JCB Engines Cummins India 4B 3.9, 6B 5.9 Operation And Maintenance Manual - PDF DOWNLOAD

BULLETIN NO. 3243818-00 (July 2003)

Operation And Maintenance Manual 4B 3.9 / 6B 5.9 Engines

Cummins India Limited Low Horsepower Business Unit Registered Office : Kothrud, Pune 411 038. (India) Telex : 0145-7244/0145-7541 KCL IN Phones : 5380240, 5385435, 5381105.

Fax : (020) 5387125

Admn. Office : 35A/1/2, Erandwana, Pune 411 038.

Telex : 0145-7254 CDSS IN Phones : 5431234, 5430066.

Fax : (91) (20) 5439490 Toll Free : 1-600-332000 E-mail : Powermaster-India@Cummins.com

Works : Plot No. 19-25A, Silver Industrial Estate, Bhimpore, Daman - 398 210 (India) Phones : (0260) 2222618 / 2221837 Fax : (91) (0260) 2222618

No part of this manual may be copied, photocopied, reproduced, translated or stored in a retrieval system by any means electronic, mechanical or otherwise without prior permission in writing of Cummins India Limited, Kothrud, Pune 411 038.

24 Hour Emergency Service In the very unlikely event of you are not receiving the normal prompt attention from our field force, following are the residence telephone numbers of our officers for assistance.

While asking for assistance please provide the following information.

1.

Your Name & Phone or Fax Number.

2.

Engine Serial Number.

3.

Name of the Customer.

4.

Engine Location.

5.

General Description of Assistance required.

Cummins India Limited Low Horsepower Business Unit

Registered Office : Kothrud, Pune 411 038 (India) Telex No. : 0145-7244/0145-7541 KCL IN Phones : 5380240, 5385435, 5381105 Fax : (020) 5387125 Visit us at : www.cumminsindia.com

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

Telex : 0145-7254 CDSS IN

Phones : 5431234, 5430066 Fax : (91) (20) 5439490 Rampraveen Swaminathan .............. 9822008330 Sharad Manjrekar ............................ 9822012618

N.P. Thimmaiah ................ 9822060809 Suhas Ghatnekar ............... 982101183

Jayant Mukerji ................... 9822004712 D. Chakraborty ................... 9822012543

Cummins Diesel Sales and Service (India) Ltd. 35A/1/2, Erandawana, Pune 411 038 (India) Telex No. : 0145-7254/0145-7307 CDSS IN Phones : 5430066, 5431703, 5431234, 5430166, 5430356 E-mail : Powermaster-India@Cummins.com Fax : (91) 20-5339490 Free-Toll No. : 1-600-332000 Harpale S. D. ................................. (020) 5460530 BANGALORE : Sahagal S. K.. ...... (080) 3632279 Nerlikar A. V. ................................... (020) 5383633 MUMBAI : Bathe S. G. .................. (022) 4973483 Nageshwaran V .................................. (020) 5434472 KOLKATA : Bhowmick K. K. ......... (033) 4220273 DELHI : Rithal T. S. ....................... (011) 6494100 RAIPUR : Kaul Rewati .................... (0771) 427148

YK

HYDERABAD : Deshmukh V. N. ... (040) 7605096 JAIPUR : Pawar M. G. .................. (0141) 225863 LUCKNOW : Sharma A.K. .............. (0522) 385692 CHENNAI : Shenoy V. K. .............. (044) 4416429 RANCHI : Vora J. R. ...................... (0651) 240322

NOTES

- 22 -

INDEX

Sr.

Contents

Page No.

1.

Introduction ............................................................................................. 1

2.

General Safety Instructions ................................................................... 2

3.

Engine Specifications ............................................................................. 4

4.

Engine Diagram ...................................................................................... 6

5.

Engine Systems Overview ..................................................................... 8

6.

Engine Operation .................................................................................. 12

7.

Fuel, Oil & Coolant Specifications ...................................................... 17

8.

Engine Maintenance Chart ................................................................... 21

9.

Engine Maintenance ............................................................................. 47

10.

Injuction Fuel Pump Replacement Adjustment and Repair ............... 67

11.

Troubleshooting ..................................................................................... 74

12.

Engine Wiring Diagram ......................................................................... 93

13.

Service Network ................................................................................... 96

Section 1

INTRODUCTION

This is an engine Operation & Maintenance Manual, not a repair manual. This manual contains information needed to correctly operate and maintain your engine as recommended by Cummins. This manual does not cover equipment maintenance procedures. Please consult the equipment manufacturer for specific maintenance recommendations.

This engine is manufactured by Tata Cummins Limited and engineered by Cummins Low Horsepower Business Unit to suit specific application. Service for this engine will be rendered by Cummins Diesel Sales & Services (CDS & S) through its authorised dealer’s network. Please contact local service dealer or CDS & S Area / Regional / Zonal Office for any type of service / technical support. Please refer Section No. 12 for phone numbers and addresses of CDS & S offices and their dealers.

In order to get the optimum performance of the engine, please, •

adhere to maintenance practices specified in this manual

•

use recommended fuel & oils

•

use genuine Cummins parts

•

get service only from authorised dealers of CDS & S

•

use all safety & recommended installation practices.

In case you need any type of assistance, please contact Cummins India Ltd. - LHP Business Unit or CDS & S on the following addresses :

-1-

Section 2

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.

•

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.

-2-

GENERIC SYMBOLS

Generic Symbols

The following group of symbols have been used in this manual to help communicate the intent of the instructions.

When one of the symbols appears, it conveys the meaning defined below :

WARNING : Serious personal injury or extensive property damage can result if the warning instructions are not followed.

CAUTION : Minor personal injury can result or a part, an assembly or the engine can be damaged if the caution instructions are not followed.

Indicates a REMOVAL or DISASSEMBLY step.

Indicates an INSTALLATION or ASSEMBLY step.

INSPECTION is required.

CLEAN the part or assembly.

PERFORM a mechanical or time MEASUREMENT.

LUBRICATE the part or assembly.

Indicates that a WRENCH or TOOL SIZE will be given.

TIGHTEN to a specific torque.

PERFORM an electrical MEASUREMENT.

Refer to another location in this manual or another publication for additional information.

The component weighs 23 kg (50 lb) or more. To avoid personal injury, use a hoist or get assistance to lift the component.

-3-

Section 3

GENERAL ENGINE SPECIFICATIONS

GENERAL ENGINE DATA Bore

............................................................................................................................. 102 mm (4.02 in)

Stroke

............................................................................................................................. 120 mm (4.72 in)

Displacement 4B ..................................................................................................................... 3.92 liters (239 in3) 6B ..................................................................................................................... 5.88 liters (359 in3) Compression ratio ...........................................................................................................................................

4B 3.9 / 6B 5.9 Industrial, naturally aspirated ................................................................ 18.5 : 1 4BT 3.9 / 6BT 5.9 Industrial, turbocharged ..................................................................... 17.5 : 1 4BTA 3.9 / 6BTA 5.9 Industrial, turbocharged and aftercooled ...................................... 16.5 : 1 B3.9 / B5.9* Automotive, charge air cooled .................................................................... 17.6 : 1 Firing order 6 cylinder ....................................................................................................................... 1-5-3-6-2-4 4 cylinder ............................................................................................................................. 1-3-4-2 Valve Settings Intake Valve Adjustment .................................................................................... 0.25 mm (0.01 in) Exhaust Valve Adjustment ........................................................................... 0.51 mm ( 0.020 in) Engine rotation (viewed from front of engine) .............................................................................. clockwise Engine weight (with standard accessories) 4 cylinder engines .......................................................................... 325 to 350 kg (715 to 770 lb) 6 cylinder engines .......................................................................... 410 to 440 kg (910 to 970 lb)

LUBRICATION SYSTEM Oil pressure At idle (minimum allowable) ................................................................................................. 69 kPa (10 psi) At rated speed (minimum allowable) .................................................................................. 207 kPa (30 psi) Regulating valve opening pressure ......................................................................... (1991) 449 kPa (65 psi) (1994) 517 kPa (75 psi) Differential pressure to open oil filter bypass valve ............................................. (1991) 138 kPa (20 psi) (1994) 172 kPa (25 psi) Oil capacity of standard engine 4 cylinder engines .................................................................................... 9.5 liters (10 U.S. Qts.) 6 cylinder engines .................................................................................. 14.2 liters (15 U.S. Qts.) -4-

Total system capacity 4 cylinder engines ............................................................................... 11.0 liters (11.6 U.S. Qts.) 6 cylinder engines ............................................................................... 16.4 liters (17.3 U.S. Qts.)

