Engine Workshop Manual: G-Drive Package B5.9G Series

Engine Workshop Manual
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G-Drive Package
B5.9G Series
English 01-2010 A024J818 (Issue 2)

Workshop Manual A024J818 (Issue 2)
B.5.9.G Series Engine 01-2010
FOREWORD
This manual is designed to be of assistance to all Personnel concerned with the maintenance and
overhaul of the B.5.9G Series Engine.
It presents a complete and detailed Description of the Engine, together with precise instruction on
servicing and overhaul procedure and dimensions which should be closely followed when overhauling
any part of the Engine to the Manufacturers standards.
Effective maintenance can only be carried out if the personnel concerned are fully conversant with
the various components of the Engine.
Before maintenance operations are commenced, this manual should be carefully studied, and it should
at all 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 maintained
property.
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
a result 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 before commencing any work, they have the latest information available.
Consult your Authorised Distributor for further information or assistance if required. It is essential
that the utmost care is taken with the application, installation and operation of any diesel engine
due to their potentially dangerous nature. Careful reference should also be made to other Cummins
Power Generation Limited literature, in particular the Health and Safety Manual 0908-0110.
Should you require further assistance contact:

Cummin India Limited
Power Generation Business Unit
35A/1/2, Erandwane
Pune, 411038
India
Tel: +91 2030248600

Fax: +91 2066028090
E-mail: [email protected]
Web Site: www.cumminspower.com
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INDEX
Sr. Contents Page No.
1. General Safety Instructions ................................................................... 7
2. Engine Systems : Overview .................................................................. 9
3. Engine Operation .................................................................................. 13
4. Fuel, Oil & Coolant Specifications ...................................................... 19
5. Maintenance Schedule ......................................................................... 23
6. Engine Maintenance ............................................................................. 25
7. Adjustment, Replacement and Repair B Series ................................. 35
8. Trobule Shooting ................................................................................... 51
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NOTES
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Section 1
GENERAL SAFETY INSTRUCTIONS
Improper practices or carelessness can cause burns, cuts, mutilation or other bodily injury or death.
Read & understand all of the safety precautions and warnings before performing any repair. This list contains
the general safety precautions that must be followed to provide personal safety.
NOTE : On receipt of engine by truck, ensure unloading of the engine by skilled

personnel. The personnel have to use necessary personal protective equipment to avoid
accipdents. Engines are to be un loaded using the lifting hooks fitted on the engines.
During the engine installation ensure proper fitment of Anti Vibration Mounting Pad.
Warning : Ensure that the shipping bracket is removed during the engine installation.
• Make sure that the work area surrounding the product is dry, well lit, ventilated, free from clutter, loose
tools, parts, ignition sources and hazardous substances.
• Always wear protective glasses and protective shoes while working on the engine.
• Rotating parts can cause cuts, mutilation or strangulation.
• Do no wear loose fitting or torn clothing.
• Disconnect the battery (negative) cable first and discharge before beginning any repair work.
• Use ONLY the proper engine barring techniques for manually rotating the engine. Do not attempt to rotate
the crankshaft by pulling or prying the fan. This practice can cause serious personal injury, property
damage or damage to fan bladed causing premature failure of the engine.
• If the engine has been operating and the coolant is hot, allow the engine to cool before you slowly
loosen the filler 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.
• Be alert for possible pressure when disconnecting any device from a system that utilises pressure. Do
not check for pressure leaks with your hand. High pressure oil or fuel can cause serious injury.
• Corrosion inhibitor contains alkali. Do not get the substance in your eyes. Avoid prolonged or repeated
contact with your skin. Do not swallow internally. In case of contact, immediately wash skin with soap
and water.
• To avoid burns, be alert for hot parts and hot fluids in lines, tubes and compartments.
• Always use tools that are in good condition. Use only genuine Cummins replacement parts.
• Always use the same fastener part number when replacing fasteners. Do not use fasteners of lessor
quality of replacements are necessary.
• Avoid inhalation of vapours, ingestion and prolonged contact with used engine oil.
CAUTION : Ensure aligment and torgue of related fosteners while connecting aternator
to the engine fly wheel housing.
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-8-
Section 2
ENGINE SYSTEMS : OVERVIEW
This section describes flow through various engine systems. The information given here are of general nature.
This is intended to help the user to understand four principle engine systems viz. Air, Fuel, Lub & Cooling
system. Good understanding in engine systems will help in troubleshooting and preventive maintenance.
4.1 Air System :
Air enters through air cleaner to turbocharger inlet. Turbocharged air passes through intake manifold,
gets distributed to all six power cylinders. After combustion, burnt gases go out through exhaust manifold
& rotates the turbine wheel. Exhaust gases emit out through flexible bellow & muffler.
Exhaust System
1. Exhaust Valve
Dual Entry 2. Exhaust Manifold (Pulse-Type)
Turbine
Housing 3. Dual Entry to Turbocharger
4. Turbocharger Exhaust Outlet.
Pulse
Exhaust
Manifold
Intake System
1. Intake Air Inlet to Turbocharger
2. Turbocharger Air to Aftercooler
3. Aftercooler
4. Intake Manifold (Integral part of Cylinder Head)
5. Intake Valve
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4.2 Fuel System :
Fuel is sucked from base tank by suction inlet pipe and suction strainer. Lift pump lifts the fuel &
delivers to the filtration system. There is a two stage cleaning of fuel; once by water separator & then
by microfine fuel filter. Cleaned fuel enters to Bosch fuel injection pump which pressurise and delivers
the high pressured fuel to Bosch type injectors fitted on each cylinder. Returned fuel is routed back to
the tank through return pipe.
CAUTION : Ensure adequate tightness on feed pump fuel inlet banjo to avoid fuel
starvation.
4.3 Lub system :
Lubricating pump draws oil from the oil pan & forces it to the lubrications system. The pressure regulating
valve controls oil pressure. The filter bypass valve ensures supply of oil when filter gets choked. The
piston pines are lubricated by the splash from piston cooling nozzles. Oil pump idler gear is forced
lubricated. The reminder of the front gear train is lubricated by oil carry over splash.
The schematic given under shows the flow of lubricating oil to all parts of the engine.
1. Lubricating Oil Pump

