S-3.8 Cool Pac Operator Manual

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Workshop ManualS3.8 EngineEnglish – Original Instructions01-2010A030K288 (Issue 2)

FOREWORDThis manual is designed to be of assistance to all Personnel concerned with the maintenance andoverhaul of the S 3.8 Series Engine.It presents a complete and detailed Description of the Engine, together with precise instruction onservicing and overhaul procedure and dimensions which should be closely followed when overhaulingany part of the Engine to the Manufacturers standards.Effective maintenance can only be carried out if the personnel concerned are fully conversant with thevarious components of the Engine.Before maintenance operations are commenced, this manual should be carefully studied, and it should atall times be kept where it will be needed in the workshop.Thoroughly read the Workshop Manual before operating the generator set.Safe operation and top performance can be obtained only when equipment is operated and maintainedproperty.This manual is for guidance and assistance with recommendations for correct and safe procedures.Cummins Power Generation Limited cannot accept any liability whatsoever for problems arising as aresult of following recommendations in this manual.The information contained within the manual is based on information available at the time of going to print.In line with Cummins Power Generation Limited policy of continuous development and improvement,information may change at any time without notice. The Installers should therefore ensure that beforecommencing any work, they have the latest information available.Consult your Authorised Distributor for further information or assistance if required. It is essential that theutmost care is taken with the application, installation and operation of any diesel engine due to theirpotentially dangerous nature. Careful reference should also be made to other Cummins PowerGeneration Limited literature, in particular the Health and Safety Manual 0908-0110.Should you require further assistance contact:Cummin India LimitedPower Generation Business Unit35A/1/2, ErandwanePune, 411038IndiaTel: 91 2030248600Fax: 91 2066028090E-mail: cpgiservicesupport@cummins.comWeb Site: www.cumminspower.com3

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010TABLE OF CONTENTSDESCRIPTIONPAGE NO.To the Owner and Operator . 6Routine Service and Parts . 710 Maintenance Steps for Cummins Engines . 8Section 1. 9Operating InstructionsNew and rebuilt engine break-in . Section 2. 15Special Operating InstructionsSection 3. 17Engine Operation in Cold WeatherSection 4. 18Maintenance of Engine Laid up for Long PeriodSection 5. 19Maintenance OperationsSection 6. 25Lubricants, Fuels & CoolantSection 7 . 29Checking Valve TimingSection 8. 37Tightening TorquesSection 9. 39Troubleshooting5

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010To the Owner and OperatorGeneral InformationPreventative maintenance is the easiest and least expensive type of maintenance. Follow themaintenance schedule outlined in this manual.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.Personnel at Cummins Authorized Repair Locations have been trained to provide expert service andparts support.6

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010Routine Service and PartsGeneral InformationPersonnel at Cummins Authorized Repair Locations can assist you with the correct operation andservice of your engine. Cummins has a worldwide service network of Distributors and Dealers who havebeen trained to provide sound advice, expert service, and complete parts support.Problem SolvingGeneral InformationNormally, any problem that arises with the sale, service, or repair of your engine can be handled by aCummins 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 hisservice agreement.2. If the disagreement is with a Distributor, call the nearest Cummins Division or Regional Office;however, most problems are solved below the Division or Regional Office level. Beforecontacting, write down the following information: Engine model and serial numberType and make of equipmentTotal hours of operationWarranty start dateNature of problemSummary of the current arranged in order of occurrenceName and location of the Cummins Distributor or Dealer7

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-201010 MAINTENANCE STEPS FOR CUMMINS ENGINES1.KEEP DIRT OUT OF THE ENGINE.2.MAINTAIN A LUBRICATING FILM ON ALL BEARING SURFACES.3.REGULATE THE ENGINE’S FUEL.4.CONTROL OPERATING TEMPERATURE.5.GUARD AGAINST CORROSION.6.LET THE ENGINE BREATHE.7.PREVENT OVER-SPEEDING.8.KNOW YOUR ENGINE’S CONDITION.9.CORRECT PROBLEMS WHILE THEY ARE SIMPLE.10.SCHEDULE & CONTROL YOUR ENGINE MAINTENANCE.8

