque values - PES6A - 93 N.m
- faulty alternator
PES6MW - 105 N.m
5. For checking of fuel shut off valve, activate the ignition Motorpal Mf - 105 N.m
switch and check the plunger travel 14. Install the gear case cover access cap. Hand tight.
15. Install the fuel lines, control linkage and fuel shutoff
A = 86.6 mm (3.4 in.) - Ignition switch in off position solenoid.
AFTERCOOLER UNDER PRESSURE B = 60.2 mm (2.4 in) - Ignition switch activated
ELECTRICAL Note : (1) Brand new pumps from factory and serviced pump
Note : The solenoid must operate without binding
1. For a problem of engine not cranking, the possible reasons from service shop are always in locked condition.
may be
- battery terminals loose or corroded (2) Both the Robert Bosch and Motorpal fuel pumps
have a timing pin for locking the fuel pump shaft, during
- discharged batteries
fitment, however the timing pins are different.
- loose electrical wiring
- damaged starter pinion and flywheel ring gear
- electrical starter faulty
engine timing pin.
- choked radiator
access plug hole.
- overfueling
- blown fuse
- burned out bulb
- incorrect
COOLANT LOOP
(7-11 ft.lb.)
- faulty alternator
PES6MW - 105 N.m
may be
engine timing pin.
- choked radiator
access plug hole.
- overfueling
- blown fuse
- burned out bulb
- incorrect
COOLANT LOOP
(7-11 ft.lb.)
- faulty alternator
PES6MW - 105 N.m
may be
……………………………………………………………………………………Adjust …………………………….…
• Valve Lash • Valve Lash
Clearance Clearance
…………………………………………………………………………..Check/lnspect ………………………….
• Air Cleaner • Air Cleaner • Air Cleaner
• Intake System • Intake System • Intake System
• Coolant Parameters • Antifreeze • Air Compressor
(PPM & PH) • Fan Hub • Belt Tensioner
• Belt Tensioner Bearing
Bearing • Belt Tension
• Belt Tension • Vibration Damper
C SERIES ENGINE MAINTENANCE SCHEDULE
Daily Refueling Every 9,000 Km Every 32,000 Km Every 64,000 Km
(5,000 Miles) Or 6 Months (20,000 Miles) Or 12 Months (40,000 Miles) Or 2 Years
250 Hours 1000 Hours 2000 Hours
Check ……………………………………………………………. Change/Replace ……………………………………….
• Oil Level • Lube Oil • Lube Oil • Lube Oil
• Coolant Level • Lube Filter • Lube Filter • Lube & SLO
Bypass Filter
• Drive Belt • Fuel Filter • Water Softner • Water Softener
• Fuel WaterTrap • Super L.O. • Fuel Filter • Fuel Filter
Bypass filter
• Corrosion Resistor/ • S.L.O. Bypass filter • Antifreeze
Mark on the vibration damper and correspondingly on the gear
Use timing pin to locate Top Dead Centre of compression stroke
case cover. Rotate the crankshaft by 360 degrees in clockwise

Page 3A-12
W
W
H
Y
E
E
F
H
L
Y
E
E
F
L
L
CAUTION : Be sure to disengage the pin after locating TDC.
CYL
CYL
I E
I E
6
* *
6
PROCEDURE FOR VALVE SETTING
Check / adjust valves for cylinder as follows:
CYL
#
I E
I E
CYL
5
- 0.014”
- 0.026”
*
5
Set the remaining valves as follows:
CYL
*
I E
I E
CYL
4
EXHAUST VALVE CLEARANCE

INTAKE VALVE CLEARANCE
#
CYL
I E
I E
CYL
3
*
3
Valves to be set
for cylinder no. 1.
Valves to be set
*
I E
I E
CYL
CYL
#
2
2
direction.
Section - 3A
I E
I E
# #
CYL
CYL
1
1
-
1.
2.
3.
4.
#
*
……………………………………………………………………………………Adjust …………………………….…
Clearance Clearance
…………………………………………………………………………..Check/lnspect ………………………….


Bypass Filter
Bypass filter

Page 3A-12
W
W
H
Y
E
E
F
H
L
Y
E
E
F
L
L
CYL
CYL
I E
I E
6
* *
6
CYL
#
I E
I E
CYL
5
- 0.014”
- 0.026”
*
5
CYL
*
I E
I E
CYL
4

#
CYL
I E
I E
CYL
3
*
3
Valves to be set
for cylinder no. 1.
Valves to be set
*
I E
I E
CYL
CYL
#
2
2
direction.
Section - 3A
I E
I E
# #
CYL
CYL
1
1
-
1.
2.
3.
4.
#
*
……………………………………………………………………………………Adjust …………………………….…
Clearance Clearance
…………………………………………………………………………..Check/lnspect ………………………….


Bypass Filter
Bypass filter

Page 3A-12
W
W
H
Y
E
E
F
H
L
Y
E
E
F
L
L
CYL
CYL
I E
I E
6
* *
6
CYL
#
I E
I E
CYL
5
- 0.014”
- 0.026”
*
5
CYL
*
I E
I E
CYL
4

#
CYL
I E
I E
CYL
3
*
3
Valves to be set
for cylinder no. 1.
Valves to be set
*
I E
I E
CYL
CYL
#
2
2
direction.
Section - 3A
I E
I E
# #
CYL
CYL
1
1
-
1.
2.
3.
4.
#
*
Section 3A Page 3A-15 Section 3A Page 3A-16 Section 3A Page 3A-17
IMPORTANT CLEARANCES IMPORTANT TORQUE VALUES IMPORTANT TORQUE VALUES – CONTD…..

C SERIES
CHECK POINT INCH C SERIES
Crankshaft endplay 0.006/0.013 N-m SS

N-m SS
Con rod side clearance 0.004/0.012 Main brg C/s 50/95/170 21 mm
Lift Pump C/s 24 12 mm
Camshaft end clearance 0.0047/0.0134 Connecting rod 40/80/120 19 mm
Fuel Dual Filter 32 24 mm
Liner protrusion 0.0005/0.0043 Cyl. head Mtg C/s 40/150/220 16 mm
Lub Oil Pressure 80 22 mm
Min. clearance between 0.009 G.E.hsg. mtg C/s 24 12 mm
regulator
lower block edge & bottom Pan rail 60 19 mm
L.O. cooler mtg C/s 24 13 mm
of liner Camshaft thrust plate 24 12 mm
R C plate protrusion ±0.006 Cover intake 24 12 mm
Lube Pump Mtg C/s 5/24 24 mm
Belt Tension 43 15 mm
Wtr Pump mtg C/s 24 13 mm
GEAR TRAIN BACKLASHES Belt Tension 24 5 mm
Rear Cover Plate 9 10 mm
Crank to cam gear 0.006/0.010 Bracket allen
Crank to lube pump idler 0.003/0.013 Suction tube and 9 10 mm
Fan Hub Mtg C/s 24 12 mm
Lube pump gears 0.003/0.013 Brace mtg C/s
Fan Hub pulley 43 17 mm
Cam gear to fuel pump gear 0.006/0.010 Oil Pan mtg C/s 24 13 mm
Vibration Damper 200 18 mm
Drain Plug on Oil Pan 80 3/8”
Exh mfd mtg C/s 43 17 mm
RUNOUT Rocker Cover Mtg C/s 55 10 mm
Turbo nuts 32 15 mm
Flywheel housing face 0.008 Rocker Cover Mtg C/s 24 15 mm
Flywheel Hsg Mt C/s 60 19 mm
Flywheel housing bore 0.008 Fuel Pump drive 93 14 mm
Flywheel 137 18 mm
Shaft nut PES 6 A
VALVE SETTING Starter 77 19 mm
PES 6MW 105 11/16”
Intake 0.014 Injector nozzle 24 12 mm
Motorpal mf Pump 105 11/16” Hold Down C/s
Exhaust 0.026
Fuel Pump mtg Nuts 43 14 mm
Engage Timing Pin
Set 1,2,4, Intake Gear Cover mtg C/s 24 12 mm NOTE : S S INDICATES SOCKET SIZE
1,3,5, Exhaust
NOTE : SS INDICATES SOCKET SIZE
Remove pin, rotate crank by 360 degrees and set all other valves.

C SERIES

N-m SS
regulator
Turbo nuts 32 15 mm
Flywheel 137 18 mm
Shaft nut PES 6 A
PES 6MW 105 11/16”
Exhaust 0.026
Engage Timing Pin
1,3,5, Exhaust

C SERIES

N-m SS
regulator
Turbo nuts 32 15 mm
Flywheel 137 18 mm
Shaft nut PES 6 A
PES 6MW 105 11/16”
Exhaust 0.026
Engage Timing Pin
1,3,5, Exhaust
Section – 3B S-SERIES GENSET RATINGS AND SPECIFICATIONS Page 3B-2
Parameter 30 kVA 35 kVA 40 kVA 45 kVA 50 kVA 62.5 kVA
Engine Model S 3.8 G2 S 3.8 G3 S 3.8 G4 S 3.8 G5 S 3.8 G6 S 3.8 G7
Prime Power Rating at 1500 RPM 37 HP/24 kWe 43 HP/28 kWe 52 HP/32 kWe 58 HP/36 kWe 65 HP/40 kWe 76 HP/50 kWe
No. of Cylinders 4 4 4 4 4 4
Engine Configuration In line In line In line In line In line In line
Governor Class Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2 Mechanical A2
Natural, Natural, Turbocharged, Turbocharged, Turbocharged, Turbocharged, After
Water cooled Water cooled Water cooled Water cooled Water cooled cooled, Water cooled
Bore & Stroke in mm 97 x 128 97 x 128 97 x 128 97 x 128 97 x 128 97 x 128
Compression Ratio 17:1 17:1 17:1 17:1 17:1 17:1
Battery Capacity 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah 12 V 120 Ah
Alternator Size (Prime) UC22C UC22C UC22C UC22T UC22D UC22V
Alternator Voltage Regulation +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5% +/- 1.5%
Alternator Insulation Class H H H H H H
Lubrication Oil Capacity 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs. 7-9 ltrs.
Coolant Capacity–with Radiator (ltrs) 11.00 11.00 11.00 11.00 11.00 11.00
Noise Level at 3 mts Distance (dB) 90 90 90 90 90 90
2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg
1700 x 620 x 1436 1700 x 620 x 1436 1700 x 620 x 1100 1700 x 620 x 1100 1700 x 620 x 1100 2070 x 773 x 1206
(L x B xH) in mm. With S.B. alternator
Air Cleaner Oil Bath Type Oil Bath Type Dry Type Dry Type Dry Type Dry Type
Collaboration effort from Cummins and Tata Engineering
Company manufactured by Power System India Ltd., one of the
3B-1
Naturally Aspirated / Turbocharged / Turbocharged & After
1054 * 628 * 995 mm

S-3.8-G NOMENCLATURE
Direct Injection Mico Pump & Nozzle

eleven Cummins ventures in India
Dry weight engine only 360 kgs.

17:1
S - Small end horsepower
3.8 - Displacement in liters
1-3-4-2
Displacement 3.785 liters
Length * width * height

Bore x stroke 97 x 128
Compression Ratio
Metric Dimensions
Inline 4 Cylinders
Water Cooled
Section – 3B
Firing Order :
Four Stroke
G - Genset
Features
Cooled
Electrical System & Engine Wiring……………………………….3B-8
Lubricating System………………………………………………...3B-6
Valve Setting Procedure ………………………………………….3B-7

Engine Maintenance ……………………………………………..3B-3
Genset ratings & Specifications ………………………………….3B-2
Air System ………………………………………………………….3B-6

Coolant System ……………………………………………………3B-6
Fuel System ……………………………………………………….3B-6

FIP removal & Fitment…………………………………………….3B-6
Page
Engine Nomanclature, Features ………………………………..3B-1
Torque Values ……………………………………………………3B-5

Page 3B
S-SERIES SPECIFICATIONS
Section 3B
Contents
2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg
1700 x 620 x 1436 1700 x 620 x 1436 1700 x 620 x 1100 1700 x 620 x 1100 1700 x 620 x 1100 2070 x 773 x 1206
3B-1
1054 * 628 * 995 mm



17:1
1-3-4-2

Compression Ratio
Metric Dimensions
Inline 4 Cylinders
Water Cooled
Section – 3B
Firing Order :
Four Stroke
G - Genset
Features
Cooled

Air System ………………………………………………………….3B-6

Coolant System ……………………………………………………3B-6
Fuel System ……………………………………………………….3B-6

Page
Torque Values ……………………………………………………3B-5

Page 3B
Section 3B
Contents
2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg 2.0”Hg
1700 x 620 x 1436 1700 x 620 x 1436 1700 x 620 x 1100 1700 x 620 x 1100 1700 x 620 x 1100 2070 x 773 x 1206
3B-1
1054 * 628 * 995 mm



17:1
1-3-4-2

Compression Ratio
Metric Dimensions
Inline 4 Cylinders
Water Cooled
Section – 3B
Firing Order :
Four Stroke
G - Genset
Features
Cooled

Air System ………………………………………………………….3B-6

Coolant System ……………………………………………………3B-6
Fuel System ……………………………………………………….3B-6

Torque Values ……………………………………………………3B-5
Page

Page 3B
Section 3B
Contents
to torque exceeding three-fourth of its maximum capacity. Before
When selecting torque wrench, remember that it should not be subject
5 * * Further
+20 )
o
tightening
Page 3B-5
by 90
o
0.4 - 0.6
10 to 20
50 to 55
+1
Torque (KgfM)
+1
3.5
2.5
2.5
2.5
3.5
1.5
4.5
4.5
3.5
3.5
0.8
0.5
0.5
+1
+1
+1
10
11
11
30
10
5
6
6
9
9
4
3
3
3
6
8
5
tightening, clean threads and apply a little oil to them.
M14 x 1.5
M12 x 1.5
2nd stage
M24 x 1.5
16. Timing gear nut (Injection pump) M14 x 1.5
3rd stage
1st stage
6. Protective sleeve in cylinder head M14 x 1

TIGHTENING TORQUES
18. Camshaft center pin (timer on camshaft)
M10
M10
M10
M10
39. Screw plug oil pressure relief valve M24

M12
M18
M12
15. Timing gear housing on crankcase M10
M8
M8
M8
M8
M8
M6
33. Nuts to banjo union on leak oil line

2. Counterweight bolts on crankshaft
27. Screw on water pump pulley hub

9. Cap nuts on high pressure lines
14. Oil cooler bolts on Cyl. Cr. case
21. Flywheel housing on crankcase
29. Starter motor on clutch housing
38. Suction pipe on oil pump cover

8. Nozzle holder in cylinder head
13. Push rod chamber cover bolts
23. Oil pump pressure relief valve
35. Centre bolt of oil filter housing

32. Fuel filter bowl mounting bolts
in 3 stages as per sequence
5. Screw plug in cylinder head
37. Oil pump cover on oil pump

17. Timing gear housing cover
30. Clamping bolt for altenator

19. Vibration damber lock bolt
11. Cylinder head cover bolts
10. Rocker arm support bolts
34. Banjo bolt of leak oil line

12. Screw plug in crankcase
20. Flywheel mounting bolts

7. Nozzle in nozzle holder
3. Connecting rod bearing
31. Nut on alternator pulley

28. Exhaust manifold bolts
1. Main bearing cap bolts
36. Oil Filter on crankcase

22. Oil pump to crankcase
Tighten cylinder head
25. OIl sump screw - M 8

24. Oil sump screw - M 6
cap bolts M 15 x 1.5
4. Cylinder head nuts -
26. Oil sump drain plug

cap nuts - M14
Description
Section 3B
Engine
Section – 3B Page 3B-4

MAINTENANCE SCHEDULE S-3.8-G ENGINES – CONTD…..
A Check B Check C Check D Check
q Daily 300 hours/every 3 months 600 hours/every 6 months 1200 hours/every 12 months
Instruments Cooling System q Check valve clearance and adjust, if q Apply grease to fan hub &
q Check if all q Check coolant concentration, replace or necessary (engine warm). belt tensioner.
Instruments are add Coolant if necessary. q Lubricate water pump with bearing q Clean the fuel tank for the
functioning. q Clean radiator core with compressed air. grease. dirt and the sediments.
Air System q Clean fuel filter bowl and replace filter
Others q Check restriction indicator-whether in element No. 1. Remove the drain plug of
q Check for leakage of operating condition, showing red signal. fuel filter No. 2 and drain off sediment.
coolant, fuel and lube q Clean air cleaner element for dry type air Bleed the system.
oil and rectify. cleaner. q Check the thermostat for proper
q In case, red signal shown in restriction functioning and operating temperature.
indicator. Please take up the element for q Check engine for trouble-free operation
cleaning. (colour of exhaust gases and nozzle
q Check oil condition and oil level in air operation).
cleaner oil bath. Add oil if necessary.
Others
q Check connections of starter motor and
alternator and tighten if necessary.
q Tighten cylinder head nuts (with engine
warm) and in correct sequence.
q Check valve clearance and adjust, if
necessary (engine warm).

MAINTENANCE SCHEDULE S-3.8-G ENGINES
Lubrication q Repeat all A checks q Check battery mounting. Clean battery q Repeat all A, B, & C Checks
q Check oil level, top up Lubrication posts and terminals. Tighten terminals q Check tightening of Oil Pan
if necessary q Change oil in sump, drain off while still and smear Vaseline/petroleum Jelly. mounting Cap Screws.
hot and clean magnetic drain plug. Check level of electrolyte and top up q Check fan belt tension,
Fuel System q Lubricate the FIP linkage by using oil with distilled water, if necessary. replace if necessary.
q Check fuel level in can. q Remove and clean air ducting hoses.
fuel tank and secure q Check oil level in FIP and governor and q Remove and clean engine breather cap
the tank cap. top up if necessary. (stainer) in kerosene oil, blow air in
q Clean engine oil filler housing. Replace reverse direction and refit. Replace
Cooling System oil filter cartridge and ‘O’ ring. Fill oil filter rubber gasket, if necessary.
q Check coolant level in housing with recommended engine oil.
radiator and top up if Fuel System
necessary and q Change both fuel filters.
secure the cap. q Remove drain plug of fuel filter bowls
and drain off sediment.
5 * * Further
+20 )
o
tightening
Page 3B-5
by 90
o
0.4 - 0.6
10 to 20
50 to 55
+1
Torque (KgfM)
+1
3.5
2.5
2.5
2.5
3.5
1.5
4.5
4.5
3.5
3.5
0.8
0.5
0.5
+1
+1
+1
10
11
11
30
10
5
6
6
9
9
4
3
3
3
6
8
5
M14 x 1.5
M12 x 1.5
2nd stage
M24 x 1.5
16. Timing gear nut (Injection pump) M14 x 1.5
3rd stage
1st stage

TIGHTENING TORQUES
M10
M10
M10
M10

M12
M18
M12
M8
M8
M8
M8
M8
M6











cap bolts M 15 x 1.5

cap nuts - M14
Description
Section 3B
Engine

Others

3 plus 90 to110 degrees

Page 3B-5
0.4 - 0.6
10 to 20
M24 x 1.5 50 to 55
+1
Torque (KgfM)
M14 x 1.5 3.5
2.5
2.5
2.5
3.5
1.5
4.5
4.5
3.5
3.5
0.8
0.5
0.5
+1
3rd stage 11
11
30
10
5
1st stage 6
M12 x 1.5 2
6
2nd stage 9
9
4
3
3
7
6
16. Timing gear nut (Injection pump) M14 x 1.5 8
5

TIGHTENING TORQUES
Short thread bolts M14M 15 x 1.5 or nuts
M10
M10
M10
M10

M12
M18
M12
M8
M8
M8
M8
M8
M6




Long thread bolts M 15 x 1.5








Description
Section 3B
Engine

Others
Section 3B
SECTION - 3C
Section 3B Page 3B-6 Page 3B-7
AIR SYSTEM Fitment by Spill cut adjustment
Intake 1. Rotate Crankshaft in clockwise direction and bring # 1 piston to 20
0
Oil bath / dry type air cleaner B T D C. (achieved by aligning yellow mark on flywheel with pointer in
Oil bath air cleaner pan capacity 0.600 to 0.650 litre inspection window of flywheel housing)
Dry type air element max allowable restriction is 25” of water column. 2. Slide Fuel Pump in position ensuring that ‘notched gear teeth’ on F I
Exhaust P Cam gear aligns with pointer (can be viewed by removing breather
Industrial silencer fitted on Cylinder Block.)
A Holset make turbocharger, model H1C 3. Follow ‘spill cut adjustment procedure’ for fine adjustment of Fuel
//
Maximum exhaust backpressure is 2.0 of Hg. Pump
o o
Maximum exhaust gas, temp range at full load is 407 C to 565 C
1. Fuel line from Fuel pump.
Minimum exhaust pipe size is 50 mm.
2. Remove delivery valve holder, peg, spring and delivery valve of # 1
COOLANT SYSTEM Cylinder
Flow ---- Thermostat ----- Water pump / Radiator ----- Water 3. Connect `swan neck pipe’ to # 1 delivery valve holder to measure
pump ----- Oil cooler ----- Cyl block ---- Cylinder head ------ fuel drop correctly.
Thermostat 4. Connect Diesel container to supply connection of Fuel Pump
0
Thermostat start to open - 72 C to 76 C
0 (container should be two feet above Fuel pump)
Thermostat fully open
0 0
- 83 C to 87 C 5. Loosen mounting bolts of Fuel Pump body to mounting flange.
Engine water pump - centrifugal type 6. Swivel Fuel Pump body either away, towards the engine to ensure
Aluminum core radiator without de-aeration system. one drop of fuel from Swain neck pipe in approximately 20 seconds
Capacity with radiator - 11 liters 7. Tighten fuel pump body cap screw in above position
0
Coolant is - Water : Ethylene Glycol -- 50:50) 8. Turn crankshaft in Reverse direction by app. 30 . The fuel will start
Cooling system pressure - 0.5 bar ( 7 psi) flowing freely. Then slowly turn the crankshaft in direction of rotation till
ENGINE MODEL - S 3.8 G2-G7

0 0
Operating temperature - 75 C to 95 C fuel flow nearly stops.
9. Remove swan neck pipe and diesel container. Connect all
LUBRICATING SYSTEM connections.
Flow 10. Ensure proper fitment of delivery valve holder / peg / spring and
Oil Pan ------ Strainer ----- Oil Pump Relief / regulator valve 57psi delivery valve.
Full flow filter --- filter By pass valve 1.8 to 2.6 kgs/sq cm ----- Heat 11. This completes the timing.
exchanger ----Cooler By pass valve 1.5 to 2 kgs/sq cm ------Main oil
Valve setting procedure
rifle -------- Cam, main bearings ----- Rocker lever assly shaft.
Engine mounted lube oil pump and cooler. 1. Open inspection window on top of flywheel housing.
Lube oil filter - Replaceable paper Element 2. Rotate crankshaft in clockwise direction to align red-mark on
A stamped steel front sump oil pan to reduce engine weight flywheel with pointer (in inspection window)
3. This will bring either # 1 or # 4 piston in T D C of compression stroke
Oil pan capacity for all rating of engines is low 7 ltrs. – high 9 ltrs. 4. For Valve setting # 1 piston has to be in T D C of compression
Minimum Engine Oil pressure stroke. Confirm by checking that both pushrods of Cylinder No. 1 are
@ rated speed - 4 bar (58.0 psi) free.
@ low idle - 1 bar (14.5 psi) 5. Adjust clearance of intake and exhaust valves serially for valve No.
(Not Cylinder No.) 1,2,3,5 ( viewed from engine front end)
Oil change at 300 Hours or 3 months which ever is earlier 0
Recommended Oil is 15W40, CF4
6. Rotate Crankshaft 360 and set remaining valves.
0
Maximum lube oil consumption is 1.5% of fuel consumption. Cold setting (50 max cooling system temperature)
Tappet clearance Inlet 0.20 mm
FUEL SYSTEM Tappet clearance Exhaust 0.30 mm
Priming fuel system by Fuel feed pump Sequence of valves E I I E E I I E
Maximum Suction lift - 1 meter Clearances
Maximum fuel head 4 meters Crank axial play 0.19 –0.29 mm
0
Maximum fuel inlet temperature 71 C Con rod end play 0.10 – 0.40 mm
MICO pump, MICO injector Can Shaft axial play 0.11 –0.39 mm
Fuel filter -Replaceable paper Element Permissible Radial run out of Fly wheel 0.05 mm
Nozzle Pressure - 200 + 10 bar
2 ELECTRICAL SYSTEM & INSTRUMENT PANEL (12 V)
Old nozzle at least - 180 bar (183.5 Kg/cm )
2
Max. variation in nozzle pressure - 5 bar (5.1 Kg/cm )
Electric L O pressure gauge
Note : Ensure fuel return line is dipped in to the diesel to prevent air Electric Water temp gauge
lock (air entry into fuel system during shut down) Electric Hour meter
Starting switch
PAGE 3B-8
FUEL INJECTION PUMP-REMOVAL & FITMENT Battery Charging indicator12 V
Removal 12 Volts, - ve earthling
1. Remove all Fuel connections with Fuel Pump Battery - 12 Volts, 120 AH
2. Remove mounting capscrews on fuel pump mounting flange Alternator - 12 V DC 35 Amps
mounted on Cylinder Block Starter Motor - 12 V Flange Mounted
Section 3B
SECTION - 3C
Section 3B Page 3B-6 Page 3B-7
Intake 1. Rotate Crankshaft in clockwise direction and bring # 1 piston to 20
0
//
o o
0
0 (container should be two feet above Fuel pump)
Thermostat fully open
0 0
- 83 C to 87 C 5. Loosen mounting bolts of Fuel Pump body to mounting flange.
0

0 0
Oil pan capacity for all rating of engines is low 7 ltrs. – high 9 ltrs. 4. For Valve setting # 1 piston has to be in T D C of compression
0
0
2
Electric L O pressure gauge
Starting switch
PAGE 3B-8
Section 3B Page 3B-6 Section 3B Page 3B-7
Intake 0
1. Rotate Crankshaft in clockwise direction and bring # 1 piston to 20
SECTION - 3C
//
o o
0 0 (container should be two feet above Fuel pump)
0 0
Thermostat fully open - 83 C to 87 C 5. Loosen mounting bolts of Fuel Pump body to mounting flange.
0
0 0
Oil pan capacity for all rating of engines is low 7 ltrs. – high 9 ltrs.
4. For Valve setting # 1 piston has to be in T D C of compression

0
0
2 Electric L O pressure gauge
Starting switch
PAGE 3B-8

Section – 3C Page 3C-4 Section – 3C Page 3C-5
Section 3C Page 3C
Description of Component Nm lbf.ft. AIR INTAKE SYSTEM
Injector pipe nuts – LPWS 22.0 16.0 Maximum allowable intake restriction 254 mm H20 CWC -SERIES
Glow plug – LPWS Contents Page
Oil Strainer tube nut 27.0 20.0 COOLING SYSTEM
Main bearing housing nuts Max. coolant temp at engine outlet 103 Deg. C Engine Nomenclature, Features …………………………………3C-1
Minimum radiator opening : 750 mm x 750 mm
Injector pipe nuts – LPA, LPW 28.0 21.0 Technical Data CWC genset……………………………………..3C-2
1 Coolant recommendation 50:50 water : Ethylene Glycol
Radiator fan nut – LPW, LPWS 30.0 22.0 Standard dimensions & Weight ………………………………….3C-2
Fuel Pump clamp
34.0 25.0 Torque Values ……………………………………………………..3C-3
Valve rocker nut LUBRICATING SYSTEM
Connecting rod bolt * Oil pan capacity LPW-3/LPW-4 3.75/ 5.5 liters Air System………………………………………………………….3C-5
35.0 26.0
Radiator fan spacer – Build 70 Minimum engine oil pressure Coolant System ……………………………………………………3C-5
Cylinder head bolt – LPA * @ rated speed & load 2 bar
Lubricating System ………………………………………………..3C-5
@ low idle 1 bar
Stage 1 8.0 6.0 Fuel System ………………………………………………………..3C-5
Stage 2
4 FUEL SYSTEM Electrical System ………………………………………………….3C-5
With ‘High Boss’ crankcase 61.0 48.0 Maximum Suction lift 3048mm
4
Prior to ‘High Boss’ crankcase 48.0 35.0 Maximum fuel head 600mm
Starter motor bolt Max. fuel inlet temperature 71 deg. Centigrade
Oil pump relief value 41.0 30.0 Fuel tank Capacity 100 liters
Oil filter adaptor bolt – LPWT4
No Tappet Setting is Required.
Injector nozzle nut – LPA, LPW 46.0 34.0
Fuel pump delivery valve holder 47.0 35.0
Injectors – LPWS ELECTRICAL SYSTEM
68.0 50.0
Flywheel bolt * - not LPWT4 Battery Changing alternator 45 amps
Flywheel housing screw 79.0 58.0 Starter 1.4 kW / 2 kW 12 Volts
Flywheel bolt * - LPWT4 Cable core 35 sq.mm
81.0 65.0
Injector nozzle nut – LPWS
Cylinder head bolt – LPW, LPWT, LPWS *
Stage 1 8.0 6.0
Stage 2 48.0 35.0
Stage 3 88.0 65.0
1
Crankshaft pulley 1, 2 or pulley bolt 300.0 221.0
Notes to Both Tables:

1 – Left hand thread
2 – Early engines
3 – Builds 28, 51, 52, 57, 58, 59
4 – The lower torque figure is used on earlier engines and the higher
figure for later ‘High Boss’ cylinder barrels On earlier barrels the bosses
and threads are below the top fin. On the ‘High Boss’ arrangement the
bosses and threads are at the top of the barrel
Starter Motor Terminal Torques
Starter Motor Battery Link

+ Terminal 1 Terminal 2
Lucas / Magnetti Nm 4.0-4.2 3.1-3.2
Marrelli lbf ft 2.95-3.01 2.3-2.4
Nm 5.89-11.77 5.89-11.77
Denso Starter lbf ft 4.34-8.68 4.34-8.68
Section – 3C Page 3C-1 Section – 3C Page 3C-2 Section – 3C Page 3C-3
TECHNICAL DATA CWC SERIES, 50HZ GENSETS TORQUES VALUES

ENGINE NOMENCLATURE
LPA2 and 3 – two and three cylinder, direct injection, naturally The tolerance for all torque settings is + 10% except those marked
CWC 15, 3 CWC 20, 3 CWC 25, 3
aspirated axial fan cooled diesel engines. Generating Set Model with a * when it is +5% -0%. For practical purposes the figures have
Phase Phase Phase
LPW2, 3 and 4 – two, three and four cylinder, direct injection, Set Output 380-440 V 50 Hz 380-440 V 50Hz 380-440 V 50 Hz been rounded.
naturally aspirated water cooled diesel engines.
Rated Output 12 kWe 15kVA 16 kWe 20kVA 20 kWe 25kVA
LPWT4 – Four cylinder, direct injection, turbocharged water cooled
diesel engine. Engine Make Lister Petter Lister Petter Lister Petter Description of Component Nm lbf. ft
LPWG2, 3 and 4 – two, three and four cylinder, gas fuelled, Model LPW3 LPW3 LPW4 Turbocharger oil drain pipe clips 2.0 1.5
Cylinder (firing order) 3 (1-2-3) 3 (1-2-3) 4 (1-3-4-2) Stop/run control assembly screw
LPWS2, 3 and 4 – two, three and four cylinder, indirect injection, In-line (four In-line (four In-line (four 1, 2 7.0 5.0
naturally aspirated water cooled diesel engines. Engine Build (Cycle) Crankshaft pulley stud
Stroke) Stroke) Stroke)
Governor / Class Mechanical/A2 Mechanical/A2 Mechanical/A2 Turbocharger oil drain flange bolts 9.0 6.5
ENGINE SERIAL NUMBER Natural Natural Natural End cover nuts or bolts
Aspiration
The engine serial number is stamped on a plate attached to the Aspiration Aspiration Aspiration
Cooling Water Water Water Fuel filter bracket screw
engine.
It is necessary to identify the type and build of each engine to Bore & Stroke in mm 86 x 80 86 x 80 86 x 80 Inlet and exhaust manifold bolts
enable the correct maintenance procedures, as described later in Oil pump setscrew
Compression Ratio 18.5:1 18.5:1 18.5:1
this publication, to be carried out. 9.0 6.5
Cubic Capacity 1.395 ltr 1.395 ltr 1.860 ltr Camshaft thrust plate screws
Engine Serial Number Code Battery 12V/55Ah 12V/55Ah 12V/55Ah Governor weight plate screws
01011987 LPW3 A 09
RPM 3000rpm 3000rpm 3000rpm Air cowling fasteners – LPA
01………….. Year of manufacture
BHP 27 27 36 Cylinder head cover nut
011987…… Consecutive number of engine Mean piston Speed at
7.99m/sec 7.99m/sec 7.99m/sec Crankcase door bolt 11.0 8.0
LPW3……… Model 3000 rpm
Engine Block Coolant Alternator adjusting link
(T-Turbocharger, S-Indirect injection) 2.5 ltrs (6.5) 2.5 ltrs (6.5) 3 ltrs (7.0)
Capacity (Incl. Radiator) 16.0 12.0
Fixing bolt to backplate
LPWG3…… G=gas fuelled) Exhaust Gas Flow 82.8 ltr/sec 82.8 ltr/sec 110.4 ltr/sec
(Pipe dia) (44mm) (44mm) (44mm) Water pump studs (not bolts)
A………….. Anticlockwise rotation (Looking from flywheel end)
Exhaust Gas Temperature 520 deg C
520 deg C 520 deg C Fuel filter union plug 20.0 15.0
09………… Build of engine (Max Back Pressure) (760mm H2O)
Alternator Make Stamford Stamford Stamford Fuel lift pump nuts
Alternator Model BCA 162 E BCA 162G BCA 162J Injector clamp nut
Alternator Voltage Axial fan bracket bolt – LPA
+ 2% + 2% + 2%
Regulation
Alternator bolt
Alternator Insulation Class F F F
Single Load step to Water pump bolts and nuts
100% 100% 100%
NFPA 110 3
Deep sump bolts
Dry Weight engine only 157 kg 157 kg 189 kg
Centre bearing housing bolts 21.0 15.5
STANDARD DIMENSIONS AND WEIGHT Exhaust manifold stud – LPWT4
Engine/DG Set Length Width Height Weight Turbocharger fixing nuts

Model (mm) (mm) (mm) (kg) Turbocharger exhaust flange nuts
LPW-3 595 482 574 157
LPW-4 695 482 574 189 Turbocharger oil feed plugs
CWC-15 kVA DG Set 1255 612 955 383 Breather separator fixing bolts –
CWC-25 kVA DG Set 1255 612 955 420
LPWT4

ENGINE NOMENCLATURE
CWC 15, 3 CWC 20, 3 CWC 25, 3
Phase Phase Phase
Aspiration
engine.
01011987 LPW3 A 09
+ 2% + 2% + 2%
Regulation
Alternator bolt
100% 100% 100%
NFPA 110 3
Deep sump bolts

LPW-3 595 482 574 157
CWC-25 kVA DG Set 1255 612 955 420
LPWT4

ENGINE NOMENCLATURE
CWC 15, 3 CWC 20, 3 CWC 25, 3
Phase Phase Phase
Aspiration
engine.
01011987 LPW3 A 09
+ 2% + 2% + 2%
Regulation
Alternator bolt
100% 100% 100%
NFPA 110 3
Deep sump bolts

LPW-3 595 482 574 157
CWC-25 kVA DG Set 1255 612 955 420
LPWT4
Section 3C Page 3C
Fuel Pump clamp
34.0 25.0 Torque Values ……………………………………………………..3C-3
35.0 26.0
@ low idle 1 bar
Stage 2
4
68.0 50.0
81.0 65.0
Stage 1 8.0 6.0
Stage 2 48.0 35.0
Stage 3 88.0 65.0
1

2 – Early engines
3 – Builds 28, 51, 52, 57, 58, 59

Marrelli lbf ft 2.95-3.01 2.3-2.4
Nm 5.89-11.77 5.89-11.77
Section 3C Page 3C
Fuel Pump clamp
34.0 25.0 Torque Values ……………………………………………………..3C-3
35.0 26.0
@ low idle 1 bar
Stage 2
4
68.0 50.0
81.0 65.0
Stage 1 8.0 6.0
Stage 2 48.0 35.0
Stage 3 88.0 65.0
1

2 – Early engines
3 – Builds 28, 51, 52, 57, 58, 59

Marrelli lbf ft 2.95-3.01 2.3-2.4
Nm 5.89-11.77 5.89-11.77
Section - 4 Page 4
PARTS INFORMATION
Contents Page
Engine Gasket Sets / Repair Kits
Indigenous upper Engine Gasket Set ……………………………...4-1
Indigenous lower Engine Gasket Set ………………………………4-2
Imported upper Engine Gasket Set ...………………………………4-3
Imported Lower Engine Gasket Set ………………………………..4-4
P.T. Pump Gasket Set ……………………………………………….4-5
Water Pumps Repair Kits…………………………………………….4-5
Air Compressor Repair Kits ………………………………………….4-5
Turbocharger Repair Kits ……………………………………………4-7
Conversion Kits Parts Nos. of
Spin on type to Cummins conventional type filters ………………4-8
NHRS to NRTO ……………………………………………………….4-9
Radiator to Heat Exchanger………………………………………..4-10
Heat Exchanger to Radiator ………………………………………4-10
Turbochargers ……………………………………………………….4-11
High Altitude Compensation Kits …………………………………..4-17
Pipe Couplings……………………………………………………….4-17
ECP retrofit Kits……………………………………………………...4-18
Short Block Assembly of Various Models …………………………….4-19
Oversize Main Bearings ………………………………………………..4-20
Conrod Bearings …………………………………………………….4-21
Thrust Bearings ……………………………………………………4-22
Supersedence ………………………………………………………….4-22
Part No. Structure Old and New ………………………………………4-23
AR and B check Kit part Nos.
Break Up of filter Element & Seal Ring …………………………..4-24
B-check Kits Model Wise ………………………………………….4-25
Air System
Hose Elbows Dia wise Part Nos. …………………………………..4-26
Air Cleaner elements Part Nos. ……………………………………4-27
Air Cleaner Assemblies and Elements ……………………………4-29
Plain Air Hump Hoses ………………………………………………4-33
Cooling System
Flex Master Coupling Part Nos. & Sizes ………………………….4-34
Cooling Water Plain Hoses Dia. & Length wise Part Nos.………4-35
CAC, Pre Mix Part Nos. …………………………………………….4-36
Miscellaneous
Replacement Parts ECPG………………………………………….4-37
Part Nos. Information ECP …………………………………………4-38
Part Nos. of Belts for Various Applications ……………………….4-39
Clamp T-Bolt Dia. Wise part Nos.………………………………….4-41
Cummins Branded A.V. Mounts
How to Fix ……………………………………………………………4-42
Do’s and Don’ts ……………………………………………………...4-43
Engine Model Wise Part Nos. ……………………………………...4-44
Technical Details …………………………………………………….4-44
Cummins Branded Batteries
Part Nos. Model Wise ………………………………………………4-45
Section -4 Page 4-3
UPPER ENGINE GASKET SET – IMPORTED
ENGINE SERIES GASKET SET COMMENTS

BIG CAM III, II, I 4024945 NTC-400 & BELOW
SMALL CAM 855 4024946 STANDARD FFC.
SMALL CAM 672 & 3802076 NON SUPER CHARGER.
743 MODEL
KT-19 3800727 STANDARD APPLICATIONS
KTA/KTTA-19 3800728 STANDARD APPLICATIONS.
KT/KTA/KTTA-38 3800730 STANDARD APPLICATIONS.
V/VT/VTA-28 3803697 WET/DRY EXHT MANIFOLD.
L10 4025155 ALL STD APPLICATIONS
N14 4024928 ALL STD APPLICATIONS
4B3.9 3804896 ALL STD APPLICATIONS
6CT8.3 4025271 ALL STD APPLICATIONS
Section -4 Page 4-2

INDIGENIOUS LOWER ENGINE GASKET SET

N/NT/NTC/NTA-495 BM0062427 STANDARD APPLICATIONS
N/NT/NTA-743 BM0062431 STANDARD APPLICATIONS.
KT(A)-1150 AR4072229 GENSET

KT(A)-1150 AR4072227 FOR WET HSG. APPLICATION
VT-1710 3240084 FOR WET HSG. APPLICATION

VT (A)-1710 3247965 GENSET
6B/BT/BTA 3815598 STANDARD APPLICATIONS
ENGINE OVERHAUL GASKET SET.
STANDARD APPLN.
N/NT/NTA-855 AR0095138 (UPPER + LOWER) GASKET SET
NTA 855 (FFC) 3880384 ALL STD APPLICATIONS
VT1710 3247965 ENGINE OVERHAUL
GASKET SET (UPPER + LOWER)
KTA-3067 4072225 STANDARD APPLICATIONS

ENGINE GASKET SETS
INDIGENIOUS UPPER ENGINE GASKET SET
N/NT/NTA-743 BM0050745 STANDARD APPLICATIONS
V/VT/VTA-1710 3240239 GENSET APPLICATION
KT-1150 4072231 ALL APPLICATIONS
KTA-1150 4072233 ALL APPLICATIONS
KT/KTA-2300 4072226 ALL APPLICATIONS

Section -4 Page 4-3

743 MODEL
Section -4 Page 4-2




VT (A)-1710 3247965 GENSET
STANDARD APPLN.

ENGINE GASKET SETS

Section -4 Page 4-3

743 MODEL
Section -4 Page 4-2




VT (A)-1710 3247965 GENSET
STANDARD APPLN.

ENGINE GASKET SETS

TURBOCHARGER REPAIR KITS
ENGINE MODEL TURBO. MODEL / MAKE TURBO. REPAIR KIT REMARKS

B SERIES H1C HOLSET 4027309
NT/NTA 495 H2A / H1 E HOLSET 3545399
KT(A) 1150 HC5A HOLSET 3545577 3545577 GASKETS
KT (A) 2300 OF TURBO. &
KTA 3067 HX80 HOLSET 3545647 3545647 SEALS & BRGS.
KTA 50G3
NT (A) 743 3545661 3575210 KIT ONLY
NT (A) 855 FOR TURBO. 3522294
4LGK HOLSET
KT (A) 1150 3573210 OTHERWISE USE
VT (A) 1710 KIT 3545661.
V28 HC3 HOLSET 3545661
KT(A) 1150
KT (A) 2300 T18A CUMMINS / GARRETT 3032634
KTA 3067
NH / NT T35 CUMMINS / GARRETT AR7956
Section -4 Page4-5
PT PUMP GASKET SET
FOR ALL TYPE OF PT PUMP BM68356 INDIGENOUS GASKET SET
REPAIR KITS FOR WATER PUMPS
REPAIR KIT PART NO SUITABLE FOR WATER PUMP ENGINE MODELS

4084185 BM50446, 3168255, 3166497 NH/NT
AR3239763 AR4284, AR4283, BM87127 NH/NT
AR3239764 AR45347, 3000886 NT 855 FFC
AR 3881258 BM78360, BM78359, BM78358 N743
3801804 (Minor) 3801787 NT-855 G5
3803202 (Major) “ “
REPAIR KITS FOR AIR COMPRESSOR
REPAIR KIT PART NO. SUITABLE FOR AIR COMPR. ENGINE MODELS
AR4154 AR7944, AR 8312, 3246699 NH/NT Single Cylinder
AR3880524 3239940, 3241154 K6/KV Twin Cylinder
Section -4 Page 4-4

LOWER ENGINE GASKET SET – IMPORTED

BIG CAM II,I 3801468 NTC-400 & BELOW
SMALL CAM 855 3014459 FFC & PISTON COOLING
SMALL CAM 855 3801463 NON FFC-NON PISTON COOL
SMALL CAM 855 3801464 NON FFC PISTON COOLED.
SMALL CAM 672 3801466 NON FFC-NON SUPERCHARGED
& 743 MODEL
SMALL CAM 672 & 3801467 NON FFC SUPERCHARGED.
743 MODEL
NHRS/NRTO 3802075 STANDARD APPLICATIONS.
V/VT/VTA-28 3017564 STANDARD APPLICATIONS.
KT- 19 3801006 STANDARD APPLICATIONS.
KTA/KTTA- 19 3801007 STANDARD APPLICATIONS.
KT/KTA./KTTA-38 3804301 STANDARD APPLICATIONS.

KTA 50G3
NT (A) 743 3545661 3575210 KIT ONLY
NT (A) 855 FOR TURBO. 3522294
4LGK HOLSET
VT (A) 1710 KIT 3545661.
KT(A) 1150
KTA 3067
Section -4 Page4-5
PT PUMP GASKET SET

4084185 BM50446, 3168255, 3166497 NH/NT
AR3239763 AR4284, AR4283, BM87127 NH/NT
AR3239764 AR45347, 3000886 NT 855 FFC
AR 3881258 BM78360, BM78359, BM78358 N743
3801804 (Minor) 3801787 NT-855 G5
3803202 (Major) “ “
Section -4 Page 4-4


& 743 MODEL
743 MODEL

KTA 50G3
NT (A) 743 3545661 3575210 KIT ONLY
NT (A) 855 FOR TURBO. 3522294
4LGK HOLSET
VT (A) 1710 KIT 3545661.
KT(A) 1150
KTA 3067
Section -4 Page4-5
PT PUMP GASKET SET

4084185 BM50446, 3168255, 3166497 NH/NT
AR3239763 AR4284, AR4283, BM87127 NH/NT
AR3239764 AR45347, 3000886 NT 855 FFC
AR 3881258 BM78360, BM78359, BM78358 N743
3801804 (Minor) 3801787 NT-855 G5
3803202 (Major) “ “
Section -4 Page 4-4


& 743 MODEL
743 MODEL
Page 4-9
(USE HOLSET TURBO P/N 3503428

TATA P & H 955 CRANE SUITABLE
CONFIGURATION / APPLICATION
GENSET APPLICATION
MARINE APPLICATION
CONVERSION KITS - NHRS TO NRTO
(USE HOLSET TURBO

P/N 3502428 - 4LGK)
93M/101M SHOVEL
TATA P&H CRANE

45 DEG, INCLINE
SIDE MOUNTED
TOP MOUNTED
H4TD DUMPER
- 4 LGK)
FOR HOLSET TURBO
PART NUMBER
3246425
3239378
3246430
3240881
3246432
3246427
3246428
3246429
3246431
Section - 4
Section -4 Page 4-8

USEFUL PART NOS. OF CONVERSION KITS
CONVERSION FROM SPIN - ON TYPE FILTERS TO CUMMINS CONVENTIONAL TYPE FILTERS
These cases are to be referred to Parts Dept. Pune since these cases are to be studied individually. It is suggested to check-up the possibility of
fitment of our std. filters & fittings considering space, access to filters & revert to Pune.
Few Suggested Part Nos. Conversion Kits for Spin-on to Cummins Filters
Engine Fuel Filter Lub Oil Filter Water Filter By-pass Filter
Model Kit Kit Kit Kit
NTA-855 3246376 AR 9465 3247797 AR 3879436
MP 3881814
VTA 1710 3246379 AR 3247613 3247505 AR 3879436
(LW50) MP 3881865
KTA 1150 3246376 AR 3246375 3879345 & AR 3879436
MP 3881778 MP 3881784
KTA 1150 3240303 AR 3240301 3240300 AR 3879436
(PC 650) MP 3881784
KTA 2300 3247364 AR 3247365 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782
KTA 3067 3241565 AR 3239410 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782

TURBOCHARGER REPAIR KITS – CONTD…..
ENGINE MODEL TURBO. MODEL / TURBO. REPAIR REMARKS

MAKE KIT
NH / NT / VT T46/T50 CUMMINS/GARRETT 3803042 (Minor) 3801096

ST50 / VT5O CUMMINS / 3801101 (Major)
GARRETT 3803042
NTC 495 HT 4B GARRETT 3545840 FOR TURBO. P/N

3227391
HT4B HOLSET 3545679
HT3B/HT60 HOLSET 3545669
TV SERIES 3545824 (Minor)

GARRETT 3545836 (Major)
BHT4C HOLSET 3803201
NT 855 Big Cam HT 3B HOLSET 3801523 For Turbo 35255035
NT 855 Loco HTB HOLSET 3545661 For Turbo 35255035

Page 4-9

GENSET APPLICATION
MARINE APPLICATION
(USE HOLSET TURBO

P/N 3502428 - 4LGK)
93M/101M SHOVEL
TATA P&H CRANE

45 DEG, INCLINE
SIDE MOUNTED
TOP MOUNTED
H4TD DUMPER
- 4 LGK)
FOR HOLSET TURBO
PART NUMBER
3246425
3239378
3246430
3240881
3246432
3246427
3246428
3246429
3246431
Section - 4
Section -4 Page 4-8

NTA-855 3246376 AR 9465 3247797 AR 3879436
MP 3881814
VTA 1710 3246379 AR 3247613 3247505 AR 3879436
(LW50) MP 3881865
KTA 1150 3246376 AR 3246375 3879345 & AR 3879436
MP 3881778 MP 3881784
KTA 1150 3240303 AR 3240301 3240300 AR 3879436
(PC 650) MP 3881784
KTA 2300 3247364 AR 3247365 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782
KTA 3067 3241565 AR 3239410 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782


MAKE KIT

GARRETT 3803042

3227391
HT4B HOLSET 3545679


Page 4-9

GENSET APPLICATION
MARINE APPLICATION
(USE HOLSET TURBO

P/N 3502428 - 4LGK)
93M/101M SHOVEL
TATA P&H CRANE

45 DEG, INCLINE
SIDE MOUNTED
TOP MOUNTED
H4TD DUMPER
- 4 LGK)
FOR HOLSET TURBO
PART NUMBER
3246425
3239378
3246430
3240881
3246432
3246427
3246428
3246429
3246431
Section - 4
Section -4 Page 4-8

NTA-855 3246376 AR 9465 3247797 AR 3879436
MP 3881814
VTA 1710 3246379 AR 3247613 3247505 AR 3879436
(LW50) MP 3881865
KTA 1150 3246376 AR 3246375 3879345 & AR 3879436
MP 3881778 MP 3881784
KTA 1150 3240303 AR 3240301 3240300 AR 3879436
(PC 650) MP 3881784
KTA 2300 3247364 AR 3247365 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782
KTA 3067 3241565 AR 3239410 3879345 AR 3879436
(3 NOS.) & (2 NOS.) &
3881858 MP 3881782
MAKE KIT
GARRETT 3803042
3227391
HT4B HOLSET 3545679
MODEL/ CONVERSION OF KIT PART NO. REMARKS
APPLICATION TURBOCHARGER
NT 495 G GARRETT TO HOLSET H2A 3239561 Less Turbocharger for Radiator Cooled Engine
NT 495 G GARRETT TO HOLSET H2A 3239564 With Turbocharger (3529298-00) for Heat Exg.
Cooled Engine
NT 495 G GARRETT TO HOLSET H2A 3239563 Less Turbocharger for Heat Exgr. Cooled
Engine
NT / NTC 495 C HOLSET H2A TO WATER COOLED 3880489* With Turbocharger P/N 3533964 (Old Turbo
ALL RIGS / AIR BRG. HSG. H1E TURB. P/N 3529296 H2A)
COMPRESSOR
NTA 495 C HOLSET H2A TO WATER COOLED 3880490* With Turbocharger P/N 3533964 (Old Turbo
COMPRESSOR
NTA 495 C HOLSET H2A TO WATER COOLED 3880869 With Turbocharger P/N 3533964. (Old Turbo
L & T, W36 F.E. BRG. HSG. H1E TURB. P/N 3529296 H2A.)
LOADER
*In addition to above kit one of the following is required.
Piping P/N to be used In place of current pipe P/N
AR 3880491 3873914
AR 3880492 3873520
AR 3880493 3235007
AR 3880494 3235523
CONVERSION KITS - TURBOCHARGERS
* 495 SERIES
MODEL / CONVERSION OF KIT PART NO. REMARKS
NT 495 G T35 TO HOLSET H2A 3239066 With Turbo. P/N (3529298)
for Radiator Cooled Engine
NT 495 G T35 TO HOLSET H2A 3239065 Less Turbocharger for
Radiator Cooled Engine
NT 495 G T35 TO HOLSET H2A 3239068 With Turbo (3529298)
for Heat Exg. Cooled Engine
Heat Exgr. Cooled Engine
NT 495 C T35 TO HOLSET H2A 3240428 With Turbocharger P/N 3529296
BEML 1420 Payloader
NT 495 C GARRETT TO HOLSET 3240429 With Turbocharger P/N 3529296 Old Turbo.
BEML 1420 Payloader H2A to be replaced P/N 3227391
OR NTC 495 C or 3228232
NT 495 G GARRETT TO HOLSET 3239562 With Turbo P/N (3529298)
H2A for Radiator Cooled Engine
* This kit includes parts which attach to crankshaft suitable for new
Crankshaft i.e. reduced bolt circle diameter (PCD) on the crank nose.
COUPLING
Page 4-10
WITH PIPE
3879633
3990531
3679714
COUPLING
WITH PIPE
CONVERSION KITS - RADIATOR TO HEAT EXCHANGER
CONVERSION KITS - HEAT EXCHANGER TO RADIATOR
3660142 N
3241721*
3679936
3679566
(Holset Turbo & pulse tuned Exht. Mfd)
WITH PLAIN HOSES
(ST 50 Turbo & Std Exht. Manifold)

WITH PLAIN HOSES
W/P-AR3246489
3246318
3880142
3246317
3246243
3246399
3246405
3247555
3879625
3240788
3230457
3679730
3239961
3239457
3241466
###
N/A
-
NT/NTC/NTA-495-G
KTA-2300 / 3067 G
VTA- 1710-G3/ G5
VTA 1710-G3, G5
VT/VTA – 1710 G
ENGINE MODEL
ENGINE MODEL
N/NT/NTC-495
KT/KTA- 1150
KT(A)-1150.G
VTA-1710-G
KTA-2300 G
KTA-3067 G
NTA - 743
NTA-855
NTA-400
NTA 743
NT - 743
Section - 4
N – 743
N - 855
Cooled Engine
Engine
COMPRESSOR
COMPRESSOR
LOADER
AR 3880491 3873914
AR 3880492 3873520
AR 3880493 3235007
AR 3880494 3235523

* 495 SERIES


BEML 1420 Payloader
OR NTC 495 C or 3228232

COUPLING
Page 4-10
WITH PIPE
3879633
3990531
3679714
COUPLING
WITH PIPE
3660142 N
3241721*
3679936
3679566
WITH PLAIN HOSES

WITH PLAIN HOSES
W/P-AR3246489
3246318
3880142
3246317
3246243
3246399
3246405
3247555
3879625
3240788
3230457
3679730
3239961
3239457
3241466
###
N/A
-
NT/NTC/NTA-495-G
KTA-2300 / 3067 G
VTA- 1710-G3/ G5
VTA 1710-G3, G5
VT/VTA – 1710 G
ENGINE MODEL
ENGINE MODEL
N/NT/NTC-495
KT/KTA- 1150
KT(A)-1150.G
VTA-1710-G
KTA-2300 G
KTA-3067 G
NTA - 743
NTA-855
NTA-400
NTA 743
NT - 743
Section - 4
N – 743
N - 855
Cooled Engine
Engine
COMPRESSOR
COMPRESSOR
LOADER
AR 3880491 3873914
AR 3880492 3873520
AR 3880493 3235007
AR 3880494 3235523

* 495 SERIES


BEML 1420 Payloader
OR NTC 495 C or 3228232

COUPLING
Page 4-10
WITH PIPE
3879633
3990531
3679714
COUPLING
WITH PIPE
3660142 N
3241721*
3679936
3679566
WITH PLAIN HOSES

WITH PLAIN HOSES
W/P-AR3246489
3246318
3880142
3246317
3246243
3246399
3246405
3247555
3879625
3240788
3230457
3679730
3239961
3239457
3241466
###
N/A
-
NT/NTC/NTA-495-G
KTA-2300 / 3067 G
VTA- 1710-G3/ G5
VTA 1710-G3, G5
VT/VTA – 1710 G
ENGINE MODEL
ENGINE MODEL
N/NT/NTC-495
KT/KTA- 1150
KT(A)-1150.G
VTA-1710-G
KTA-2300 G
KTA-3067 G
NTA - 743
NTA-855
NTA-400
NTA 743
NT - 743
Section - 4
N – 743
N - 855
SectIon- 4 Page 4-15
* 855 SERIES
CONVERSION KITS –TURBOCHARGERS - CONTD……
MODEL / APPLICATION CONVERSION OF KIT PART NO. REMARKS
TURBOCHARGER
NTA 855 C HM R35 ST50 TO HOLSET 3240293 * With Turbo. Use Turbo.
DUMPER * 4LGK 3502490-4 LGK
NTA 855 G FFC SCHWEITZER P/N 3229094 3241208 With Turbo. for Radiator / HE Cooled
TO HOLSET 4 LGK Engine. Use 4 LGK
NT 855 C KG T50 TO HOLSET 4LGK 3240527 Less Turbo. Use Turbo.
KHOSLA AIR 3521595-4 LGK
COMP
NT 855 C HOLSET 4LGK TO WATER 3880878 With Turbocharger P/N

ALL RIGS / AIR COOLED BRG. HSG. 4LGK AR 3880874.
COMPRESSOR TURBO.
NTA 855 C HOLSET 4LGK TO WATER 3880876 With Turbocharger P/N
ALL RIGS / AIR COOLED BRG. HSG. 4 LGK AR 3880820
COMPRESSOR TURBO.
* This kit includes Intercooler Element, its Hsg. & mounting parts & is to be used when the basic engine is NT-855.
CONVERSION KITS –TURBOCHARGERS - CONTD….