2. Pressure Regulating Valve Main Oil Rifle
3. Oil Cooler
4. Filter Bypass Valve
Piston Cooling
5. Oil Filter Nozzle Filter
Oil Cooler
Bypass
6. Turbocharger Oil Supply Valve
Gerotor
7. Oil Return to Pan Oil Filter
Lubrication
Pump
8. Piston Cooling Nozzle Pressure
Regulator
9. Oil Pump idler Gear
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4.4 Cooling System :
B Series cooling system is a 10 PSI closed pressurised system.
Coolant is sucked by the engine driven water pump from the bottom tank of the radiator. Coolant passes
through oil cooler, all cylinder jackets and cylinder head to reach finally at thermostat housing. Coolant
get divided either to the inlet of the water pump or to the radiator depending on coolant temperature.
Complete coolant get diverted to the radiator after coolant temperature reached 90 deg. C.
Flow of coolant through the engine is shown in the following sketch.
Cylinder Block
1. Coolant Inlet
2. Pump Impeller
3. Coolant Flow Past Oil Cooler
4. Coolant Flow Past Cylinders Cylinder Head
5. Coolant to Cylinder Head 1. Coolant Flow from Cylinder Block
2. Coolant to Thermostat Housing
1. Coolant Flow Past Injector 5. By-Pass Closed

2. Thermostat 6. Coolant Flow Back to Radiator
3. Coolant By-Pass Passage
4. Coolant Flow to Pump Inlet
1.1 Exhaust System

Pipe exhaust gases to the outside of any enclosure. Locate the exhaust outlets away
from any air inlets to avoid gases re-entering the enclosure. Exhaust installations are
subject to various detrimental conditions such as extreme heat, infrequent operation and
light loads. Regularly inspect the exhaust system both visually and audibly to see that
the entire system remains fume tight and safe for operation.
WARNING : inhalation of exhaust gasses can result in severe personal injury or death.
use extreme care during installation to provide a tight exhaust system. terminate exhaust
pipes away from enclosed or sheltered areas, windows, doors and vents.
WARNING : Exhaust pipes are very hot and they can cause severe personal injury or
death from direct contact or from fire hazard. shield or insulate exhaust pipes if there
is danger of personal contact or when routed through walls or near other combustible
materials.
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NOTES
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Section 3
ENGINE OPERATION
5.1 Starting the engine :
Before starting the engine, perform daily maintenance checks. Please refer Section 7&8 of this manual
for details of maintenance checks.
CAUTION :
To prevent damage to the starter, do not engage the starting motor more than 10 to 12
seconds. Wait 2 minutes between each attempt to start.
If the engine does not start after three attempts, check the fuel supply system. Absence
of blur or white exhaust smoke during cranking indicates that no fuel is being delivered.
Move the throttle position to idle as soon as the engine starts.
Engine oil pressure must be indicated on the gauge within 15 seconds after starting.
5.2 Stopping the engine :
Remove the load from the engine. Run the engine few minutes before routine shut down, on no load.
It will allow the lubricating oil and coolant to carry heat away from the combusion chamber, bearings,
shafts etc. This is especially emportant for Turbocharged engines.
Minimum oil pressures required
Idle : 10 PSI
Full Speed & Load : 30 PSI
5.3 Operating the engine :
WARNING : Guarding should not be removed when the engine is is running condition.
• Do not operate the engine at full throttle below peak torque engine speed for extended periods (More
than 1 minute) of time.
• Allow the engine to idle 3 to 5 minutes before shutting it off after a full load operation.
• Monitor the oil pressure and coolant temperature gauges frequently. Shut off the engine if oil pressure
or coolant temperature does not meet specifications.
• Continuous operation of the engine with low or high coolant temperature can damage the engine.
• Most failures give an early warning. Look and listen for changes in performance, sound or engine
appearance that can indicate service or engine repair is needed. Some changes to look for are as follow:
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i) Engine misfires
ii) Vibration
iii) Unusual engine noise
iv) Fuel, oil or coolant leakage
v) Sudden change in engine operating temperature or oil pressure
vi) Excessive smoke
vii) Loss of power
viii) An increase in oil consumption
ix) An increase in fuel consumption
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Engine preservation procedure
Introduction
On any engine not in service, whether installed in equipment or waiting to be installed, the unpainted surfaces
and various internal passages are subject to rust and corrosion.
Every engine going out of factory is processed and is suitable for storage upto six months from the date of
despatch. However sometimes engines are required to be stored for more than six months, also on many
occasions engines as installed in equipment are not put in service. Hence it is necessary to process such
engines for storage. Based on above the procedure for preservation can be catagorised as below.
i. Engine preservation procedure for engines to be stored upto six months, from the date of engine shipment
from factory.
ii. Engine preservation procedure to be carried out for engine storage beyond six months from date of
shipment from factory.
iii. Engine preservation procedure for engines installed in equipment.
NOTE : The rate of corrosion varies with climatic condition. Variance in climatic condition
makes it very difficult to state the length of time an engine can be stored without rust
and corrosion damage. However the procedures outlined below are useful for various
climatic conditions except for arctic conditions and vary low temperatures.
1. Engine preservation procedure for engines to be stored upto six months, from the date of engine
shipment from factory.
NOTE : Every engine going out of factory is processed for storage upto six months.
Hence no additional processing is required except proper storage, as given on next page.
i) If engine has to be stored in the engine box, as received from factory
Sr. No. Description
a Store engine box along with kit boxes, in enclosed place protected from water / rain water,
dust etc.
b Tag all these boxes indicating following,
ENGINE SHIPMENT DATE :
THE ENGINE HAS BEEN TREATED FOR

PRESERVATION FOR A PERIOD OF SIX
MONTHS FROM THE ENGINE
SHIPMENT DATE MENTIONED ABOVE.
c Do not stack any material on engine box to avoid damage to engine / engine box.
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ii) If engine has to be stored with out engine box, and / or skid.
Sr No. Description
a Store engine along with kit boxes, in enclosed place protected from water / rain water, dust etc.
b Tag all these boxes indicating following,
ENGINE SHIPMENT DATE :
THE ENGINE HAS BEEN TREATED FOR

