Cummins S3.8 Engine Manual (EN)

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FOREWORD This manual is designed to be of assistance to all Personnel concerned with the maintenance and overhaul of the S 3.8 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:

cpgiservicesupport@cummins.com Web Site: www.cumminspower.com 3

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Workshop Manual S3.8 Engine A030K288 (Issue 2) 01-2010 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...................................................................................................... 1 Engine Operation in Cold Weather Section 4...................................................................................................... 1 Maintenance of Engine Laid up for Long Period Section 5...................................................................................................... 1 Maintenance Operations Section 6......................................................................................................

Lubricants, Fuels & Coolant Section 7 ..................................................................................................... Checking Valve Timing Section 8...................................................................................................... Tightening Torques Section 9...................................................................................................... Troubleshooting 9 + 5 7 8 9 25 29 37 39 5

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Workshop Manual S3.8 Engine A030K288 (Issue 2) 01-2010 To the Owner and Operator General Information Preventative maintenance is the easiest and least expensive type of maintenance. Follow the maintenance 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 and parts support. 6

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Workshop Manual S3.8 Engine A030K288 (Issue 2) 01-2010 Routine Service and Parts General Information Personnel at Cummins Authorized Repair Locations can assist you with the correct operation and service of your engine. Cummins has a worldwide service network of Distributors and Dealers who have been trained to provide sound advice, expert service, and complete parts support. Problem Solving General Information Normally, any problem that arises with the sale, service, or repair of your engine can be handled by a 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. 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. Before contacting, write down the following information: Engine model and serial number Type and make of equipment Total hours of operation Warranty start date Nature of problem Summary of the current arranged in order of occurrence Name and location of the Cummins Distributor or Dealer 7

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