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Workshop Manual

S3.8 Engine

English – Original Instructions

01

-20

10

A030K288 (Issue 2)

• Page 1
  Workshop Manual S3.8 Engine English – Original Instructions A030K288 (Issue 2)
• Page 2
  FOREWORD…

• Page 3: Table Of Contents

  TABLE OF CONTENTS DESCRIPTION PAGE NO. To the Owner and Operator …………….6 Routine Service and Parts …………….7 10 Maintenance Steps for Cummins Engines ……….8 Section 1………………….Operating Instructions New and rebuilt engine break-in …………..Section 2…………………. 1 Special Operating Instructions Section 3………………….

• Page 4: To The Owner And Operator

  Keep records of regularly scheduled maintenance. Use the correct fuel, lubricating oil and coolant in your engine. Cummins Inc. uses the latest technology and highest quality components to produce its engines. ® Cummins Inc. recommends using genuine Cummins new parts and ReCon exchange parts.

• Page 5: Routine Service And Parts

  Cummins Authorized Repair Location in your area. If the problem has not been handled satisfactorily, follow the steps outlined below: 1. If the disagreement is with a Dealer, talk to the Cummins Distributor with whom the has his service agreement.

• Page 6: 10 Maintenance Steps For Cummins Engines

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 10 MAINTENANCE STEPS FOR CUMMINS ENGINES KEEP DIRT OUT OF THE ENGINE. MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES. REGULATE THE ENGINE’S FUEL. CONTROL OPERATING TEMPERATURE. GUARD AGAINST CORROSION. LET THE ENGINE BREATHE.

• Page 7: Section 1

  Section 1 OPERATING INSTRUCTIONS The engine operator must assume responsibility of engine care while engine is being operated. There are comparatively few rules which operator must observe to get best service from a Cummins Diesel Engine. GENERAL-ALL APPLICATION Fill engine with amount of oil listed as low- level oil pan capacity.
• Page 8
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Check Air Connection Check air connection to air cleaner and air crossovers to assure all are secured. Check Engine Coolant Supply Remove the radiator cap and check engine coolant level. Add coolant as needed.
• Page 9
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 the oil can immediately flow to the bearings and the time required by the oil to attain the correct pressure is minimised. If this instruction is ignored the bearing may get damaged. The oil filter must be kept clean as far…
• Page 10
  Since it is extremely difficult to distinguish between genuine and non-genuine filter elements, obtain these only from Cummins Dealers. PREPARING THE ENGINE FOR A OPERATION During warm-up period, apply load gradually PREPARING THE ENGINE FOR A DAY’S WORK until oil temperature reaches 14°…
• Page 11
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Oil Pressure before shutting it down to allow lubricating oil and water to carry heat away from the combustion Normal engine oil Pressure at temperature 221 chamber, bearings shafts etc. This is especially (105 C) should be between 2.5 to 5 Kg/cm…
• Page 12
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 NOTES…

• Page 13: Section 2

  The adjustment to the fuel injection pump should We are giving below special instructions to be be carried out at authorised MICO dealers followed while operating Cummins Diesel workshops. Engines at high altitudes and low ambient 2) LOW TEMPERATURE OPERATION temperature.

• Page 14
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Recommended Antifreeze Agents Before adding the antifreeze agent into the cooling system. The specification for low silicate antifreeze which meets ASTM 4985 test (GM6038M spec) criteria. i.Inspect the cooling system for leakages and clean it thoroughly.

• Page 15: Section 3

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 3 ENGINE OPERATION IN COLD WEATHER Satisfactory performance of a diesel engine a change to warmer climate normally required operating in low ambient temperature conditions only a minimum of revision. Most of the…

• Page 16: Section 4

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 4 MAINTENANCE OF ENGINE LAID UP FOR LONG PERIOD For engines which are not likely to be operated doing so. for a long period the following maintenance After the cylinder head cover has been…

• Page 17: Section 5

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 5 MAINTENANCE OPERATIONS Maintenance is the key to lower operating costs. A diesel engine requires regularly scheduled maintenance to keep it running efficiently. MAINTENANCE SCHEDULE A maintenance schedule should be established Preventive maintenance is the easiest and least using the check-sheet as a guide;…