NTA 743 C HOLSET 4 LGK TO 3880877 With Turbocharger P/N
ALL RIGS / AIR WATER COOLED AR 3880874
COMPRESSOR BRG. HSG. 4LGK
TURBO
N 743 T C HOLSET 4 LGK TO 3880875 With Turbocharger P/N
ALL RIGS / AIR WATER COOLED AR 3880889.
COMPRESSOR BRG. HSG. 4 LGK TURBO
Section -4 Page4-13
CONVERSION KITS –TURBOCHARGERS - CONTD…
* 743 SERIES
MODEL / CON VERSION OF KIT PART NO. REMARKS
NT 743 G T50 TO HOLSET 4 LGK 3240293 Less Turbo. for Radiator / HE Cooled
Engine. Use Turbo. 3502490 - 4 LGK
NTA 743 G T50 TO HOLSET 4 LGK 3240298 Less Turbo. for Radiator / HE Cooled
NT 743 C T50 TO HOLSET 4 LGK 3240901 Less Turbo.
R-25 TEREX With turbo AR 3240902 With Turbo. AR 3240902
HM DUMPER (Turbo – 3521595)
NT 743 C GARRETT TO HOLSET 3239962 Less Turbo for Radiator / HE Cooled
4LGK Engine. Use Turbo. 3502490 - 4 LGK
NTA 743G (3227900 Garrett Turb.)
NT 743 M GARRETT TO HOLSET 3241932 Less Turbo for Radiator / HE Cooled
4 LGK Engine. Use Turbo. 3502490 - 4 LGK
NT 743 C HOLSET 4LGK TO 3880875 With Turbocharger P/N
ALL RIGS / AIR WATER COOLED AR3880805
TURBO
* 855 SERIES
TURBOCHARGER
COMP

COMPRESSOR TURBO.
COMPRESSOR TURBO.

TURBO
Section -4 Page4-13
* 743 SERIES
TURBO
* 855 SERIES
TURBOCHARGER
COMP

COMPRESSOR TURBO.
COMPRESSOR TURBO.

TURBO
Section -4 Page4-13
* 743 SERIES
TURBO
ELECTRONIC CONTROL PANEL (ECP) RETROFIT KITS AT A GLANCE
Existing
New Setup 1 MW KVI6 KVI2 V28 K6 743 855 VT1710
Setup
MGP EFC-ECP 3238431 3238424 3238417 3238409 3238400 3238408
MGP ECP (HYD.GOV) 3238432 3238425 3238418 3238410 3238401 3238387 3238393
MGP ECP (IMP CONT.) 3238433 3238426 3238419 3238411 3238402 3238397
MGP ECP (VI CONT.) 3238434 3238427 3238420 3238412 3238403 3238390 3238396
MGP ECP (VII CONT.) 3238435 3238428 3238421 3238413 3238404 3238391 3238398
EIP ECP(VI CONT.) 3238436 3238429 3238422 3238414 3238405 3238388 3238394
EIP ECP( VII CONT.) 3238367 3238368 3238369 3238415 3238406 3238389 3238395
EIP ECP (IMP CONT.) 3238437 3238430 3238423 3238416 3238407 3238392 3238399
MGP- MECHANICAL GUAGE PANEL
ECP- ELECTRONIC CONTROL PANEL
EIP - ELECTRONIC INSTRUMENT PANEL
HYD. GOV. - HYDRAULIC GOVERNOR
IMP CONT. - IMPORTED CONTROLLER_P.No.3062322
V - I CONT. - VERSION I CONTROLLER P.No. 3873853
V - II CONT. - VERSION II CONTROLLER - P.No. 3413905
EFC - ELECTRONIC FUEL CONTROL
EXAMPLE OF THE ABOVE : MGP-EFC-ECP -- MEANS CONVERSION OF AN ENGINE HAVING MECHANICAL GUAGE PANEL (MGP)
& HYDRAULIC GOVERNOR TO ------- EFC GOVERNOR & ECP.
Page 4-17
AR 3879743
AR 3879742
AR 3880051
AR 3880214
AR 3880050
3881602
3239755
3880355
3239329
3239329
3239156
3879280
HIGH ALTITUDE COMPENSATlON KITS
CONVERSION KITS - PIPE COUPLINGS
HD 785
LW 35
LW 50
BEML
BEML
BEML
BEML
BEML
D 155
D 355
R35
HM
COMPRESSOR (N-855-C)
WORKOVER RIG OF IOC

DOZER WITH HOLSET
DOZER WITH HOLSET

FOR N-743 D-8O-A-12
COMPRESSOR WITH
COMPRESSOR WITH
CPT-600/150 SCREW
FOR N-495 D-50-A-12
N 855 C IR BHEL 450

FOR N-495 CPT-365
FOR N-743 CPT-600
KTA 1150 C
NTA 855-C
NTA 855 C
VT 1710 C
KT 2300 C
HOLSET TURBO
HOLSET TURBO
KT1150 C
DHULIAJAN
TURBO.
TURBO
Section - 4
1.
2.
3.
4.
5.
6.

CONVERSION KITS – TURBOCHARGERS - CONTD……
* 1150 SERIES
MODEL / CONVERSION OF KIT PART REMARKS

APPLICATION TURBOCHARGER NO.
KTA 1150 G HOLSET HC5A OR AR 3880195 With Turbo. for radiator /
(1500 RPM) GARRETT T-18-A TO HE Cooled Engine. Use
HOLSET 4 LGK Turbo 3522295
KT 1150 G HOLSET HC5A OR AR 3880194 With Turbo for radiator /
(1500 RPM) GARETT-18A TO HE cooled engine
(1500 RPM) GARETT-18A TO HE cooled Engine, use
KT 1150 C HC5A TO 4 LGK AR 3880194 With Turbo for radiator /
HM 72-71 HE cooled Engine, use
Turbo 3522296
Existing
Setup
MGP EFC-ECP 3238431 3238424 3238417 3238409 3238400 3238408
MGP ECP (HYD.GOV) 3238432 3238425 3238418 3238410 3238401 3238387 3238393
MGP ECP (IMP CONT.) 3238433 3238426 3238419 3238411 3238402 3238397
MGP ECP (VI CONT.) 3238434 3238427 3238420 3238412 3238403 3238390 3238396
MGP ECP (VII CONT.) 3238435 3238428 3238421 3238413 3238404 3238391 3238398
EIP ECP(VI CONT.) 3238436 3238429 3238422 3238414 3238405 3238388 3238394
EIP ECP( VII CONT.) 3238367 3238368 3238369 3238415 3238406 3238389 3238395
EIP ECP (IMP CONT.) 3238437 3238430 3238423 3238416 3238407 3238392 3238399
Page 4-17
AR 3879743
AR 3879742
AR 3880051
AR 3880214
AR 3880050
3881602
3239755
3880355
3239329
3239329
3239156
3879280
HD 785
LW 35
LW 50
BEML
BEML
BEML
BEML
BEML
D 155
D 355
R35
HM
WORKOVER RIG OF IOC

DOZER WITH HOLSET
DOZER WITH HOLSET

FOR N-743 D-8O-A-12
COMPRESSOR WITH
COMPRESSOR WITH
CPT-600/150 SCREW
FOR N-495 D-50-A-12
N 855 C IR BHEL 450

FOR N-495 CPT-365
FOR N-743 CPT-600
KTA 1150 C
NTA 855-C
NTA 855 C
VT 1710 C
KT 2300 C
HOLSET TURBO
HOLSET TURBO
KT1150 C
DHULIAJAN
TURBO.
TURBO
Section - 4
1.
2.
3.
4.
5.
6.
* 1150 SERIES
Turbo 3522296
Existing
Setup
MGP EFC-ECP 3238431 3238424 3238417 3238409 3238400 3238408
MGP ECP (HYD.GOV) 3238432 3238425 3238418 3238410 3238401 3238387 3238393
MGP ECP (IMP CONT.) 3238433 3238426 3238419 3238411 3238402 3238397
MGP ECP (VI CONT.) 3238434 3238427 3238420 3238412 3238403 3238390 3238396
MGP ECP (VII CONT.) 3238435 3238428 3238421 3238413 3238404 3238391 3238398
EIP ECP(VI CONT.) 3238436 3238429 3238422 3238414 3238405 3238388 3238394
EIP ECP( VII CONT.) 3238367 3238368 3238369 3238415 3238406 3238389 3238395
EIP ECP (IMP CONT.) 3238437 3238430 3238423 3238416 3238407 3238392 3238399
Page 4-17
AR 3879743
AR 3879742
AR 3880051
AR 3880214
AR 3880050
3881602
3239755
3880355
3239329
3239329
3239156
3879280
HD 785
LW 35
LW 50
BEML
BEML
BEML
BEML
BEML
D 155
D 355
R35
HM
WORKOVER RIG OF IOC

DOZER WITH HOLSET
DOZER WITH HOLSET

FOR N-743 D-8O-A-12
COMPRESSOR WITH
COMPRESSOR WITH
CPT-600/150 SCREW
FOR N-495 D-50-A-12
N 855 C IR BHEL 450

FOR N-495 CPT-365
FOR N-743 CPT-600
KTA 1150 C
NTA 855-C
NTA 855 C
VT 1710 C
KT 2300 C
HOLSET TURBO
HOLSET TURBO
KT1150 C
DHULIAJAN
TURBO.
TURBO
Section - 4
1.
2.
3.
4.
5.
6.

* 1150 SERIES

Turbo 3522296
CON ROD BEARINGS
MODEL STANDARD 0.010” 0.020” 0.030” 0.040”
495/743/855 203670 203671 203672 203673 203674
855 203660 203661 203662 203663 203664
855 / N14 214950 214951 214952 214953 214954
V1710 /28 200600 200601 200602 200603 200604
1150 205840 205841 205842 205843 N/A
2300 3047390 3047391 3047392 3047393 3047394
KTA 3067/50G 3047390 3047391 3047392 3047393 3047394
B Series 3901170 3901171 3901172 3901173 3901174
C Series 3901430 3901431 3901432 3901433 3901434
L10 3016760 3016761 3016762 3016763 3016764

MAIN BEARINGS
MODEL STANDARD 0.010” 0.020” 0.030” 0.040” THRUST RING
495 3240000 3240001 3240002 3240003 AR7094 3067568
743 & 855 3239990 3239991 3239992 3239993 AR7114 3067568
1150 AR12270 AR12271 AR12272 AR12273 205112
V1710/28 AR4220 AR4221 AR4222 AR4223 AR4224 180280
2300 AR12250 AR12251 AR12252 AR12253 AR12254 3000139
KTA3067/50G 3018210 3018211 3018212 3018213 3018214 3000139
4B 3802010 3802011 3802012 3802013 3802014 *
6B 3802070 3802071 3802072 3802073 3802074 *
C Series 3945917 3945918 3945919 3945920 3945921 *
L10 4025125 4025126 4025127 4025128 4025129 4025120

*B & C Series engine MB Set Thrust Main Brg as a part of MB shell.

SHORT BLOCK ASSEMBLY OF VARIOUS MODELS *
PART NO. MODEL REMARKS

3247096 NT-495 (SO. No. E84823201) P/N 3228805
NTC-495 Long nose crankshaft, AR96687
Cyl. Block, 200710 Piston and AR3013282 Con. Rod.
3879880 NTA-495 AR3247490 Crank, AR95562 Piston, BM 66968GC Cover, AR3015523 CR
3879881 NT-180 ND LOCO AR1945 Crankshaft, 200710 Piston
Genset AR3013282 Conrod, BM66968 GC
3239043 N-743 Genset I D80 Dozer of BEML
3239456 NT-743 / NTA-743 C Also for R25 HM Dumper
3240199 N-855
3879939 NT-855-C-355 (FFC) Can use for UH-181 Hyd. Excavator, Ex400 and PC300 Engines.
3239195 NTA-855 Non FFC I LW 35
AR 3241910 KT-1150 C/G (D-155) Also for 20-71 HM Front End Loader
AR 3241911 KTA-1150 G/C (D-355) also for PC-650 Application
3241912 VT-1710 G
AR 3241914 VT-1710 C - LW-50
3241913 VTA-1710 G
3881506 VTA-1710-Loco
* Please refer EBR of engine and the break-up of Short Block Kit to decide the suitability of particular part number.
CON ROD BEARINGS
MODEL STANDARD 0.010” 0.020” 0.030” 0.040”
495/743/855 203670 203671 203672 203673 203674
855 203660 203661 203662 203663 203664
855 / N14 214950 214951 214952 214953 214954
V1710 /28 200600 200601 200602 200603 200604
1150 205840 205841 205842 205843 N/A
2300 3047390 3047391 3047392 3047393 3047394
KTA 3067/50G 3047390 3047391 3047392 3047393 3047394
B Series 3901170 3901171 3901172 3901173 3901174
C Series 3901430 3901431 3901432 3901433 3901434
L10 3016760 3016761 3016762 3016763 3016764

MAIN BEARINGS
495 3240000 3240001 3240002 3240003 AR7094 3067568
743 & 855 3239990 3239991 3239992 3239993 AR7114 3067568
1150 AR12270 AR12271 AR12272 AR12273 205112
V1710/28 AR4220 AR4221 AR4222 AR4223 AR4224 180280
2300 AR12250 AR12251 AR12252 AR12253 AR12254 3000139
KTA3067/50G 3018210 3018211 3018212 3018213 3018214 3000139
4B 3802010 3802011 3802012 3802013 3802014 *
6B 3802070 3802071 3802072 3802073 3802074 *
C Series 3945917 3945918 3945919 3945920 3945921 *
L10 4025125 4025126 4025127 4025128 4025129 4025120



3247096 NT-495 (SO. No. E84823201) P/N 3228805
3240199 N-855
3239195 NTA-855 Non FFC I LW 35
3241912 VT-1710 G
AR 3241914 VT-1710 C - LW-50
3241913 VTA-1710 G
3881506 VTA-1710-Loco
CON ROD BEARINGS
MODEL STANDARD 0.010” 0.020” 0.030” 0.040”
495/743/855 203670 203671 203672 203673 203674
855 203660 203661 203662 203663 203664
855 / N14 214950 214951 214952 214953 214954
V1710 /28 200600 200601 200602 200603 200604
1150 205840 205841 205842 205843 N/A
2300 3047390 3047391 3047392 3047393 3047394
KTA 3067/50G 3047390 3047391 3047392 3047393 3047394
B Series 3901170 3901171 3901172 3901173 3901174
C Series 3901430 3901431 3901432 3901433 3901434
L10 3016760 3016761 3016762 3016763 3016764

MAIN BEARINGS
495 3240000 3240001 3240002 3240003 AR7094 3067568
743 & 855 3239990 3239991 3239992 3239993 AR7114 3067568
1150 AR12270 AR12271 AR12272 AR12273 205112
V1710/28 AR4220 AR4221 AR4222 AR4223 AR4224 180280
2300 AR12250 AR12251 AR12252 AR12253 AR12254 3000139
KTA3067/50G 3018210 3018211 3018212 3018213 3018214 3000139
4B 3802010 3802011 3802012 3802013 3802014 *
6B 3802070 3802071 3802072 3802073 3802074 *
C Series 3945917 3945918 3945919 3945920 3945921 *
L10 4025125 4025126 4025127 4025128 4025129 4025120



3247096 NT-495 (SO. No. E84823201) P/N 3228805
3240199 N-855
3239195 NTA-855 Non FFC I LW 35
3241912 VT-1710 G
AR 3241914 VT-1710 C - LW-50
3241913 VTA-1710 G
3881506 VTA-1710-Loco
Section-4 Page 4-24
BREAK-UP AT ‘AR’ PART NUMBERS I.E. FILTER ELEMENT AND SEAL RING.
Sr. Part Number Break-up at ‘AR’ Part Description
No. Number
Part No. Qty.
1 3238202 3166557 1 Element Fuel Filter Small
0151881 1 Seal Ring
2 3238203 3166556 1 Element LO Filter Small
0173368 1 Seal Ring
3 3238204 3166554 1 Element LO Filter Std.
0173368 1 Seal Ring
4 3236205 3166555 1 Element Fuel Filter Std
0151881 1 Seal Ring
5 3879488 3873576 1 Element SLOBP
3167229 1 Seal Ring
PART NUMBER STRUCTURE OLD & NEW
OLD P/N Structure New P/N Structure
Digit-> 1 2 3 4 5 6 7 8 9 10 11 12 CD 1 2 3 4 5 6 7 8 9 10 11 12
1 0 0 0 2 9 6 5 K 0 2 9 6 5
2 0 5 0 4 3 8 5 K 2 5 0 4 3 8 5
3 3 2 2 5 7 2 5 K 9 3 2 2 5 7 2 5
4 A R 0 0 0 7 0 5 8 0 0 K 4 A R 7 0 5 8
5 A R 0 0 1 2 0 9 8 0 0 K 1 A R 1 2 0 9 8
6 A R 3 2 4 1 8 5 5 0 0 K 1 3 2 4 1 8 5 5
7 A R 3 8 8 0 1 5 7 0 0 K 3 3 8 8 0 1 5 7
8 B M 0 0 0 3 4 1 0 0 0 K 1 B M 3 4 1 0
9 B M 0 0 9 5 1 6 1 0 0 K 0 B M 9 5 1 6 1
10 3 5 2 9 2 9 6 0 0 K 4 3 5 2 9 2 9 6
11 4 0 5 5 2 8 1 0 0 K 4 4 0 5 5 2 8 1
12 S T 0 0 0 0 6 8 5 C K 2 S T 6 8 5 C
13 S T 0 0 0 1 2 8 1 K 3 S T 1 2 8 1
14 S T 0 0 0 1 1 7 7 1 K 4 S T 1 1 7 7 1
15 S 0 0 0 0 6 0 4 K 2 S 6 0 4
16 S 0 0 0 0 1 9 5 A K 1 S 1 9 5 A
17 A S 0 8 0 7 8 0 0 S S K 5 A S 8 0 7 8 S S
18 A S 1 6 0 2 0 0 0 S S K 9 A S 1 6 0 2 0 S S
19 A S 1 6 0 0 9 4 6 M C K 0 A S 1 6 0 0 9 4 6 M C
20 A S 0 6 0 7 9 4 0 M S K 1 A S 6 0 7 9 4 0 M S
21 A S 1 6 0 1 4 0 6 M O K 2 A S 1 6 0 1 4 6 M O
Page 4-22
A) ‘AR’ Part Numbers i.e. Filter Element and Seal Ring.

0.020”O/S
P/N Number
3001709
3001197
3802702
3945923
3238204
3238205
3238202
3238203
157282
180282
(AR and B Check Kit Part Numbers)
(lntroduced from June 1 , 1997)

OVERSIZE THRUST RINGS
0.010”O/S
st
SUPERSEDENCE
3001708
3001196
3802541
3945922
4023204
157281
180281
Lube Oil Filter Small

New Filter ‘AR’ Part
Lube Oil Filter Std.

Fuel Filter Small
Fuel Filter Std.

3000139
3067568
3802519
3945929
4025120
205112
180280
Std.
L10 Series
Section-4
C Series
KV 12/16
B Series
Engine
NH/NT
V1710
No.
Sr.
K6
1
2
3
4
Section-4 Page 4-24

No. Number
Part No. Qty.
0151881 1 Seal Ring
0173368 1 Seal Ring
0173368 1 Seal Ring
0151881 1 Seal Ring
5 3879488 3873576 1 Element SLOBP
3167229 1 Seal Ring

Digit-> 1 2 3 4 5 6 7 8 9 10 11 12 CD 1 2 3 4 5 6 7 8 9 10 11 12
1 0 0 0 2 9 6 5 K 0 2 9 6 5
2 0 5 0 4 3 8 5 K 2 5 0 4 3 8 5
3 3 2 2 5 7 2 5 K 9 3 2 2 5 7 2 5
4 A R 0 0 0 7 0 5 8 0 0 K 4 A R 7 0 5 8
5 A R 0 0 1 2 0 9 8 0 0 K 1 A R 1 2 0 9 8
6 A R 3 2 4 1 8 5 5 0 0 K 1 3 2 4 1 8 5 5
7 A R 3 8 8 0 1 5 7 0 0 K 3 3 8 8 0 1 5 7
8 B M 0 0 0 3 4 1 0 0 0 K 1 B M 3 4 1 0
9 B M 0 0 9 5 1 6 1 0 0 K 0 B M 9 5 1 6 1
10 3 5 2 9 2 9 6 0 0 K 4 3 5 2 9 2 9 6
11 4 0 5 5 2 8 1 0 0 K 4 4 0 5 5 2 8 1
12 S T 0 0 0 0 6 8 5 C K 2 S T 6 8 5 C
13 S T 0 0 0 1 2 8 1 K 3 S T 1 2 8 1
14 S T 0 0 0 1 1 7 7 1 K 4 S T 1 1 7 7 1
15 S 0 0 0 0 6 0 4 K 2 S 6 0 4
16 S 0 0 0 0 1 9 5 A K 1 S 1 9 5 A
17 A S 0 8 0 7 8 0 0 S S K 5 A S 8 0 7 8 S S
18 A S 1 6 0 2 0 0 0 S S K 9 A S 1 6 0 2 0 S S
19 A S 1 6 0 0 9 4 6 M C K 0 A S 1 6 0 0 9 4 6 M C
20 A S 0 6 0 7 9 4 0 M S K 1 A S 6 0 7 9 4 0 M S
21 A S 1 6 0 1 4 0 6 M O K 2 A S 1 6 0 1 4 6 M O
Page 4-22

0.020”O/S
P/N Number
3001709
3001197
3802702
3945923
3238204
3238205
3238202
3238203
157282
180282

0.010”O/S
st
SUPERSEDENCE
3001708
3001196
3802541
3945922
4023204
157281
180281


Fuel Filter Small
Fuel Filter Std.

3000139
3067568
3802519
3945929
4025120
205112
180280
Std.
L10 Series
Section-4
C Series
KV 12/16
B Series
Engine
NH/NT
V1710
No.
Sr.
K6
1
2
3
4
Section-4 Page 4-24

No. Number
Part No. Qty.
0151881 1 Seal Ring
0173368 1 Seal Ring
0173368 1 Seal Ring
0151881 1 Seal Ring
5 3879488 3873576 1 Element SLOBP
3167229 1 Seal Ring

Digit-> 1 2 3 4 5 6 7 8 9 10 11 12 CD 1 2 3 4 5 6 7 8 9 10 11 12
1 0 0 0 2 9 6 5 K 0 2 9 6 5
2 0 5 0 4 3 8 5 K 2 5 0 4 3 8 5
3 3 2 2 5 7 2 5 K 9 3 2 2 5 7 2 5
4 A R 0 0 0 7 0 5 8 0 0 K 4 A R 7 0 5 8
5 A R 0 0 1 2 0 9 8 0 0 K 1 A R 1 2 0 9 8
6 A R 3 2 4 1 8 5 5 0 0 K 1 3 2 4 1 8 5 5
7 A R 3 8 8 0 1 5 7 0 0 K 3 3 8 8 0 1 5 7
8 B M 0 0 0 3 4 1 0 0 0 K 1 B M 3 4 1 0
9 B M 0 0 9 5 1 6 1 0 0 K 0 B M 9 5 1 6 1
10 3 5 2 9 2 9 6 0 0 K 4 3 5 2 9 2 9 6
11 4 0 5 5 2 8 1 0 0 K 4 4 0 5 5 2 8 1
12 S T 0 0 0 0 6 8 5 C K 2 S T 6 8 5 C
13 S T 0 0 0 1 2 8 1 K 3 S T 1 2 8 1
14 S T 0 0 0 1 1 7 7 1 K 4 S T 1 1 7 7 1
15 S 0 0 0 0 6 0 4 K 2 S 6 0 4
16 S 0 0 0 0 1 9 5 A K 1 S 1 9 5 A
17 A S 0 8 0 7 8 0 0 S S K 5 A S 8 0 7 8 S S
18 A S 1 6 0 2 0 0 0 S S K 9 A S 1 6 0 2 0 S S
19 A S 1 6 0 0 9 4 6 M C K 0 A S 1 6 0 0 9 4 6 M C
20 A S 0 6 0 7 9 4 0 M S K 1 A S 6 0 7 9 4 0 M S
21 A S 1 6 0 1 4 0 6 M O K 2 A S 1 6 0 1 4 6 M O
Page 4-22

0.020”O/S
P/N Number
3001709
3001197
3802702
3945923
3238204
3238205
3238202
3238203
157282
180282

0.010”O/S
st
SUPERSEDENCE
3001708
3001196
3802541
3945922
4023204
157281
180281


Fuel Filter Small
Fuel Filter Std.