COOLING SYSTEM Thermostat Begins to open .......................................................................................................... 81°C (180°F) Fully open .................................................................................................................. 95°C (203°F) Pressure cap for 99°C (210°F) system ................................................................................. 50 kPa (7 psi) Pressure cap for 104°C (220°F) system ............................................................................ 103 kPa (15 psi) Coolant capacity (engine only) 4 cylinder (non-aftercooled, charge air cooled)* ..................................... 7.0 liters (7.4 U.S. Qts) 4 cylinder (jacket water aftercooled) ...................................................... 7.9 liters (8.4 U.S. Qts.) 6 cylinder (non aftercooled, charge air cooled)* ................................... 9.0 liters (9.5 U.S. Qts.) 6 cylinder (jacket water aftercooled) .................................................... 9.9 liters (10.5 U.S. Qts.)

INTAKE AIR AND EXHAUST SYSTEM Maximum allowable intake restriction at rated speed and load (wit dirty air filter element) Naturally Aspirated ................................................................................. 50.8 cm H 2O (20 in H2O) Turbocharged .......................................................................................... 63.5 cm H2O (25 in H2O) Maximum turbocharger outlet restriction at rated speed and load ......................... 76.2 mm Hg (3 in Hg) Maximum exhaust restriction at rated speed and load Automotive with oxidation catalyst load .................................................. 152.4 mm Hg (6 in Hg) Automotive ............................................................................................. 114.3 mm Hg (4.5 in Hg) Industrial ..................................................................................................... 76.2 mm Hg (3 in Hg)

FUEL SYSTEM Fuel transfer pump maximum inlet restriction ........................................................... 100 mm Hg (4 in Hg) Fuel transfer pump output pressure at rated speed Distributor fuel injection pumps (maximum) ......................................................... 70 kPa (10 psi) In-line fuel injection pumps (minimum) ............................................................... 172 kPa (25 psi) Fuel filter restriction (maximum pressure drop across filters) .............................................. 35 kPa (5 psi) Fuel return restriction (maximum) ......................................................................... 518 mm Hg (20.4 in Hg)

-5-

Section 4

ENGINE DIAGRAMS The illustrations which follow show the locations of the major external engine components, the filters, and other service and maintenance points. Some external components will be at different locations for different engine models.

Engine Air Inlet Intake Air Preheater (Optional)

High Pressure Fuel Lines

Fuel Filter / Water Separator

In-line Fuel Injection Pump

3/4 NPTF (inch) Water (Heater)

Air Compressor Air Intake

1/4 NPTF (inch) Fuel Inlet Connection

Magnetic Pick-up Location 3/4-16 UNF Air Compressor

Fuel Lift Pump

Engine Data Plate

1/8 NPTF (inch) Oil Pressure

Dipstick

Inlet Side

ew900gb

Rear Engine Lifting Bracket Turbo Exhaust Outlet

Fuel Return Connection

Flywheel Flex Plate Mounting Holes

Flywheel Housing ew900gd

Rear View -6-

Turbo Wastegate

Fuel Injection Nozzles

Oil Fill Front Engine Lifting Bracket

Water Outlet

Lubricating Oil Filter

Lubricating Oil Cooler

Water Inlet Starter Motor and Solenoid

1/2 NPTF Water (Heater Return)

Provision for Oil Immersion Heater ew900gc Oil Drain

Turbocharger Side View

Turbo Air Outlet

Turbo Air Inlet

Engine Air Inlet Automatic Belt Tensioner

Fan Pulley Fuel Pump Drive Cover

Alternator

Water Pump

Air Compressor Air Outlet

Water Inlet

Front Gear Cover

Vibration Damper

Fan Drive Belt

ew900ge

Front View -7-

Section 5

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 Dual Entry Turbine Housing 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

-8-

1.

Exhaust Valve

2.

Exhaust Manifold (Pulse-Type)

3.

Dual Entry to Turbocharger

4.

Turbocharger Exhaust Outlet.

4.2

Fuel System : Fuel is sucked from base tank (1) by suction inlet pipe (2) and suction strainer (3). Lift pump (4) lifts the fuel & delivers to the filtration system. There is a two stage cleaning of fuel; once by water separator (5) & then by microfine fuel filter (6). Cleaned fuel enters to MICO fuel injection pump (7) which pressurise and delivers the high pressured fuel to MICO DSLA type injectors fitted on each cylinder. Returned fuel is routed back to the tank through return pipe (8).

-9-

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

3.

Oil Cooler

4.

Filter Bypass Valve

5.

Oil Filter

6.

Turbocharger Oil Supply

7.

Oil Return to Pan

8.

Piston Cooling Nozzle

9.

Oil Pump idler Gear

Main Oil Rifle

Piston Cooling Nozzle Filter Bypass Valve Oil Filter Pressure Regulator

- 10 -

Oil Cooler Gerotor Lubrication Pump

4.4

Cooling 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 5. Coolant to Cylinder Head

1.

2.

3.

4.

Coolant Flow Past Injector Thermostat Coolant By-Pass Passage Coolant Flow to Pump Inlet

- 11 -

GreenBlack 11

Cylinder Head 1. Coolant Flow from Cylinder Block 2. Coolant to Thermostat Housing 5. By-Pass Closed 6. Coolant Flow Back to Radiator

Section 6

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.

Normal Starting Procedure : 1.

Press starter push button, simultaneously turn the key to “Start” position.

2.

Release the key switch immediately when engine cranks. Key will come to “Run” position.

3.

Watch the lub oil pressure indication. Release the push button when engine oil pressure indicated is more than 1 kg/cm2.

Caution : To prevent damage to the starter, do not engage the starting motor more than 30 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.

Caution : Avoid idling the engine for more that 10 Minutes.

Long idling periods may be harmful to your engine because combustion chamber temperatures can drop so low that the fuel will not burn completely. Carbon can then form which may clog the injector spray holes and also cause valve and piston rings to stick.

5.2

Stopping the engine : Idle the engine a few minutes before routine shut down.

After full load operation, idle the engine 3 to 5 minutes before shutting it off. It will allow the lubricating oil and coolant to carry heat away from the combustion chamber, bearings, shafts etc. This is especially important for Turbocharged engines.

Turn the switch to the “Off” Position.

Do NOT Operate the engine on load when : 1.

temperature of the coolant exceeds 98°C. (200°F).

2.

lubricating oil pressure is low. 18 psi (210°F).

- 12 -

Minimum oil pressures required

5.3

Idle

:

10 PSI

Full Speed & Load

:

30 PSI

Operating the engine :

•

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:

u

Engine misfires

u

Vibration

u

Unusual engine noise

u

Fuel, oil or coolant leakage

u

Sudden change in engine operating temperature or oil pressure

u

Excessive smoke

u

Loss of power

u

An increase in oil consumption

u

An increase in fuel consumption

- 13 -

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.

For such conditions, please refer to Cummins India Limited for engine storage requirements.

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.

- 14 -

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.

2)

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.

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. NO. a

b

c

DESCRIPTION

REMARKS

Prepare engine for Ensis, Long storage Process.

Fabricate and install a plate to close the water pump inlet connection.

Fill the cooling system with Ensis oil Rustilo DW 901, (Castrol India make) up to thermostat outlet connection, using external priming pump trolley.

Leave the drain cocks open until all air is completely vented out. Progressively close the cocks until the ensis oil flows from the

Keep the Ensis oil in the engine for 5 minutes and then drain it completely, from engine.

Remove the fabricated plate at water pump inlet and close the opening by plastic cap. (Collect the drained oil in clean container for reuse.)

thermostat housing.

ii) Fuel Passage : No external treatment is required. 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 15W40. (CF-4 category)

Use engine Lub oil trolley pump for priming.

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.

- 15 -

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.

vii)

In case of any doubts, contact CSS & S / Dealer.

Down-Hill Operation The Cummins Diesel Engine is effective as a brake on downhill grades, but care must be exercised not to overspeed the engine going downhill. The governor has no control over engine speed when it is being pushed by the loaded vehicle. Overspeeding will cause severe damage to the engine.

- 16 -

Section 7

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 (ASTM D445)

1.3 to 5.8 centistrokes (1.3 to 5.8 mm per second) at 1.4F (40C)

Cetane Number (ASTM D-613

40 Minimum above 32 F 45 minimum below 32 F

Sulfur Content (ASTM D-129 or 1552)

Not to exceed 1.0 mass percent

Active Sulfur (ASTM D1796)

Copper Strip Corrosion not to exceed No. 2 rating after three hours at 122F (50C)

Water and Sediment (ASTM D1796)

Not to exceed 0.1 volume percent

Carbon Residue (Rams bottom, ASTM D524 or Conradson, ASTM D189)

Not to exceed 0.35 mass percent on 10 volume percent residuum

Density (ASTN D 287)

42 to 30 API gravity at 60F (0.816 to 0.876 g/cc at 15 C)

Cloud Point (ASTM D97)

10 F (6 C) below lowest ambient temperature which the fuel is expected to operate

Ash (ASTM D 482)

Not to exceed 0.02 mass percent (0.05 mass percent with lubricating oil blending)

Distillation (ASTM D 86)

The distillation curve must be smooth and continuous.