• Page 18
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 ENGINE MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR ‘S’ SERIES With Spin-on type Fuel & Lube Oil Filter SYSTEM A – Check B – Check C — Check D — Check GROUP Daily Every 475 –…
• Page 19
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 SERVICE DETAILS: ensure that the following service has been carried out. This service should be carried out by the ) ROUTINE SERVICE — DAILY (A-check) authorised dealer. 1. Check coolant level in radiator, top-up if Check engine oil level, top up is necessary and secure radiator cap.
• Page 20
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 be done after 5 to 10 hours of every remounting of cylinder head). 13.Check condition of alternator and fan belt and adjust tension, if necessary. 14.Start engine and check : (a) Engine idling and running (watch for any…
• Page 21
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 MAINTENANCE SCHEDULE FOR STARTER AND ALTERNATOR…
• Page 22
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 NOTES…

• Page 23: Section 6

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 6 LUBRICANTS, FUELS & COOLANT Providing and maintaining an adequate supply of clean, high quality fuel, lubricating oil, grease and coolant in an engine is one way of insuring long life and satisfactory performance.

• Page 24
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 To prevent rush formation and freezing of water oil filter cartridge change period specified by us. The inside water jackets of crankcase and cylinder engine oil should be replace by at every 500 hrs head mix antifreezing agent as recommended.
• Page 25
  CLEANING OF COOLING SYSTEM Cummins strongly recommends the use of SAE 15W40 lub oil with API, CF4 classification Wait until the temperature falls below 50° C before for all Cummins engines to get the various draining. advantages and optimum performance from the engine.
• Page 26
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 in 5 Litre Can. Premix Coolant Co o la n t ‘Ethylene Glycol’ (Type JIS K 2234­ 94, Class 2) Coolant recommended to prevent Corrosion of Engine & Radiator. I t also broadens…

• Page 27: Section 7

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 7 CHECKING VALVE TIMING 1. Attach suitable graduated disc to the vibration in order to bring No. 1 piston to BDC damper pulley and mark ‘BDC’ position on the periphery of the vibration damper pulley by turning crankshaft by 180 from ‘TDC’…

• Page 28
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 gears/ damaged woodruff keys / mismatched timing gears (i.e. ‘1’ mark on crankshaft gear tooth is not matched with ‘3-3’ mark on camshaft gear. 11. Identify the defect and rectify. REMOVAL OF FUEL INJECTION PUMP (Linkages, oil line etc.
• Page 29
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 into timing gear housing in such a manner that the tooth of the injection pump gear marked with a notch is in alignment with pointer in timing housing smaller cover. Fig. 5. Fit mounting bolts with spring washer and tighten.
• Page 30
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 pump away from the engine slowly when the flow of fuel decreases. Fig. 10 and ultimately the flow nearly stops, giving a drop in 15 to 20 seconds. Fig. 11. Check flywheel…
• Page 31
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 eakages if any and screw on the hand primer knob fully. 17.Connect accelerator linkage. Caution : Ensure adequate tightness on feed pump fuel inlet banjo to avoid fuel starvation. REMOVAL AND INSTALLATION OF INJECTOR…
• Page 32
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 INSTALLATION Apply a light coat of grease/oil to new sealing ring and place it in cylinder head. Fig. 18. Screw in protective sleeve into cylinder head with adapter, 000 589 0309 and tighten to specified torque.
• Page 33
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 thicker shims). When testing nozzle, never put your hand under the jet of a spraying nozzle. The jet will penetrate into the skin which is dangerous. CHECK NOZZLE FOR LEAKAGE Push nozzle tester lever down slowly until needle on pressure gauge shows 20 kg/cm’…
• Page 34
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 3 Immerse nozzle needle and nozzle body in Mark injection pump by the letter “Z” behind the clean diesel oil and check slide ability by pump designation after the work has been carried means of drop test.

• Page 35: Section 8

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 SECTION 8 TIGHTENING TORQUES When selecting torque wrench, remember that it should not be subject to torque exceeding three-fourth of its maximum capacity. Before tightening, clean threads and apply a little oil to them.

• Page 36
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 NOTES…

• Page 37: Section 9

  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Section 9 TROUBLE SHOOTING Cause Remedy When Starting Trouble Starter Motor does not operate Key not inserted properly into main Insert Key correctly. line switch. Battery not in order : Inadequate charging condition.

• Page 38
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 II. During Operation Trouble Cause Remedy No fuel in tank Refill tank. After filling a tank which Engine fails. has been completely emptied. at first vent the fuel system. Fuel filter is dirty Clean.
• Page 39
  Workshop Manual A030K288 (Issue 2) S3.8 Engine 01-2010 Trouble Cause Remedy G) Oil pressure suddenly drops. Lack of oil in crankcase. Refill Cau t io n : In ca s e o f a Line between engine housing and Tighten connecting screws.

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