3000139
3067568
3802519
3945929
4025120
205112
180280
Std.
L10 Series
Section-4
C Series
KV 12/16
B Series
Engine
NH/NT
V1710
No.
Sr.
K6
1
2
3
4
AIR CLEANER ELEMENTS
B CHECK KITS WITH CAC AIR SYSTEM, HOSE, ELBOWS
Sr.
Part No Part Desc
No
Part Desc. P/N Record # PRT.NO. DIA “IN” DIA “OUT” 1 0151688 AIR FILTER
2 0213714 ELEMENT AIR FILTER (118020)
B CHECK KIT 3238280 1 3022915 5.5” 5”
3 0255183 AIR FILTER
B CHECK KIT- V/VT/VTA/1710 3238281 2 3030770 4” 4” 4 0503009 ELEMENT INNER
5 0503010 ELEMENT OUTER
B CHECK KIT- KT/KTA 2300-G 3238282
3 3030513 6” 5.5” 6 0504106 ELEMENT INNER
B CHECK KIT- KT/KTA 2300-G 3238283 7 0504107 ELEMENT OUTER
4 3030514 7” 5.5”
8 0504209 ELEMENT INNER
BCHECKKIT-KTA 50G3 RAD 3238284
5 3230541 5” 4” 9 0504602 ELEMENT INNER
B CHECK KIT N-495-G 3238289 10 0650055 AIR FILTER
6 3030772 5.5” 5.5” 11 3001692 AIR FILTER
B CHECK KIT N-743-G 3238290
7 3030769 3.5” 3.5”
8 3235134 5.5” 3.5” 14 3013211 AIR FILTER
B CHECK KIT N-743G/N855-G 3238293 9 3904062 3” 3” 16 3022209 AIR FILTER
B CHECK KIT NT(A)495-G 3238294 10 3235929 5.5” 2.75”
18 3229497 ELEMENT AIR CLEANER
B CHECK KIT NT(A)743/855-G 3238295 11 3030513 6” 5.5” 19 3230273 ELEMENT INNER
B CHECK KIT NT(A)495-G 3238296
12 3030514 7” 5.5” 21 3233498 ELEMENT A.C.
B CHECK KIT NT/NTA743 3238297 22 3236027 ELEMENT AIR CLEANER
13 3030515 7” 5.5”
23 3237742 ELEMENT INNER A/C
B CHECK KIT INHIBITOR 495 3238313
14 3875465 3.5” 3.5” 24 3237949 OUTER ELEMENT
B CHECK KIT - NTA855-LW35 3238316 25 3237951 OUTER ELEMENT
15 3912602 3” 3” 26 3237954 ELEMENT AIR CLEANER
KIT B CHECK KTTA-1150 3238385
Dimension in Inches 27 3237956 OUTER ELEMENT
B CHECK KIT VT1710 RADIATOR 3238285 28 3237958 OUTER ELEMENT
29 3237960 OUTER ELEMENT
KIT, B CHECK S SERIES AX1002399
B CHECK KIT 3238487 31 3237963 ELEMENT
32 3238364 ELEMENT AIR FILTER
33 3238364 ELEMENT AIR FILTER INNER
34 3414782 ELEMENT FILTER
Sr.
Part No Part Desc
No
B CHECK KIT 3238280 1 3022915 5.5” 5”
3 3030513 6” 5.5” 6 0504106 ELEMENT INNER
4 3030514 7” 5.5”
5 3230541 5” 4” 9 0504602 ELEMENT INNER
6 3030772 5.5” 5.5” 11 3001692 AIR FILTER
7 3030769 3.5” 3.5”
8 3235134 5.5” 3.5” 14 3013211 AIR FILTER
B CHECK KIT NT(A)495-G 3238294 10 3235929 5.5” 2.75”
12 3030514 7” 5.5” 21 3233498 ELEMENT A.C.
13 3030515 7” 5.5”
14 3875465 3.5” 3.5” 24 3237949 OUTER ELEMENT
Sr.
Part No Part Desc
No
B CHECK KIT 3238280 1 3022915 5.5” 5”
3 3030513 6” 5.5” 6 0504106 ELEMENT INNER
4 3030514 7” 5.5”
5 3230541 5” 4” 9 0504602 ELEMENT INNER
6 3030772 5.5” 5.5” 11 3001692 AIR FILTER
7 3030769 3.5” 3.5”
8 3235134 5.5” 3.5” 14 3013211 AIR FILTER
B CHECK KIT NT(A)495-G 3238294 10 3235929 5.5” 2.75”
12 3030514 7” 5.5” 21 3233498 ELEMENT A.C.
13 3030515 7” 5.5”
14 3875465 3.5” 3.5” 24 3237949 OUTER ELEMENT
Section 4
Section - 4
AIR CLEANER ELEMENTS – CONTD….
Sr.
Part No Part Desc
No
3872652 (14”)
3872651 (12”)
3872650 (12”)
3166836
3875557
3392542
###
3877401
3392613
3166842
3166840
3166838
3166836
ASSLY. AIR CLEANER

ASSLY. AIR CLEANER
44 3875391 ELEMENT AIR CLEANER OUTER
3872667 (14”)
3872666 (14”)
3872665 (14”)
3872664
3872663
3872662
3872661
3872660
3872659
3872658
3872657
3872656
3872655
3872654 (17.5”)
3872653 (16”)
45 3875393 ELEMENT AIR CLEANER INNER
50 3875611 ELEMENT AIRCLEANER
AIR CLEANER ASSEMBLIES AND ELEMENTS
INNER ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
3233498
3233498
3233498
3233498
3233498
3236027
3236027
504602
504209
504209
3226019
SINGLE ELEMENT
3230338
3230273
3230273
3233498
3875560
3879155
3875393
3875393
3875393
3233498
3233498
3233498
3233498
INNER ELEMENT
59 4055279 ELEMENT A/C INNER 16”
60 4055280 AIR CLEANER ELEMENT OUTER
61 4055575 ELEMENT A/C 12”
62 4055576 ELEMENT A/C OUTER 12”
65 4055583 ELEMENT A/C INNER 10"
67 3238057 KIT AIRCLEANER 1 MW
68 3238149 KIT AIR CLEANER ELEMENTS
3237951
3237949
3237949
3237962
3875559
3879154
3414931 for Dresser 170T Dumper Truck A/C
3875492
3879391 for Belaz Dumper Trucks
3237962
3237962
3237962
3237962
OUTER ELEMENT
OUTER ELEMENT
3237963
3237963
3237963
3237962
3237962
3237962
3237962
3237962
3237960
3237960
3237958
3237956
3237956
3237953
3237954
78 3238202 ELEMENT ASSEMBLY
80 3238323 KIT AIR CLEANER ELEMENT
Page 4-30
Page 4-29
81 3238358 KIT AIR CLEANER ELEMENT 16”
82 3238362 KIT A/C ELEMENT HYUNDAI EXCV
Sr.
Part No Part Desc
No
Section 4
Section - 4
###
3166836
3875557
3392542
3877401
3392613
3166842
3166840
3166838
3166836
3872664
3872663
3872662
3872661
3872660
3872659
3872658
3872657
3872656
3872655
3872652 (14”)
3872651 (12”)
3872650 (12”)
3872667 (14”)
3872666 (14”)
3872665 (14”)
3872653 (16”)
3872654 (17.5”)

ASSLY. AIR CLEANER
ASSLY. AIR CLEANER

504602
504209
504209
3233498
3233498
3233498
3233498
3233498
3236027
3236027
3226019

3230338
3230273
3230273
3233498
3875560
3879155
3875393
3875393
3875393
3233498
3233498
3233498
3233498
INNER ELEMENT
61 4055575 ELEMENT A/C 12”

SINGLE ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
INNER ELEMENT

3237951
3237949
3237949
3237962
3875559
3879154
3875492
3237962
3237962
3237962
3237962

3237963
3237963
3237963
3237962
3237962
3237962
3237962
3237962
3237960
3237960
3237958
3237956
3237956
3237953
3237954

OUTER ELEMENT
OUTER ELEMENT



Page 4-30
Page 4-29

Sr.
Part No Part Desc
No
Section 4
Section - 4
###
3166836
3875557
3392542
3877401
3392613
3166842
3166840
3166838
3166836
3872664
3872663
3872662
3872661
3872660
3872659
3872658
3872657
3872656
3872655
3872652 (14”)
3872651 (12”)
3872650 (12”)
3872667 (14”)
3872666 (14”)
3872665 (14”)
3872653 (16”)
3872654 (17.5”)

ASSLY. AIR CLEANER
ASSLY. AIR CLEANER

504602
504209
504209
3233498
3233498
3233498
3233498
3233498
3236027
3236027
3226019

3230338
3230273
3230273
3233498
3875560
3879155
3875393
3875393
3875393
3233498
3233498
3233498
3233498
INNER ELEMENT
61 4055575 ELEMENT A/C 12”

SINGLE ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
SINGLE ELEMENT
INNER ELEMENT

3237951
3237949
3237949
3237962
3875559
3879154
3875492
3237962
3237962
3237962
3237962

3237963
3237963
3237963
3237962
3237962
3237962
3237962
3237962
3237960
3237960
3237958
3237956
3237956
3237953
3237954

OUTER ELEMENT
OUTER ELEMENT



Page 4-30
Page 4-29

Page 4-33
Length
6.625
2.75
3.5
4
4
5
5
8
5
6
“OUT”
6.625”
6.875”
2.75”
5.88”
7.38”
5.88”
3.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
3.5”
5.5”
5.5”
DIA
5”
8”
4”
7”
5”
3”
3”
6.625”
2.75”
“IN”
5.5”
5.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
5.5”
DIA
PLAIN AIR HUMP HOSES
5”
7”
7”
7”
8”
6”
4”
7”
5”
4”
3”
4”
PRT.NO.
3030970
3030972
4056441
4055400
4056442
3227853
3230439
4056443
3232257
3235726
3872497
3014244
3904059
3904060
103806
103807
501840
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Hump
Hose, Hump
Hose, Hump
Description
Hose, Plain
Hose, Plain
Hose, Plain
Section - 4
Record
#
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
ASSLY. AIR CLEANER INNER ELEMENT OUTER ELEMENT
3878893 3233498 3237962 LW35
3878931 3875393 3875391 Belaz Dumper
3878979 3879155 3879154 KTTA19C 210M 50T
3879160 3879074 3879075 KTA1150 B-35 BEML
3877403 3233498 3237962
3879084 # 3233498 3233962 VT1710C LW50
3392007 * 3236027 3237960 NTA743C DC230
3392384 3875393 3875391 KTA2300C 120TON
3877402 3875560 3875559

3872668 3237742 3872336
3812770 10” 3812540 3812607
3231434 3231375 3231374
501111 SINGLE ELEMENT 3235934
504606 504106 504107
503005 (Service) 503009 503010
3001893 3012212 3012213
3872768 (Imported Use AR3879590 as replacement.)
3813038 (Nissan) 504209 3237956
3877423 3233498 3237962
3878243 (Obsolete) 504106 504107 (DC/230 Dozer)
3875256 3233498 3237962 KV16-M
3877554 (Obsolete) # 3233498 3237962 VT1710 H50
3414702 4020552 4020551
4055573 4055583 4055584
4020943 4020552 4020551
4055647 3879155 3879154
Page 4-33
Length
6.625
2.75
3.5
4
4
5
5
8
5
6
“OUT”
6.625”
6.875”
2.75”
5.88”
7.38”
5.88”
3.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
3.5”
5.5”
5.5”
DIA
5”
8”
4”
7”
5”
3”
3”
6.625”
2.75”
“IN”
5.5”
5.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
5.5”
DIA
5”
7”
7”
7”
8”
6”
4”
7”
5”
4”
3”
4”
PRT.NO.
3030970
3030972
4056441
4055400
4056442
3227853
3230439
4056443
3232257
3235726
3872497
3014244
3904059
3904060
103806
103807
501840
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Hump
Hose, Hump
Hose, Hump
Description
Hose, Plain
Hose, Plain
Hose, Plain
Section - 4
Record
#
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1
3878893 3233498 3237962 LW35
3878931 3875393 3875391 Belaz Dumper
3878979 3879155 3879154 KTTA19C 210M 50T
3879160 3879074 3879075 KTA1150 B-35 BEML
3877403 3233498 3237962
3879084 # 3233498 3233962 VT1710C LW50
3392007 * 3236027 3237960 NTA743C DC230
3392384 3875393 3875391 KTA2300C 120TON
3877402 3875560 3875559

3872668 3237742 3872336
3812770 10” 3812540 3812607
3231434 3231375 3231374
504606 504106 504107
503005 (Service) 503009 503010
3001893 3012212 3012213
3813038 (Nissan) 504209 3237956
3877423 3233498 3237962
3875256 3233498 3237962 KV16-M
3877554 (Obsolete) # 3233498 3237962 VT1710 H50
3414702 4020552 4020551
4055573 4055583 4055584
4020943 4020552 4020551
4055647 3879155 3879154
Page 4-33
Length
6.625
2.75
3.5
4
4
5
5
8
5
6
“OUT”
6.625”
6.875”
2.75”
5.88”
7.38”
5.88”
3.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
5.5”
3.5”
5.5”
DIA
5”
8”
4”
7”
5”
3”
3”
6.625”
2.75”
“IN”
5.5”
5.5”
5.5”
3.5”
5.5”
5.5”
5.5”
5.5”
5.5”
DIA
5”
7”
7”
7”
8”
6”
4”
7”
5”
4”
3”
4”
PRT.NO.
3030970
3030972
4056441
4055400
4056442
3227853
3230439
4056443
3232257
3235726
3872497
3014244
3904059
3904060
103806
103807
501840
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible Hump
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Flexible
Hose, Hump
Hose, Hump
Hose, Hump
Description
Hose, Plain
Hose, Plain
Hose, Plain
Section - 4
Record
#
10
11
12
13
14
15
16
17
18
19
20
21
22
23
1

3878893 3233498 3237962 LW35
3878931 3875393 3875391 Belaz Dumper
3878979 3879155 3879154 KTTA19C 210M 50T
3879160 3879074 3879075 KTA1150 B-35 BEML
3877403 3233498 3237962
3879084 # 3233498 3233962 VT1710C LW50
3392007 * 3236027 3237960 NTA743C DC230
3392384 3875393 3875391 KTA2300C 120TON
3877402 3875560 3875559
3872668 3237742 3872336
3812770 10” 3812540 3812607
3231434 3231375 3231374
504606 504106 504107
503005 (Service) 503009 503010
3001893 3012212 3012213
3813038 (Nissan) 504209 3237956
3877423 3233498 3237962
3875256 3233498 3237962 KV16-M
3877554 (Obsolete) # 3233498 3237962 VT1710 H50
3414702 4020552 4020551
4055573 4055583 4055584
4020943 4020552 4020551
4055647 3879155 3879154
Page 4-36
5 lt.
10 lt.
20 lt.
205 lt.
0.5 lt.
1 lt.
2 lt.
5 lt.
10 lt.
Qty.
Qty.
COOLANT ADDITIVE CONCENTRATE
Coolant Additive Concentrate


PREMIXED COOLANT
Description
Premixed Coolant
Premixed Coolant
Premixed Coolant
Premixed Coolant
Description
Section – 4
3167221
3167222
3167223
3167224
3167214
3167215
3167216
3167217
3167218
Number
Number
Part
Part
Page 4-35
COOLING SYSTEM WATER PLAIN HOSES COOLING
Length
10 .00
12 .00
14 .00
20 .00
24 .00
26 .00
32 .00
36 .00
58 .00
14.25
12.00
17.00
11.00
16.00
18.00
22.00
30.00
40.00
50.00
52.00
5 .00
8 .00
2.00
3.00
2.50
3.00
4.00
2.00
2.50
3.00
3.12
3.50
2.88
3.00
2.25
3.50
3.75
4.00
2.50
3.00
4.00
5.00
5.50
6.50
6.00
7.00
8.00
2.62
3.00
4.00
7.00
4.50
2.75
3.50
4.25
3.50
5.00
4.00
DIMENSION ARE IN INCHES
1 . 00
1 . 00
1 . 00
1 . 25
1 . 25
1 . 25
1 . 50
1 . 50
1 . 50
1 . 50
1 . 50
1 . 75
1 . 75
2 . 00
2 . 00
2 . 00
2 . 00
2 . 00
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
0.38
0.38
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
2.25
2.38
2.50
2.50
2.50
2.75
3.00
3.00
3.00
3.50
3.50
5.00
ID
179912 H
179917 N
143996 H
144021 C
144000 B
144032 A
144052 K
136840 E
144008 F
63495 B
3024128
3200316
3026395
63241 M
64998 G
Part No.
67369 C
64998 H
64998 D
63241 H
63241 N
67185 H
67369 A
64998 E
63411 A
63495 A
70458 A
67185 B
67185 A
63241 F
67185 F
64998 J
Section – 4
102234
104296
107063
149274
143992
144034
144038
144044
144047
200517
215950
107195
102522
110980
9539 A
64030
67369
63223
64978
60985
66167
61814
61554
63495
61961
67185
9539
Section – 4 Table 1 OVERALL DIMENSIONS OF FLEXMASTER COUPLINGS (COOLANT) Page 4-34

ASSEMBLY NO. A DIA. PIPE SIZE B DIA. C DIM. D DIM.
3872278 25.40 (1.00 INCH) 47.0 79.5 64.00
3872252 31.75 (1.25 INCH) 55.0 97.0 70.75
3872284 38.10 (1.50 INCH) 60.0 104.0 75.90
3872258 57.15 (2.25 INCH) 86.0 128.0 103.60
3872294 63.50 (2.50 INCH) 91.3 130.0 104.00
3872268 76.20 (3.00 INCH) 123.1 174.5 125.00
3872299 88.90 (3.50 INCH) 138.1 189.0 170.00
3872304 127.00 (5.00 INCH) 170.0 225.0 103.00
Table 2 INSERTION DEPTHS, TORQUE VALUES & PART NUMBERS
Pipe “D” “D” RING
ASSEMBLY *TORQUE SLEEVE RUBBER PLAIN LOCK
OD Min. Max. CLAMP RETAINING SCREW NUT
PART NO. inch-lbs COUPLING RING WASHER WASHER
Inch inch inch SCREW
1 00 3872278 0.72 1.21 20-24 3872279 3872280. 3872281 3872282 3872283 70704 S-600 3235449
1.25 3872252 1.16 1.40 24-36 3872253 3873254 3872255 3872256 3872283 70704 S-600 3235449
1.50 3872284 1.18 1.45 24-36 3872285 3872286 3872287 3872288 3872257 S-626 S-605 S-221
2.25 3872258 1.17 1.83 45-50 3872259 3872260 3872261 3872262 3672257 S-626 S-605 S-221
2.50 3872294 1.17 1.83 45-50 3872295 3872296 3872297 3872298 3872257 S-626 S-605 S-221
3.00 3872268 1.67 2.30 180-200 3872269 3872270 3872271 3872272 3872273 S-602 S-604 S-223
3.50 3872299 1.67 2.48 180-200 3872300 3872301 3872302 3872303 3872253 S-602 S-604 S-223
5.00 3872304 1.75 2.07 180-200 3872305 3872306 3872307 3872308 3872253 S-602 S-604 S-223
* Torque to Inch-Lbs. As shown in the Table or to a minimum of 1/16” clearance between Clamp lugs, (Refer Figure 3) whichever occurs first.
HOW TO ORDER
To obtain complete assembly of pipe coupling, order should be placed on Assembly Part No. given in Table 2.
Generally with proper installation/maintenance, the only replacement components that may be needed is, the Rubber ring which may be ordered on the
respective Rubber ring part ‘number given in Table above.
Page 4-36
5 lt.
10 lt.
20 lt.
205 lt.
0.5 lt.
1 lt.
2 lt.
5 lt.
10 lt.
Qty.
Qty.


PREMIXED COOLANT
Description
Premixed Coolant
Premixed Coolant
Premixed Coolant
Premixed Coolant
Description
Section – 4
3167221
3167222
3167223
3167224
3167214
3167215
3167216
3167217
3167218
Number
Number
Part
Part
Page 4-35
Length
10 .00
12 .00
14 .00
20 .00
24 .00
26 .00
32 .00
36 .00
58 .00
14.25
12.00
17.00
11.00
16.00
18.00
22.00
30.00
40.00
50.00
52.00
5 .00
8 .00
2.00
3.00
2.50
3.00
4.00
2.00
2.50
3.00
3.12
3.50
2.88
3.00
2.25
3.50
3.75
4.00
2.50
3.00
4.00
5.00
5.50
6.50
6.00
7.00
8.00
2.62
3.00
4.00
7.00
4.50
2.75
3.50
4.25
3.50
5.00
4.00
1 . 00
1 . 00
1 . 00
1 . 25
1 . 25
1 . 25
1 . 50
1 . 50
1 . 50
1 . 50
1 . 50
1 . 75
1 . 75
2 . 00
2 . 00
2 . 00
2 . 00
2 . 00
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
0.38
0.38
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
2.25
2.38
2.50
2.50
2.50
2.75
3.00
3.00
3.00
3.50
3.50
5.00
ID
179912 H
179917 N
143996 H
144021 C
144000 B
144032 A
144052 K
136840 E
144008 F
63495 B
3024128
3200316
3026395
63241 M
64998 G
Part No.
67369 C
64998 H
64998 D
63241 H
63241 N
67185 H
67369 A
64998 E
63411 A
63495 A
70458 A
67185 B
67185 A
63241 F
67185 F
64998 J
Section – 4
102234
104296
107063
149274
143992
144034
144038
144044
144047
200517
215950
107195
102522
110980
9539 A
64030
67369
63223
64978
60985
66167
61814
61554
63495
61961
67185
9539
3872278 25.40 (1.00 INCH) 47.0 79.5 64.00
3872252 31.75 (1.25 INCH) 55.0 97.0 70.75
3872284 38.10 (1.50 INCH) 60.0 104.0 75.90
3872258 57.15 (2.25 INCH) 86.0 128.0 103.60
3872294 63.50 (2.50 INCH) 91.3 130.0 104.00
3872268 76.20 (3.00 INCH) 123.1 174.5 125.00
3872299 88.90 (3.50 INCH) 138.1 189.0 170.00
3872304 127.00 (5.00 INCH) 170.0 225.0 103.00
1 00 3872278 0.72 1.21 20-24 3872279 3872280. 3872281 3872282 3872283 70704 S-600 3235449
1.25 3872252 1.16 1.40 24-36 3872253 3873254 3872255 3872256 3872283 70704 S-600 3235449
1.50 3872284 1.18 1.45 24-36 3872285 3872286 3872287 3872288 3872257 S-626 S-605 S-221
2.25 3872258 1.17 1.83 45-50 3872259 3872260 3872261 3872262 3672257 S-626 S-605 S-221
2.50 3872294 1.17 1.83 45-50 3872295 3872296 3872297 3872298 3872257 S-626 S-605 S-221
3.00 3872268 1.67 2.30 180-200 3872269 3872270 3872271 3872272 3872273 S-602 S-604 S-223
3.50 3872299 1.67 2.48 180-200 3872300 3872301 3872302 3872303 3872253 S-602 S-604 S-223
5.00 3872304 1.75 2.07 180-200 3872305 3872306 3872307 3872308 3872253 S-602 S-604 S-223
HOW TO ORDER
Page 4-36
5 lt.
10 lt.
20 lt.
205 lt.
0.5 lt.
1 lt.
2 lt.
5 lt.
10 lt.
Qty.
Qty.


PREMIXED COOLANT
Description
Premixed Coolant
Premixed Coolant
Premixed Coolant
Premixed Coolant
Description
Section – 4
3167221
3167222
3167223
3167224
3167214
3167215
3167216
3167217
3167218
Number
Number
Part
Part
Page 4-35
Length
10 .00
12 .00
14 .00
20 .00
24 .00
26 .00
32 .00
36 .00
58 .00
14.25
12.00
17.00
11.00
16.00
18.00
22.00
30.00
40.00
50.00
52.00
5 .00
8 .00
2.00
3.00
2.50
3.00
4.00
2.00
2.50
3.00
3.12
3.50
2.88
3.00
2.25
3.50
3.75
4.00
2.50
3.00
4.00
5.00
5.50
6.50
6.00
7.00
8.00
2.62
3.00
4.00
7.00
4.50
2.75
3.50
4.25
3.50
5.00
4.00
1 . 00
1 . 00
1 . 00
1 . 25
1 . 25
1 . 25
1 . 50
1 . 50
1 . 50
1 . 50
1 . 50
1 . 75
1 . 75
2 . 00
2 . 00
2 . 00
2 . 00
2 . 00
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
2 . 25
0.38
0.38
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
0.62
2.25
2.38
2.50
2.50
2.50
2.75
3.00
3.00
3.00
3.50
3.50
5.00
ID
179912 H
179917 N
143996 H
144021 C
144000 B
144032 A
144052 K
136840 E
144008 F
63495 B
3024128
3200316
3026395
63241 M
64998 G
Part No.
67369 C
64998 H
64998 D
63241 H
63241 N
67185 H
67369 A
64998 E
63411 A
63495 A
70458 A
67185 B
67185 A
63241 F
67185 F
64998 J
Section – 4
102234
104296
107063
149274
143992
144034
144038
144044
144047
200517
215950
107195
102522
110980
9539 A
64030
67369
63223
64978
60985
66167
61814
61554
63495
61961
67185
9539
3872278 25.40 (1.00 INCH) 47.0 79.5 64.00
3872252 31.75 (1.25 INCH) 55.0 97.0 70.75
3872284 38.10 (1.50 INCH) 60.0 104.0 75.90
3872258 57.15 (2.25 INCH) 86.0 128.0 103.60
3872294 63.50 (2.50 INCH) 91.3 130.0 104.00
3872268 76.20 (3.00 INCH) 123.1 174.5 125.00
3872299 88.90 (3.50 INCH) 138.1 189.0 170.00
3872304 127.00 (5.00 INCH) 170.0 225.0 103.00
1 00 3872278 0.72 1.21 20-24 3872279 3872280. 3872281 3872282 3872283 70704 S-600 3235449
1.25 3872252 1.16 1.40 24-36 3872253 3873254 3872255 3872256 3872283 70704 S-600 3235449
1.50 3872284 1.18 1.45 24-36 3872285 3872286 3872287 3872288 3872257 S-626 S-605 S-221
2.25 3872258 1.17 1.83 45-50 3872259 3872260 3872261 3872262 3672257 S-626 S-605 S-221
2.50 3872294 1.17 1.83 45-50 3872295 3872296 3872297 3872298 3872257 S-626 S-605 S-221
3.00 3872268 1.67 2.30 180-200 3872269 3872270 3872271 3872272 3872273 S-602 S-604 S-223
3.50 3872299 1.67 2.48 180-200 3872300 3872301 3872302 3872303 3872253 S-602 S-604 S-223
5.00 3872304 1.75 2.07 180-200 3872305 3872306 3872307 3872308 3872253 S-602 S-604 S-223
HOW TO ORDER
33-11-C
PC-220
UH-181
H-55
300-CK
HM101/93M
H 40/36
TATA 955
TATA 1055
PC-300
PC-650
D-355
D-155
LW-50
LW-35
HD-785
D-80
D-120
R-25
R-35
LW-35
APPLICATION
Section – 4
LIST OF REPLACEMENT PARTS - ECPG PART NUMBER INFORMATION
ECP Engine Model

Sr. Part name Part
No. Number For engines with 142 teeth on 3414797 KV, KTA 50, 1710, 1150
flywheel ring gear
1 ECP-G Assembly 4083935 For engines with 118 teeth on 4053453 495, 743, 855,
2 Enclosure, Front 4084218 flywheel ring gear
REF. S.B.M
G 451107A
D 2811606
D 6011430
D 621108B
G 5061146
G 1062410
G 6011580
G 4111290
G 421116A
G 411125C
G 9111070
D 451103C
G 4511110
G 1011890
G 501163B/C
G 5011 78A
G 6411320
G 6411350
G 501153A
G 506136A
G 8311100
3 Enclosure, Rear 4084219
4 Seal, ring 4083975 ECP Engine Wiring Harness
5 I/O board 4084217 1MW 4054729
6 CPU board 4084216 KV16 4054727
7 FRC cable, 26 pin 4084223 KV12 4053890
8 FRC cable, 14 pin 4084222 V28 4053889
9 Datalink cable 4084227 K6 4053888
10 Gasket for Connector “A” (19 pin connector) 4084283 N4.8G 4053456
11 Gasket for Connector “B” (10 pin connector) 4084242 855 4052728
FAN BELT
191491
-
3058383
178611
178597
178597
3058383
-
S-2362
S-2362
-
191491
S-2362
3040384
178668
-
178611
-
-
-
VARIOUS BELT P.N. FOR APPLICATIONS

12 Gasket for Connector “C” (7 pin connector) 4084282 743 4053886
13 Gasket for datalink connector 4084224 495 4053887
14 Heat sink 4084285 OEM Connector 4054744
15 Key switch 504975 Coolant Water Temperature 3865346
Sensor
16 Parameter selection push button 4071721
Connector Water Temperature 3823256
17 Toggle switch (for Idle/Rated mode selection) 500278 Sensor
18 Vibration Isolator 3229922 Lub Oil Pressure Sensor 3392445
19 Mounting bracket 4084240 Magnetic Pick Up 3875360
Sensors Intake Manifold Temp. 3865345
-
4
-
2
2
2
3
3
4
2
-
2
2
QTY
2
-
1 Coolant temperature sensor 3865346 Sensor (AUX)
Low Coolant Water Level 3331472
2 Air Intake temperature sensor 3865345
(LCWL) Switch
3 Lube oil pressure sensor 3408496 Low Lub Oil Pressure Switch 3056344
200328
-
200328
200328
-
200328
-
200328
-
-
3040384
-
-
-
200328
200328
WTR.PUMP
200328
-
4 Coolant level sensor 3331472 Adapter for Coolant Water 4053490
5 Adapter for Coolant temperature sensor 4053490 Temp. Sensor
6 Adapter for Air intake temperature sensor 4053490 Adapter for Intake Manifold 4053490
Temp. Sensor
7 Magnetic pick up 3875360
Harness Wiring for (LCWL) Switch 3331473
Actuator and Actuator housing
QTY
1 Fuel Actuator 3330601
1
-
-
1
-
1
-
-
2
-
-
-
1
1
1
-
2 Fuel actuator housing 4071944
3 Fuel tube 4084238
178567
178456
3040349
ALTR.P.NO
178456
178509
178570
3040448
178567
178567
178509
178587
178567
178456
178567
3040448
-
3040349
3040349
178567
-
4 ECPG 0 & M Manual 3243803-00
Harness
Engine harness
1 K6 engine 4084232
2 Extension harness 10 meters 4072993
Page 4-39
QTY
4 OEM harness 4054744
1
1
1
1
1
2
1
1
1
1
1
-
1
1
1
-
5 Coolant level sensor extension harness 3331473
33-11-C
PC-220
UH-181
H-55
300-CK
HM101/93M
H 40/36
TATA 955
TATA 1055
PC-300
PC-650
D-355
D-155
LW-50
LW-35
HD-785
D-80
D-120
R-25
R-35
LW-35
APPLICATION
Section – 4
LIST OF REPLACEMENT PARTS - ECPG PART NUMBER INFORMATION
ECP Engine Model

Sr. Part name Part
No. Number For engines with 142 teeth on 3414797 KV, KTA 50, 1710, 1150
flywheel ring gear
REF. S.B.M
G 451107A
D 2811606
D 6011430
D 621108B
G 5061146
G 1062410
G 6011580
G 4111290
G 421116A
G 411125C
G 9111070
D 451103C
G 4511110
G 1011890
G 501163B/C
G 5011 78A
G 6411320
G 6411350
G 501153A
G 506136A
G 8311100
5 I/O board 4084217 1MW 4054729
6 CPU board 4084216 KV16 4054727
7 FRC cable, 26 pin 4084223 KV12 4053890
8 FRC cable, 14 pin 4084222 V28 4053889
11 Gasket for Connector “B” (10 pin connector) 4084242 855 4052728
FAN BELT
191491
-
3058383
178611
178597
178597
3058383
-
S-2362
S-2362
-
191491
S-2362
3040384
178668
-
178611
-
-
-