PRESERVATION FOR A PERIOD OF SIX
MONTHS FROM ENGINE SHIPMENT DATE
MENTIONED ABOVE.
c Ensure that all engine openings and opening on kit items such as radiators, air cleaners,
silencers etc. are covered by water proof protective caps / plastic tapes.
d Do not rotate the engine, as engine is in dry condition.
2) Engine preservation procedure to be carried out for engine storage beyond six months from date
of shipment from factory.
The engine system wise details of the process are described below.
Cooling System Passage :
SR. DESCRIPTION REMARKS

NO.
a Prepare engine for Ensis, treatment Long Fabricate and install a plate to close the
storage Process. water pump inlet connection.
Fill the cooling system with Ensis oil Rustilo Leave the drain cocks open until all air is
b completely vented out. Progressively close
DW 901, (Castrol India make) up to
thermostat outlet connection, using external the cocks until the ensis oil flows from the
priming pump trolley. thermostat housing.
c Keep the Ensis oil in the engine for 5 minutes Remove the fabricated plate at water pump inlet
and then drain it completely, from engine. and close the opening by plastic cap. (Collect the
drained oil in clean container for reuse.)
ii) Fuel Passage :

For preserving the fuel system 5 to 10% of engine anticorrosion oil has to be added to the fuel in the fuel
tank as well as to the oil in the housing of the injection pump. The operate the engine for a few minutes.
The above fuel mixture provided sufficient protection against corrosion even if the injection pump is not operated
for a long period of time. The remove pump cover and spray pump elements and springs with engine oil
containing 5 to 10% of anticorrosion oil. Screw on pump cover and spray outside of the pump with the mixture.
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iii) Lubricating Oil Passage :

SR. NO. DESCRIPTION REMARKS
a Prepare engine for Lub oil priming. Use lub oil priming pump for priming.
b Prime the engine with engine lub oil Use engine Lub oil trolley pump for priming.
15W40. (CH-4 category) Circulate the lub oil till the lub pressure gauge
shows 1 kg/cm sq. pressure. It will take max
five min. to reach this lub oil pressure.
Bar the engine during the process.
c Drain the Lub oil from the oil pan.
NOTE :
a) The above procedure for engine preservation is to be carried out / repeated at the end
of every six months during the storage period. The procedure may have to be done at
OEM works or at customer’s place depending upon location of engine.
b) Loosen the belt tension on fan belt, alternator belt, water pump belt and other accessories
driven by belt.
c) Tag the engine indicating preservation process date and due date for next preservation
(6 months period).
ENGINE PRESERVATION PROCESS DATE :
THE ENGINE HAS BEEN TREATED FOR PRESERVATION
FOR A PERIOD OF SIX MONTHS.
DUE DATE FOR NEXT PRESERVATION PROCESS
(IF NOT INSTALLED IN THE EQUIPMENT).
DATE :
3) Engine preservation procedure for engines installed in equipments.

Many times, the engines shipped from factory are installed on the equipment or Genset within six months
from date of shipment from factory. However these engines as installed in the equipment are not put in
the service for a long period. For such engines the engine coolant and engine lub oil is generally filled
in the engine. Hence no special ensis process is required, but periodic running of engine as given below
is mandatory requirement.
Run the engine once in eery week for 5 to 10 min. at Low idle RPM. “B” check to be carried out
at every six months as mentioned in Section 6.
4) Preparing a preserved (treated) engine for putting in service.
When an engine is removed from storage and put into service the operation listed below should be performed.
i) Clean off all accumulated dirt from exterior of engine
ii) Remove all protective caps, tape and wrappings from connections such as Breathers, Fuel in and
out, connection Water in and out connections etc.
iii) Use suitable solvent, cleaner or decreaser to remove rust preventive compound from unpainted
external surfaces of the engine.
iv) Refill oil pan with fresh lubricating oil. Replace the fuel, lub oil filters and lub oil bypass filters,
only in case wherein engine is stored beyond six months from the date of shipment.
v) Check and correct the engine belt tensioning.
vi) Refer Section 1 for engine starting instructions.
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NOTES
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Section 4
FUEL, OIL & COOLANT SPECIFICATIONS

For proper operation of any engine, it is essential that good quality of lubricating oil, fuel and engine coolant
are used, so that your engine will perform at its optimum level.
6.1 Fuel Specifications :
• Use only good quality ASTM No. 2-D climatized diesel fuel.
• In extreme cold conditions, a winter blend of fuel should be used to avoid waxing in the fuel
filters.
• Do not use diesel contaminated by dirt or water. Contaminate fuel can cause severe damage to
engine fuel system.
• Maintain fuel storage tanks properly.
Table 6.1 Fuel Oil Properties : Recommended specifications
Property Recommended Specifications
Viscosity 1.3 to 5.8 centistrokes

(ASTM D445) (1.3 to 5.8 mm per second) at 1.4F (40C)
Cetane Number 40 Minimum above 32 F

(ASTM D-613 45 minimum below 32 F
Sulfur Content Not to exceed 1.0 mass percent

(ASTM D-129 or 1552)
Active Sulfur Copper Strip Corrosion not to exceed No. 2 rating after
(ASTM D1796) three hours at 122F (50C)
Water and Sediment Not to exceed 0.1 volume percent

(ASTM D1796)
Carbon Residue Not to exceed 0.35 mass percent on 10 volume percent residuum
(Rams bottom, ASTM D524 or
Conradson, ASTM D189)
Density (ASTN D 287) 42 to 30 API gravity at 60F (0.816 to 0.876 g/cc at 15 C)
Cloud Point 10 F (6 C) below lowest ambient temperature which the fuel is

(ASTM D97) expected to operate
Ash Not to exceed 0.02 mass percent (0.05 mass percent with
(ASTM D 482) lubricating oil blending)
Distillation The distillation curve must be smooth and continuous.

(ASTM D 86)
Acid Number Not to exceed 0.1 Mg KOA per 100 ML.