Acid Number (ASTM D 664)

Not to exceed 0.1 Mg KOA per 100 ML.

- 17 -

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, CF4 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.

- 18 -

Coolant Recommendations / Specifications Antifreeze is essential in any climate.

It broadens the operating temperature range by lowering the coolant freezing point and by raising its boiling point. Do not use more than 50 percent antifreeze in the mixture unless additional freeze protection is required.

Never use more than 68 percent antifreeze under any condition.

Use soft water in the Coolant mixture contaminants in hard water neutralize the corrosion inhibitor Components.

Water must not exceed 300 ppm hardness or contain more than 100 ppm of either chloride or sulphate.

Specification : Use low silicate antifreeze which meets ASTM 4985 test criteria.

Concentration : Antifreeze must be used in any climate for both freeze and boiling point protection.

Use a 50 percent concentration level (40 percent to 60 percent range) of ethylene glycol or propylene glycol in most climates.

Antifreeze at 68 percent concentration provides the maximum freeze protection and must never be exceeded under any condition. Antifreeze protection decreases above 68 percent.

Ethylene Glygcol

Propylene Glycol

40% = -23C

40% = -21C

50% = 37C

50% = -33C

60% = 54C

60% = - 49C

68% = -71C

68% = -63C

Caution : Do not add cold coolant to a hot engine.

Engine castings can be damaged. Allow the engine to cool to below 50C (120F) before adding coolant.

NOTE : On applications that use a coolant recovery system, check to make sure the coolant is at the appropriate level on the coolant recovery tank depending on engine temperature.

- 19 -

Coolant Level Check Warning : Do not remove the radiator cap from a hot engine. Wait until the temperature is below 50C (120F) before removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam. Remove the filler cap slowly to relieve coolant system pressure.

NOTE : Never use a sealing additive to stop leaks in the coolant system. This can result in coolant system plugging and inadequate coolant flow causing the engine to overheat. The coolant level must be checked daily.

Properties of Water : Coolant used in cooling system is mixture of water & corrosion inhibitor : Water quality is important for cooling system performance. Therefore it is important that high quality water is used which is free from suspended matter/mud. Distilled or Deionised water can be used in cooling system, however coolant treatment by using corrosion inhibitor is must. Waterused in cooling system must meet following specifications.

Hardness (as CaCO3)

-

170 ppm max.

Chlorides (as CI)

-

40 ppm max.

Sulfur (as SO4)

-

100 ppm max.

pH

-

5 to 9

It is suggested to get Water quality checked from authorised laboratories if water quality is in doubt.

NOTE : For optimum cooling system efficiency always operate engine with radiator cap in place.

- 20 -

Section 8

MAINTENANCE SCHEDULE A Check

B Check

C Check

D Check

❑ 0-50 hrs /

❑ 225-250 hours / every 3 months

❑ 475-500 hours / every 6 months

❑ 950-1000 hours every 12 months

❑ Repeat all A Checks.

❑ Repeat Checks

B

❑ Repeat all A, B & C Checks

❑ Check Toppet clearances and adjust, if necessary.

❑ Check Fan belt tension, replace if necessary.

0-30 days Cooling System ❑ Fill coolant and recommended ensure proper venting. ❑ Check coolant level in Radiator.

Fuel System ❑ Clean fuel strainer, fuel tank breather. ❑ Check fuel shut off mounting & tighten the mounting screw.

Lubrication ❑ Change engine oil. ❑ May be switched over to equivalent oil of CF-4, Grade 15W40 including C u m m i n s Vo l vo l i n e Oil. ❑ Change engine full flow oil filter. ❑ Record oil pressure.

❑ Adjust the speed control level if required.

Cooling System

Air System

❑ Check the condition and tension of radiator drive belt.

❑ Check plugs intake pipe proper sealing.

in for

❑ Check function vacuum indicator.

of

❑ Check coolant level & top up if necessary.

❑ Check the radiator fins for contamination or blockage.

all

A

&

Lubrication ❑ Check dipstick clamping and correct if required.

❑ Fuel tank cleaning.

❑ Clean hoses.

Cooling System

condition

of

❑ Check condition of hoses and replace if faulty. ❑ Check fan drive belt.

❑ Clean and check fuel injector nozzles.

❑ Check fan drive belt.

❑ Check leakage and replace hoses if required.

Air System

❑ Change fuel/water separator element.

Air System

Other

❑ Clean fuel strainer, fuel tank breather.

Exhaust System ❑ Ensure smoke level is normal and no leak from Piping. ❑ Check for Proper support to Exh. pipe. ❑ Check and record exhaust back pressure (inches of Hg) Electrical System ❑ Check condition.

❑ Adjust the throttle lever if required. ❑ Clean element in reverse direction with clean dry air pressure.

Electrical System ❑ Check terminals.

❑ Check sealing.

air

❑ Check radiator.

sealing

cleaner of

Mechanical System ❑ Adjust valve lashes as recommended.

Electrical System

Air System

battery

Fuel System

❑ Check fuel shut off mounting & tighten the mounting screw.

Fuel System

❑ Check fuel shut off mounting & tighten the mounting screw.

❑ Check radiator fins and radiator fan blades for damage. ❑ Check fuel lift pump diaphragm.

Fuel System

❑ Check hoses and clamp for proper sealing.

❑ Check G / set and G/ set room.

❑ Check operating parameters & record. ❑ Replace the coolant.

Cooling System

❑ Check fuel pipes and replace if required.

❑ Check leaks if any.

/

❑ Clean battery terminals. ❑ Check wiring harness for tightness of terminal clamping. ❑ Check wiring harness and connections and tighten if required.

battery

- 21 -

Lubrication System

❑ Check hump hose and replace if required.

Mechanical System ❑ Adjust valve lashes and recommended.

Electrical System ❑ Check battery switches and replace if required. ❑ Check starter / battery charging alternator and repair if required.

1ST FREE CHECK FREE CHECK COUPON FOR ‘B’ SERIES ENGINE FOR INDUSTRIAL APPLICATION (0 TO 50 HOURS OR WITHIN 30 DAYS FROM INSTALLATION) ESN:

MACHINE SR. NO.:

MODEL:

HRS:

RATING:

DATE: DELIVERY DATE:

√ Tick mark COOLING SYSTEM : ❑

FILL COOLANT AS RECOMMENDED & ENSURE PROPER VENTING

❑

ENSURE THE COOLING SYSTEM IS FREE FROM LEAKAGES

❑

ENSURE COOLANT LEVEL IN RESERVOIR BOTTLE

FUEL SYSTEM : ❑

CLEAN FUEL STRAINER & FUEL TANK BREATHER

❑

CHECK PROPER MOUNTING OF FUEL SHUTT OFF COIL

❑

ENSURE THE SPEED CONTROL LEVER IS ADJUSTED PROPERLY

INTAKE AIR SYSTEM : ❑

ENSURE ALL PLUGS ARE TIGHT & PROPERLY SEALED

❑

ENSURE ALL HOSES AND CLAMP ARE PROPERLY TIGHTENED

❑

CHECK PROPER FUNCTIONING OF VACUUM INDICATOR

EXHAUST SYSTEM : ❑

ENSURE SMOKE LEVEL IS NORMAL & NO LEAKAGE FROM PIPING

❑

CHECK FOR PROPER SUPPORT TO EXH PIPE

❑

CHECK & RECORD EXHAUST BACK PRESSURE (INCH OF Hg )

ELECTRICAL SYSTEM : ❑

CHECK BATTERY CONDITION AS RECOMMENDED.

Hours Run :

Lube Oil Press:

Kg/sq.cm

Coolant Temp:

Deg C

THE WARRANTY STANDS NULL AND VOID IF SERVICE IS NOT CARRIED OUT AS SITPULATED.

(# COST OF SPARES AND CONSUMABLES TO BE BORNE BY CUSTOMER. ANY OTHER REPAIRS NOT COVERED UNDER WARRANTY CLAUSE WILL BE BORNE BY CUSTOMER) 1ST Free Check: All the checks-points attended by a service representative of M/S To the satisfaction & the equipment is working in normal condition.