13 Gasket for datalink connector 4084224 495 4053887
14 Heat sink 4084285 OEM Connector 4054744
Sensor
-
4
-
2
2
2
3
3
4
2
-
2
2
QTY
2
-
(LCWL) Switch
200328
-
200328
200328
-
200328
-
200328
-
-
3040384
-
-
-
200328
200328
WTR.PUMP
200328
-
Temp. Sensor
QTY
1
-
-
1
-
1
-
-
2
-
-
-
1
1
1
-
3 Fuel tube 4084238
178567
178456
3040349
ALTR.P.NO
178456
178509
178570
3040448
178567
178567
178509
178587
178567
178456
178567
3040448
-
3040349
3040349
178567
-
4 ECPG 0 & M Manual 3243803-00
Harness
Engine harness
1 K6 engine 4084232
Page 4-39
QTY
1
1
1
1
1
2
1
1
1
1
1
-
1
1
1
-
H-55
D-80
R-25
R-35
PART NUMBER INFORMATION
D-355
D-155
D-120
LIST OF REPLACEMENT PARTS - ECPG
LW-50
LW-35
LW-35
300-CK
PC-220
PC-300
PC-650
UH-181
HD-785
H 40/36
33-11-C
TATA 955
TATA 1055
ECP Engine Model
Section – 4
HM101/93M
Sr. Part name Part
For engines with 142 teeth on 3414797 KV, KTA 50, 1710, 1150
APPLICATION
No. Number
flywheel ring gear
1MW 4054729
D 2811606
D 6011430
G 5061146
G 1062410
G 6011580
G 4111290
G 9111070
G 4511110
G 1011890
G 6411320
G 6411350
G 8311100
D 621108B
G 451107A
G 421116A
G 506136A
G 501153A
D 451103C
5 I/O board 4084217 G 411125C

G 5011 78A
REF. S.B.M
G 501163B/C
6 CPU board 4084216 KV16 4054727

7 FRC cable, 26 pin 4084223 KV12 4053890
8 FRC cable, 14 pin 4084222 V28 4053889
855 4052728
-
-
-
-
-
-
-
11 Gasket for Connector “B” (10 pin connector) 4084242
495 4053887
S-2362
S-2362
S-2362
191491
178611
178597
178597
191491
178668
178611
13 Gasket for datalink connector 4084224

3058383
3058383
3040384
OEM Connector 4054744

FAN BELT
14 Heat sink 4084285

Sensor
-
-
-
-
-
-
4
2
2
2
2
2
3
3
4
2
2
2

QTY

(LCWL) Switch
-
-
-
-
-
-
-
-
-
-
-

200328
200328
200328
200328
200328
200328
200328
200328

3040384
WTR.PUMP
Temp. Sensor
-
-
-
-
-
-
-
-
-
-
-
-
1
1
1
1
1
2
1
1

QTY

-
-
3 Fuel tube 4084238

4 ECPG 0 & M Manual 3243803-00
178567
178456
178456
178509
178570
178567
178567
178509
178587
178567
178456
178567
178567
Harness
3040349
3040448
3040448
3040349
3040349
Engine harness
ALTR.P.NO
1 K6 engine 4084232
-
-

1
1
1
1
2
1
1
1
1
2
1
1
1
1
1
1
1
1
QTY

Page 4-39
H-55
D-50
D-50
D-120
LW-50
LW-35
LW-25
CLAMP ‘T’ BOLT
G-30-D
PC-650
PC-220
H 40/36
33-11-D
CUMMINS BRANDED AV MOUNTS
FOR AIR HUMP HOSE
Tata 1055
Section – 4
D 82/40/30 B
APPLICATION
PRT.NO Inner Dia. In How to fix this problem ?
Inches You have an advantage with Cummins GERB spring-mount that it
125739 4 does not need fixing with bolts.
125740 4.5 Lift the machine locally and use shims under the mounts to level the
125741 6 machine, else slide the mounts to an area that is compressed more.
D 2811060
D 4111120
G 4111290
G 3011840
G 9111070
G 3011840
G 1062410
G 8311100
D 601116 J
G 501153 A
G 601160 B
REF. S.B.M
D 651103 H
G 64011350
Measure the height once again and carry on the process till you are
G 501163B/C
125742 7.5
** Poly ‘V’ Belt

( Imported Only)
Wrapped ‘V’ Belt
131891 3.75 satisfied.
135144 3.5 Take care that the gap between two mounts does not exceed over
(Indigenously Available)
135621 3.125 1250mm, preferably 1000mm as the frame in such cases are
136752 5 normally weak and more flexible.
-
-
-
-
-
There is minimal chance that spring – mount heights are different,
140311 4.125
because of varied property of the mounts. Cummins GERB mounts
17836
140312 4.625
178579
502325
178611
178579
178553
3911587
3229931
3236740
are designed in a manner that will not break or loose its property
140313 6.125
FAN BELT
unless it is working in an overloaded condition or is mishandled.
140314 7.625
(Imported in Use)
140315 3.875
140331 3.675
140332 3.125
*** Indigenous Not Available

140333 5.125
-
-
-
-
-
2
3
1
2
2
1
2
3
3
149437 5.5
QTY
152026 6.5
-
-
-
-
-
-
-
-
-
-
100835 8.5
172295 3.5
200328
200328
178496
200328
204557 6.625
VARIOUS BELT P.N. FOR APPLICATIONS - CONTD…..
WTR.PUMP
-
-
-
-
-
-
-
-
-
-
1
1
1
1
QTY
-
-
-
-
-
-
-
178685
178567
178685
3040349
3040349
3040349
3040349
ALTR.P.NO
-
-
-
-
-
-
-
1
1
1
1
1
1
1
QTY
Page 4-40
Tata 1055
H-55
H 40/36
PC-650
D-120
PC-220
D-50
LW-50
LW-35
D-50
D 82/40/30 B
G-30-D
LW-25
33-11-D
APPLICATION
Section – 4
CLAMP ‘T’ BOLT
FOR AIR HUMP HOSE

125739 4
G 501153 A
G 4111290
G 501163B/C
D 2811060
( Imported Only)
G 3011840
G 9111070
G 64011350
G 3011840
G 601160 B
D 651103 H
D 4111120
G 1062410
G 8311100
REF. S.B.M
D 601116 J
does not need fixing with bolts.
125742 7.5 Measure the height once again and carry on the process till you are

178579
17836
(Imported in Use)
3911587
502325
3229931
3236740
178611
-
-
FAN BELT
-
178579
178553
-
140311 4.125
140312 4.625
140313 6.125
140314 7.625
140315 3.875
140331 3.675
140332 3.125
140333 5.125
2
2
2
1
2
-
-
-
QTY
-
149437 5.5
152026 6.5
100835 8.5
-
-
-
-
200328
200328
-
178496
WTR.PUMP
200328
172295 3.5
204557 6.625
-
-
-
-
1
1
-
QTY
1
1
178685
-
-
-
3040349
3040349
3040349
178567
ALTR.P.NO
-
178685
3040349
Page 4-40
1
-
-
-
1
1
1
QTY
-
1
Tata 1055
H-55
H 40/36
PC-650
D-120
PC-220
D-50
LW-50
LW-35
D-50
D 82/40/30 B
G-30-D
LW-25
33-11-D
APPLICATION
Section – 4
CLAMP ‘T’ BOLT
FOR AIR HUMP HOSE

125739 4
G 501153 A
G 4111290
G 501163B/C
D 2811060
( Imported Only)
G 3011840
G 9111070
G 64011350
G 3011840
G 601160 B
D 651103 H
D 4111120
G 1062410
G 8311100
REF. S.B.M
D 601116 J
does not need fixing with bolts.
125742 7.5 Measure the height once again and carry on the process till you are

178579
17836
(Imported in Use)
3911587
502325
3229931
3236740
178611
-
-
FAN BELT
-
178579
178553
-
140311 4.125
140312 4.625
140313 6.125
140314 7.625
140315 3.875
140331 3.675
140332 3.125
140333 5.125
2
2
2
1
2
-
-
-
QTY
-
149437 5.5
152026 6.5
100835 8.5
-
-
-
-
200328
200328
-
178496
WTR.PUMP
200328
172295 3.5
204557 6.625
-
-
-
-
1
1
-
QTY
1
1
178685
-
-
-
3040349
3040349
3040349
178567
ALTR.P.NO
-
178685
3040349
Page 4-40
1
-
-
-
1
1
1
QTY
-
1
Section – 4
CUMMINS BRANDED AV MOUNTS (ISOLATOR VIBRATION)
Sr. No.
a) Selection - kva rating wise for Cummins Engines
17
16
15
14
13
12
11
10
DO’S & DONT’S
9
8
7
6
5
4
3
2
1
Engine kva Type Qty.per Part Nos.
Do’s Model of AVM Engine Old New
For a good isolation efficiency insist on approx. 10mm deflection. S3.8G2 30 KS-48 4 3238478 AX1001324
S3.8G3 35 KS-48 4 3238478 AX1001324
For roof top installation, deflection should be 11-13mm.
NTA855G2BC
NTA855G2
NTA855G
NTA855G1
NTA743G
N8-G2
N8-G1
NTA495G
NTC495G
NT495G
6BT/A5.9G1
S3.8G7
S3.8G6
S3.8G5
S3.8G4
S3.8G3
S3.8G2
S3.8G4 40 KS-48 4 3238478 AX1001324
No need to boil Cummins GERB Springmounts.
Eng.Models
S3.8G5 45 kS-48 4 3238478 AX1001324
No particular direction of installation – any way you wish. S3.8G6 50 KS-48 6 3238478 AX1001324
S3.8G7 62.5 KS-48 6 3238478 AX1001324
6BT5.9G1 75-82.5 KS-81 6 3238479 AX1001325
Dont’s
NT495G 100 KS-81 6 3238479 AX1001325
Do not install more number of mounts for more isolation. 6BTA5.9G1 120 KS-81 6 3238479 AX1001325
Optimise engine weight w.r.t. loading capacity of each mount. NTC495G 125 KS-81 6 3238479 AX1001325
Genset is bound to move over any flexible support system as it NTA495G 140 KS-81 6 3238479 AX1001325
N8-G1 160 KS-81 8 3238479 AX1001325
crosses resonance – technically it is not a problem as the entire
N8-G2 180 KS-81 8 3238479 AX1001325
machine moves as one body & there is no relative movement.
75-82.5
NTA743G 200 KS-81 8 3238479 AX1001325
kva
CUMMINS BRANDED BATTERIES PART NOS, MODELWISE

Never use double isolation, i.e one under the DG set and one under NTA855G1 225 KS-82 8 3238480 AX1001326
62.5
320
285
250
225
200
180
160
140
125
100
50
45
40
35
30
the girder. NTA855G 250 KS-82 8 3238480 AX1001326
NTA855G2 285 KS-82 8 3238480 AX1001326
NTA855G2BC 320 KS-82 8 3238480 AX1001326
INSTALLATION OF DG OVER N14G1 320 KS-82 8 3238480 AX1001326
GERB springmounts type KS KTA1150G 380 KS-82 8 3238480 AX1001326
The mounts are supplied with adhesive pads placed on top and KTA19G3 450 KS-84 10 3238481 AX1001327
Battery Rating
KTA19G4 500 KS-84 10 3238481 AX1001327
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-150-NL
24v-150-NL
24v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
(Volts-AH)
bottom.
VTA28G3 600 KS-84 10 3238481 AX1001327
These pads are not sticky initially and start working once loaded. VTA28G5 625 KS-fs 1300 10 3238482 AX1001328
Clean the contact surfaces before placing the spring – mounts. KTA2300G 750 KS-fs 1300 12 3238482 AX1001328
Position the mounts according to the layout calculated COG of KTA38G5 1000 KS-fs 1300 12 3238482 AX1001328
machine (for retrofit / field replacement, replacement is one to one on KTA50G3 1250 KS-fs 1300 14 3238482 AX1001328
KTA50G8 1425-1500 KS-fs 1300 16 3238482 AX1001328
existing mounting location). QSK45G4 1450 KS-fs 1300 16 3238482 AX1001328
Place the equipment evenly on springmounts. QSK45G6 1550 KS-fs 1300 16 3238482 AX1001328
Though not essential, optionally bolt the base frame to the spring QSK60G3 1875 KS-fs 1300 20 3238482 AX1001328
mounts. QSK60G4 2000 KS-fs 1300 20 3238482 AX1001328
Using mounting bolts is optional and are provided in the package.
Supplier Model
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
b) Selection - As per weight in tons for non-Cummins engines
Approx. Weight Speed AVM QTY. per Part Nos.
In case the DG is to be unloaded first and springmounts to be (in tons) Model Engine Old New
fixed later 0.7 – 1.10 1500 KS-48 4 3238478 AX1001324
Up to 1.60 1500 KS-48 6 3238478 AX1001324
Unload the DG on wooden blocks that are 120mm high. Make sure
Up to 2.10 1500 KS-81 6 3238479 AX1001325
the wooden blocks are not kept at the proposed location of the Up to 3.00 1500 KS-82 6 3238480 AX1001326
springmounts. Up to 4.00 1500 KS-84 8 3238481 AX1001327
Insert the mounts at specified locations. Up to 5.50 1500 KS-84 8 3238481 AX1001327
If possible lift the DG with a crane or 4 – 6 jacks. Remove the wooden Up to 7.00 1500 KSfs-1300 8 3238482 AX1001328
Up to 8.25 1500 KSfs-1300 10 3238482 AX1001328
Cummins Part No.

packings. Synchronise all the jacks in a way that all mounts get Up to 10.40 1500 KSfs-1300 12 3238482 AX1001328
loaded simultaneously.
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002394
AX1002394
AX1002394
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
Up to 12.50 1500 KSfs-1300 14 3238482 AX1001328
Up to 14.00 1500 KSfs-1300 16 3238482 AX1001328
Post Installation Checks Up to 16.00 1500 KSfs-1300 18 3238482 AX1001328
Up to 17.50 1500 KSfs-1300 20 3238482 AX1001328
Check all the mount heights including the top and bottom adhesive
Technical Details
pads. The installed final height of any spring – mount should not be
Maximum Dimension Height (mm) Weight
less than shown in the following table. Practically the height difference Model
Load* F(Kg) A=B (mm) Original ** Minimum (Kg)
of +/-2 mm should be acceptable which will be compensated by the KS-48 322 110 73 60 2.0
spring flexibility while in operation. KS-81 540 120 114 92 3.0
Qty per
Page 4-45
Eng.
In case there is a variation in mount heights – it should be in uniform KS-82 600 120 113 94 3.1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
KS-84 815 120 113 97 3.2
manner from one end to another. However if the mount height is KSfs 1300 999 120 97 86 3.3
found to be zig-zag, the most probable reason is major foundation * Normal loading 80% of maximum load.
unevenness or base frame bending. ** Supply height is lower than original height
Section – 4
Sr. No.
17
16
15
14
13
12
11
10
DO’S & DONT’S
9
8
7
6
5
4
3
2
1
Engine kva Type Qty.per Part Nos.
S3.8G3 35 KS-48 4 3238478 AX1001324
For roof top installation, deflection should be 11-13mm.
NTA855G2BC
NTA855G2
NTA855G
NTA855G1
NTA743G
N8-G2
N8-G1
NTA495G
NTC495G
NT495G
6BT/A5.9G1
S3.8G7
S3.8G6
S3.8G5
S3.8G4
S3.8G3
S3.8G2
S3.8G4 40 KS-48 4 3238478 AX1001324
No need to boil Cummins GERB Springmounts.
Eng.Models
S3.8G5 45 kS-48 4 3238478 AX1001324
S3.8G7 62.5 KS-48 6 3238478 AX1001324
6BT5.9G1 75-82.5 KS-81 6 3238479 AX1001325
Dont’s
NT495G 100 KS-81 6 3238479 AX1001325
N8-G1 160 KS-81 8 3238479 AX1001325
N8-G2 180 KS-81 8 3238479 AX1001325
machine moves as one body & there is no relative movement.
75-82.5
NTA743G 200 KS-81 8 3238479 AX1001325
kva

62.5
320
285
250
225
200
180
160
140
125
100
50
45
40
35
30
NTA855G2 285 KS-82 8 3238480 AX1001326
NTA855G2BC 320 KS-82 8 3238480 AX1001326
Battery Rating
KTA19G4 500 KS-84 10 3238481 AX1001327
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-150-NL
24v-150-NL
24v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
(Volts-AH)
bottom.
VTA28G3 600 KS-84 10 3238481 AX1001327
Position the mounts according to the layout calculated COG of KTA38G5 1000 KS-fs 1300 12 3238482 AX1001328
KTA50G8 1425-1500 KS-fs 1300 16 3238482 AX1001328
Supplier Model
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
fixed later 0.7 – 1.10 1500 KS-48 4 3238478 AX1001324
Up to 1.60 1500 KS-48 6 3238478 AX1001324
Up to 2.10 1500 KS-81 6 3238479 AX1001325
Up to 8.25 1500 KSfs-1300 10 3238482 AX1001328
Cummins Part No.

loaded simultaneously.
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002394
AX1002394
AX1002394
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
Up to 12.50 1500 KSfs-1300 14 3238482 AX1001328
Up to 14.00 1500 KSfs-1300 16 3238482 AX1001328
Up to 17.50 1500 KSfs-1300 20 3238482 AX1001328
Technical Details
Qty per
Page 4-45
Eng.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
KS-84 815 120 113 97 3.2
manner from one end to another. However if the mount height is KSfs 1300 999 120 97 86 3.3
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
DO’S & DONT’S Engine kva Type Qty.per Part Nos.
Sr. No.
Section – 4
S3.8G3 35 KS-48 4 3238478 AX1001324
For roof top installation, deflection should be 11-13mm. S3.8G4 40 KS-48 4 3238478 AX1001324
No need to boil Cummins GERB Springmounts. S3.8G5 45 kS-48 4 3238478 AX1001324
N8-G2
N8-G1
S3.8G7
S3.8G6
S3.8G5
S3.8G4
S3.8G3
S3.8G2
NT495G
S3.8G7 62.5 KS-48 6 3238478 AX1001324
NTA855G
NTA743G
NTA495G
NTC495G
NTA855G2
NTA855G1
6BT5.9G1 75-82.5 KS-81 6 3238479 AX1001325
6BT/A5.9G1
Dont’s
NT495G 100 KS-81 6 3238479 AX1001325
NTA855G2BC
Eng.Models
N8-G1 160 KS-81 8 3238479 AX1001325
N8-G2 180 KS-81 8 3238479 AX1001325
machine moves as one body & there is no relative movement. NTA743G 200 KS-81 8 3238479 AX1001325
kva
320
285
250
225
200
180
160
140
125
100
50
45
40
35
30
75-82.5
62.5
NTA855G2 285 KS-82 8 3238480 AX1001326

NTA855G2BC 320 KS-82 8 3238480 AX1001326
bottom. KTA19G4 500 KS-84 10 3238481 AX1001327
VTA28G3 600 KS-84 10 3238481 AX1001327
KTA38G5 1000 KS-fs 1300 12 3238482 AX1001328
(Volts-AH)
Position the mounts according to the layout calculated COG of

24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-150-NL
24v-150-NL
24v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
12v-150-NL
Battery Rating
KTA50G8 1425-1500 KS-fs 1300 16 3238482 AX1001328
fixed later 0.7 – 1.10 1500 KS-48 4 3238478 AX1001324
Up to 1.60 1500 KS-48 6 3238478 AX1001324
Up to 2.10 1500 KS-81 6 3238479 AX1001325
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-24
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
9GP1500N7-12
Supplier Model

Up to 8.25 1500 KSfs-1300 10 3238482 AX1001328
loaded simultaneously. Up to 12.50 1500 KSfs-1300 14 3238482 AX1001328
Up to 14.00 1500 KSfs-1300 16 3238482 AX1001328
Up to 17.50 1500 KSfs-1300 20 3238482 AX1001328
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002394
AX1002394
AX1002394
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
AX1002396
Technical Details
Cummins Part No.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
KS-84 815 120 113 97 3.2

Eng.
manner from one end to another. However if the mount height is

Qty per
KSfs 1300 999 120 97 86 3.3

Page 4-45
Section - 4 Page 4
PARTS INFORMATION
Contents Page
31
30
29
28
27
26
25
24
23
22
21
20
19
18
Sr. No.
Engine Gasket Sets / Repair Kits
Section – 4
Indigenous upper Engine Gasket Set ……………………………...4-1
Indigenous lower Engine Gasket Set ………………………………4-2
Imported upper Engine Gasket Set ...………………………………4-3
Imported Lower Engine Gasket Set ………………………………..4-4
N14G1
P.T. Pump Gasket Set ……………………………………………….4-5
KTA50G8
KTA50G3
KTA38G5
VTA28G5
VTA28G3
KTA19G4
KTA19G3
Q5K45G6
QSK60G4
QSK60G3
QSK45G4
KTA2300G
KTA1150G
Water Pumps Repair Kits…………………………………………….4-5
Eng.Models
Air Compressor Repair Kits ………………………………………….4-5
Turbocharger Repair Kits ……………………………………………4-7
Conversion Kits Parts Nos. of
Spin on type to Cummins conventional type filters ………………4-8
NHRS to NRTO ……………………………………………………….4-9
kva
Radiator to Heat Exchanger………………………………………..4-10
2000
1875
1550
1450
1250
1000
750
625
600
500
450
380
320
1425-1500
Heat Exchanger to Radiator ………………………………………4-10
Turbochargers ……………………………………………………….4-11
High Altitude Compensation Kits …………………………………..4-17
make & range of DG. Hence included in system.

Pipe Couplings……………………………………………………….4-17
ECP retrofit Kits……………………………………………………...4-18
Short Block Assembly of Various Models …………………………….4-19
# Where two starters are fitted, two batteries are required.

Note: # Battery of 24v-180-HL with Part No. AX1002395 is Hi-Life
Oversize Main Bearings ………………………………………………..4-20
Conrod Bearings …………………………………………………….4-21
(Volts-AH)
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
24v-180-NL
Battery Rating
Thrust Bearings ……………………………………………………4-22
Supersedence ………………………………………………………….4-22
Part No. Structure Old and New ………………………………………4-23
AR and B check Kit part Nos.
Break Up of filter Element & Seal Ring …………………………..4-24
B-check Kits Model Wise ………………………………………….4-25
Air System
Hose Elbows Dia wise Part Nos. …………………………………..4-26
Air Cleaner elements Part Nos. ……………………………………4-27
Air Cleaner Assemblies and Elements ……………………………4-29
Plain Air Hump Hoses ………………………………………………4-33
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
9GP1800N7-24
Supplier Model
Cooling System
Flex Master Coupling Part Nos. & Sizes ………………………….4-34
Cooling Water Plain Hoses Dia. & Length wise Part Nos.………4-35
CUMMINS BRANDED BATTERIES PART NOS, MODELWISE – CONTD…

CAC, Pre Mix Part Nos. …………………………………………….4-36
Miscellaneous
Replacement Parts ECPG………………………………………….4-37
Part Nos. Information ECP …………………………………………4-38
Part Nos. of Belts for Various Applications ……………………….4-39
Part No.
Cummins
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AX1002397
AXL 002397
Clamp T-Bolt Dia. Wise part Nos.………………………………….4-41
Cummins Branded A.V. Mounts
How to Fix ……………………………………………………………4-42
Do’s and Don’ts ……………………………………………………...4-43
Engine Model Wise Part Nos.……………………………………...4-44
Technical Details …………………………………………………….4-44
Eng.
# In addition to above, we have batteries of 12v-180-NL, Part No. AX 1002393 though not used on above range, may be required for other
2
2
2
2
2
2
2
2
1
1
1
1
1
1
Qty per
Cummins Branded Batteries
Part Nos. Model Wise ………………………………………………4-45
Page 4-46
Section - 5 Page 5 Section - 5 Page 5-1 Section-3 Page 5-2
GENERAL INFORMATION LUBRICATING OIL RECOMMENDATIONS Important Properties and their limits for fresh oil
Contents Page The lubricating oil used in Cummins Diesel engine should be
Properties Limits Testing Methods
multifunctional and capable of performing its functions for
Lubricating Oil & Recommendations …………………………………..5-1 Viscosity 12.5 to 16.4@ 100 dec. ASTM D-445
prescribed period.
Fuel Oil & Recommended Properties ………………………………….5-4 TBN 10.5 minimum ASTM D-2896
High Speed Diesel Requirements………………………………………5-5 ENGINE LUBRICATING OIL RECOMMENDATIONS – DIESEL Sulphated ash 1.85 mass % maximum ASTM D-874
FUEL
Engine Storage Procedures……………………………………………..5-6
Water Should be negligible ASTM D-95
content (2 to 3 crackles max.)
Conversion Factors & Practices ………………………………………5-8
• Cummins India Limited recommends the use of Valvoline
Fraction, Decimal, Millimeter Conversion…………………………….5-10 Power Supreme — SAE 15W 40 engine lubricating oil. OR * These Limits are for reference and exact applicable values can
be obtained from the respective oil manufacturer against
Capscrew Markings & Torque Values ……………………………….5-17
Customer can use any other SAE 15W 40 multigrade heavy-duty specific brands.
Drive Belt Tension …………………………………………………….5-21
engine lubricating oil meeting CF4 API categories. This oil should
Pipe Plug Torque Values ………………………………………………5-22 have a minimum TBN of 10.5 to counteract the higher Sulphur Oil Change Interval
content of high speed diesel available in India. The above Oil does not wear but gets contaminated and the additive package
Tap Drill Chart …………………………………………………………..5-23
specifications are available for normal ambient temperature gets depleted. After contamination, It can no longer perform its
conditions. In case of arctic conditions refer given below : functions satisfactorily. Hence, oil need to be changed BEFORE the
additive package gets depleted.
Cummins Recommended SAE Oil Viscosity Grades vs Ambient
Temperatures Cummins India Ltd. recommends oil to be changed at every
300 hrs of engine operation or six months whichever is earlier.
Note : N-495 & QSK-60 with big oil sump, oil change period is
500 hrs or 6 months whichever is earlier.
Properties of Lubricating Oil–Valvoline Power Supreme Extra

15W 40 / equivalent for engines running with LDO fuel.
Property Value
0 0 o
Note : For temperature consistently below - 25 C (-13 F) refer to Sp. Gravity@29 C 0.867
o
lub oil manufacturer for recommendations Kinematic Viscosity @ 40 C 116.8
o
Kinematic Viscosity @100 C 15.10
Viscosity Index 135
o
Flash point, COC, C 230
o
Pour point C max -30
Sulphated ash % by Wt. 2.52
TBN mg/KOH/g 20.38
o
CCS Viscosity, cP 6900@-10 C
prescribed period.
FUEL
Tap Drill Chart …………………………………………………………..5-23

Property Value
0 0 o
o
o
Viscosity Index 135
o
o
TBN mg/KOH/g 20.38
o
prescribed period.
FUEL
Tap Drill Chart …………………………………………………………..5-23

Property Value
0 0 o
o
o
Viscosity Index 135
o
o
TBN mg/KOH/g 20.38
o
No.
Sr.
Section - 5
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Oil Contamination Guidelines
RECOMMENDED FUEL OIL PROPERTIES
Property Guidelines
Fuel Oil
Water content, percent by volume, max.
Kinematic viscosity CS at 38 C (100.4 F)

Total sediments, mg. per 100 ml. max.
Total sulphur, percent by mass max.

Sediment, percent by mass max.
Flash point: (a) Abel, C min..