(ASTM D 664)
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6.2 Lubricating oil Specifications :
The lubricating oil used in a diesel engine performs the following functions :
1. It provides a film between the moving parts to reduce wear & friction.
2. It acts as a heat transfer media to carry heat away from the critical areas, thus provides cooling.
3. It dampens & cushions the components that operate under high stress, such as gears & tubes.
4. It protects the critical components from oxidation & corrosion.
In order to get all these functions done, it is essential that recommended lubricating oil MUST be used in the
engine.
Recommendations :
Quality of Lubricating oil is one of the key drive factors to decide the performance, durability and total cost
of operation of diesel engine. Hence we have always been recommending the best available/suitable engine
oil to be used in our engine.
Cummins India Limited strongly recommends the use of SAE 15W40 lub oil with API, CH4 classification
for all Cummins engines to get the various advantages and optimum performance from the engine.
This oil should have a minimum TBN of 10.5 to counteract the higher sulphur content of high speed diesel
available in India.
NOTE : Above limits are for reference only and exact applicable values can be obtained
from the respective oil manufacturer against specific brand of oil.
The responsibility of meeting oil quality lies with the oil manufacturer and Cummins
will not be responsible for problems occurring on engines due to poor quality of oil.
If in doubt about the lub oil quality, contact lub oil manufacturing company and get
the oil analysed in laboratories.
CAUTIONS : Beware of spurious oils in the market. Bad quality of lubricating oil is
detrimental to engine performances. Hence, oil should always be procured from the
original manufacturer or the authorized distributors.
Lubricating oil to be used on the engine must meet all the qualities as per
manufacturer’s specifications. Cummins recommends audit checks of fresh engine oil
to ensure the quality of oil. Facility to check suitability of oil for using it in the engine
is available with Cummins Service Network.
Do not intermix different brands of oil since two different brands may not be
compatible with each other. It is therefore recommended that the brand which is used
for initial fill, should only be used for top-up.
However, in case of non-availability of specific brand, different brand of oil may be

used at the time of oil change. In that case, drain all the existing oil and flush the lub
oil system with new brand oil and then charge the system with new brand oil.
- 20 -
COOLANT RECOMMENDATIONS Coolant recovery Bottle is to be filled externally,

with Coolant. Radiator is to be filled slowly, upto
Cummins recommends, use of Premix Coolant,
bottom of Fill Neck.
for engine cooling. This is ‘Ready to Use’ type
Coolant is available in 5 Litre Can. (Cummins Check Coolant Level Daily, before starting Gen-set.
Part No.: 3816986, Valvoline Part No.: 4962836,
CAUTION – Do-not add cold coolant to
fleetguard Part No: CC2769) (Coolant is ‘Ethylene
hot engine. Engine castings can be
Glycol & water’ (Type JIS K 2234-94, Class 2)
damaged. Allow engine to cool below
Coolant is recommended to prevent Corrosion of
500 C, before adding Coolant.
Engine & Radiator. It also broadens the
Operating Temperature range by Lowering the Do-Not remove Cap, Radiator, from hot engine. Allow
coolant freezing point & by raising it’s boiling engine to cool below 50 0 C, before adding Coolant.
point. Failure to do so, can result in personal injury from
steamy coolant.
NOTE :
Do-Not use sealing additives, to stop leaks in the
This Premix Coolant Do-Not require, any addition
cooling system. This can result in coolant system
OR mixing of Raw Water. Coolant is to be used,
plugging & inadequate coolant flow, causing, engine
directly from Coolant Can (Ready To Use)
to Over heat.
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NOTES
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Section 7
MAINTENANCE SCHEDULE
ENGINE MAINTENANCE SCHEDULE & MANDATORY CHECKS FOR ‘B’ SERIES – G DRIVE
SYSTEM A – Check B – Check C - Check D - Check
GROUP Daily Every 225 – 250 Hrs Every 475 – 500 Hrs Every 950 – 1000 Hrs
OR 6 months, which OR 12 months, which OR 24 months, which is
is earlier is earlier earlier
LUBRICATION ■ Check Oil level ■ Repeat all A Checks ■ Repeat all A & B ■ Repeat all A - B & C
SYSTEM ■ Change Lubrication Oil Checks Checks
■ Change Lube Oil Filter ■ Clean Breather ■ Check Blow Bye
COOLING ■ Check Coolant level in ■ Repeat all A Checks ■ Repeat all A & B ■ Repeat all A - B & C
SYSTEM Radiator & Recovery ■ Check coolant level & Checks Checks
Bottle top up, if required ■ Check Coolant ■ Check Belt Tension &
■ If required, fill Premix ■ Check Fan Hub & Fan condition replace Belt, if required
Coolant, at the Rate Drive arrangement ■ Check Recovery Bottle ■ Replace Coolant &
of 9 Lit / min. * Check Seal of cap, & Seal use Premix Coolant
■ Check Belt condition Radiator ■ Check connections & only
sealings of Radiator ■ Replace Cap. Radiator
■ Clean Radiator, externally
FUEL ■ Check fuel Strainer ■ Repeat all A Checks ■ Repeat all A & B ■ Repeat all A - B & C
SYSTEM ■ Clean Breather on ■ Change Fuel Filter & Checks Checks
Fuel Tank Fuel Water Separator ■ Check all joints in Fuel ■ Clean Fuel Tank
■ Drain Sediments from ■ Drain sediments from Lines & tighten. ■ Replace Fuel Hoses if
Fuel Water Separator Fuel Tank ■ Check Feed Pump & required
cleanBaby Filter
AIR ■ Check Vacuum ■ Repeat all A Checks ■ Repeat all A & B ■ Repeat all A - B & C
SYSTEM Indicator for Air ■ Clean Air Filter in Checks Checks
Restriction (Red Band) reverse direction, ■ Check Turbocharger
■ Check sealings & using dry air with max End clearances
condition of Air Filter 0.5 kg/sqcm pressure
OTHER ■ Check for leaks & ■ Repeat all A Checks ■ Repeat all A & B ■ Repeat all A - B & C
CHECKS rectify if required ■ Check Battery Checks Checks
& ■ Run Engine & condition ■ Check AVMs and ■ Tighten all clamps
ENGINE Record, all ■ Clean Battery Leads replace if required ■ Check Valve lashes &
TESTING Parameters ■ Secure all connectors adjust, if required
in Engine Electrical
system.
NOTE : The daily checks can be performed by the operator whereas weekly (and above)
are to be done by Specialist only.
* Belt to be checked by skilled service engineer only
- 23 -
NOTES
- 24 -
Section 8
ENGINE MAINTENANCE
8.1 Daily :
Preventive Maintenance begins with a day-to-day