Sign

:

Sign

:

Name

:

Name

:

Designation

:

Designation :

Customer

:

Dealer

:

Name & Add (Copy – Customer / Dealer / HO)

(Approved By ASM – CDSS)

2ND FREE CHECK FREE CHECK COUPON FOR ‘B’ SERIES ENGINE FOR INDUSTRIAL APPLICATION (225 TO 250 HOURS OR WITHIN 3 MONTHS FROM COMMISIONING) ESN:

MACHINE SR. NO.:

MODEL:

HRS:

DATE:

RATING:

DELIVERY DATE:

√ Tick Mark (REPEAT ALL EARLIER FREE CHECK POINTS) LUBRICATION SYSTEM : ❑

CHANGE LUBE OIL WITH CF4 – SAE 15W40 OR EQUIVALENT & MAINTAIN LEVEL

❑

CHANGE ENGINE FULL FLOW LUBE OIL FILTER

❑

RECORD LUBE OIL PRESSURE

COOLING SYSTEM : ❑

CHECK COOLANT LEVEL & TOP UP IF NECESSARY

❑

CHECK CONDITION OF FAN BELT & ADJUST TENSION IF REQD

❑

CLEAN RADIATOR FINS & ENSURE FREE FROM DUST/ BLOCKAGE

FUEL SYSTEM : ❑

CHANGE FUEL FILTER / WATER SEPARATOR

INTAKE AIR SYSTEM : ❑

CLEAN ELEMENT WITH DRY AIR IN REVERSE DIRECTION

ELECTRICAL SYSTEM : ❑

CLEAN BATTERY TERMINALS.

❑

CHECK THE BATTERY CONDITION.

Hours Run :

Lube Oil Press:

Kg/sq.cm

Coolant Temp:

Deg C

THE WARRANTY STANDS NULL AND VOID IF SERVICE IS NOT CARRIED OUT AS SITPULATED.

(# COST OF SPARES AND CONSUMABLES TO BE BORNE BY CUSTOMER. ANY OTHER REPAIRS NOT COVERED UNDER WARRANTY CLAUSE WILL BE BORNE BY CUSTOMER) 2ND Free Check : All the checks-points attended by a service representative of M/S To the satisfaction & the equipment is working in normal condition.

Sign

:

Sign

:

Name

:

Name

:

Designation

:

Designation

:

Customer

:

Dealer

:

Name & Add (Copy – Customer / Dealer / HO)

(Approved By ASM – CDSS)

3RD FREE CHECK FREE CHECK COUPON FOR ‘B’ SERIES ENGINE FOR INDUSTRIAL APPLICATION

(475 TO 500 HOURS OR WITHIN 6 MONTHS FROM COMMISIONING) ESN:

MACHINE SR. NO.:

MODEL:

HRS:

DATE:

RATING:

DELIVERY DATE:

√ Tick Mark (REPEAT ALL EARLIER FREE CHECK POINTS) LUBRICATION SYSTEM : ❑

CHECK CONDITION OF HOSES & ENSURE NO LEAKAGE

COOLING SYSTEM : ❑

CHECK CONDITION OF HOSES & REPLACE IF FAULTY

❑

CHECK CONDITION OF FAN BELT & REPLACE IF REQD

FUEL SYSTEM : ❑

CHECK CONDITION OF FUEL PIPES & REPLACE IF REQD

INTAKE AIR SYSTEM : ❑

CHECK CONDITION OF ELEMENT & REPLACE IF FAULTY

EXHAUST SYSTEM : ❑

CLEAN EXHAUST PIPING IF REQUIRED

MECHANICAL SYSTEM : ❑

ADJUST VALVE LASHES AS RECOMMENDED

ELECTRICAL SYSTEM : ❑

CHECK BATTERY CONDITION.

❑

CHECK WIRING HARNESS & ALL BATTERY & CONTROL SAFETY TERMINALS.

Hours Run :

Lube Oil Press:

Kg/sq.cm

Coolant Temp:

Deg C

THE WARRANTY STANDS NULL AND VOID IF SERVICE IS NOT CARRIED OUT AS SITPULATED. (# COST OF SPARES AND CONSUMABLES TO BE BORNE BY CUSTOMER. ANY OTHER REPAIRS NOT COVERED UNDER WARRANTY CLAUSE WILL BE BORNE BY CUSTOMER) 3rd Free Check: All the checks-points attended by a service representative of M/S To the satisfaction & the equipment is working in normal condition.

Sign

:

Sign

:

Name

:

Name

:

Designation

:

Designation:

Customer

:

Dealer

:

Name & AddM (Copy – Customer / Dealer / HO)

(Approved By ASM – CDSS)

4TH FREE CHECK FREE CHECK COUPON FOR ‘B’ SERIES ENGINE FOR INDUSTRIAL APPLICATION (950 TO 1000 HOURS OR WITHIN 1 YEAR FROM COMMISIONING) ESN:

MACHINE SR. NO.:

MODEL:

HRS:

DATE:

RATING:

DELIVERY DATE:

√ Tick Mark (REPEAT ALL EARLIER FREE CHECK POINTS) LUBRICATION SYSTEM : ❑

CHECK LEAKAGE & REPLACE HOSES IF REQUIRED

COOLING SYSTEM : ❑

REPLACE THE COOLANT AS RECOMMENDED & CLEAN THE RADIATOR PROPERLY.

FUEL SYSTEM : ❑

CHECK CONDITION OF FUEL PIPES & REPLACE IF REQD

❑

CHECK FUEL LIFT PUMP DIAPHRAGM & REPLACE IF REQUIRED

❑

CHECK FUEL INJECTORS & CALIBRATE IF REQD

INTAKE AIR SYSTEM : ❑

CHECK ALL HOSES & REPLACE IF REQUIRED

MECHANICAL SYSTEM : ❑

ADJUST VALVE LASHES AS RECOMMENDED

ELECTRICAL SYSTEM : ❑

CHECK SAFETY CONTROL SWITCH & REPLACE IF REQUIRED.

❑

CHECK STARTER / BATTERY / CHARGING ALTERNATOR & REPAIR IF REQUIRED

Hours Run :

Lube Oil Press:

Kg/sq.cm

Coolant Temp:

Deg C

THE WARRANTY STANDS NULL AND VOID IF SERVICE IS NOT CARRIED OUT AS SITPULATED.

(# COST OF SPARES AND CONSUMABLES TO BE BORNE BY CUSTOMER. ANY OTHER REPAIRS NOT COVERED UNDER WARRANTY CLAUSE WILL BE BORNE BY CUSTOMER) 4th Free Check: All the checks-points attended by a service representative of M/S To the satisfaction & the equipment is working in normal condition.

Sign

:

Sign

:

Name

:

Name

:

Designation

:

Designation:

Customer

:

Dealer

:

Name & AddM (Copy – Customer / Dealer / HO)

(Approved By ASM – CDSS)

Section 9

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.

- 47 -

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.

- 48 -

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).

- 49 -

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. Reset vacuum indicator.

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.

8.3

Every 3 months or 250 Hours : Change Fuel Filter : Remove the two filters from the dual filter adapter.

- 50 -

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.

- 51 -

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 : 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.

- 52 -

8.4

Every 12 months or 1000 Hours : Adjust Valve Clearance : Remove the valve covers.

REPLACING THE HIGH PRESSURE LINES Disconnect the high pressure lines from the injectors and complete the following steps.

Remove the line clamp capscrews from the intake cover.

- 53 -

Remove the lines from the injection pump.

Use two wrenches to prevent the delivery valve holder from turning. Use crowfoot wrench while loosening fuel liner.

Assemble the lines in the reverse order of removal.

The installation torque on the clamp capscrew is 24 N•m (18ft-lbs) Bleed the fuel system.

REPLACING THE FUEL DRAIN MANIFOLD Remove the banjo fitting screws and washers.

- 54 -

Disconnect the drain line fitting.

USE NEW SEALS FOR THE FITTINGS. Assemble the drain line and fuel drain manifold in the reverse order of disassembly.

Replace all sealing washers from the drain lines.

USE NEW SEALING WASHERS FOR THE FUEL DRAIN MANIFOLD. The installation torque for the banjo fitting screw is 9 N•m (6.5 ft-lbs).

REPLACING THE INJECTION PUMP SUPPLY LINE Remove the bleed screw banjo fitting and complete the following steps.

Remove the supply line.

- 55 -

CK 55

Assemble the supply line in the reverse order of removal.

The installation torque for the bleed screw banjo fitting is 32 N•m (23.5 ft-lbs).

REPLACING THE INJECTORS Preparatory Steps : •

Clean around the injectors.

•

Disconnect the high pressure fuel supply lines.

•

Disconnect the fuel drain manifold.

Hold the injector body with an adjustable wrench while you loosen the hold down nut with a 24 mm box wrench.

CAUTION : THE INJECTOR MUST NOT ROTATE IN BORE OF THE CYLINDER HEAD. THIS WILL DAMAGE THE CYLINDER HEAD. Clean the injector nozzle bore.

- 56 -

Assemble the injector and new copper sealing washer.

ALIGN THE INJECTOR ALIGNMENT BALL WITH THE NOTCH IN THE BORE. USE ONLY ONE COPPER WASHER.

Install the injector in the reverse order of removal.

The installation torque on the injector retaining nut is 55 N•m (40 ft-lbs).

CAUTION : SOME SOCKETS CAN DAMAGE THE SEALING SURFACE OF THE FUEL DRAIN OUTLET.

REPLACING THE FUEL PUMP OF MOTOR POL. Remove the access cap and gear retaining nut and washer.

- 57 -

Remove all fuel lines, control linkage support bracket and the solenoid wiring.