Distillation percent recovery at 366 C min.
Copper strip corrosion for 3 hours at 212 F (100 C)
Pour point, max.
Cetane Number, min.
Carbon residue (Ramsbottom) percent by mass, max.
Ash, percent by mass max.
Acidity, total mg. of KOH/g max.
Acidity, Inorganic
Characteristics
0
Viscosity change @ 100 C + 1 SAE Viscosity grade or Cummins Diesel Engines have been developed to take the advantage of
(ASTM D-445) 4 cSt from the new oil
high energy content and generally lower cost of No. 2 Diesel Fuels.
Fuel Dilution 5 Percent Experience has shown that a Cummins Diesel Engine will also operate
Total acid number (TAN) 2.5 number increase from the satisfactorily on No. 1 fuels or other fuels within the following
(ASTM D-664) new oil value, maximum specifications.
Total base number (TBN) 2.5 minimum or, one half original Property Recommended
0
(ASTM D-2896) (New Oil) value or equal to TAN
Specifications
Water content ASTM (D-95) 0.2 percent maximum Viscosity 1.3 to 5.8 centistokes
REQUIREMENTS FOR HIGH SPEED DIESEL FUEL AS PER IS 1460: 1974

0
(ASTM D445) (1.3 to 5.8 mm per second)
Potential Contaminants 0 0
at 104 F (40 C)
Silicon (Si)
0
15 ppm increase over new oil
0
0
Sodium (Na) 20 ppm increase over new oil Cetane Number 40 Minimum above 32 F
0
0
Boron (B) (ASTM D-613) 45 Minimum below 32 F
Potassium (K) 20 ppm increase over new oil
0
Sulphur Content Not to exceed 1.0 mass
Soot 1.5 percent mass of used oil (ASTM D-129 or 1552) percent.
maximum
Requirement
Active Sulphur Copper Strip Corrosion not
NOTE : The contamination guidelines presented above are (ASTM D130) to exceed No. 2 rating after
0.05
0.50
0.20
1.0
0.05
0.01
1.0
2.0 to 7.5
90
38
Not worse than No.1

6 C (42.8 F)
42
nil
guidelines only. This does not mean values that fall on the
0
0 0
three hours at 122 F (50 C)
acceptable side of these guidelines be interpreted as indicating the
oil is suitable for further service.
Water and Sediment Not to exceed 0.1 volume
0
* ASTM (The American Society for Testing and Materials) (ASTM D1796) percent.
publishes these methods in their Annual Book of
Standards, Part 23. Other methods should not be used Carbon Residue Not to exceed 0.35 mass
without consulting Cummins Diesel Sales & Service (l) Ltd. (Rams bottom, percent on 10 volume
ASTM D524 or percent residium.
** SAE Viscosity grades are published by the Society of Conradson,
Automotive ASTM D189)
Engineers in their annual SAE Handbook as SAE
Recommended 0 0
-
-
A
-
-
-
-
-
-
-
-
Density (ASTM D287) 42 to 30 API gravity at 60 F (0.816
Practice J300d, and are shown in Table 1 of this bulletin. 0
to 0.876 g/cc at 15 C).
Appendix (P : of IS 1448)
*** AES (Atomic Emission Spectroscope) and AAS (Atomic
Method of test Ref. to

0 0
Absorption Spectroscopy) are not standard ASTM Cloud Point 10 F (6 C) below lowest
methods, however most used oil analysis laboratories are (ASTM D97) ambient temperature at which the
capable of determining additive metal concentration by one fuel is expected to operate
of these methods and sample results determined by the
same laboratory using the same method can be safely Ash Not to exceed 0.02 mass
P : 40
P:2
P:8
-
P : 30
P : 25
P : 18
P : 15
P : 33 or P : 35
P : 20
P : 10
P:9
P:4
P:2
compared. (ASTM D482) percent (0.05 mass percent with
lubricating oil blending).
Procurement :
Oil should always be procured from the original manufacturer or the Distillation The distillation curve must
authorized distributors.
Page 5-5
(ASTM D86) be smooth and continuous.
Lubricating oil to be used on the engine must meet all qualities as per
manufacturers’ specifications. Cummins recommends audit checks of Acid Number Not to exceed 0.1 Mg KOH
fresh engine oil to ensure the quality of oil. (ASTM D664) per 100 ml.
No.
Sr.
Section - 5
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Property Guidelines
Fuel Oil



Pour point, max.
Cetane Number, min.
Acidity, Inorganic
Characteristics
0
Viscosity change @ 100 C + 1 SAE Viscosity grade or Cummins Diesel Engines have been developed to take the advantage of
Total base number (TBN) 2.5 minimum or, one half original Property Recommended
0
Specifications
Water content ASTM (D-95) 0.2 percent maximum Viscosity 1.3 to 5.8 centistokes

0
at 104 F (40 C)
Silicon (Si)
0
0
0
Sodium (Na) 20 ppm increase over new oil Cetane Number 40 Minimum above 32 F
0
0
Potassium (K) 20 ppm increase over new oil
0
Sulphur Content Not to exceed 1.0 mass
maximum
Requirement
0.05
0.50
0.20
1.0
0.05
0.01
1.0
2.0 to 7.5
90
38
Not worse than No.1

6 C (42.8 F)
42
nil
guidelines only. This does not mean values that fall on the
0
0 0
three hours at 122 F (50 C)
0
Recommended 0 0
-
-
A
-
-
-
-
-
-
-
-
to 0.876 g/cc at 15 C).

0 0
P : 40
P:2
P:8
-
P : 30
P : 25
P : 18
P : 15
P : 33 or P : 35
P : 20
P : 10
P:9
P:4
P:2
Procurement :
authorized distributors.
Page 5-5
(ASTM D86) be smooth and continuous.
manufacturers’ specifications. Cummins recommends audit checks of Acid Number Not to exceed 0.1 Mg KOH
14
13
12
11
10
9
8
7
6
5
4
3
2
1
Sr.
No.
Property Guidelines
0
Fuel Oil
Viscosity change @ 100 C + 1 SAE Viscosity grade or
Section - 5
Cummins Diesel Engines have been developed to take the advantage of

Characteristics
Pour point, max.

Acidity, Inorganic
Cetane Number, min.

Total base number (TBN) 2.5 minimum or, one half original
0
Property Recommended
Specifications
Water content ASTM (D-95) Viscosity 1.3 to 5.8 centistokes

0.2 percent maximum
0

at 104 F (40 C)
0

Silicon (Si) 15 ppm increase over new oil

0

Cetane Number 40 Minimum above 32 F
Sodium (Na) 20 ppm increase over new oil
0
0
0
Potassium (K) 20 ppm increase over new oil Sulphur Content Not to exceed 1.0 mass
maximum
0
nil
90
38
42
0 0
1.0
1.0
guidelines only. This does not mean values that fall on the three hours at 122 F (50 C)
0.05
0.50
0.20
0.05
0.01

Requirement
2.0 to 7.5
0

6 C (42.8 F)
Not worse than No.1
0 0
-
-
-
-
-
-
-
-
-
-
-
-
Recommended
A

to 0.876 g/cc at 15 C).
0 0
-

P:2
P:8
P:9
P:4
P:2

P : 40
P : 25
P : 15
P : 30
P : 18
P : 10
P : 20
Procurement :
authorized distributors. (ASTM D86) be smooth and continuous.
P : 33 or P : 35
Acid Number Not to exceed 0.1 Mg KOH
Page 5-5
manufacturers’ specifications. Cummins recommends audit checks of

Section 5
ENGINE STORAGE
Preparing a preserved (treated) engine for putting in service.
On any engine not in service, whether installed in equipment or
waiting to be installed, the unpainted machined surfaces are subject When an engine is removed from storage and put into service the
operation listed below process should be performed.
1/4
15/64
7/32
13/64
3/16
11/64
5/32
9/64
1/8
7/64
3/32
5/64
1/16
3/64
1/32
1/64
Fraction
to rust and corrosion. Often an engine is not prepared for storage
(Temporary/Long time storage) with all types of rust-proofing (i) Clean off all accumulated dirt from exterior of engine.
measures taken, however, every engine going out of the factory is
always processed with rust preventive oil for shipment purpose. (ii) Remove all protective caps, tape and wrappings from
connections such as Breathers, Fuel in and out, connection,
The rate of corrosion varies with climatic conditions. Variances in
Water in and out connections etc.
climatic conditions make it impossible to state the length of time an
engine can be stored without rust and corrosion damage. Following (iii) Use suitable solvent, cleaner or degreaser to remove rust
procedure covers the basic method of preparing the engine for preventive compound from unpainted external surfaces of the
0.2500
0.2344
0.2188
0.2031
0.1875
0.1719
0.1563
0.1406
0.1250
0.1094
0.0938
0.0781
0.0625
0.0469
0.0313
0.0156
Inch
Temporary/Long storage. engine.
Procedure (iv) Refill oil pan with fresh lubricating oil. Replace the fuel, lub oil
The engine system wise details of the process are described filters and lub oil bypass filters, only in case wherein engine is
below. stored beyond six months from the date of shipment.
Cooling System Passage :
(v) Check and correct the engine belt tensioning.
FRACTION, DECIMAL, MILLIMETER, CONVERSION

Sr. No. Description Remarks
(vi) In case of any doubts, contact CSS & S/ Dealer.
6.350
5.953
5.556
5.159
4.763
4.366
3.969
3.572
3.175
2.778
2.381
1.984
1.588
1.191
0.794
0.397
mm
a Prepare engine for Ensis, Fabricate and install a plate to
Long Storage Process close the water pump inlet
connection.
B. Inspection
b Fill the cooling system Leave the drain cocks open
with Ensis oil RUSTILO until all air is completely vented
DW901, (Castrol India out. Progressively close the 1. When an engine has been stored for six months or less, it is
make) up to thermostat cocks until the ensis oil flows necessary to make only a routine initial inspection. This
outlet connection, using from the thermostat housing. inspection includes adjustment of injectors, valves and belts
external priming pump and checking cylinder head capscrews, oil filter and
trolley. connections, air filter, screens and straps.
C Keep the Ensis oil in the Remove the fabricated plate at 2.

2
Pressurize the lubricating system about 1 kg/cm including the
engine for 5 minutes and water pump inlet and close the turbocharger or supercharger prior to starting the engine.
Fraction
3/4
47/64
23/32
45/64
11/16
43/64
21/32
41/64
5/8
39/64
19/32
37/64
9/16
35/64
17/32
33/64
then drain it completely, opening by plastic cap. (Collect
from engine. the drained oil in clean 3. Flush entire fuel system with clean fuel until all preservative oil
container for reuse.) is removed. This can be done by running the engine on NO
LOAD IDLE for five minutes with clean high speed diesel oil.
Lubricating Oil Passage :
4. When recommissioning a stored engine, care should be taken
Sr. No. Description Remarks to see that any foreign matter which may collect on screens and
strainers during initial operation is removed before considering
Inch
0.7500
0.7344
0.7188
0.7031
0.6875
0.6719
0.6563
0.6406
0.6250
0.6094
0.5938
0.5781
0.5625
0.5469
0.5313
0.5156
a Prepare engine for Lube Use lube oil priming pump for
oil priming. priming. the engine properly prepared for future service.
b Prime the engine with Use engine Lube oil trolley for Engine is ready to start for regular operations.
engine lube oil 15W40 priming. Circulate the Lube oil
(CF-4 category). till the lube pressure gauge
shows 1kg/cm sq. pressure. It
will take max. five min. to reach
this lube oil pressure. Bar the
mm
19.050
18.653
18.256
17.850
17.463
17.066
16.669
16.272
15.875
15.478
15.081
14.684
14.288
13.891
13.494
13.097
engine during the process
C Drain the Lube oil from
the oil pan.
Page 5-8
If the engines are going to be stored for more than 6 months, repeat
the engine preservative treatment as mentioned above after every six
months.
Section 5
ENGINE STORAGE
1/4
15/64
7/32
13/64
3/16
11/64
5/32
9/64
1/8
7/64
3/32
5/64
1/16
3/64
1/32
1/64
Fraction
0.2500
0.2344
0.2188
0.2031
0.1875
0.1719
0.1563
0.1406
0.1250
0.1094
0.0938
0.0781
0.0625
0.0469
0.0313
0.0156
Inch
(v) Check and correct the engine belt tensioning.

Sr. No. Description Remarks
(vi) In case of any doubts, contact CSS & S/ Dealer.
6.350
5.953
5.556
5.159
4.763
4.366
3.969
3.572
3.175
2.778
2.381
1.984
1.588
1.191
0.794
0.397
mm
a Prepare engine for Ensis, Fabricate and install a plate to
connection.
B. Inspection
C Keep the Ensis oil in the Remove the fabricated plate at 2.

2
Pressurize the lubricating system about 1 kg/cm including the
Fraction
3/4
47/64
23/32
45/64
11/16
43/64
21/32
41/64
5/8
39/64
19/32
37/64
9/16
35/64
17/32
33/64
strainers during initial operation is removed before considering
Inch
0.7500
0.7344
0.7188
0.7031
0.6875
0.6719
0.6563
0.6406
0.6250
0.6094
0.5938
0.5781
0.5625
0.5469
0.5313
0.5156
a Prepare engine for Lube Use lube oil priming pump for
oil priming. priming. the engine properly prepared for future service.
mm
19.050
18.653
18.256
17.850
17.463
17.066
16.669
16.272
15.875
15.478
15.081
14.684
14.288
13.891
13.494
13.097
the oil pan.
Page 5-8
months.
ENGINE STORAGE
Section 5
1/4
1/8
7/32
3/16
5/32
9/64
7/64
3/32
5/64
1/16
3/64
1/32
1/64
15/64
13/64
11/64
Fraction
Inch
0.2500
0.2344
0.2188
0.2031
0.1875
0.1719
0.1563
0.1406
0.1250
0.1094
0.0938
0.0781
0.0625
0.0469
0.0313
0.0156
Sr. No. Description Remarks (v) Check and correct the engine belt tensioning.
a Prepare engine for Ensis, Fabricate and install a plate to (vi) In case of any doubts, contact CSS & S/ Dealer.
mm
6.350
5.953
5.556
5.159
4.763
4.366
3.969
3.572
3.175
2.778
2.381
1.984
1.588
1.191
0.794
0.397
connection.
B. Inspection
2
C Keep the Ensis oil in the Remove the fabricated plate at 2. Pressurize the lubricating system about 1 kg/cm including the
3/4
5/8

9/16
47/64
23/32
45/64
11/16
43/64
21/32
41/64
39/64
19/32
37/64
35/64
17/32
33/64
Fraction
a Prepare engine for Lube Use lube oil priming pump for strainers during initial operation is removed before considering
the engine properly prepared for future service.
Inch
oil priming. priming.

0.7500
0.7344
0.7188
0.7031
0.6875
0.6719
0.6563
0.6406
0.6250
0.6094
0.5938
0.5781
0.5625
0.5469
0.5313
0.5156
mm
19.050
18.653
18.256
17.850
17.463
17.066
16.669
16.272
15.875
15.478
15.081
14.684
14.288
13.891
13.494
13.097

the oil pan.
Page 5-8
months.
From U. S. From Metric
U. S. Customary Metric Customary To U. S.
Quantity
To Metric Customary
Unit Name Abbr. Unit Name Abbr. Multiply By Multiply By
Length foot ft millimeters mm 304.801 0.00328
Power horsepower hp Kilowatt kW 0.746 1.341
Pressure pounds force per psi Kilopascal kPa 6.8948 0.145037

sq.inch
inches of mercury in Hg kilopascal kPa 3.3769 0.29613
inches of water in H2O Kilopascal kPa 0.2488 4.019299
inches of mercury in Hg millimeters of mercury mm Hg 25.40 0.039370
inches of water in H2O millimeters of water mm H20 25.40 0.039370
bars bars kilopascal kPa 100.001 0.00999
bars bars millimeters of mercury mm Hg 750.06 0.001333
0 0 0 0
Temperature fahrenheit F centigrade C ( F-32) / 1.8 (1.8 x C) + 32

WEIGHT AND MEASURES - CONVERSION FACTORS

Quantity Customary
To Metric
Multiply By
Unit Name Abbr. Unit Name Abbr. Multiply By
2 2
Area sq. inch in sq. millimeters mm 645.16 0.001550
sq. centimeters cm
2
6.452 0.155
2
sq. foot ft sq. meter m
2
0.0929 10.764
Fuel pounds per lb/hp-hr grams per kilowatt g/kW-hr 608.277 0.001645
Consumption horsepower hour hour
2.352
Fuel miles per gallon mpg kilometers per liter km/I 0.4251
Performance gallons per mile gpm I/km 2.352 0.4251

liters per kilometer
Force pounds force lbf Newton N 4.4482 0.224809
Length inch in millimeters mm 25.40 0.039370

FRACTION, DECIMAL, MILLIMETER CONVERSIONS – CONTD…
Fraction inch mm Fraction inch mm

17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Conversion Factor : 1 inch = 25.4 mm
Quantity
To Metric Customary

sq.inch
0 0 0 0


Quantity Customary
To Metric
Multiply By
2 2
sq. centimeters cm
2
6.452 0.155
2
2
0.0929 10.764
2.352



17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Quantity
To Metric Customary

sq.inch
0 0 0 0


Quantity Customary
To Metric
Multiply By
2 2
sq. centimeters cm
2
6.452 0.155
2
2
0.0929 10.764
2.352



17/64 0.2656 6.747 49/64 0.7656 19.447
9/32 0.2813 7.144 25/32 0.7813 19.844
19/64 0.2969 7.541 51/64 0.7969 20.241
5/16 0.3125 7.938 13/16 0.8125 20.638
21/64 0.3281 8.334 53/64 0.8281 21.034
11/32 0.3438 8.731 27/32 0.8438 21.431
23/64 0.3594 9.128 55/64 0.8594 21.828
3/8 0.3750 9.525 7/8 0.8750 22.225
25/64 0.3906 9.922 57/64 0.8906 22.622
13/32 0.4063 10.319 29/32 0.9063 23.019
27/64 0.4219 10.716 59/64 0.9219 23.416
7/16 0.4375 11.113 15/16 0.9375 23.813
29/64 0.4531 11.509 61/64 0.9531 24.209
15/32 0.4688 11.906 31/32 0.9688 24.606
31/64 0.4844 12.303 63/64 0.9844 25.003
1/2 0.5000 12.700 1 1.0000 25.400
Section-5 Page 5-13 Section-5 Page 5-14
CONVERSION PRACTICES
Work
liquid
Length Gallons convert to litres by multiplying by 3.785 and rounding to the
Torque
Velocity
Volume:
Multiply lengths in inches by 25.4 and carry to one less decimal place. same decimal place.
Example : 1.565 inches (39.75 mm) Example :16 gal.[60 I]
Quantity
Section – 5
displacement
Weight (mass)
1.5650 inches (39.751 mm) Small volumes (less than one litre) may be given in milliliters (ml) which
Note that zeros in the ten-thousands place are significant and define are equal to the old designation, cubic centimetres. Multiply cubic
the accuracy of measurement. They cannot be dropped. Dropping a inches by 16.39 and round to the nearest whole number.
decimal place affects the accuracy of the metric equivalent. Example: 21 cu. in. [344 ml)
Pressure Conversion
cubic inch
cubic inch
miles/hour
Unit Name
Fractions and whole numbers written without a decimal point should be lnches of Water (H2O) = P.S.I. X 27.7
gallon (U.S.)
gallon (lmp*)
carried to two decimal places in the conversion unless a strong reason Inches of Water (H2O) = Hg X 13.6
pounds (avoir.)
exists to do otherwise. lnches of Mercury (Hg) = P.S.I. X 2.07
horsepower hours
lnches of Mercury (Hg) = H2O / 13.6
British Thermal Unit

Example : 2-5/16 in. (58.74 mm]
Pound force per foot

Pound force per inch
Certain items which are standard and have no direct metric equivalent To Determine Torque In Ft. Lbs.
are not converted to metric. These include capscrew sizes, drill bits Ft. Lbs. = Dyno Constant X H.P. or B.H.P X Dyno Constant
in
in
lb
3
3
U. S. Customary
gal.
gal.
etc.
ft-lb
in-lb
mph
BTU
BTU
R.P.M. R.P.M.
hp-hr
Abbr.
Mass To Determine Horsepower on Dyno
Load X R.P.M.
Multiply pounds mass by 0.454 and carry to one extra decimal place.
H.P. =
Example : 27 lbs.[12.3kg] Dyno Constant
Force
Multiply pounds force by 4.448 and round to the same decimal place. To Determine Fuel Rate in Lbs. Per Hour
liter
liter
liter
Example :12.5 lbs.[65.6 N] Lbs. Fuel X 60
joules
Fuel Rate =
kilograms
Unit Name
Spring force is an exception to our standard practice. While the correct Time in minutes
kilowatt-hour
kilowatt-hour
metric unit is the newton, most foreign scales are in kilograms force.
Newton-meter
Newton-meter
kilometers/hour
cubic centimeter
Therefore we will list both units, newton in brackets and kilograms in To Determine Cubic inch Displacement
2
parenthesis. Piston Displacement = (.7854) X (Bore) X (Stroke) X (No. of Cylinders)
Metric
Example : 12.5 lbs. [65.6 N] (5.68 kg)
To Determine Axle Ratio
Torque 60 X R.P.M.
Axle Ratio = with 1 to 1 Transmission Ratio
I
I
I
J
In the customary system we use inch pound for small torque values
kg
cm
kph
3
Rev./Mile X M.P.H.
N-m
N-m
kW-hr
Abbr.
kW-hr
and foot pounds for larger values. Both are converted to the newton
metre in the metric system. When converting foot pounds, multiply by
To Determine Piston Speed
1.356 and round to the nearest whole number. When working with inch
Stroke (in.) X R.P.M.
pounds, multiply by 0.113 and round to the nearest tenth.
Piston speed (Feet per minute) =
Example : 20 ft. lb. [27 N.m]
6
20 in. lb. [2.3 N.m]
To Determine Brake Specific Fuel Consumption
0.746
0.113
4.546
1054.5
1.6093
0.4536
16.387
3.7853
Pressure Fuel Rate
0.01639
1.35582
0.000293
To Metric
From U. S.
Customary
Multiply By
Pressure is given pascals(Pa). Since one pound per square inch BSFC =
equals 6.894 pascals, we will always use the kilo prefix, or Brake Horsepower
kilopascals(kPa). To determine pressure in kPa, multiply psi by 6.894 To Determine Torque Wrench Values with Adapter
and round to the nearest whole number.
Example : 50 psi[345 kPa] TW X (L + A)
TA =
Pressure given as inches of mercury or water will convert to millimetres L
mercury or water. See the section on length for conversion practices. Explanation of Terms:
3414
1.341
0.6214
0.06102
To U. S.
0.000948
2.204623
0.219976
0.264179
8.850756
61.02545
0.737562
TA = Amount of torque applied at the end of the adapter.
Customary
Multiply By
From Metric
Volume and Displacement TW = Torque Wrench reading.
Page 5-12
Engine displacement is given in litres to the nearest tenth. Multiply L = Length of wrench.
cubic inches by 0.01639. A = Length of adapter.
Example: 555 cu. in. [9.11 Liter]
Work
Weight (mass)
displacement
liquid
Volume:
Velocity
Torque
Section – 5
Quantity
horsepower hours
pounds (avoir.)
cubic inch
cubic inch
gallon (lmp*)
gallon (U.S.)

Unit Name
miles/hour
Pressure Conversion
U. S. Customary
Example : 2-5/16 in. (58.74 mm] lnches of Mercury (Hg) = H2O / 13.6
hp-hr
BTU
BTU
in
in
gal.
gal.
mph
lb
in-lb
ft-lb
Abbr.
etc.
3
R.P.M. R.P.M.

Load X R.P.M.
H.P. =
Force
kilowatt-hour
kilowatt-hour
joules
kilometers/hour
cubic centimeter
liter
liter
liter
kilograms
Newton-meter
Unit Name
Newton-meter
Fuel Rate =
Metric
2
Example : 12.5 lbs. [65.6 N] (5.68 kg)
Torque 60 X R.P.M.
kW-hr
kW-hr
Abbr.

N-m
N-m
kph
cm
kg
J
Rev./Mile X M.P.H.
3
Multiply By
Customary
6
From U. S.
To Metric
0.000293
0.01639
1.35582
20 in. lb. [2.3 N.m]

1054.5
1.6093
0.4536
16.387
3.7853
0.746
0.113
4.546

Pressure Fuel Rate
From Metric
Multiply By
Customary
TA =
0.000948
2.204623
0.219976
0.264179
8.850756
61.02545
0.737562
To U. S.
0.06102
0.6214
Pressure given as inches of mercury or water will convert to millimetres

1.341
L
3414
Page 5-12
Work
Weight (mass)
displacement
liquid
Volume:
Velocity
Torque
Section – 5
Quantity
horsepower hours
pounds (avoir.)
cubic inch
cubic inch
gallon (lmp*)
gallon (U.S.)

Unit Name
miles/hour
Pressure Conversion
U. S. Customary
Example : 2-5/16 in. (58.74 mm] lnches of Mercury (Hg) = H2O / 13.6
hp-hr
BTU
BTU
in
in
gal.
gal.
mph
lb
in-lb
ft-lb
Abbr.
etc.
3
R.P.M. R.P.M.

Load X R.P.M.
H.P. =
Force
kilowatt-hour
kilowatt-hour
joules
kilometers/hour
cubic centimeter
liter
liter
liter
kilograms
Newton-meter
Unit Name
Newton-meter
Fuel Rate =
Metric
2
Example : 12.5 lbs. [65.6 N] (5.68 kg)
Torque 60 X R.P.M.
kW-hr
kW-hr
Abbr.

N-m
N-m
kph
cm
kg
J
Rev./Mile X M.P.H.
3
Multiply By
Customary
6
From U. S.
To Metric
0.000293
0.01639
1.35582
20 in. lb. [2.3 N.m]

1054.5
1.6093
0.4536
16.387
3.7853
0.746
0.113
4.546

Pressure Fuel Rate
From Metric
Multiply By
Customary
TA =
0.000948
2.204623
0.219976
0.264179
8.850756
61.02545
0.737562
To U. S.
0.06102
0.6214
Pressure given as inches of mercury or water will convert to millimetres

1.341
L
3414
Page 5-12
*CAPSCREW MARKINGS AND TORQUE VALUES
CAUTION
When replacing capscrew, always use a capscrew of the same measurement and strength as the capscrew being replaced. Using the wrong
capscrews can result in engine damage.
Metric capscrews and nuts are identified by the grade number stamped on the head of the capscrew or on the surface of the nuts. U. S. Customary
capscrews are identified by radial lines stamped on the head of the capscrew.
The following examples indicate how capscrews are identified
Metric - M8-1.25 x 25 U. S. Customary [5/16 x 18 x 1 - 1/2]
M8 1.25 X 25 5/16 18 1-1/2
Major thread diameter in millimeters Major thread diameter in inches
Distance between threads in millimeters Number of threads per inch
Length in millimeters Length in inches
NOTE:
1. Always use the torques values listed in the following tables when specific torque values are not available.
2. Do not use the torque values in place of those specified in other sections of this manual.
3. The torque values in the table are based on the use of lubricated threads.
4. When the ft-lb values less than 10, convert the ft-lb value to in-lb to obtain a better torque with an in-lb torque wrench.
Example: 6 ft-lb equals 72 in-lb
NEWTON-METER TO FOOT-POUND CONVERSION CHART
N.m ft-lb N.m ft-lb N.m ft-lb
1 8.850756 in-lb 55 41 155 114
5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184
NOTE : To convert from Newton-Meters to Kilogram-Meters divide Newton-Meters by 9.803.
Page5-15
KTA-3067-G -The fuel consumption at full load is 150 gms/bhp/hr
Full load of engine is 800 kW, i.e. generated units is 800 units as
= 210. Lit/Hr.
To evaluate units generated per litre of diesel
\800 Units/210 Ltrs = 3.8 Units/Ltr of diesel

177
.84
To determine fuel consumption
Specific Gravity of diesel is 0.84

=
150 x 1180
1000 x .84
1kWh = 1 Unit
Section - 5
Example -
CAUTION

M8 1.25 X 25 5/16 18 1-1/2
NOTE:

1 8.850756 in-lb 55 41 155 114

5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184

Page5-15
= 210. Lit/Hr.

177
.84

=
150 x 1180
1000 x .84
1kWh = 1 Unit
Section - 5
Example -
CAUTION

M8 1.25 X 25 5/16 18 1-1/2
NOTE:

1 8.850756 in-lb 55 41 155 114

5 44 in-lb 60 44 160 118
6 53 in-lb 65 48 165 122
7 62 in-lb 70 52 170 125
8 71 in-lb 75 55 175 129
9 80 in-lb 80 59 180 133
10 89 in-lb 85 63 185 136
1 0.737562 ft-lb 90 66 190 140
12 9 95 70 195 144
14 10 100 74 200 148
15 11 105 77 205 151
16 12 110 81 210 155
18 13 115 85 215 159
20 15 120 89 220 162
25 18 125 92 225 165
30 22 130 96 230 170
35 26 135 100 235 173
40 30 140 103 240 177
45 33 145 107 245 180
50 37 150 111 250 184

Page5-15
= 210. Lit/Hr.