awareness of condition of the engine & its
systems.
Before Start up, check oil & coolant level and

look for leaks, loose parts, frayed belts etc.
Check Oil Level :
Never operate the engine with the oil level

below “L” (Lower) mark or above “H”
(Higher) mark.
Lubricating oil Capacity between Low & High

marks is 2.10 Litres.
Check Coolant Level :
Check the coolant level by removing radiator

cap.
CAUTION :
Never remove the cap when the coolant

is Hot. Always use caution when
removing the cap to avoid personal
injury.
Check fuel water trap :
Drain the water from fuel/water separator.
- 25 -
8.2 Every 3 months or 250 Hours :
Change / Replace Lub oil :
Warm up the engine.
Remove the plug and allow the oil to drain.
A drain pan with capacity of 20 litres will be

adequate.
Check condition of fused oil :
Thin/black oil indicates fuel dilution. Milky discoloration

indicates coolant dilution.
Contact the nearest Cummins Dealer for corrective

action, if necessary.
Change/Replace lub oil filter :
Clean around the filter head. Remove the filter & clean
the gasket surface.
- 26 -
Fill the filter with clean lubricating oil.
Apply a light film of lubricating oil to the gasket sealing

surface before installing the filter.
CAUTION :
Mechanical Overtightening of the filter may

distort the threads or damage the filter
element seal.
Install the oil pan drain plug and tighten to 75 N. M.

(55 ft-lbs).
- 27 -
Ensure that proper brand & grade of lubricating oil is

used.
Fill the engine with the required amount of oil.
Lubricating oil capacity : 14.3 Litres.
Operate the engine at idle speed & inspect for any

leaks at drain plug or at the filter.
Shut the engine off. Allow 5 minutes for oil to drain

down. Check the oil level with the dipstick.
Check Air Cleaner :
Check the vacuum indicator.
If it is showing red mark, clean/ replace the air cleaner

element.
Check air intake system :
Inspect the intake piping for damage, cracked hoses,

loose clamps etc.
Never operate the engine without air cleaner.
Check coolant concentration :
Please refer Section 6 for details.
Change Fuel Filter :
Remove the two filters from the dual filter adapter.
- 28 -
Fill the new filters with clean fuel.
Lubricate the seal with clean lubricating oil.
Install the filters.
CAUTION :
Mechanical overtightening may distort the

threads or damage the filter element seal.
- 29 -
Bleeding the fuel System :
Controlled venting is provided at the injection

pump. Small amount of air introduced by
changing the filters will be vented automatically.
However, manual bleeding will be required if :
• Fuel filter is not filled properly
• Injection pump is replaced
• high pressure fuel lines are replaced.
Venting the low pressure lines :
Open the bleed screw.
Operate the hand lever (lift pump) until the fuel

flowing from the fitting is free of air.
Tighten the bleed screw.
Venting the low pressure lines :
Loosen the fittings at the injectors, and crank

the engine to allow entrapped air to bleed from
the lines. Tighten the fittings.
CAUTION :
High Pressure could cause

penetration of skin. !
Do not bleed a hot engine as this could cause
fuel to spill onto a hot exhaust manifold creating
a danger of fire.
- 30 -
Adjust Valve Clearance :
Remove the valve covers.
Valve Clearances :
Intake Clearance : 0.254 mm (0.010 Inch)
Exhaust Clearance : 0.508 mm (0.020 Inch)
Check / Set valves with engine cold - below 60 deg.

C as described in Step 1 & Step 2 below.
NOTE :
The clearance is correct when some

resistance is ‘FELT’ when the feeler gauge
is slipped between the valve stem &
rocker lever.
Step 1 :
Locate the TDC for cylinder no. 1.
Check /Adjust the valves indicated in the sketch.
Make the pulley & rotate the crankshaft 360 degrees.
CAUTION :
Ensure that the engine timing pin is

disengaged.
- 31 -
Step 2 :
Set the valves as indicated in the sketch.
Tighten the lock nut to 24 N.m. (18 ft lbs.) and

recheck the valve lash.
Checking of belt, belt tension, belt tensioner & fan

hub :
Measure the belt deflection at the longest span

of the belt.
Maximum deflection : 9.5 - 12.7 mm
Check belt tension.
NOTE :
Cummins belt tension gauge ST-

1293 should be used. The required
gauge value is 80-110 lbs.
Check the drive belt, tensioner bearing & fan

hub.
Remove the drive belt.
- 32 -
Inspect the belt for damage
Check the tensioner bearing.
NOTE :
The tensioner pulley should spin freely with no

rough spots detected under hand pressure.
Check the fan hub bearing.
NOTE :
The fan hub should spin freely

without excessive end play.
Install the drive belt.
- 33 -
NOTES
- 34 -
Section 7
ADJUSTMENT, REPLACEMENT AND REPAIR B SERIES

Section A - Adjustment, Replacement and Repair B series
Injection Pump Replacement (Inline)

Preparatory Steps :
• Clean debris. • Remove all fuel lines.
• Remove control linkage. • Remove fuel shutoff solenoid.
Removing
Engine Barring Gear
Locate TDC for cylinder number 1. Push the TDC pin

into the hole in the camshaft gear while slowly rotating
the crankshaft.
CAUTION : Be sure to disengage the pin

after locating TDC to prevent damage to
the pin.
Injection Pump
22 mm (PES.A Pump), 27 mm (PES. MW Pump),

30 mm (PES.P Pump)
Remove the gear cover access cap.
Remove the nut and washer from the fuel pump

shaft.
75 mm T-Bar Puller
Pull the fuel pump drive gear loose from the shaft.
- 35 -
Section A - Adjustment, Replacement and