Locate TDC for Cylinder Number 1 by barring engine slowly while pushing in on TDC pin.

BE SURE TO DISENGAGE THE PIN AFTER LOCATING TDC.

Loosen timing pin cover on fuel pump.

Engage timing pin into fuel pump weight carrier.

- 58 -

Put the spring behind pin and place the timing pin cover.

Pull the pump drive gear loose from the drive shaft.

- 59 -

Remove the 4 mounting nuts and take off the injection pump.

CAUTION : DO NOT DROP DRIVE GEAR KEY WHEN REMOVING PUMP.

D.

Installation of Motorpal fuel pump :

1.

Ensure engine is at TDC for Cylinder No. 1, use barring tool to Bar engine.

2.

Install new ‘O’ ring for Pilot bore (B). Please refer Figure 1.

3.

Lubricate mounting flange with clear engine oil.

4.

Position the pump flange on mounting studs.

- 60 -

5.

Install the mounting nuts (Spanner 15 mm). Torque these nuts to 32 ft lbs.

6.

Install the fuel pump drive gear and nut with lock washer (Socket 27 mm). Torque this nut to 7-11 ft lbs.

7.

Please note that the new Motorpal fuel pump will be in a locked timing condition. (Refer Figure 2).

- 61 -

Remove fuel pump timing pin plug. Remove and reverse the position of the pin and install the pin plug and sealing washer. Ensure spring is behind Timing Pin. Torque access plug to 11 ft lbs. (Spanner 27 mm)

8.

Dis-engage the engine timing pin.

9.

Tighten the fuel pump drive nut to 126 N•m or 93 lb-ft.

CAUTION : PLEASE DO NOT TIGHTEN THIS NUT WHEN ENGINE TIMING PIN IS ENGAGED.

- 62 -

10.

Assemble access cover to gear drive nut.

11.

Install lube oil supply hose to fuel pump.

12.

Install all high pressure pipes / low pressure piping for fuel pump.

13.

Install electrical wiring for solenoid fuel pump.

INJECTION PUMP VENTING 1.

Slacken fuel drain adaptor on fuel pump.

2.

Press black feed pump handle back and forth (up and down movement) to bleed all air from fuel pump, till clear diesel flow comes out of fuel return passage.

3.

Tighten fuel drain adaptor on fuel pump.

- 63 -

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.

Note : Never rotate engine with the help of fan.

- 64 -

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.

- 65 -

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.

- 66 -

Section 10

MICO PUMP ADJUSTMENT, REPLACEMENT, REPAIR ON B SERIES Section A - Adjustment, Replacement and Repair B series

Injection Pump Replacement 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 shaft.

the nut and

washer from the fuel pump

75 mm T-Bar Puller Pull the fuel pump drive gear loose from the shaft.

- 67 -

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.

- 68 -

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.

- 69 -

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)

- 70 -

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 Wrench Size MM (Inch)

Torque Nom

(Ft-lb)

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°

- 71 -

Socket or Wrench Size MM (Inch)

Torque Nom

(Ft-lb)

(5/16)

Crossover Clamp ..............................................................................

5

(4)

13

Exhaust Manifold ..............................................................................

43

(32)

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)

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)

10

- 72 -

Socket or Wrench Size MM (Inch)

Torque Nom

(Ft-lb)

(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) (32)

15

Oil Fill Tube Mounting .......................................................................

43

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

- 73 -

Section 11

TROUBLESHOOTING

- 74 -

- 75 -

- 76 -

- 77 -

- 78 -

- 79 -

- 80 -

- 81 -

- 82 -

- 83 -

- 84 -

- 85 -

- 86 -

- 87 -

- 88 -

- 89 -

- 90 -

- 91 -

ELECTRICAL SYSTEM

Engine Does not Crank

Check battery condition Check battery voltage at start/crank position Check battery loose connection

- 92 -

Check fuel in tank if fuel is present

Engine Not Starting

Engine Crank but does not start

Check solined coil for hold. Current should not be more than 1 Amps. Adjust the coil TraveĂŒ if required.

Check Keyswitch fr loose connection, check 24V at +ve and -ve check contants, if found faulty replace keyswith

Check Push Button for loose connection and contacts if found faulty repalce push button

Take out air in fuel system

Check Water Temp and Oil pressure saftey controls for loose connection and contact if found faulty replace

+ve

-ve

If 12V supply is available at 37 and negative, adjust coil travel / replace the coil

Check Staarter for loose connections and resistance bet statring coil if found faulty replace the starter.

Section 12

ENGINE WIRING DIAGRAM

- 93 -

- 94 -

NOTES

- 95 -

Section 13 CUMMINS DIESEL SALES & SERVICE NETWORK

- 96 -

ZONAL/REGIONAL/AREA SERVICE OFFICES (NORTH ZONE) Cummins Diesel Sales & Service (India) Limited DELHI (ZONAL OFFICE) 911-912, Hemkunt Tower 98, Nehru Place New Delhi-110019 Phone : O : (011)6416947/6445756/ 6445759/ R : (011)6494100 VN (0120)4508658 RGA Fax : (011)6212817 Mobile : 9810399301 Office Incharge : Zonal Manager : T S Rithal Area Service Manager : S C Bansod Area Parts Manager : C V Varghese / Sunil Sharma Area Service Manager : Vinod Gautam E-Mail : cdssdel@gndel.global.net.in JAIPUR (REGIONAL OFFICE) 405 & 406, Geeta Enclave, G8, Viniba Marg, C Scheme, Jaipur 302001 Phone : R : (0141)225863 MGP Office Incharge : Zonal Manager : M G Pawar Area Service Manager : S Hegde

SERVICE DEALERS AGRA Rohelkhand Engines & Machines (P) Ltd 159-A, Garden Road, Balugunj, Agra - 282 001 ( UP ).

Phone : (0562) 363478 , 360203(O/R) Fax : (0562) 363478 Cont. : Rahul Sondhi / A K Varma Cable : REAMCUM AGRA Mobile : 9837037337 / 9836028973 FARIDABAD Svam Power Plants Private Ltd. A-3/2, Nehru Ground, NIT Faridabad-121001 (Haryana) Phone : (0129)5412423,5412872, 5412735 (O) (011) 6835778, 6830362 (R) Fax : (0129) 5413247 Cont. : Sudhir Malhotra Cable : SVAM FARIDABAD Mobile : 9811017488 GHAZIABAD Ghaziabad Engines and Machines Pvt Ltd. 20 H.I.G. Brij Vihar, P.O. Chandra Nagar, Ghaziabad -201011 (UP).

Phone : (0120) 4623071,4623072, (O) (0118) 4507787 (GS) Fax : (0120) 4628423 Cont. : Gaurav Sondhi E-Mail : geam@vsnl.com Cable : PRIMEPOWER GHAZIABAD

LUCKNOW (REGIONAL OFFICE) B-191 Nirala Nagar, Opposite Ramkrishna Math, Lucknow (UP) Phone : O : (0522)383220/389174 R : (0522)331307 AKS Fax : (0522)787880 Office Incharge : Zonal Manager : A K Sharma Area Service Manager : V Murli CHANDIGARH (AREA OFFICE) SCO 36, 2nd Floor, Sector 31 A, Chandigarh-160047 Phone : O : (0172)663087 / 639535 / 622678 R : (0172)646771 Fax : (0172)615351 Office Incharge : Area Service Manager : R.G. Agarwal E-Mail : cdss_chd@satyammail.com

NOIDA (AREA OFFICE) C-42 ,Sector-2 , Noida-201301 (UP) Phone : O : (0120)4441670 R : (0120)4441756 Fax : (0120)4441671 Office Incharge : Area Service Manager - B K Chaudhari E-Mail : cdss.noi@gecsl.com SINGRAULI (AREA OFFICE) P.B.No.06, PO Singrauli Colliery,486889, Dist.Sidhi (MP) Phone : O : (07805)66643/67247 R : (07805)66482 Fax : (07805)66587 Office Incharge : Area Service Manager : Ramesh Babu E-Mail : cdsssing@satyam.net.in

GURGAON (AREA OFFICE) 17, First Floor, Sector 14, Shopping Complex, Opp. HUDA Office, Gurgaon - 122 001.

Phone : O : (0124) 6316182 / 6316183 Area Service Manager : A N Limaye Resi. : (0124)6221610 Mobile : 9810399311 E-Mail : cdss.grg@gecsl.com

JAIPUR Upper Rajasthan Sales&Service (Pvt) Ltd B-2, Jayanti Market, M I Road, Jaipur 302 001.

Phone : (0141) 367884,379713,362022, 330747 (SC)(O) 382942 (RS)343237(PV) Fax : (0141) 362559 Cont. : Rajeev Singh/M P Venugopalan E-Mail : ursssc@jp1.dot.net.in Telex : 0365-2298 URSS IN Cable : CUMTHAR JAIPUR JAMMU PAL Engineers (J & K) Digiana Camp, Gangyal, Jammu -180010. ( J & K ).