177
.84

=
150 x 1180
1000 x .84
1kWh = 1 Unit
Section - 5
Example -
CAPSCREW MARKINGS AND TORQUE VALUES – METRIC – CONTD…..
Capscrew steel
8.8 10.9 12.9
Capscrew Head Markings
Body Size Torque Torque Torque

Diam. Cast Iron Aluminium Cast Iron Aluminium Cast Iron Aluminium
mm N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb
6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Section-5 Page 5-19

Capscrew Body Size Cast Iron Aluminium Cast Iron Aluminium
N.m ft-lb N.m ft-lb N.m ft-lb N.m ft-lb
7/16-14 60 45 45 35 90 65 45 35
-20 65 50 55 40 95 70 55 40
1/2 -13 95 70 75 55 130 95 75 55
-20 100 75 80 60 150 110 80 60
9/16-12 135 100 110 80 190 140 110 80
-18 150 110 115 85 210 155 115 85
5/8 -11 180 135 150 110 255 190 150 110
-18 210 155 160 120 290 215 160 120
3/4 -10 325 240 255 190 460 340 255 190
-16 365 270 285 210 515 380 285 210
7/8 -9 490 360 380 280 745 550 380 280
-14 530 390 420 310 825 610 420 310
1 -8 720 530 570 420 1100 820 570 420
-14 800 590 650 480 1200 890 650 480
Section-5 Page 5-18

CAPSCREW MARKINGS AND TORQUE VALUES – CONTD….
Capscrew Markings and Values - U.S. Customary

SAE Grade Number
These are all SAE Grade 5 (3) line
Capscrew Torque - Grade 5 Capscrew Capscrew Torque Grade 8 Capscrew

N.M ft-lb N.m ft-lb N.m ft-lb N.m ft-lb
1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/8 - 18 20 15 16 12 30 22 16
12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
Capscrew steel
8.8 10.9 12.9

6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Section-5 Page 5-19

7/16-14 60 45 45 35 90 65 45 35
-20 65 50 55 40 95 70 55 40
1/2 -13 95 70 75 55 130 95 75 55
-20 100 75 80 60 150 110 80 60
9/16-12 135 100 110 80 190 140 110 80
-18 150 110 115 85 210 155 115 85
5/8 -11 180 135 150 110 255 190 150 110
-18 210 155 160 120 290 215 160 120
3/4 -10 325 240 255 190 460 340 255 190
-16 365 270 285 210 515 380 285 210
7/8 -9 490 360 380 280 745 550 380 280
-14 530 390 420 310 825 610 420 310
1 -8 720 530 570 420 1100 820 570 420
-14 800 590 650 480 1200 890 650 480
Section-5 Page 5-18


SAE Grade Number

1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/8 - 18 20 15 16 12 30 22 16
12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
Capscrew steel
8.8 10.9 12.9

6 9 5 7 4 12 9 7 4 14 9 7 4
7 14 9 11 7 18 14 11 7 23 18 11 7
8 25 18 18 14 33 25 18 14 40 29 18 14
10 45 33 30 25 60 45 30 25 70 50 30 25
12 80 60 55 40 105 75 55 40 125 95 55 40
14 125 90 90 65 165 122 90 65 195 145 90 65
16 180 130 140 100 240 175 140 100 290 210 140 100
18 230 170 180 135 320 240 180 135 400 290 180 135
Section-5 Page 5-19

7/16-14 60 45 45 35 90 65 45 35
-20 65 50 55 40 95 70 55 40
1/2 -13 95 70 75 55 130 95 75 55
-20 100 75 80 60 150 110 80 60
9/16-12 135 100 110 80 190 140 110 80
-18 150 110 115 85 210 155 115 85
5/8 -11 180 135 150 110 255 190 150 110
-18 210 155 160 120 290 215 160 120
3/4 -10 325 240 255 190 460 340 255 190
-16 365 270 285 210 515 380 285 210
7/8 -9 490 360 380 280 745 550 380 280
-14 530 390 420 310 825 610 420 310
1 -8 720 530 570 420 1100 820 570 420
-14 800 590 650 480 1200 890 650 480
Section-5 Page 5-18


SAE Grade Number

1/4 - 20 9 7 8 6 15 11 8 6
- 28 12 9 9 7 18 13 9 7
5/8 - 18 20 15 16 12 30 22 16
12
- 24 23 17 19 14 33 24 19 14
3/8 - 16 40 30 25 20 55 40 25 20
- 24 40 30 35 25 60 45 35 25
TAP-DRILL CHART - U. S. CUSTOMARY AND METRIC
NOTE ON SELECTING TAP-DRILL SIZES : The tap drill sizes shown on this card give the theoretical tap drill size for approximately 60% and 75% of full
thread depth. Generally, it is recommended that drill sizes be selected in the 60% range as these sizes will provide about 90% of the potential holding
power. Drill sizes in the 75% range are recommended for shallow hole tapping (less than 1 1/2 times the hole diameter) in soft metals and mild steel.
Tap Size Drill Tap Size Drill Tap Size Drill Tap Size Drill
60% 75% Size 60% 75% Size 60% 75% Size 60% 75% Size
48 4.40mm 7.50mm 13.25mm
1.95mm 12-24 16 19/64 5/8-11 17/32
5/64 4.50mm 7.60mm M15x1.5 13.50mm
3-48 47 15 N M15x1.5 13.75mm
2.00mm M5.5x.9 4.60mm 7.70mm 5/8-11 35/64
M2.5x.45 2.05mm 12-24 12-28 14 M9x1.25 7.75mm M16x2 14.00mm
46 13 7.80mm 14.25mm
3-48 3056 45 4.70mm 7.90mm 5/8-18 9/16
2.10mm M5.5x9 4.75mm 3/8-16 5/16 M16x2 M16x1.5 14.50mm
M2.5x .45 M2.6x.45 2.15mm 12-28 3/16 M9x1.25 M9x1 8.00mm 5/6-18 37/64
3-56 4-36 44 12 0 14.75mm
2.20mm 4.80mm 8.10mm M16x1.5 15.00mm
M2.6x.45 2.25mm 11 M9x1 8.20mm 19.32

PIPE PLUG TORQUE VALUES
Size Torque Torque

Thread Actual Thread O. D. In Aluminium Components In Cast Iron or
Steel Components
in in N.m ft-lb N.m ft-lb
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100

DRIVE BELT TENSION
SAE melt Size Belt Tension Gauge Part No. Belt Tension new Belt Tension Range Used *
Click-type Burroughs N lbf N lbf
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822524 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 1110 200 360 to 710 80 to 160
10 rib 3822525 3823138 1330 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240
12 rib K section 3822525 3823138 1330 300 890 to 1070 200 to 240
NOTE : This chart does not apply to automatic belt tensioners.

* A belt is considered used if it has been in service for ten minutes or longer.
* If used belt tension is Iess than the minimum value, tighten the belt to the maximum used belt value.
48 4.40mm 7.50mm 13.25mm
1.95mm 12-24 16 19/64 5/8-11 17/32
5/64 4.50mm 7.60mm M15x1.5 13.50mm
3-48 47 15 N M15x1.5 13.75mm
2.00mm M5.5x.9 4.60mm 7.70mm 5/8-11 35/64
M2.5x.45 2.05mm 12-24 12-28 14 M9x1.25 7.75mm M16x2 14.00mm
46 13 7.80mm 14.25mm
3-48 3056 45 4.70mm 7.90mm 5/8-18 9/16
2.10mm M5.5x9 4.75mm 3/8-16 5/16 M16x2 M16x1.5 14.50mm
M2.5x .45 M2.6x.45 2.15mm 12-28 3/16 M9x1.25 M9x1 8.00mm 5/6-18 37/64
3-56 4-36 44 12 0 14.75mm
2.20mm 4.80mm 8.10mm M16x1.5 15.00mm
M2.6x.45 2.25mm 11 M9x1 8.20mm 19.32

Size Torque Torque

Steel Components
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100

DRIVE BELT TENSION
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822524 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 1110 200 360 to 710 80 to 160
10 rib 3822525 3823138 1330 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240

48 4.40mm 7.50mm 13.25mm
1.95mm 12-24 16 19/64 5/8-11 17/32
5/64 4.50mm 7.60mm M15x1.5 13.50mm
3-48 47 15 N M15x1.5 13.75mm
2.00mm M5.5x.9 4.60mm 7.70mm 5/8-11 35/64
M2.5x.45 2.05mm 12-24 12-28 14 M9x1.25 7.75mm M16x2 14.00mm
46 13 7.80mm 14.25mm
3-48 3056 45 4.70mm 7.90mm 5/8-18 9/16
2.10mm M5.5x9 4.75mm 3/8-16 5/16 M16x2 M16x1.5 14.50mm
M2.5x .45 M2.6x.45 2.15mm 12-28 3/16 M9x1.25 M9x1 8.00mm 5/6-18 37/64
3-56 4-36 44 12 0 14.75mm
2.20mm 4.80mm 8.10mm M16x1.5 15.00mm
M2.6x.45 2.25mm 11 M9x1 8.20mm 19.32

Size Torque Torque

Steel Components
1/16 0.32 5 45 in-lb 15 10
1/8 0.41 15 10 20 15
1/4 0.54 20 15 25 20
3/8 0.68 25 20 35 25
1/2 0.85 35 25 55 40
3/4 1.05 45 35 75 55
1 1.32 60 45 95 70
1-1/4 1.66 75 55 115 85
1-1/2 1.90 85 65 135 100

DRIVE BELT TENSION
0.380 in 3822524 620 140 270 to 490 60 to 110
0.440 in 3822524 620 140 270 to 490 60 to 110
1/2 in 3822524 ST-1138 620 140 270 to 490 60 to 110
11/16 in 3822524 ST-1138 620 140 270 to 490 60 to 110
3/4 in 3822524 ST-1138 620 140 270 to 490 60 to 110
7/8 in 3822524 ST-1138 620 140 270 to 490 60 to 110
4 rib 3822524 ST-1138 620 140 270 to 490 60 to 110
5 rib 3822524 ST-1138 670 150 270 to 530 60 to 120
6 rib 3822524 ST-1293 710 160 290 to 580 65 to 130
8 rib 3822525 ST-1293 1110 200 360 to 710 80 to 160
10 rib 3822525 3823138 1330 250 440 to 890 100 to 200
12 rib 3822525 3823138 1330 300 530 to 1070 120 to 240

24 M0x1.25 6.75mm 1/4-18NPT M24x2 22.00mm
M4.5x75 3.90mm 5/16-18 H 11.25mm 1”x-8 7/8
23 6.80mm 11.50mm M24x2 22.25mm
5/32 6.90mm 29/84 M24x1.5 22.50mm
10-24 22 5.16-24 I 11.75mm 1”-8 57/64
M5x1 4.00mm M8x1.25 M8x1 7.00mm 11.50mm M24x1.5 22.75mm
10-32 21 J 1/2-20 29/84 M25x2 23.00mm
20 7.10mm 9/16-12 15/32 1”-12 29/32
M5x.9 4.10mm 5/16-24 K M14x2 12.00mm M25x2 23.25mm
M5x1 M5x.8 4.20mm 9/32 12.25mm 1”x12 1”-14 59/64
10-32 19 M8x1 7.20mm 9/16-12 31/64 M25x1.5 23.50mm
M5x.9 4.25mm 7.25mm M14x2 M14x1.5 12.50mm M20x1.5 23.75mm
M5x.8 4.30mm 7.30mm 9/16-18 1/2 1”-14 15/16
18 L M14x1.5 M14x1.25 12.75mm
11/64 7.40mm M14x1.25 13.00mm
17 M 9/16-18 33/64
M3.5x6 2.90mm 1 9.40mm 47/64
32 5.80mm M11x1.5 9.50mm M20x1.5 18.75mm
3.00mm 5.90mm 3/8 19.00mm
M3.5x6 31 A V 3/4
3-4C 3.10mm 15/64 9.60mm 19.25mm
1/8 M7x1 6.00mm 9.70mm 7/8-9 49/64
3.20mm B 9.75mm M22x2.5 19.50mm
M4x.75 3.25mm 6.10mm M11X1.5 9.80mm 7/8-9 25-32
30 C 7/16-14 W 19.75mm
M4x.7 3.30mm M7x1 6.20mm 9.90mm M22x2.5 M22x2 20.00mm
M4x.75 3.40 D --20 25/64 7/8-14 51/64
M4x.7 8-32 29 M7x.75 6.25mm 10.00 M22x2 20.25mm
3.50mm 6.30mm 7/16-20 X M22x1.5 20.50mm
8-36 28 E M12x1.75 10.20mm 7/8-14 13/18
8.32 9/64 1/4 Y 20.75mm
3.60mm M7x.75 6.40mm 13/32 M22x1.5 M24x3 21.00mm
8.36 27 6.50mm Z 53/64
3.70mm 5/16-18 F M12x1.75 M12x1.5 10.50mm 21/25mm
26 6.60mm 1/2-13 27/64 27/32
M4.5x75 3.75mm G M12x1.5 M12x1.25 10.75mm M24x2 21.50mm
10-24 25 6.70mm M12x1.25 11.00mm 21.75mm
3.80mm 17/64 1/2 –13 7/16 55/84

4-36 4-40 43 4.90mm P 15.25mm
2.30mm 10 8.25mm 39/64
2.35mm 9 8.30mm M17x1.5 15.50mm
4-40 4-48 42 M6x1 5.00mm 3/8-16 1/8-27NPT 21/64 M17x1.5 M18x2.5 15.75mm
3/32 8 8.40mm 5/8
M3x.6 2.40mm 5.10mm 3/8-24 Q M18x2.5 M18x2 16.00mm
4-48 41 1/4-20 7 M10x1.5 8.50mm M18x2 16.25mm
2.45mm 13/64 8.60mm 3/4-10 41/64
40 6 R M18x1.5 16.50mm
M3x.6 M3x.5 2.50mm M6x1 5.20mm 3/8-24 8.70mm 3/4-10 M19x2.5 21/32
39 5 1/8-27NPT 11/32 M18x1.5 16.75mm
5-40 38 M6x.75 5.25mm M10x1.25 8.75mm M19x2.5 17.00mm
M3x.5 2.60mm 5.30mm M10x1.5 8.80mm 43/64
5-40 5-44 37 1/4-20 4 S 17.25mm
2.70mm M6x.75 5.40mm 8.90mm 3/4-16 3/4-16 11/16mm
5-44 6-32 36 1/4-28 3 M10x1.25 M10x1 9.00mm M20x2.5 17.50mm
2.75mm 5.50mm T 17.75mm
7/64 7/32 9.10mm 45/64
35 5.60mm 23/64 M20x2.5 M20x2 18.00mm
2.80mm 1/4 –28 2 M10x1 9.20mm M20x2 18.25mm
34 5.70mm 9.30mm 23/32
6-32 6-40 33 5.75mm 7-16-14 U M20x1.5 18.50mm
24 M0x1.25 6.75mm 1/4-18NPT M24x2 22.00mm
M4.5x75 3.90mm 5/16-18 H 11.25mm 1”x-8 7/8
23 6.80mm 11.50mm M24x2 22.25mm
5/32 6.90mm 29/84 M24x1.5 22.50mm
10-24 22 5.16-24 I 11.75mm 1”-8 57/64
10-32 21 J 1/2-20 29/84 M25x2 23.00mm
20 7.10mm 9/16-12 15/32 1”-12 29/32
M5x.9 4.10mm 5/16-24 K M14x2 12.00mm M25x2 23.25mm
M5x1 M5x.8 4.20mm 9/32 12.25mm 1”x12 1”-14 59/64
10-32 19 M8x1 7.20mm 9/16-12 31/64 M25x1.5 23.50mm
M5x.8 4.30mm 7.30mm 9/16-18 1/2 1”-14 15/16
18 L M14x1.5 M14x1.25 12.75mm
11/64 7.40mm M14x1.25 13.00mm
17 M 9/16-18 33/64
M3.5x6 2.90mm 1 9.40mm 47/64
32 5.80mm M11x1.5 9.50mm M20x1.5 18.75mm
3.00mm 5.90mm 3/8 19.00mm
M3.5x6 31 A V 3/4
3-4C 3.10mm 15/64 9.60mm 19.25mm
1/8 M7x1 6.00mm 9.70mm 7/8-9 49/64
3.20mm B 9.75mm M22x2.5 19.50mm
M4x.75 3.25mm 6.10mm M11X1.5 9.80mm 7/8-9 25-32
30 C 7/16-14 W 19.75mm
M4x.75 3.40 D --20 25/64 7/8-14 51/64
M4x.7 8-32 29 M7x.75 6.25mm 10.00 M22x2 20.25mm
3.50mm 6.30mm 7/16-20 X M22x1.5 20.50mm
8-36 28 E M12x1.75 10.20mm 7/8-14 13/18
8.32 9/64 1/4 Y 20.75mm
3.60mm M7x.75 6.40mm 13/32 M22x1.5 M24x3 21.00mm
8.36 27 6.50mm Z 53/64
3.70mm 5/16-18 F M12x1.75 M12x1.5 10.50mm 21/25mm
26 6.60mm 1/2-13 27/64 27/32
10-24 25 6.70mm M12x1.25 11.00mm 21.75mm
3.80mm 17/64 1/2 –13 7/16 55/84

4-36 4-40 43 4.90mm P 15.25mm
2.30mm 10 8.25mm 39/64
2.35mm 9 8.30mm M17x1.5 15.50mm
4-40 4-48 42 M6x1 5.00mm 3/8-16 1/8-27NPT 21/64 M17x1.5 M18x2.5 15.75mm
3/32 8 8.40mm 5/8
M3x.6 2.40mm 5.10mm 3/8-24 Q M18x2.5 M18x2 16.00mm
4-48 41 1/4-20 7 M10x1.5 8.50mm M18x2 16.25mm
2.45mm 13/64 8.60mm 3/4-10 41/64
40 6 R M18x1.5 16.50mm
M3x.6 M3x.5 2.50mm M6x1 5.20mm 3/8-24 8.70mm 3/4-10 M19x2.5 21/32
39 5 1/8-27NPT 11/32 M18x1.5 16.75mm
5-40 38 M6x.75 5.25mm M10x1.25 8.75mm M19x2.5 17.00mm
M3x.5 2.60mm 5.30mm M10x1.5 8.80mm 43/64
5-40 5-44 37 1/4-20 4 S 17.25mm
2.70mm M6x.75 5.40mm 8.90mm 3/4-16 3/4-16 11/16mm
5-44 6-32 36 1/4-28 3 M10x1.25 M10x1 9.00mm M20x2.5 17.50mm
2.75mm 5.50mm T 17.75mm
7/64 7/32 9.10mm 45/64
35 5.60mm 23/64 M20x2.5 M20x2 18.00mm
2.80mm 1/4 –28 2 M10x1 9.20mm M20x2 18.25mm
34 5.70mm 9.30mm 23/32
6-32 6-40 33 5.75mm 7-16-14 U M20x1.5 18.50mm
24 M0x1.25 6.75mm 1/4-18NPT M24x2 22.00mm
M4.5x75 3.90mm 5/16-18 H 11.25mm 1”x-8 7/8
23 6.80mm 11.50mm M24x2 22.25mm
5/32 6.90mm 29/84 M24x1.5 22.50mm
10-24 22 5.16-24 I 11.75mm 1”-8 57/64
10-32 21 J 1/2-20 29/84 M25x2 23.00mm
20 7.10mm 9/16-12 15/32 1”-12 29/32
M5x.9 4.10mm 5/16-24 K M14x2 12.00mm M25x2 23.25mm
M5x1 M5x.8 4.20mm 9/32 12.25mm 1”x12 1”-14 59/64
10-32 19 M8x1 7.20mm 9/16-12 31/64 M25x1.5 23.50mm
M5x.8 4.30mm 7.30mm 9/16-18 1/2 1”-14 15/16
18 L M14x1.5 M14x1.25 12.75mm
11/64 7.40mm M14x1.25 13.00mm
17 M 9/16-18 33/64
M3.5x6 2.90mm 1 9.40mm 47/64
32 5.80mm M11x1.5 9.50mm M20x1.5 18.75mm
3.00mm 5.90mm 3/8 19.00mm
M3.5x6 31 A V 3/4
3-4C 3.10mm 15/64 9.60mm 19.25mm
1/8 M7x1 6.00mm 9.70mm 7/8-9 49/64
3.20mm B 9.75mm M22x2.5 19.50mm
M4x.75 3.25mm 6.10mm M11X1.5 9.80mm 7/8-9 25-32
30 C 7/16-14 W 19.75mm
M4x.75 3.40 D --20 25/64 7/8-14 51/64
M4x.7 8-32 29 M7x.75 6.25mm 10.00 M22x2 20.25mm
3.50mm 6.30mm 7/16-20 X M22x1.5 20.50mm
8-36 28 E M12x1.75 10.20mm 7/8-14 13/18
8.32 9/64 1/4 Y 20.75mm
3.60mm M7x.75 6.40mm 13/32 M22x1.5 M24x3 21.00mm
8.36 27 6.50mm Z 53/64
3.70mm 5/16-18 F M12x1.75 M12x1.5 10.50mm 21/25mm
26 6.60mm 1/2-13 27/64 27/32
10-24 25 6.70mm M12x1.25 11.00mm 21.75mm
3.80mm 17/64 1/2 –13 7/16 55/84

4-36 4-40 43 4.90mm P 15.25mm
2.30mm 10 8.25mm 39/64
2.35mm 9 8.30mm M17x1.5 15.50mm
4-40 4-48 42 M6x1 5.00mm 3/8-16 1/8-27NPT 21/64 M17x1.5 M18x2.5 15.75mm
3/32 8 8.40mm 5/8
M3x.6 2.40mm 5.10mm 3/8-24 Q M18x2.5 M18x2 16.00mm
4-48 41 1/4-20 7 M10x1.5 8.50mm M18x2 16.25mm
2.45mm 13/64 8.60mm 3/4-10 41/64
40 6 R M18x1.5 16.50mm
M3x.6 M3x.5 2.50mm M6x1 5.20mm 3/8-24 8.70mm 3/4-10 M19x2.5 21/32
39 5 1/8-27NPT 11/32 M18x1.5 16.75mm
5-40 38 M6x.75 5.25mm M10x1.25 8.75mm M19x2.5 17.00mm
M3x.5 2.60mm 5.30mm M10x1.5 8.80mm 43/64
5-40 5-44 37 1/4-20 4 S 17.25mm
2.70mm M6x.75 5.40mm 8.90mm 3/4-16 3/4-16 11/16mm
5-44 6-32 36 1/4-28 3 M10x1.25 M10x1 9.00mm M20x2.5 17.50mm
2.75mm 5.50mm T 17.75mm
7/64 7/32 9.10mm 45/64
35 5.60mm 23/64 M20x2.5 M20x2 18.00mm
2.80mm 1/4 –28 2 M10x1 9.20mm M20x2 18.25mm
34 5.70mm 9.30mm 23/32
6-32 6-40 33 5.75mm 7-16-14 U M20x1.5 18.50mm
Section – 6
Section – 6
Section -6 Page 6
System
System
System
TROUBLE SHOOTING
Fuel
Fuel
Air
Contents Page
AFC Air Leak, Bellows
Injector Flow Incorrect

Fuel Pump Calibration Incorrect
Damaged /Worn AFC Plunger Seal / Barrel
AFC Calibration Incorrect
Water in Fuel and / or Waxing
High-Speed Governor Set too Low
Incorrectly Assembled Governor Weights
Incorrectly Assembled idle Springs
Throttle Linkage or Adjustment
Excessive Injector Check Ball Leakage
Damaged Injector O-Ring
Cracked Injector Body or Cup
Wrong Injector Cups
Scored Gear Pump or Worn Gears
Broken Fuel Pump Drive Shaft
Plugged Injector Spray Holes
External or Internal Fuel Leaks
Restricted Fuel Lines
Air Leaks in Suction Lines
Poor Quality Fuel / Grade Fuel
Out of Fuel or Fuel Shut Off Closed
Stuck Drain Valve
Improper Use of Starter Aid / Air Temp.

Dirty Turbocharger Compressor
Air leaks Between Cleaner and Engine
Thin Air in Hot Weather or High Altitude
High Exhaust Back Pressure
Restricted Air Intake
Trouble shooting Cummins Engines…………………………………...6-1
PT (Type G) Fuel System Trouble shooting …………………………..6-4
OF ENGINE - CONTD…..
Fault Code diagnostics ECM, ECPG etc.……………………………...6-5
TROUBLE SHOOTING
TROUBLE SHOOTING
OF ENGINE
CAUSES
CAUSES
COM PLAINTS COM PLAINTS
Hard Starting or Failure to Start
l l l l l
l
l
l l l
l l
l l
l
l
Hard Starting or Failure to Start
l
l l
Engine M isses
l l
Engine M isses
l
Excessive Black Smoke at Idle
l l l
l
Excessive White Smoke at Idle
l l
l
Excessive Smoke Under Load
l
l
l
Excessive Smoke Under Load
l
l
Excessive Acceleration Smoke
l l
l l
l l
l l
l
l
l
l
l
Excessive Acceleration Smoke
l l l
l l l
l l
Low Power or Loss of Power
l
l
l
l
l
l
l
l l
l l
l
Cannot Reach Governed RPM Cannot Reach Governed RPM
l
Low Air Output
l
l
l
l
Low Air Output
Sluggish Engine Acceleration
l
l
l
l
l
l
l
Excessive Fuel Consumption
l
l
l
l
l l
l l
l
l
l
l l l l
l l
Poor Deceleration
l l l l
Poor Deceleration
l l l
l l l l
l
Erratic Idle Speed
l l
Erratic Idle Speed
l l
l l l
Engine Dies
l
Engine Dies
Surging at Governed RPM Surging at Governed RPM
Excessive Oil Consumption Excessive Oil Consumption
Crankcase Sludge
l
Crankcase Sludge
Dilution
l
l
Dilution
l
Low Oil Pressure Low Oil Pressure
Coolant Temperature too Low Coolant Temperature too Low
Coolant Temperature too High Coolant Temperature too High
Oil Temperature Too High Oil Temperature Too High
Piston Liner and Ring Wear
l l
l l l
Wear of Bearings and Journals Wear of Bearings and Journals
Worn Valves and Guides Worn Valves and Guides
Fuel Knocks (Combustion Noise)
l
l
l

M echanical Knocks M echanical Knocks
Gear Train Whine Gear Train Whine
Page 6-1
Excessive Engine Vibration
Page 6-2
Excessive Noise
l
Excessive Noise
l
Excessive Crankcase Pressure Excessive Crankcase Pressure
Section -6 Page 6
TROUBLE SHOOTING
Air
Fuel
Fuel
System
System
System
Contents Page
Section – 6
Section – 6
Stuck Drain Valve

Wrong Injector Cups






CAUSES
CAUSES

OF ENGINE



TROUBLE SHOOTING
TROUBLE SHOOTING
l
l
l
l
l
Hard Starting or Failure to Start Hard Starting or Failure to Start
l l
l l
l
l l
l
Engine M isses Engine M isses
l l
l l l
l
Excessive Black Smoke at Idle Excessive Black Smoke at Idle
l
Excessive White Smoke at Idle Excessive White Smoke at Idle
l l l l l
l l l
l
l
l l
l
l
l
l
l
l
l
Excessive Smoke Under Load Excessive Smoke Under Load
l
l
l
l
l
l
Excessive Acceleration Smoke Excessive Acceleration Smoke
l l
l l
l
l l
l
l l
l
l
l
l
l
l
l
l
l l
l
Low Power or Loss of Power Low Power or Loss of Power

l l l
l l l
l
l l
l l
l
l
l
l
Low Air Output Low Air Output
l
l
l
l
l
l
l
l
Sluggish Engine Acceleration Sluggish Engine Acceleration
l
l
l
l
l
l
l
l
l
l l
l l
l
Poor Deceleration
l l
Poor Deceleration
Erratic Idle Speed Erratic Idle Speed
l
l
l l
l
Engine Dies
l l l l
l l
l l l
Engine Dies
l l l l
Surging at Governed RPM
l l l
l l l l

l
Crankcase Sludge Crankcase Sludge
l
l
Dilution
l
Dilution
Piston Liner and Ring Wear Piston Liner and Ring Wear
l l Wear of Bearings and Journals Wear of Bearings and Journals
l l l
l
l
l
l
Fuel Knocks (Combustion Noise) Fuel Knocks (Combustion Noise)

Excessive Engine Vibration Excessive Engine Vibration
l
Excessive Noise
l
l
Excessive Noise
Page 6-1
Page 6-2
Section -6 Page 6
TROUBLE SHOOTING
Air
Fuel
Fuel
System
System
System
Contents Page
Section – 6
Section – 6
Stuck Drain Valve

Wrong Injector Cups






CAUSES
CAUSES

OF ENGINE



TROUBLE SHOOTING
TROUBLE SHOOTING
l
l
l
l
l
l l
l l
l
l l
l
l l
l l l
l
l
l l l l l
l l l
l
l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
l l
l
l l
l
l
l
l
l
l
l
l
l l
l

l l l
l l l
l
l l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
Poor Deceleration
l l
Poor Deceleration
l
l
l l
l
Engine Dies
l l l l
l l
l l l
Engine Dies
l l l l
l l l
l l l l

l
l
l
Dilution
l
Dilution
l l l
l
l
l
l

l
Excessive Noise
l
l
Excessive Noise
Page 6-1
Page 6-2
Section -6 Page 6
TROUBLE SHOOTING
Air
Fuel
Fuel
System
System
System
Contents Page
Section – 6
Section – 6
Stuck Drain Valve

Wrong Injector Cups






CAUSES
CAUSES

OF ENGINE



TROUBLE SHOOTING
TROUBLE SHOOTING
l
l
l
l
l
l l
l l
l
l l
l
l l
l l l
l
l
l l l l l
l l l
l
l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
l l
l
l l
l
l
l
l
l
l
l
l
l l
l

l l l
l l l
l
l l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
Poor Deceleration
l l
Poor Deceleration
l
l
l l
l
Engine Dies
l l l l
l l
l l l
Engine Dies
l l l l
l l l
l l l l

l
l
l
Dilution
l
Dilution
l l l
l
l
l
l

l
Excessive Noise
l
l
Excessive Noise
Page 6-1
Page 6-2
Section -6 Page 6
TROUBLE SHOOTING
Air
Fuel
Fuel
System
System
System
Contents Page
Section – 6
Section – 6
Stuck Drain Valve