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010Section 1OPERATING INSTRUCTIONSThe 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 CumminsDiesel Engine.GENERAL-ALL APPLICATIONNew and rebuilt Engine Break-InS-3.8 engines are tested before being shippedfrom the factory and are ready to be put to work.Note : One receipt of engine by truck,ensure unloading of the engine byskiled personnel. The Personnel have touse necessary personal protectiveequipment to avoid accidents. Enginesare to be un loaded using the liftinghooks fitted on the engines. During theengine installation ensure properfitment of Anti Vibration Mounting Pad.Warning : Ensure that the shippingbracket is removed during the engineinstallation.Fill engine with amount of oil listed as lowlevel oil pan capacity.2.Allow five (5) minutes or more for oil to drainto the oil pan. If engine and/ or oiltemperature is below 400 F (40 C), a longerperiod may be required for full drain.3.Insert dipstick into gauge tube fully seated;hold for five (5) ten (10) seconds, thenwithdraw slowly.4.Add enough additional oil to fill engine tolisted high-level capacity. The dipstick hasmark to high & low oil level.5. Start engine and operate at idle for 3minutes. Stop engine wait for 10 minutes andfill to high mark. Additional oil may berequired to fill oil filters and lines.You will get better life from engine by,1. Avoiding operation for long periods atengine idle speeds, or at maximumhorsepower levels in excess of fiveminutes.Do not confuse with complete oil system capacitywhich also includes drilled passages, lines andfilters.2. Developing the habit of watching engineinstruments closely during operation andletting up on throttle if oil temperaturereaches. 2500F (1210C) or coolant temperatureexceeds 2030F (950C)3.1.Priming the Lubricating SystemChecking engine oil level prior to engine start.4.For continuous rating, load can be appliedafter the engine is commissioned.New or Rebuilt Engines.Pre-Starting Instructions-First Time Priming theFuel System.1.Fill fuel filter with clean No. 2 diesel fuel oilmeeting the specification outlined.2.Check the oil level of the MICO fuel pumpwith the dipstick provided.3.Check & fill fuel tanks.Oil Pan CapacitiesHighLow(liters)(liters)86Fig. 1-1 : Pre-lubricating TurboNote : On turbocharged engines,remove oil inlet line from theturbocharger and pre-lubricate bearingby adding 2 to 3 oz. (50 to 60cc) of cleanlubricating oil. Reconnect oil supplyline.9

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010Check Air ConnectionCheck air connection to air cleaner and aircrossovers to assure all are secured.Check Engine Coolant SupplyRemove the radiator cap and check engine coolantlevel. Add coolant as needed.COOLING SYSTEMCheck and top up radiator with Specified coolantif required. If the coolant starts boiling, therecould be a defect in the cooling system whichmay be on account of :Fig. 1-2: Engine Fuel Filteri. Less coolant or dirt/scale havingaccumulated inside cooling waterpassages, especially in the radiator cores.Fuel System BleedingIf the performance of the engine is affecteddue to presence of air in the fuel system(commonly known as air lock) the defect can beremoved by bleeding the fuel system as follows :ii. Choking of the radiator air passages due toforeign material or damaged radiator fins.iii. Loss of coolant by evaporation andleakage through defective radiator cap.iv. Loose water pump drive belt.a.Loosen bleeding screw on primary filter.v. Coolant leakage from the cooling system.b.Unscrew lift pump lever knob and prime tilldiesel coming out of the bleeding screw ofthe primary filter is free from any air bubble.c.Tighten bleeding screw and plunger knob.Always use genuine radiator cap. A proper radiatorcap firmly fitted maintains pressure in the coolingsystem and makes the engine more efficient bypermitting a slightly higher operating temperature.The vacuum in the radiator is relieved by a valveprovided in the cap. The radiator pressure capvalue is 7 PSI. Degrease and clean coolingsystem regularly.d. Repeat this process on bleeding screw onthe secondary fuel filter and then on the fuelinjection pump gallery. If the air bubblescontinue coming out of the bleeding screws,either there is less diesel in the tank or thereis an air leak in the suction pipe. Check andrectify.Caution : Do not add cold water tooquickly to hot engine.Overflow ValveFUEL SYSTEM1.Bleeding screw primary filterIn case the engine running is found to be irregularor shows a tendency to fall or there is loss ofpower, this may be due to faulty operation of theoverflow valve in the fuel filter system.2.Bleeding screw secondary filterIf necessary, replace it.3.Drain plug secondary filter.Nozzle Operation4.5.Drain plug primary filter.Bleeding screw on fuel injection pump.If the engine is running irregularly or there is adiesel knock or the fuel consumption is abnormal,The photograph shows different points for fuelsystem. The description of these points are,10