Phone : (0191) 432696 (O)(Jammu) Cont. : P. Luthare JHANSI Krishan Diesels L-10 ,Ras Bahar Colony, Nandanpura, Jhansi -284003. ( UP ).

Phone : (0517) 480083 (O) Fax : (0517) 380083 Cont. : Pradyum Pathak Cable : KRISDIESEL JHANSI

- 97 -

KANPUR Avadh Engines& Machines Private Ltd 117/H-1/61, Pandu Nagar, Behind JK Temple, Kanpur-208005 (UP) Phone : (0512) 218012, 215633, 213013,14 (O) 294360(SM) (R) Fax : (0512) 219576 Cont. : S Mehra E-Mail : powerknp@sancharnet.in Cable : KANPOWER KANPUR Mobile : 9839085741 KARNAL Gulati Diesels Plot No.18, Sector-3,HSIDC, Industrial Area,Karnal-132001 Phone : (0184) 272101, 272201 Fax : (0184) 272101 Cont. : Ajay Gulati / Amit Gulati E-Mail : gulati_diesels@rediffmail.com Mobile : 09812043138(AG) 09812063555(AG) KOTA Kota Diesel Sales & Service.

1-KA-28, Vigyan Nagar, Jhalawar Road, Kota- 324005 (Rajasthan).

Phone : (0744) 436733, 438533, 425833 Fax : (0744) 425833 Cont. : Rajesh Bagrecha E-Mail : rajesh99@ndf.vsnl.net.in Cable : DIESEL KOTA Mobile : 9829035725 (RB)

LUCKNOW Excel Diesel B 1/ 63, Sector B, Aliganj ,Lucknow-226024 Phone : (0522) 322319, 334557(O) Fax : (0522) 376622 Cont. : A K Panday / B Banerjee E-Mail : exceldsl@yahoo.com Pager : 9610205333 Parts Asst, 9610204044/9610205830 Service LUDHIANA Caysee Diesels Pvt Ltd Jasmer Commercial Cplx., Near Lohia Scooter Showroom, Ferozepur Rd, Ludhiana-141001 Phone : (0161)402756,424475(O) Fax : (0161) 405160 Cont. : Balwinder Singh E-Mail : caysee@satyam.net.in Cable : ENGINECARE LUDHIANA MIRZAPUR Bharat Diesel Sales & Service Mirzapur- Varanasi Road, Bharuhana Mirzapur - 231001 (UP).

Phone : ( 05442) 62987 (O) / 63087 (R) Fax : (05442) 62987 Cont. : B N Singh / S S Hasan Cable : SERVICE MIRZAPUR MOHALI J.K.Supplies and Solutions C-7 , Phase -I , Industrial Estate, Mohali - 160055 Phone : (0172) 267053, 267590 Fax : (0172) 267053 Cont. : RS Chahal / EG Kutty E-Mail : jkss@glide.net.in

MUZAFFARNAGAR Uttar Pradesh Engines & Machines Pvt. Ltd. G-8, Industrial Area, Begrajpur, Muzaffar Nagar-251203 (UP).

Phone : (01396) 52525/52526/52180/52707 (O) Cont. : Rahul Sondhi / R B Singh Cable : FERGUSON MUZAFFARNAGAR Mobile : 09837058272 RBS NEW DELHI OVN Trading Engineers Pvt Ltd. BT 1/90, Mangalpuri Industrial Area, Phase I, New Delhi - 110083 Phone : (011) 7911591/79115860 Fax : (011) 7916379 Mobile : 9811033223 Pager : 9602420792 RAMPUR S.K. Diesels Sales & Service Pvt Ltd Moradabad Road, Rampur - 244901 ( UP ).

Phone : (0595) 350036, 353038 (O) Fax : (0595) 350037 Cont. : S K Agrawal / S K Bansal Cable : PRIMETECH RAMPUR Mobile : 9837026711 SHIMLA Manoj Diesel Sales & Service Pvt Ltd Uttam Bhavan, 2nd Floor, Dorga Estate, Near 103 Tunnel, Shimla 171 004 Phone : (0177) 240145, 242436 (O) 252510 (MA), 211667 (R) Fax : (0177) 211667 / 32792 Cont. : Manoj Ahluwalia / Lalit Kapoor E-Mail : mdss@satyam.net.in Cable : HIMDIESEL SHIMLA Mobile : 09816077088 (MA)

- 98 -

SINGRAULI Chintamani Diesel Sales & Service Pvt Ltd. Post Box No. 25, Opp. LIG Colony, Dist,Sidhi , Singrauli-486889 (MP).

Phone : (07805) 66562, 66495,66309 (O) 66523 ,66362(R) Fax : (07805 ) 66501 Cont. : S D Shirodkar / S R Shirodkar E-Mail : chdsssgr@satyam.net.in Cable : CHINTAMANI SINGRAULI SONEPAT V R SVAM Power Plants Pvt.Ltd Near Saroha Properties,31 KMS, GT Karnal Road, Kundli Sonepat-131001 (Haryana) Phone : (01264)70860 / 70995(O) (01264)70995 (R) Fax : (01264)70995 Cont. : Sudhir Malhotra / Neeraj Batra Mobile : 9810017299 (RS) 9812024289(NB) UDAIPUR Rajasthan Diesel Sales & Service.

E-39/40, Mewar Industrial Area, Madri, Road No.5, Udaipur-313001 (Rajasthan).

Phone : (0294) 491351,490095,491663 (SC) 410760 (Mrs.Murdia),450863(VB) (R) Fax : (0294) 525431/491697 Cont. : Mrs. Murdia/R K Gupta/ Vijay Bagrecha/R S Mohan Telex : 0335-243 RDSS IN Cable : POWER UDAIPUR VARANASI M.M.Diesels Pvt Ltd 1Shri Ram Shopping Centre, 1st Floor, Near Roadways Bus Stand, G.T. Road, Cantl., Varanasi 221 002 (UP) Phone : (0542)224639(O) Fax : (0542)224639/360197 Cont. : M.M.Singh / A.K.Srivastav Cable : MORPOWER E-Mail : mmsvns@satyam.net.in

ZONAL/REGIONAL/AREA SERVICE OFFICES (WEST ZONE) Cummins Diesel Sales & Service (India) Limited MUMBAI (ZONAL OFFICE) 298,Perin Nariman Street, Fort,Mumbai-400001 Phone : O : (022)2663566/2662247/2662041/ 2610586/2674843 (022)4131844 SGB (022)5436513 BSK Fax : (022)2660790 Telex : (011)84889 Mobile : 9820136143 VN Office Incharge : Zonal Manager : S G Bathe Area Parts Manager : A K Rishi Area Marketing Manager : N S Moorjani E-Mail : cdssmum@vsnl.net

BARODA (AREA OFFICE) 202, “Mangaltirth” 2nd Floor, 15, Sampatrao Colony, Alkapuri, Baroda-390005(Gujarat) Phone : O : (0265)330627/340623/326585/326587 R : (0265)340718 Fax : (0265)340623 Office Incharge : Zonal Manager : S D Karnik Area Service Manager : K K Upadhyaya E-Mail : cdss_brd@satyam.net.in

PANJIM (AREA OFFICE) No.3 Ground Floor,”Sesa Ghor”, 20, Patto Complex Panjim-403001(Goa) Phone : O : (0832)230074/420371 R : (0832)229600 Fax : (0832)230074 Telex : (0194)330 Office Incharge : Area Service Manager - T M Raja E-Mail : cdssgoa@goatelecom.com

SERVICE DEALERS

MUMBAI C S Diesel Engineering Pvt. Ltd. 15, QRGH Laxmi Industrial Estate, New Link Road, PO Azad Nagar Andheri (W) Mumbai-400053 Phone : (022) 6361225/6360777(O) Fax : (022) 6365729 Cont. : CP SHAH / S C SHAH / E.G.Jagtap E-Mail : csdiesel@giasbm01.vsnl.net.in Telex : (011) 78128 CSD IN Cable : CUMMINSENG MUMBAI

RAJKOT Sealand Diesel Pvt. Ltd PB No.162, 13 / 14 Galaxy Commercial Center, 2nd Floor, Jawahar Road, Rajkot - 360001 (Gujarat) Phone : (0281)225433 / 226499 (O), (0281)453108 / 452726 AA, (0281)72063 KPR (0281)446068 SA Fax : (0281)223056 Cont. : Alex Louis / KP Raman E-Mail : info@sealanddiesel.com Telex : (0169)304 BOBY IN Cable : SEALAND RAJKOT Website : www.sealanddiesel.com