Repair B Series
10mm, 15 mm
Remove the four mounting nuts and the

capscrews that fasten the pump support to the
cylinder block.
Remove the fuel pump.
Installing
Engine Barring Gear
Make sure the engine has cylinder number 1 at

TDC.
Injection Pump - Timing
The injection pump also has a timing pin (1),

located in the governor housing, to position the
pump shaft to correspond with TDC for cylinder
number 1. After the pump is installed the pin is
to be reversed and stored in the housing (2).
NOTE : The industrial governor is shown in the

illustration. The procedure is the same for
automotive governors.
24 mm
Remove the access plug.
- 36 -
Section A - Adjustment, Replacement and

Repair B Series
Remove the timing pin.
If the timing tooth is not aligned with the

timing pin hole. Rotate the pump shaft
until the timing tooth aligns.
Reverse the position of the pin so the slot of

the pin will fit over the timing tooth in the
pump.
Install and secure the pin with the access

plug.
Make sure the o-ring seals for the fill orifice

and pilot are correctly installed and are not
damaged.
Lubricate the mounting flange with clean

engine oil.
- 37 -
Slide the pump shaft through the drive gear and

position the pump flange onto the mounting
studs. If the pump is equipped with a support
bracket, use your fingers to tighten the
mounting nuts.
Use your fingers to tighten the capscrews for

the support bracket, if so equipped.
15 mm
Tighten the mounting nuts.
Torque Value : 43 Nm (32 ft-lb)
10 mm
Tighten the capscrews for the rear support

bracket.
Torque Value : 24 Nm (18 ft-lb)
- 38 -
Injection Pump - Removal (Rotary

Type Pump)
13 mm
CAUTION: A diesel engine cannot

tolerate dirt or water in the fuel system.
A tiny piece of dirt or a few a drops of
water in the injection system can cause
damage to the system.
Clean all external surfaces of the injection
pump, including all line connections and fittings
that are to be disconnected. Clean the area
around the injection pump gear cover to prevent
dirt from entering the crankcase.
Remove the injection pump support bracket and

capscrews.
Gear Lash - Check

Position an indicator on the tooth of the
injection pump drive gear.
Note the total indicator travel as injection pump

drive gear backlash. Mark the pump drive gear
and camshaft gear for further analysis if the
backlash exceeds the limits.
Injection Pump Drive Gear

Backlash Limit (A)
mm in
0.076 MIN 0.003
0.330 MAX 0.01 3
NOTE: Prevent movement of adjoining gear

when checking backlash or the reading will be
the total of both gears.
- 39 -
Locking the Pump
Locate TDC for Cylinder Number 1 by slowly barring

the engine while pushing in on TDC pin.
BE SURE TO DISENGAGE THE PIN AFTER

LOCATING TDC.
14 mm
Loosen the CAV injection pump lockscrew, position

the special washer with the small opening showing,
then tighten the lockscrew against the pump drive
shaft.
Torque Value: 7 N*m [5 ft-lb]
318 inch
Loosen the lockscrew for the Stanadyne DB4 fuel

injection pump. Position the special washer behind
the lock screen head. Tighten the lockscrew.
10 mm
The special washer on the Bosch injection pump

must be removed so the lockscrew can be tightened
against the drive shaft.
NOTE : Before removing the Bosch

pump, the pump must be locked with
the No. 1 Cylinder in TDC position.
Torque Value: 30 N*m [22 ft-lb].
Wire the special washer to the Bosch pump.
- 40 -
Drive Gear - Removal
22 mm
CAUTION: Hold the crankshaft to

prevent the rotation of A the locked
injection pump.
Remove the mounting nut and lock washer from

the pump drive shaft.
75 mm T-Bar Puller or Fuel Pump Drive Gear

Puller Part No. 3824469
Pull the pump drive gear loose from the drive

shaft. The puller hole threads are MB X 1.25.
13 mm
Remove the three mounting nuts. Remove the

injection
NOTE : Refer to the applicable

Manufacturer's Service Instructions
for injection pump testing/repair. Minor
repairs are described in Component
Section 5.
- 41 -
Preparatory Steps :
• Clean debris. • Remove all fuel lines.
• Remove control linkage. • Remove fuel shutoff solenoid.

Unlocked Bosch VE Injection Pump -
Installation
VE Installation
The following procedure was written for those
without immediate access to a fuel pump timing
tool, Pan No. 3377259. The procedure for timing
an unlocked Bosch VE fuel pump with the pump
off of the engine is given in Section 5. If the
pump is installed using the following
procedure, it should be adjusted to the exact
timing using tool No. 3377259 before being put
into service. This procedure is available in Bulletin
Nos. 3810348-01and 3810486.
Locate top dead center (TDC) for Cylinder Number
1 by rotating the crankshaft while pushing in on
the timing pin until it engages.
The Robert Bosch VE pump uses a spring loaded
cam mechanism that makes positioning the
keyway more difficult.
To align the Robert Bosch VE keyway, secure the
pump in a vise and install the lock washer and
nut on the drive shaft.
8 mm Allen or 10 mm Hex
Remove the special washer by loosening the
lockscrew.
- 42 -
22 mm; 8 mm Allen or 10 mm Hex
Turn the shaft so the key is aligned with the hash

mark on the seal housing.
Lock the pump shaft by tightening the lockscrew.
Remove the drive nut and washer from the drive

shaft by striking the wrench with a sharp blow in a
counterclockwise direction.
Be sure the timing pin is disengaged.
CAUTION: Make sure the key does not

fall into the gear housing.
Install the pump.
- 43 -
Secure the pump by finger tightening the three

mounting nuts. The pump must be free to move in
the slots.
22 mm
Install the drive gear mounting nut and lock washer

on the pump drive shaft.
NOTE: This is not the final torque value. The drive

shaft nut will be torqued to the final specification
after the pump is unlocked.
8 mm Allen or 10 mm Hex
Loosen the Bosch pump lockscrew and position the

special washer behind the lockscrew head.
Tighten the lockscrew in the unlocked position.
Torque Value: 13 N*m [10 ft-Ib]
22 mm
Tighten the drive gear mounting nut.
- 44 -
13 mm
Rotate the pump to align the scribe marks on the

pump and housing.
Tighten the three mounting nuts.
Torque Value: 24 Nom [18 ft-Ib]
Disengage the TDC pin.
Be sure the backlash is correct for replaced

gears.
Use a dial indicator to measure backlash.
Pump Gear Backlash Limit
A = .076 to .330 mm [0.003 to 0.013 in]
- 45 -
10 mm
Attach the injection pump support bracket. Finger

tighten all capscrews before final tightening.
NOTE: Tighten the capscrews which attach

the bracket to the block (1) before tightening
the capscrew which secures the bracket to
the pump (2).
- 46 -
Static Injection Timing setting on Bosch Rotary VE Pump