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010the oil can immediately flow to the bearingsand the time required by the oil to attain thecorrect pressure is minimised.If this instruction is ignored the bearing may getdamaged. The oil filter must be kept clean as faras possible to protect the engine componentsfrom rapid and excessive wear and tear due toabrasion. Tighten the centre bolt to 4 Kg-m. torque.Fig. 1-3 Cross-section of Lub-oil Filterfaulty injection nozzle operation may be the cause.Generally, this is due to dirt in the fuel system.If excessive black smoke is emitted onacceleration, its could be due to drubbing ofnozzles. Get the nozzles checked at MICO dealerpoint.Fig. 1-4 : Oil Filling Point on EngineNote : In case the old filter cartridge was founddamaged/punctured, the filter top coverassembly should also be removed andrefitted after thorough cleaning.CHANGING ENGINE OILThe engine oil should be drained while it is still hot.a.Unscrew sump drain plug and allow the oilto drain out for 20 mins.b.Unscrew filler plug of oil filter, drain out oiland refit filler plug.Proceed as below :c. Unscrew centre bolt and remove oil filterbowl. Discard oil filter cartridge. The filtercartridge should not be cleaned orreused.d.Check "O' ring and seal for any damage.Replace if found damaged.e.Clean the bowl thoroughly and insert anew genuine fuel flow oil filter cartridgeinto the bowl.f.During re-assembly of the oil filter, fill thefilter bowl with one litre of engine oil throughthe drain plug and fit the filter bowl to thetop cover and tighten the centre bolt to thespecified torque. Before starting, crank theengine with the help of ignition key, so thati.Remove the two screws holding the filter topcover to the crankcase and remove it withits gasket.ii.Remove the bypass valve assembly andclean the valve and its seat.iii.Clean all oil passage in cover thoroughly.Replace "O' ring and seals if f ounddamaged.iv. Reassemble bypass valve with new sealingwasher if necessary.v.Fit new gasket on the cover.vi. Refit oil filter cover assembly to thecrankcase taking care that the gasket doesnot get damaged during fitment.vii. Tighten evenly and equally the two mountingbolts of cover to 6 Kg-m. torque.11

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010Starting the Engineviii. Clean the drain plug of the engine oil sumpand refit with a new sealing washer ifnecessary. Tighten to 4 to 6 Kg-m. torque.Starting requires the clean air & fuel to besupplied to the combustion chambers in properquantities at the correct time.ix. Fill in 8 liters of engine oil into the sump.x. Start engine and allow it to run for a fewminutes and stop.Engine Warm-upWhen the engine is started, it takes a while toget the lubricating oil film re-established betweenshafts and bearings and between pistons andliners. The most favourable clearances betweenmoving parts are obtaining only after all engineparts reach normal operating temperature. Avoidseizing pistons in liners and running dry shafts indry bearings by brining the engine up to operatingspeed gradually as it warms up.xi. After 2 minutes check level of oil indicatedon the dipstick. It should be at the uppermark and if not, top up.xii. Check oil level in fuel injection pump andgovernor. Top up, if necessary.Caution : Make sure that only genuineoil filter cartridge is used. Inspection ofnon genuine filter cartridges availablein the market at low prices haverevealed:i.Oil TemperatureThe oil temperature gauge normally should readbetween 167 F (75 C) and 221 F (1 5 C). Underfull load conditions, an oil temperature of 24 F(116 C) for a short period is not a cause for alarm.Use of inferior filtering material which cannotproperly filter the engine oil.ii.Improper dimensions which cannot preventfiltered oil getting mixed with unfiltered oil.Caution : Any sudden increase in oiltemperature which is not caused byload increase is a warning of possiblemechanical failure and should beinvestigated at once.Since it is extremely difficult to distinguishbetween genuine and non-genuine filter elements,obtain these only from Cummins Dealers.PREPARING THE ENGINE FOR A OPERATIONPREPARING THE ENGINE FOR A DAY'S WORKCheck the following :1.During warm-up period, apply load graduallyuntil oil temperature reaches 14 F (6 C).While oil is cold it does not do a good job oflubricating. Continuous operating or long periodsof idle with oil temperatures below 14 F (6 C) maycause crankcase dilution and acids in thelubricating oil which quickly accelerate enginewear.Fuel level in fuel tank, Top up, if necessaryand secure cap.2. Engine oil level - First thing in the morning orat least 2 minutes after stopping the engine.Top up, if oil level is less than midway betweenminimum and maximum marks.Water TemperatureA water temperature of 167 to 2 3 F (75 C to95 C) is the best assurance that working parts ofthe engine have expanded evenly to the mostfavourable of clearances. Maximum engine coolanttemperatures should not exceed 2 3 F (95 C).Keep thermostats always in the engine, avoid longperiod of idling and take necessary steps to keepwater temperature up to a minimum of 167 F(75 C). If necessary in cold weather, use radiatorshutters or cover a part of the radiator to preventovercooling.The oil Should not exceed the maximumlevel mark. Use only approved brand of oil.3.Radiator coolant level. Top up, if necessaryand secure radiator cap.4.Condition and tension of fan belt. Adjusttension, if necessary.5.All gauges, for proper functioning.6.Leakage of coolant, fuel or oil at all jointsof hoses and pipes and rectify, if necessary.12