AURANGABAD Trinity Sales & Services C-220, MIDC Industrial Estate, Village Pandharpur, Waluj Aurangabad -431136 Phone : (0240)554678(o) Fax : (0240)555393 Cont. : S.S.Rau / Y.Lavhale E-Mail : trinity1@bom4.vsnl.net.in trinity@bom6.vsnl.net.in Cable : TRINITY AURANGABAD VADODARA Customer Care Centre 276/2, G.I.D.C. Makarpura Industrial Estate, Vadodara - 390010 (Gujarat) Phone : (0265)656953, 648423 (O), Fax : (0265)656953 Cont. : S. K. Roy E-Mail : cum-caregcl@sancharnet.in INDORE Deccan Diesels 20-22, Anoop Nagar, Opp. Indotel Manor Hotel, Agra-Mumbai Road, Indore - 452001 (MP) Phone : (0731) 559095 / 557266 / 556811 270190 / 271190 (O), (0731) 529112 -RS Patil Fax : (0731)553979 Cont. : RS Patil /Praveen Yadav E-Mail : deccan@sancharnet.in KOLHAPUR Ghatge Patil Automobiles Ltd 517-E, Pune-Bangalore Road, Kolhapur - 416001 (Maharashtra) Phone : (0231)537801/2/3 (O) Fax : (0231) 536593 Cont. : KJ Patil / MG Moog / KG Pradeep E-Mail : gpal@bom6.vsnl.net.in Cable : GHATGEPATIL Kolhapur

NANDED Ujwal Auto Godavari Hotel Complex Nanded - 431602 (Maharashtra) Phone : (02462)22583 / 22581 (O) (02462)21428 (R) Fax : (02462)34083 Cont. : Ashok Chavan / Santosh Kachruji NASHIK Trinity sales “Raghukul”, 480/34, Gole Colony, Nashik - 422 002 (Maharashtra) Phone : (0253) 577611 / 577851(O) Fax : (0253) 578581 Mobile : 9823023255 DVT E-Mail : trinity@bom6.vsnl.net.in Cont. : D. V. Talekar NAVSARI Manik Diesel Services 13 / 14 , Siddhashila Appartments Near Bhamagra Hospital Sayaji Road, Navsari - 396445 (Gujarat) Phone : (02637) 57364 / 53424 (O), (02637) 58742 (R) Fax : (02637) 57364 Cont. : NR Udapi / HC Ramesh E-Mail : manik@navsarionline.com GOA WISS Goa Chidvilas Colony, Near Dr. Gaunekar Nursing Home, Taleigao, Goa-403002 Phone : (0832)224779 / 224742 (O), (0834)731623 ICV Fax : (0832)227846 Cont. : IC Viegas / A Gonsalves E-Mail : wissgoa@vsnl.com Telex : (0194)207 WISS IN Cable : WISS GOA Mobile : 9822101201

- 99 -

SOLAPUR Murlidhar Maruti Sales & Services Pvt. Ltd. 20/31, Murarji Peth, Solapur 413001 (Maharashtra) Phone : (0217)723939 / 620726 (O), (0217) 728131 RK Fax : (0217)621273 Cont. : Ravindra Kamble E-Mail : mmplawpl@pn2.vsnl.net.in NAVI MUMBAI Madhunil Engineering Services Plot W.109-B, MIDC T.T.C Area Khairne, Thane-Belapur Road, Navi Mumbai-400709 Phone : (022) 7680678/7687655/ (022) 5423999/5404205 (O) Fax : (022)7682047/ 5425591 Cont. : AM Pradhan / PP Kulkarni E-Mail : madhunil@bom3.vsnl.net.in Cable : MADUNIL THANE VAPI Vinayak Diesel Sales & Service Plot No.2908/1, Behind New Telephone Exchange Char Rasta, GIDC, Vapi 396195 (Gujarat) Phone : (0260)427986 / 434986 / 430986(O) Fax : (02638)430986 Cont. : PA Karulkar / VM Kulkarni E-Mail : vinayak@egujarat.net vinayak@vinayakdiesel.com Mobile : 09820282653 (PK)09824126524 , 09824157764, 09824157765, 09824157767, 09824157768

ZONAL/REGIONAL/AREA SERVICE OFFICES (CENTRAL ZONE) RAIPUR (ZONAL OFFICE) “Vanijya Bhavan “ I st Floor, Sai Nagar, Fafadih, Devendra Nagar Road , Raipur-492009 (Chhattisgarh) Phone : O : (0771) 521101/521102/521301/521311 R : (0771) 427148 RK (0771) 254380 GMD Fax : (0771) 521103 Telex : (0775) 7304 Mobile : 9827133157 RK Office Incharge : Zonal Manager : Revathi Kaul Area Service Manager : N P Anand Area Parts Manager : P P Sabnis Area Marketing Manager : M M Nath E-Mail : cdssraip@vsnl.com Pager : (0771) 9628>531449 (Raipur) (0771) 9628>531450

BILASPUR (AREA OFFICE) New Sarkanda, Near SBI, Bilaspur-495001(Chhattisgarh) Phone : O : (07752)42838 R : (07752)41207 Fax : (07752)42078 Office Incharge : Area Service Manager : P Rengaswamy E-Mail : cdssbsp@vsnl.com

SERVICE DEALERS

DURG Karm Diesels A-10, Mahesh Col., Pulgaon, Durg-491001 (Chhattisgarh) Phone : (0788)321811 (O) Fax : (0788)321811 Cont. : R S Sharma / R G Atalkar E-Mail : karmdsl@mantraonline.com Cable : KARM DIESEL MALANJKHAND Mobile : (098271)46244

ANGUL Durga Diesel Sales & Services Umashankar Bazar Turanga, PB. No.32, Dist. Dhenkanal, Angul -759122( Orissa).

Phone : (06764) 33012 / 33456 (O) Fax : (06764) 33012 Cont. : D V Tapkeer E-Mail : ddss@vsnl.net Cable : DEVDHAN ANGUL BHOPAL Mangeshee Diesel Sales & Service.

15-A, Indrapuri, Near BHEL Gate No.1, Near Govindpura Industrial Estate Road, Bhopal462022 ( MP ).

Phone : (0755) 587383 / 586839 (O) Fax : (0755) 786912 Cont. : S S Tendulkar / Seema E-Mail : mangeshi@bom6.vsnl.net.in Telex : 0705-338 MDSS IN Cable : MANGESHEE BHOPAL BHUBNESWAR Test Inspection & Services.

S-1/104 & 105, New Industrial Estate, P.O.- Rasulgarh, Bhubaneshwar - 751010 (Orissa) Phone : (0674) 580043, 580309 (O) 550023(GDK),575540(KD), Fax : (0674) 580835 Cont. : G D Kulkarni / Khokan Dhar E-Mail : tisbbsr@dte.vsnl.net.in Telex : 0675-6403 TISB IN Cable : INSPECTION BHUBANESHWAR Diamond Engg.

Plot No. 142, Netaji Subhash Road, Opp. Bhagwan Towers, Post Buddheshwari, Bhubneshwar 751006 (Orissa) Phone : (0674)572450

SAMBALPUR (AREA OFFICE) Unit No.15, Plot No.228/5255, Pradhanpara(Jamkani) PO Budharaja,Sambalpur-768004(Orissa) Phone : O : (0663)405316 / 404750 R : (0663)404750 Fax : (0663)404750 Office Incharge : Area Service Manager : P P Khedekar E-Mail : cdsssamb@dte.vsnl.net.in

NAGPUR (Area Office) 301,Shreemohinee Building,3 rd Floor, Kings Way ,Nagpur-440001 Phone : O : (0712)523203/521247 R : (0712)220716 Fax : (0712)541217 Telex : (0715)7501 Office Incharge : Area Service Manager : R P Virkar E-Mail : cdssngp@nagpur.dot.net.in

JABALPUR Diesel Sales & Service Muthye Udyog Bhawan, Opp.Telephone Exchange, Wright Town, Jabalpur-482002 (MP).

Phone : (0761) 310726, 310491 (O) 311997 (R) Fax : (0761) 310742 Cont. : S V Muthye/Shriram S Muthye E-Mail : muthyejbp@altavista.net Cable : MUTHYEUDYOG JABALPUR KORBA M.K.Diesels Private Limited 1st Floor, ALKA Complex, Transportnagar, PH Road, Korba-495679 (Chhattisgarh) Phone : (07759) 21628 (O), 22359 (O) Fax : (07759) 21128 Cont. : D C Kulkarni / AK Mathew E-Mail : mkdiesel@bom6.vsnl.net.in Cable : MKDIESEL KORBA NAGPUR Midland Diesel Services Pvt Ltd. W-46 MIDC Hingna Road, Nagpur-440018 ( Maharashtra ).