Please refer the below detailed procedure circulated by Bosch
Subject : Static timing setting on VE pump.
Procedure:
1. Fix the pump in vise. Ref a.
2. Ensure that driveshaft locking screw is unlocked [FBB plate inserted]. Ref b.
3. Bring the keyway inline with 'D' port of the pump. [5 o'clock position when observed from driveshaft
side]. Ref c, d
4. Remove the bleeder screw. Ref e.
5. Insert dial gauge with adaptor & feeler. Pre-load it to 213 mm. Ref f.
6. Rotate the driveshaft check the zero position 8 set dial gauge to Zero.
7. Rotate driveshaft in anticlockwise direction till the required lift is achieved.
8. Remove the FBB plate and tighten the locking screw to 12.5 ± 2 Nm.
9. Tie the FBB plate to the control lever.
10. Remove the diai gauge and adaptor.
11. Insert the bleeder screw and tighten it to 29 + 3 Nrn [Ensure that copper washer is present]
Note: Ensure that FBB plate is inserted between the drive shaft locking screw & pump house after mounting
the pump on the engine before starting it.
- 47 -
a) b)
c)
d) Key way -5 o’clock position
‘D’ port
- 48 -
e) f)
Use Cummins Timing Tool Part # 3377259
Thread the timing tool extension into the access

plug hole.
Finger tight only
g) h)
- 49 -
NOTES
- 50 -
Section 8
TROUBLE SHOOTING
- 51 -
- 52 -
- 53 -
- 54 -
- 55 -
- 56 -
- 57 -
- 58 -
- 59 -
- 60 -
- 61 -
- 62 -
- 63 -
- 64 -
- 65 -
- 66 -
ENDPLAY AND BACK LASH VALUES
1. Crankshaft Endplay 0.102 mm - 0.432 mm (0.004” - 0.017”)

2. Cam Shaft Endplay 0.12 mm - 0.34 mm (0.005” - 0.013”)
3. Turbocharger Endplay - Axial 0.03 mm - 0.08 mm (0.001” - 0.003”)
4. Turbocharger Endplay - Radial 0.30 mm - 0.46 mm (0.012” - 0.018”)
5. F.P. Drive Gear Backlash 0.076 mm - 0.330 mm (0.003” - 0.013”)
6. Camshaft Gear Backlash 0.076 mm - 0.330 mm (0.003” - 0.013”)
ENGINE COMPONENT TORQUE VALUES
Socket or Torque Nom (Ft-lb)

Wrench Size
MM (Inch)
10 Aftercooler Mounting ......................................................................... 24 (18)

(5/16) Aftercooler Water Hose Clamp ........................................................ 5 (41)
(15/16) Alternator Pulley ............................................................................... 80 (59)
13 or (3/4) Alternator Link (Delco 15-20-27 SI) ................................................. 43 (32)
16 Alternator Mounting Bolt 15 SI ........................................................ 43 (32)
18 Alternator Mounting Bolt and Nut 20-27 SI .................................... 77 (57)
13 Alternator Support (Upper) ................................................................ 24 (18)
Allen 5 mm Belt Tensioner Flat Bracket ............................................................. 24 (18)
15 Belt Tensioner Mounting ................................................................... 43 (32)
Camshaft Bolt ........................................................................ Step 1 27 (20)
............................................................. Step 2 Rotate 180 Degrees
13 Cam Thrust Plate ............................................................................. 24 (18)
(3/8) Coolant Heater .................................................................................. 12 (91)
12 Connecting Rod Bolt .............................................................. Step 1 35 (261)
(Alternately Tighten ................................................................ Step 2 70 (51)
in Three Steps) ...................................................................... Step 3 100 (73)
15 Crankshaft Damper & Pulley ........................................................... 125 (92)
18 Cylinder Head Mounting ................................................ Step 1 (All) 90 (66)
.................................................................... Step 2 (All Recheck to 90 (66)
................................................................ Step 3 (Long Capscrews) 120 (90)
........................................ Step 4 Recheck (Long Capscrews Only) 120 (90)
.................................................................... Step 5 (All) Rotate 90°
(5/16) Crossover Clamp .............................................................................. 5 (4)
13 Exhaust Manifold .............................................................................. 43 (32)
- 67 -

Wrench Size
MM (Inch)
13 Exhaust Outlet Pipe Brkt. Mounting ............................................... 43 (32)

13 Exhaust Outlet Pipe, Flanged .......................................................... 24 (18)
(7/16) Exhaust Outlet Pipe, V Band Clamp .............................................. 8 (6)
10 Fan Bracket Mounting ...................................................................... 24 (18)
13 Fan Pulley ......................................................................................... 24 (18)
19 Flywheel ............................................................................................ 137 (101)
15 Flywheel Housing .............................................................................. 77 (57)
13 Flywheel Housing Access Cover ..................................................... 24 (18)
(1/2) Flywheel Housing Plug ..................................................................... 36 (25)
- Front Cover Cap ......................................................... Hand Tighten
18 Front Engine Support Mounting ....................................................... 77 (57)
(1 1/8) Front Engine Support (Barrel) .......................................................... 350 (257)
17 Fuel Banjo Screw (In Fuel Pump) ................................................... 32 (24)
17 Fuel Banjo Screw (In Head) ............................................................ 24 (181)
10 Fuel Banjo Screw (In Injector) ......................................................... 9 71
10 Fuel Vent Screw (In Banjo) ............................................................. 9 (7)
80-95 Fuel Filter .......................................................................................... 3/4 Turn After Contact
14 Fuel Low Pressure Supply (Lift Pump Outlet) ................................ 24 (18)
24 Fuel Filter Adapter ............................................................................ Nut 32 (24)
17 Fuel Line Fitting (High Press) .......................................................... 24 (18)
22 Fuel Pump Drive Gear (With Pump Unlocked)
Bosch (Rotary), Lucas CAV, Stanadyne DB4 ................................ 65 (48)
Nippondenso ...................................................................................... 123 (92)
Bosch (P3000, P7100) ..................................................................... 165 (122)
10 Fuel Pump Lock (Bosch) ................................................................. 30 (22)
Fuel Pump Unlock (Bosch) .............................................................. 13 (10)
- Fuel Pump Mtg. Nut (Bosch In-Line) .............................................. 43 (32)
- Fuel Pump Solenoid
24 (Bosch VE) ....................................................................................... 43 (32)
22 (CAV) ................................................................................................. 15 (11)
10 Fuel Pump Support Bracket ............................................................ 24 (18)
10 Gear Cover ........................................................................................ 24 (18)
10 Gear Housing - to- Block ................................................................. 24 (18)
24 Injector Retaining Nut ....................................................................... 60 (44)
10 Intake Manifold Cover ...................................................................... 24 (18)
- 68 -