Wrong Injector Cups






CAUSES
CAUSES

OF ENGINE



TROUBLE SHOOTING
TROUBLE SHOOTING
l
l
l
l
l
l l
l l
l
l l
l
l l
l l l
l
l
l l l l l
l l l
l
l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
l l
l
l l
l
l
l
l
l
l
l
l
l l
l

l l l
l l l
l
l l
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l l
l
Poor Deceleration
l l
Poor Deceleration
l
l
l l
l
Engine Dies
l l l l
l l
l l l
Engine Dies
l l l l
l l l
l l l l

l
l
l
Dilution
l
Dilution
l l l
l
l
l
l

l
Excessive Noise
l
l
Excessive Noise
Page 6-1
Page 6-2
System
System
Repair
Cooling
Repair
Practices
Section – 6
Lubricating
Section – 6
Section – 6
Mechanical
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Oil Level Too High

Long Idle Periods
Faulty Thermostats
Clogged Oil Drillings
Engine Overloaded
Internal Water Leaks

Broken Cam Lobes
Oil Needs Changing
Engine Exterior Dirty
Coolant Temperature Low

Faulty Cylinder Oil Control
Engine Due for Overhaul
Oil Suction Line Restriction

Injectors Need Adjustment
CAUSES
Damaged Hose/Loose Belts

Crankcase Low or Out of Oil
Faulty Oil Pressure Regulator
Gasket Blow-By or Leakage
Exterior Leaks / Air in System

Broken or Worn Piston Rings
External and Internal Oil Leaks

Incorrect Bearing Clearances
CAUSES
CAUSES
Insufficient Coolant / Worn Pump

Valve Leakage/Adjustment Bad
Dirty Filters / Screens / Breather
Damaged Main or Rod Bearings
TROUBLE SHOOTING
Worn or Scored Liners or Pistons
Geartrain Backlash/Broken Tooth
Faulty Damper / Flywheel Balance
Low Coolant Capacity/Dirty Radiator

Broken/Bent Push Rod or Cam Box
Adjustments or Incorrect Valve and Injection Timing
Main Bearing Bore Out of Alignment

TROUBLE SHOOTING
TROUBLE SHOOTING
OF ENGINE - CONTD….
Misalignment – Engine to Driven Unit
Clogged Oil Cooler or Water Passages

Excessive Crankshaft End Clearance
Loose Mounting Bolts/Head Capscrew
Wrong Grade Oil for Weather Conditions

COM PLAINTS
Hard Starting or Failure to Start COMPLAINTS
COMPLAINTS
Engine M isses
l
l
l
l l
Engine Misses Engine Misses
l
l
l
l l l
l l l
Excessive Smoke Under Load Excessive Black Smoke at Idle Excessive Black Smoke at Idle
l l l l
l l
l
l
l
l
l l l l l
Excessive Acceleration Smoke Excessive Smoke Under Load Excessive Smoke Under Load
l
l
l
Cannot Reach Governed RPM
l l
l l
l
l
l
l l
l
Low Air Output
l l l
l l l
l l
l l
l
l
l
l
l
l
l
l
l
Poor Deceleration Excessive Fuel Consumption Excessive Fuel Consumption
Erratic Idle Speed Poor Deceleration Poor Deceleration
Engine Dies Erratic Idle Speed Erratic Idle Speed
Surging at Governed RPM Engine Dies Engine Dies
l l l l l
l
l
l
l
Excessive Oil Consumption
l
l
l
l
l
l
Crankcase Sludge
l
l l
l l
l
Dilution
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
Low Oil Pressure Dilution Dilution
l
l
l
l l
l
l l
Coolant Temperature too Low Low Oil Pressure Low Oil Pressure
l
Coolant Temperature too High
l l
l l
l
l l
l l
l l
l
Oil Temperature Too High
l l
l
l
l
l l
Wear of Bearings and Journals
l
l
l
l
l l
l
l l l l l
l l l
l l l
l l
Worn Valves and Guides
l l l
l
l l l
l l l
l
l
l
l

M echanical Knocks
l
l
l
l
l
l
l
Mechanical Knocks Mechanical Knocks

Gear Train Whine
l l
l l
l l

l l l
l
l
l l

Excessive Noise
l
l l
l
l
l
l
Excessive Noise Excessive Noise
l
l
l

Page 6-4
Excessive Crankcase Pressure

Page 6-5
Page 6-3
System
System
Repair
Cooling
Repair
Practices
Section – 6
Lubricating
Section – 6
Section – 6
Mechanical
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Oil Level Too High

Long Idle Periods
Faulty Thermostats
Engine Overloaded

Broken Cam Lobes
Oil Needs Changing


CAUSES



CAUSES
CAUSES

TROUBLE SHOOTING


TROUBLE SHOOTING
TROUBLE SHOOTING


COM PLAINTS
COMPLAINTS
Engine M isses
l
l
l
l l
l
l
l
l l l
l l l
l l l l
l l
l
l
l
l
l l l l l
l
l
l
l l
l l
l
l
l
l l
l
Low Air Output
l l l
l l l
l l
l l
l
l
l
l
l
l
l
l
l
l l l l l
l
l
l
l
l
l
l
l
l
l
Crankcase Sludge
l
l l
l l
l
Dilution
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l
l l
l
l l
l l
l
l l
l l
l l
l
l l
l
l
l
l l
l
l
l
l
l l
l
l l l l l
l l l
l l l
l l
l l l
l
l l l
l l l
l
l
l
l

M echanical Knocks
l
l
l
l
l
l
l

Gear Train Whine
l l
l l
l l

l l l
l
l
l l

Excessive Noise
l
l l
l
l
l
l
l
l
l

Page 6-4

Page 6-5
Page 6-3
System
System
Repair
Cooling
Repair
Practices
Section – 6
Lubricating
Section – 6
Section – 6
Mechanical
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Oil Level Too High

Long Idle Periods
Faulty Thermostats
Engine Overloaded

Broken Cam Lobes
Oil Needs Changing


CAUSES



CAUSES
CAUSES

TROUBLE SHOOTING


TROUBLE SHOOTING
TROUBLE SHOOTING


COM PLAINTS
COMPLAINTS
Engine M isses
l
l
l
l l
l
l
l
l l l
l l l
l l l l
l l
l
l
l
l
l l l l l
l
l
l
l l
l l
l
l
l
l l
l
Low Air Output
l l l
l l l
l l
l l
l
l
l
l
l
l
l
l
l
l l l l l
l
l
l
l
l
l
l
l
l
l
Crankcase Sludge
l
l l
l l
l
Dilution
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l
l l
l
l l
l l
l
l l
l l
l l
l
l l
l
l
l
l l
l
l
l
l
l l
l
l l l l l
l l l
l l l
l l
l l l
l
l l l
l l l
l
l
l
l

M echanical Knocks
l
l
l
l
l
l
l

Gear Train Whine
l l
l l
l l

l l l
l
l
l l

Excessive Noise
l
l l
l
l
l
l
l
l
l

Page 6-4

Page 6-5
Page 6-3
System
System
Repair
Cooling
Repair
Practices
Section – 6
Lubricating
Section – 6
Section – 6
Mechanical
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Oil Level Too High

Long Idle Periods
Faulty Thermostats
Engine Overloaded

Broken Cam Lobes
Oil Needs Changing


CAUSES



CAUSES
CAUSES

TROUBLE SHOOTING


TROUBLE SHOOTING
TROUBLE SHOOTING


COM PLAINTS
COMPLAINTS
Engine M isses
l
l
l
l l
l
l
l
l l l
l l l
l l l l
l l
l
l
l
l
l l l l l
l
l
l
l l
l l
l
l
l
l l
l
Low Air Output
l l l
l l l
l l
l l
l
l
l
l
l
l
l
l
l
l l l l l
l
l
l
l
l
l
l
l
l
l
Crankcase Sludge
l
l l
l l
l
Dilution
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l
l l
l
l l
l l
l
l l
l l
l l
l
l l
l
l
l
l l
l
l
l
l
l l
l
l l l l l
l l l
l l l
l l
l l l
l
l l l
l l l
l
l
l
l

M echanical Knocks
l
l
l
l
l
l
l

Gear Train Whine
l l
l l
l l

l l l
l
l
l l

Excessive Noise
l
l l
l
l
l
l
l
l
l

Page 6-4

Page 6-5
Page 6-3
System
System
Repair
Cooling
Repair
Practices
Section – 6
Lubricating
Section – 6
Section – 6
Mechanical
Mechanical
Maintenance
Operation and
Adjustments or
Dirty Oil Filter
Oil Level Too High

Long Idle Periods
Faulty Thermostats
Engine Overloaded

Broken Cam Lobes
Oil Needs Changing


CAUSES



CAUSES
CAUSES

TROUBLE SHOOTING


TROUBLE SHOOTING
TROUBLE SHOOTING


COM PLAINTS
COMPLAINTS
Engine M isses
l
l
l
l l
l
l
l
l l l
l l l
l l l l
l l
l
l
l
l
l l l l l
l
l
l
l l
l l
l
l
l
l l
l
Low Air Output
l l l
l l l
l l
l l
l
l
l
l
l
l
l
l
l
l l l l l
l
l
l
l
l
l
l
l
l
l
Crankcase Sludge
l
l l
l l
l
Dilution
l l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l l
l
l l
l
l l
l l
l
l l
l l
l l
l
l l
l
l
l
l l
l
l
l
l
l l
l
l l l l l
l l l
l l l
l l
l l l
l
l l l
l l l
l
l
l
l

M echanical Knocks
l
l
l
l
l
l
l

Gear Train Whine
l l
l l
l l

l l l
l
l
l l

Excessive Noise
l
l l
l
l
l
l
l
l
l

Page 6-4

Page 6-5
Page 6-3
Section -6 Page 6-6
FAULT CODE DIAGNOSTICS FAULT CODE DIAGNOSTICS - CONTD..
111 Generator Set ECM 359 Engine Will Not Start
Carboned Valves, Injector Cups
Fuel Consumption Excessive

112 Timing Fueling Flow Mismatch 378 Fueling Actuator #1 Circuit
Throttle Leakage Excessive

Smoke Black, Low Speed
Failure To Pick -Up Fuel
PT (TYPE G)
Fuel M anifold, PSI High
High Speed Surge M VS

Fuel M anifold, PSI Low
113 Timing Rail Actuator Circuit 379 Fueling Actuator #1 Circuit
Governed Speed High
Idle Undershoot M VS
Governed Speed Low
Idle Speed Too High

FUEL SYSTEM
Acceleration Slow
Deceleration Slow
394 Timing Actuator #1 Circuit
Rough Operation
115 Engine Speed Sensor Circuit
Wear Rate High

TROUBLE SHOOTING
Idle surge M VS
COM PLAINTS
116 Timing Rail Pressure Sensor Circuit 395 Timing Actuator #1 Circuit
Low Power
Air Leaks
117 Timing Rail Pressure Sensor Circuit 396 Fueling Actuator #2 Circuit
118 Fuel Pump Pressure Sensor Circuit 397 Fueling Actuator #2 Circuit
POSSIBLE CAUSES
119 Fuel Pump Pressure Sensor Circuit 398 Timing Actuator #2 Circuit
Air Signal Attenuator Filter Plugged l l l l
121 Engine Speed Sensor Circuit 399 Timing Actuator #2 Circuit
Air Leaks ll l l l l l l l l l
Aneroid Not Opening l l l l l l l 122 Intake Manifold Pressure Sensor Circuit 415 Oil Pressure - Engine Protection
Aneroid Stuck Open l l l l l 123 Intake Manifold Pressure Sensor Circuit 421 Oil Temperature - Engine Protection
Aneroid Valve Stuck Open l l l l l l 135 Oil Pressure Sensor Circuit 422 Coolant Level Switch Sensor Circuit
Cooling Line By-passing l l l l 141 Oil Pressure Sensor Circuit 423 Timing Rail Pressure in Range Error
Cranking Speed Slow l 143 Oil Pressure - Engine Protection 441 Unswitched Battery Supply Circuit
Filter Suction Restricted l l l l l l 442 Unswitched Battery Supply Circuit
144 Coolant Temperature Sensor Circuit
Fuel Dirty l l l l l
145 Coolant Temperature Sensor Circuit 449 High Fuel Pressure
Fuel with Water l l l l
Fuel Wrong Type l l l l l 146 Coolant Temperature - Engine Protection 451 Fuel Rail Pressure Sensor Circuit
Gear Pump Worn l l l l l l 151 Coolant Temperature - Engine Protection 452 Fuel Rail Pressure Sensor Circuit
Governor Plunger Chamfer, Inadequate l l 152 Coolant Temperature Sensor Circuit 455 Fuel Rail Actuator
Governor Plunger Scored l l l l l 153 Intake Manifold Temperature Sensor Circuit 467 Timing Fueling Flow Mismatch
Governor Plunger, Wrong/Worn/Sticking l l l l l l l l l l 154 Intake Manifold Temperature Sensor Circuit 468 Fueling Rail Flow Mismatch
Governor Plunger, Worn/Scored l l l l l l l l l 155 Intake Manifold Temperature - Engine Protection 471 Engine Oil Level - Engine Protection
Governor Spring Shims Low l l l l
197 Engine Coolant Level - Engine Protection 482 Low Fuel Pressure
Governor Spring Shims High l l l
212 Oil Temperature Sensor Circuit 488 Intake Manifold Temperature Sensor - Engine Protection
Governor Weights Incorrect (Heavy) l l l l l l l
Governor Weights, Pin, Wear l l l l 213 Oil Temperature Sensor Circuit 498 Oil Level Sensor Circuit
High Speed Spring Shimming Wrong l l l l l l l l l 214 Oil Temperature - Engine Protection 499 Oil Level Sensor Circuit
Idle Plunger (Button) Wrong l l l l l l l l 221 Ambient Air Pressure Sensor Circuit 514 Fuel Rail Flow Mismatch
Idle Plunger Spring Weak l l l 222 Ambient Air Pressure Sensor Circuit 546 Fuel Pressure Sensor Circuit
Idle Spring Wrong l l l l l 228 Coolant Pressure - Engine Protection 547 Fuel Pressure Sensor Circuit
Injector Adjustment Loose l l l l l l l 554 Fuel Rail Pressure Sensor Circuit
231 Coolant Pressure Sensor Circuit
Injector Cup Cracked, Wrong, Damaged l l l l l l l
232 Coolant Pressure Sensor Circuit 555 Blowby Pressure - Engine Protection
Injector Flow High l l l l l l l
Incorrect Injector l l l l l l l l l l l 233 Coolant Pressure - Engine Protection 556 Blowby Pressure - Engine Protection
Injector Orifice Size Wrong l l l l l l l l l 234 Engine Overspeed 611 Engine Was Shut Down Before Proper Engine Cooldown
Injector Plunger Worn l l l 235 Engine Coolant Level - Engine Protection 688 Engine Oil Level - Engine Protection
Pressure Valve Failure ll 236 Engine Speed/Position Sensor Circuit 689 Crankshaft Engine Position Sensor Circuit
Reversed Rotation, Drive Failure l 252 Low Oil Level 719 Blowby Pressure Sensor Circuit
Screw Adjusted, Incorrect l l l l l l l l l l 253 Oil Level - Engine Protection 729 Blowby Pressure Sensor Circuit
Shut-down Valve Restriction l l l
254 Fuel Shutoff Valve Solenoid Circuit 731 Engine Speed Sensor Circuit
Speed Settings, Unmatched auto/MVS or VS l l l l l
Spring Fatigue l l l l l l
259 Fuel Shutoff Valve Solenoid - Not Responding 778 Camshaft Engine Position Sensor Circuit
Throttle Leakage Excessive l l l l 261 Fuel Temperature - Engine Protection 1311 Customer-defined Fault Code No. 1
Throttle Linkage l l l l l l l l l l 263 Fuel Temperature Sensor Circuit 1312 Customer-defined Fault Code No. 2
Throttle Shaft Restricted l l l l 265 Fuel Temperature Sensor Circuit 1313 Customer-defined network Fault Code No. 1
Throttle Shims Excessive l l l l l l 266 Fuel Temperature - Engine Protection 1314 Customer-defined network Fault Code No. 2
Throttle Shims Insufficient l l l l 316 Fuel Pump Actuator Circuit 1315 Customer-defined network Fault Code No. 3
Torque Spring Wrong l l l l l l l l l
318 Fuel Pump Fueling Flow Mismatch 1316 Customer-defined network Fault Code No. 4
Weight Assist Setting High l l l l
326 Oil Level - Engine Protection 1317 Customer-defined Fault Code No. 3
Weight Assist Set Wrong l l l l l l l l l l
343 Electronic Control Module 1318 Customer-defined Fault Code No. 4
Section -6 Page 6-6


PT (TYPE G)

Governed Speed High
Governed Speed Low
Idle Speed Too High

FUEL SYSTEM
Acceleration Slow
Deceleration Slow
Rough Operation
Wear Rate High

TROUBLE SHOOTING
Idle surge M VS
COM PLAINTS
Low Power
Air Leaks
POSSIBLE CAUSES
Section -6 Page 6-6


PT (TYPE G)

Governed Speed High
Governed Speed Low
Idle Speed Too High

FUEL SYSTEM
Acceleration Slow
Deceleration Slow
Rough Operation
Wear Rate High

TROUBLE SHOOTING
Idle surge M VS
COM PLAINTS
Low Power
Air Leaks
POSSIBLE CAUSES
FAULT CODE DIAGNOSTICS - CONTD..
1448 Generator AC Output Frequency
1319 Alternator Temperature - Alternator Protection
1451 Generator Circuit vs Bus Voltage
1321 Common Warning Output Relay Driver Diagnostic
1452 Generator Set Circuit Breaker - Failed to Close
1322 Load Governed kW Setpoint-Analog Input Signal Circuit
1453 Generator Set Circuit Breaker - Failed to Open
1323 Load Governed kW Setpoint - Analog Input Signal Circuit
1454 Generator Set Circuit Breaker - Failed Position Contact
1324 Load Governed kVAR Setpoint - Analog Input Signal Circuit 1455 Utility Circuit Breaker Position Contact - Incorrect for
1325 Load Governed kVAR Setpoint - Analog Input Signal Circuit Application
1326 Starter Backup Disconnect 1456 Generator Circuit - Cannot Synchronize
1327 Load Governed kW Setpoint - Analog Input Signal Circuit 1457 Generator Set - Failed to Synchronize
1328 Generator Set Circuit Breaker 1458 Generator Set - Cannot Synchronize Phase
1329 Voltage Regulator 1459 Reverse kW
1331 Voltage Regulator Driver Diagnostic 1461 Reverse kVAR
1332 Off/Manual/Auto Switch Circuit 1462 High Current on Ground
1333 Off/Manual/Auto Switch Circuit 1463 Generator Announces to LonWorks Network that it is Not
1334 One or More Trims Have Been Set in Auto
1335 One or More Trims Have Been Set 1464 Generator Announces to LonWorks Network that it a
1336 Engine Shutdown "Load Dump" has Occurred
1337 LonWorks Wink Event Has Been Commanded 1465 Generator Announces to LonWorks Network that it is
"Ready to Accept Load"
1341 Paralleling Controller Requested a Generator Shutdown
1466 Modem - Lost Communication
1342 Fuel System Board - Incorrect Installation
1468 LonWorks Network - Lost Communication
1343 Base Board - Incorrect Installation
1469 Measure Speed vs AC Output Frequency
1344 Generator Interface Board - Incorrect Installation
1471 AC Output Current - High Warning
1345 Paralleling Board - Incorrect Installation
1472 AC Output Current - High Shutdown
1346 LonWorks Network Board - Incorrect Installation
1473 ECM Internal Watchdog Test Failed
1347 Slot 5 Board - Incorrect Installation
1474 Base Board - Extended I/O Software Mismatch
1475 Permission to Connect - Not Received
1476 Base Board - Not Responding to LonWorks Board
1351 LonWorks Network Board - Missing
1477 Crank Relay Contact Diagnostic
1414 Run Relay Contact Diagnostic
1478 Crank Relay Driver Diagnostic Detected an Error
1415 Run Relay Driver Diagnostic Detected an Error
1481 Voltage Regulator Driver Diagnostic
1416 Fail to Shut Down
1483 One or More Fault Codes Have Not Been Acknowledged
1417 Controller Power Down Fault
1485 EFC Driver Diagnostic
1419 Fuel Rail Driver Diagnostic
1421 Timing Rail #1 Driver Diagnostic
1487 Not in Auto LED Driver Diagnostic
1488 Warning LED Driver Diagnostic
1423 Fuel Pump Driver Diagnostic
1489 Shutdown LED Driver Diagnostic
1433 Emergency Stop Button Was Pressed
1491 Ready to Load Output Relay Driver Diagnostic
1434 Remote Emergency Stop Button Was Pressed
1492 Load Dump Output Relay Driver Diagnostic
1435 Engine is Cold - Potential Starting Problem
1493 Operator Interface Panel Power Relay Driver Diagnostic
1436 HPI-PT Fuel System Driver Diagnostic
1494 Modem Power Relay Driver Diagnostic
1438 Fail to Crank
1495 Common Shutdown Output Relay Driver Diagnostic
1439 Fuel Level Low in Day Tank
1496 Auto Mode Output Relay Driver Diagnostic
1441 Fuel Level Low in Main Tank
1497 Manual Run/Stop LED Driver Diagnostic
1442 Unswitched Battery Supply Circuit
1498 Exercise LED Driver Diagnostic
1499 Remote Start LED Driver Diagnostic
1444 kW Overload - Alternator Protection
2111 Aftercooler Water Inlet Temperature Sensor Circuit
1445 Alternator Short Circuit - Alternator Protection
1446 Generator AC Output Voltage
2113 Aftercooler Water Inlet Temperature - Engine Protection
Multiple Multiple Fault Codes on the Engine Harness
1319 Alternator Temperature - Alternator Protection
1451 Generator Circuit vs Bus Voltage
1321 Common Warning Output Relay Driver Diagnostic
1452 Generator Set Circuit Breaker - Failed to Close
1322 Load Governed kW Setpoint-Analog Input Signal Circuit
1453 Generator Set Circuit Breaker - Failed to Open
1323 Load Governed kW Setpoint - Analog Input Signal Circuit
1454 Generator Set Circuit Breaker - Failed Position Contact
1324 Load Governed kVAR Setpoint - Analog Input Signal Circuit 1455 Utility Circuit Breaker Position Contact - Incorrect for
1325 Load Governed kVAR Setpoint - Analog Input Signal Circuit Application
1326 Starter Backup Disconnect 1456 Generator Circuit - Cannot Synchronize
1327 Load Governed kW Setpoint - Analog Input Signal Circuit 1457 Generator Set - Failed to Synchronize
1328 Generator Set Circuit Breaker 1458 Generator Set - Cannot Synchronize Phase
1329 Voltage Regulator 1459 Reverse kW
1331 Voltage Regulator Driver Diagnostic 1461 Reverse kVAR
1332 Off/Manual/Auto Switch Circuit 1462 High Current on Ground
1333 Off/Manual/Auto Switch Circuit 1463 Generator Announces to LonWorks Network that it is Not
1334 One or More Trims Have Been Set in Auto
1335 One or More Trims Have Been Set 1464 Generator Announces to LonWorks Network that it a
1336 Engine Shutdown "Load Dump" has Occurred
1337 LonWorks Wink Event Has Been Commanded 1465 Generator Announces to LonWorks Network that it is
"Ready to Accept Load"
1341 Paralleling Controller Requested a Generator Shutdown
1466 Modem - Lost Communication
1342 Fuel System Board - Incorrect Installation
1468 LonWorks Network - Lost Communication
1343 Base Board - Incorrect Installation
1469 Measure Speed vs AC Output Frequency
1344 Generator Interface Board - Incorrect Installation
1471 AC Output Current - High Warning
1345 Paralleling Board - Incorrect Installation
1472 AC Output Current - High Shutdown
1346 LonWorks Network Board - Incorrect Installation
1473 ECM Internal Watchdog Test Failed
1474 Base Board - Extended I/O Software Mismatch
1475 Permission to Connect - Not Received
1476 Base Board - Not Responding to LonWorks Board
1351 LonWorks Network Board - Missing
1477 Crank Relay Contact Diagnostic
1414 Run Relay Contact Diagnostic
1478 Crank Relay Driver Diagnostic Detected an Error
1415 Run Relay Driver Diagnostic Detected an Error
1481 Voltage Regulator Driver Diagnostic
1416 Fail to Shut Down
1483 One or More Fault Codes Have Not Been Acknowledged
1417 Controller Power Down Fault
1419 Fuel Rail Driver Diagnostic
1487 Not in Auto LED Driver Diagnostic
1488 Warning LED Driver Diagnostic
1423 Fuel Pump Driver Diagnostic
1489 Shutdown LED Driver Diagnostic
1433 Emergency Stop Button Was Pressed
1491 Ready to Load Output Relay Driver Diagnostic
1434 Remote Emergency Stop Button Was Pressed
1492 Load Dump Output Relay Driver Diagnostic
1435 Engine is Cold - Potential Starting Problem
1493 Operator Interface Panel Power Relay Driver Diagnostic
1436 HPI-PT Fuel System Driver Diagnostic
1494 Modem Power Relay Driver Diagnostic
1438 Fail to Crank
1495 Common Shutdown Output Relay Driver Diagnostic
1439 Fuel Level Low in Day Tank
1496 Auto Mode Output Relay Driver Diagnostic
1441 Fuel Level Low in Main Tank
1497 Manual Run/Stop LED Driver Diagnostic
1498 Exercise LED Driver Diagnostic
1499 Remote Start LED Driver Diagnostic
1444 kW Overload - Alternator Protection
1445 Alternator Short Circuit - Alternator Protection
Multiple Multiple Fault Codes on the Engine Harness
INDEX IN-01 INDEX IN-02 INDEX IN-03

Specification Book - Janaki Sent

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Specification Book - Janaki Sent

Uploaded by

Copyright:

Available Formats

Specification

For detailed operation / maintenance / troubleshooting procedures

Driving Licence No. ____________________________

35/A/1/2, Erandwana, Pune 411 038.

Bulletin No. AX 1001506

For detailed operation / maintenance / troubleshooting procedures

Driving Licence No. ____________________________

35/A/1/2, Erandwana, Pune 411 038.

Bulletin No. AX 1001506

For detailed operation / maintenance / troubleshooting procedures

Driving Licence No. ____________________________

35/A/1/2, Erandwana, Pune 411 038.

Bulletin No. AX 1001506

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

• Disconnect the battery cables first and discharge any capacitors

• Use only the proper engine barring techniques for manually

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

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

• Disconnect the battery cables first and discharge any capacitors

• Use only the proper engine barring techniques for manually

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

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

• Disconnect the battery cables first and discharge any capacitors

• Use only the proper engine barring techniques for manually

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

Do not perform any repair when fatigued or after consuming

IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH

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

OF CHILDREN. Avoid prolonged or repeated contact with

all lifting devices such as chains, hooks or slings are in good

understand how to use them before performing any service

replacing fasteners. Do not use a fastener of poor quality if

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

skin. Do not swallow internally. In case of contact, immediately

turned off, and hot fluids in lines, tubes, and compartments.

disconnect all electrical/electronic controls before welding.

alcohol or drugs that can impair your functioning.

replacements are necessary.

Section - i INTRODUCTION ACRONYMS AND ABBREVIATIONS Page i-3

Do not perform any repair when fatigued or after consuming

IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH

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

OF CHILDREN. Avoid prolonged or repeated contact with

all lifting devices such as chains, hooks or slings are in good

understand how to use them before performing any service

replacing fasteners. Do not use a fastener of poor quality if

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

skin. Do not swallow internally. In case of contact, immediately

turned off, and hot fluids in lines, tubes, and compartments.

disconnect all electrical/electronic controls before welding.

alcohol or drugs that can impair your functioning.

replacements are necessary.

Section - i INTRODUCTION ACRONYMS AND ABBREVIATIONS Page i-3

Do not perform any repair when fatigued or after consuming

IMMEDIATELY CALL A PHYSICIAN. KEEP OUT OF REACH

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

OF CHILDREN. Avoid prolonged or repeated contact with

all lifting devices such as chains, hooks or slings are in good

understand how to use them before performing any service

replacing fasteners. Do not use a fastener of poor quality if

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

skin. Do not swallow internally. In case of contact, immediately

turned off, and hot fluids in lines, tubes, and compartments.