Workshop ManualS3.8 EngineA030K288 (Issue 2)01-2010Oil Pressurebefore shutting it down to allow lubricating oil andwater to carry heat away from the combustionchamber, bearings shafts etc. This is especiallyimportant with turbocharged engines.Normal engine oil Pressure at temperature 2210 F(1050 C) should be between 2.5 to 5 Kg/cm2 atrated speed and 1 to 2 Kg/cm2 at low idle speed.The turbocharger contains bearings and seals thatare subject to the high heat of combustion exhaustgases. While the engine is running, this heat iscarried away by oil circulation, but if the engineis stopped suddenly, the turbocharger temperaturemay rise above 3600 F. The results of extremeheat may be seized bearings or loose oil seals.Note : Please note that oil pressure willvary with temperature.Note : Individual engines may vary fromabove normal pressures. Observe andrecord pressure when engine is new toserve as guide for indication ofprogressive engine condition. (High oilpressure during start up is not a causefor alarm.) For record purposes thesereadings are more accurate and reliablewhen taken immediately after an oilchange.Do Not Idle Engine For Excessively LongPeriodsLong periods of idling are not good for an enginebecause combustion chamber temperatures dropso low the fuel may not burn completely. This willcause carbon to clog the injector spray holes andpiston rings and may result in stucked valves.Engine ExhaustThe engine exhaust is a good indicator of engineoperation and performance. A smoky exhaustmay be due to a poor grade of fuel, dirty aircleaner, overfueling or poor mechanicalconditions.If engine exhaust is smoky, corrective actionshould be taken.If engine coolant temperature becomes too low,raw fuel will wash lubricating oil off cylinder wallsand dilute crankcase oil so all moving parts of theengine will suffer from poor lubrication.If the engine is not being used, shut it down.Warning : Inhalation of exhaust gasescan result in severe personal injury ordeath. Use extreme care duringinstallation to provide a tight exhaustsystem. Terminate exhaust pipes awayfrom enclosed or sheltered areas,windows, doors and vents.Switch off the engine with the shut down coilprovided on engine.OrThe engine can be shut down by pulling downmechanical lever fitted on MICO pump.High Altitude OperationSome engines, particularly naturally aspirated, losehorsepower when operated at high altitudebecause the air is too thin to burn as much fuelas at sea level. This loss is about 5 percent foreach 1800 ft. of altitude above sea level for anaturally aspirated engine. Operate the engineusing a lower power requirement at highaltitude to prevent smoke and over-fueling.RadiatorThe radiator used on S-3.8-G engine are state ofthe art aluminium radiators. These radiators arewith aluminium tubes & fins. The top and bottomtank are of moulded plastic material. Theseradiators do not have de-aeration cooling system.Warning : Do not remove the guardingwhen the engine is in working

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. Personnel at Cummins Authorized Repair Locations have been trained to provide expert service and parts support. Workshop Manual S3.8 Engine A030K288 (Issue 2) 01-2010 6

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