Wrench Size
MM (Inch)
(5/8) Intake Heater Plug ............................................................................ 125 (90)

10 Lift Pump Mounting / Cover Plate .................................................. 24 (18)
23 Main Bearing Cap .................................................................. Step 1 60 (44)
............................................................................................... Step 2 119 (88)
............................................................................................... Step 3 176 (129)
15 Oil Fill Tube Mounting ...................................................................... 43 (32)
75-85 Oil Filter ............................................................................................ 3/4 Turn After Contact
10 Oil Cooler Assembly ......................................................................... 24 (18)
17 Oil Pan Drain Plug ........................................................................... 80 (60)
17 Oil Pan Heating Plug ....................................................................... 80 (60)
10 Oil Pan Mounting .............................................................................. 24 (18)
19 Oil Pressure Regulator Plug ............................................................ 80 (60)
13 Oil Pump Mounting ........................................................................... 24 (18)
13 Oil Suction Tube (Flange) ................................................................ 24 (18)
10 Oil Suction Tube Brace .................................................................... 24 (18)
8 Rear Seal Mounting .......................................................................... 9 (7)
13 Rocker Support ................................................................................. 24 (18)
(14) Rocker Lever Nut ............................................................................. 34 (25)
10 Starter Mounting ............................................................................... 43 (32)
10 Tach Drive Retainer .......................................................................... 3 (2)
10 Tappet Cover / Fuel Drain Line Supports ....................................... 24 (18)
10 Thermostat Housing .......................................................................... 24 (18)
T-25 Torx Timing Pin Flange Mounting ............................................................ 5 (4)
10 Turbocharger Compressor Housing V-Band ..................................... 8.5 (6)
15 Turbocharger Mounting Nut .............................................................. 43 (32)
13 Turbocharger Oil Drain Tube ............................................................ 24 (18)
(5/81) Turbocharger Oil Supply (Both Ends) .............................................. 35 (26)
13 Turbocharger Turbine Housing ......................................................... 20 (15)
Water Hose Clamps ......................................................................... 4-5 (4)
13 Water Inlet Connection ..................................................................... 43 (32)
(3/8) Water Inlet Plugs .............................................................................. 24 (18)
13 Water Pump Mounting ...................................................................... 24 (18)
15 Valve Cover ...................................................................................... 24 (18)
- Valve Cover Oil Fill .......................................................................... Hand Tighten
- 69 -
NOTES
- 70 -

Engine Workshop Manual: G-Drive Package B5.9G Series

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Engine Workshop Manual

Our energy working for you. TM

English 01-2010 A024J818 (Issue 2)

Should you require further assistance contact:

Tel: +91 2030248600

Sr. Contents Page No.

1. General Safety Instructions ................................................................... 7

2. Engine Systems : Overview .................................................................. 9

3. Engine Operation .................................................................................. 13

4. Fuel, Oil & Coolant Specifications ...................................................... 19

5. Maintenance Schedule ......................................................................... 23

6. Engine Maintenance ............................................................................. 25

7. Adjustment, Replacement and Repair B Series ................................. 35

8. Trobule Shooting ................................................................................... 51

GENERAL SAFETY INSTRUCTIONS

NOTE : On receipt of engine by truck, ensure unloading of the engine by skilled

ENGINE SYSTEMS : OVERVIEW

4.1 Air System :

4.2 Fuel System :

4.3 Lub system :

1. Lubricating Oil Pump

4.4 Cooling System :

B Series cooling system is a 10 PSI closed pressurised system.

Flow of coolant through the engine is shown in the following sketch.

1. Coolant Flow Past Injector 5. By-Pass Closed

1.1 Exhaust System

5.1 Starting the engine :

Move the throttle position to idle as soon as the engine starts.

5.2 Stopping the engine :

Minimum oil pressures required

Full Speed & Load : 30 PSI

5.3 Operating the engine :

iii) Unusual engine noise

iv) Fuel, oil or coolant leakage

v) Sudden change in engine operating temperature or oil pressure

vi) Excessive smoke

vii) Loss of power

viii) An increase in oil consumption

ix) An increase in fuel consumption

Engine preservation procedure

iii. Engine preservation procedure for engines installed in equipment.

Sr. No. Description

b Tag all these boxes indicating following,

ENGINE SHIPMENT DATE :

THE ENGINE HAS BEEN TREATED FOR

b Tag all these boxes indicating following,

ENGINE SHIPMENT DATE :

THE ENGINE HAS BEEN TREATED FOR

d Do not rotate the engine, as engine is in dry condition.

Cooling System Passage :

SR. DESCRIPTION REMARKS

ii) Fuel Passage :

iii) Lubricating Oil Passage :

3) Engine preservation procedure for engines installed in equipments.

FUEL, OIL & COOLANT SPECIFICATIONS

6.1 Fuel Specifications :

• Maintain fuel storage tanks properly.

Table 6.1 Fuel Oil Properties : Recommended specifications

Property Recommended Specifications