Phone : (07104) 35244, 37544 (O) Fax : (07104) 35245 Cont. : S R Dixit / P R Dixit E-Mail : midland@nagpur.dot.net.in Telex : 0715-7472 MDS IN Cable : DIXON NAGPUR

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RAIPUR M P Sales & Services GE Road, Near TCI Godown, Raipur-492010 (Chhattisgarh) Phone : (0771) 572527, 572670 (O) Fax : (0771) 326068 Cont. : SV Muthye / PK Patnaik E-Mail : mpssraipur@hotmail.com Cable : MUTHYE RAIPUR ROURKELA Himanshu Services Main Road,Uditnagar, Rourkela-769012 (Orissa) Phone : (0661)500552 / 580925 (BKS) 505031 (O) Fax : (0661)500574 Cont. : Manoj Agrawal / B K Sharma E-Mail : himansh@dte.vsnl.net.in anupama2@cal2.vsnl.net.in SECUNDERABAD Industrial Marketing Services.

G 015 & 016 Emerald House 1-7-264 Sarojini Devi Road, Secundarabad- 500003 ( AP ).

Phone : (040) 7847262, 7845188 (O) Fax : (040)7819422 Cont. : Sudin Chaudary E-Mail : sudinims@pol.net.in.

Telex : 0425-6094 IMS IN

ZONAL/REGIONAL/AREA SERVICE OFFICES (EAST ZONE) Cummins Diesel Sales & Service (India) Limited KOLKATA (ZONAL OFFICE) 94,Tivoli Court 1/C Ballygunge Circular Road Kolkata - 700019(WB) Phone : O : (033)2472481/2470774/2478065 R : (033)4220273 KKB (033)4121850 RPB (033)4172186 BKG Fax : (033)2473833 Telex : (021)2139 Mobile : 9827133157 KKB Office Incharge : Zonal Manager : K K Bhowmick Area Service Manager : R P Borse Area Marketing Manager : S Khan Area Parts Manager : B K Ghosh E-Mail : cdsscal@vsnl.net

RANCHI (REGIONAL OFFICE) Shanti Kunj, C 202 Vidyalaya Marg, Road No.01,Ashok Nagar, Ranchi-834002 (Jharkhand) Phone : O : (0651) 241948 / 241521 R : (0651)208322 JRV (0651) 240494 MKC Fax : (0651)304815 Telex : (0625)274 Mobile : 9835150725 VND Zonal Manager : J. R. Vora Area Service Manager : M K Chakraborty Area Parts Manager : C G Jiraithkhane Area Marketing Manager : K L Rao E-Mail : cdssran@satyammail.com

GUWAHATI (REGIONAL OFFICE) Hemchandra Road, Opposite Ideal Pharmacy, Uzanbazar, Guwahati-781001(Assam) Phone : O : (0361)520399,635686 R : (0361)547810 JRV (0361)630478 SM Fax : (0361)515604 Office Incharge : Area Service Manager : S V Prasad Pager No. : 9864022935 E-Mail : cdssguwahati@satyam.net.in

SIBSAGAR (AREA OFFICE) Opposite Veterinary Hospital, Phukan Nagar,Sibsagar-785640 (Assam) Phone : O : (03772)22544 R : (03772)22544 Fax : (03772)20896 Office Incharge : Area Service Manager : R Nandkumar E-Mail : asosbs@gw1.dot.net.in

SERVICE DEALERS

DHANBAD J.K.Diesels Katras Road, Opposite Super Bazar, Dhanbad-826001 (Jharkhand) Phone : (0326) 304397, (S / C-305865) (0326)202344 RSC Fax : (0326) 304398 Cont. : R S Chahal / T K Ghosh E-Mail : jkdiesels11@rediffmail.com Cable : JAYKAY DHANBAD

ASANSOL Jupiter Services B B College More, Ushagram, GT Road, Asansol- 713303 (West Bengal).

Phone : (0341) 202169, 206023 (O) 205350 (SC) / 207699 (R) Fax : (0341) 206993 Cont. : B S Jayant / J N Das E-Mail : jptr@dte.vsnl.net.in Telex : 0204-216 JPTR IN Cable : JUPSER ASANSOL BOKARO STEEL CITY CHAS WISS - CHAS. Post Box No. 51, 231 Cooperative Colony, Bokaro Steel City - 827001 (Jharkhand) Phone : (06542) 40542 (O) / 40752 (TN) (R) Fax : (06542) 40542 Cont. : T Nandi E-Mail : wiss.chas@gnjsr.global.net.in Cable : WISS CHAS BOKARO KOLKATA Kosaban Services 41/1 Mirza Ghalib Street, PB No.9057, Kolkata - 700016 (West Bengal) Phone : (033)2291949,2497363, Fax : (033) 2291958 Cont. : K N Koppikar, S S Baillur, E-Mail : kosaban@cal3.vsnl.net.in Telex : 021-5840 DISL IN Cable : CALKOSABAN CALCUTTA Premier Diesels Pvt Ltd. Tivoli Court, Block A, Ground Floor, 1C Ballygunge Circular Road, Kolkata - 700019.

Phone : (033) 2473004, 2804402 (O) 4472334 (NCG), 4718311 (DRD) (R) Fax : (033) 2806306 Cont. : NC Ghosh, D R Deshpande E-Mail : pdpl@cal2.vsnl.net.in Cable : AONEDIESEL CALCUTTA Mobile : 9830060142 (DRD) 9830060143 (NCG)

DIMAPUR Shikhu Diesel Sales & Service PB No.15 2 1/2 Miles, Kohima Road, Near Dimapur Airport Dimapur-797112 (Nagaland).

Phone : (03862) 21641 (O & R) Cont. : Martin Sikhu / P C Sarogi Cable : SHIKAUTO DIMAPUR GUWAHATI North-East Diesels Sales & Service Govt. Press Road, Bamunimaidan, Guwahati 781021 Phone : ( 0361) 591187 (O) Cont. : Parag Duarah/Ambarish Purkayastha E-Mail : paragduarah@satyam.net.in Mobile : 9864023819 (PD) 9864023820 (AP) Assam Diesel Sales & Service Dr S K Bhuyan Road, Uzanbazar Guwahati 781001(Assam) Phone : (0361) 544985, 543702 (O) 522447 (BKB) (R) Fax : (0361) 543702 Cont. : B K Bhuyan E-Mail : skb@gw1.dot.net.in Cable : BEEKAY GUWAHATI HAZARIBAGH WISS Hazaribagh PTC Road, Korrah Hazaribagh - 825301 (Jharkhand) Phone : (06546) 23209, 22697 (O) 23306 (Sanjay), (R) Fax : (06546)22697 Cont. : Sanjay E-Mail : wisshaz@bitsmart.com Cable : WISS HAZARIBAGH

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ASANSOL (AREA OFFICE) Joy Villa Hill View Park (East), S.B.Goari Road,Asansol-713304(WB) Phone : O : (0341)202041 R : (0341)206314 Fax : (0341)210558 Office Incharge : Area Service Manager : G V Varik E-Mail : cdssasl.@satyammail.com DHANBAD (RESIDENT ENGINEER) Office Tel. No. 0326-266133 / 267763 Fax : 0326-265241 Resi. : 0326-265185-A. K. Sinha

JAMSHEDPUR Western India S & S 28, Kagal Nagar ,Road No.2, Sonari Jamshedpur-831011 (Jharkhand) Phone : (0657) 227927, 235988 (O) Fax : (0657) 228423 Cont. : D P Jha E-Mail : wiss_jsr@satyam.net.in Cable : WISSJAM JAMSHEDPUR JORHAT Ramnarayan Diesel Sales & Service B.G.Road, Jorhat-785001 (Assam) Phone : (0376)3330015 Fax : PP(0376)3323899 Cont. : Ramnarayan Jalan E-Mail : ramayan@sancharnet.in KATHMANDU Engineering Marketing Concern GPO B.No.328 Tripureshwar, Kathmandu ( Nepal).

Phone : (00977-1) 260196, 260728, 261177 (O) Fax : (00977-1) 260306 Cont. : N M Pradhan / B M Pradhan E-Mail : pradh@.ccsl.com.np emc@ccsl.com.np MUZAFFARPUR Upper Bihar Diesels Satpura Colony Near Aghoria Bazar, PO Ramna, Muzaffarpur 842002 (Bihar) Phone : (0621) 274007 (O) Fax : (0621)264330 Cont. : A P Mulgund / S Ganguly E-Mail : archana@dte.vsnl.net.in Cable : DIESEL MUZAFFARPUR NOAMUNDI WISS Noamundi Main Road, PO : Noamundi 833 218 Dist. Singhbhum (W), (Jharkhand) Phone : (06596) 33603 (O) (06596) 33344(R) SG Fax : (06596 33603 E-mail : wissnoamundi@satyam.net.in Cable : WISS NOAMUNDI Cont : M.S. Vaidya

PATNA Lower Bihar Diesels M-3/21, Shrikrishnapuri, Patna - 800001 (Bihar).

Phone : (0612) 238743 / 233664 (O) 236472 (R) Fax : (0612) 238743 Cont. : M S Vaidya E-Mail : msvaidya@dte.vsnl.net.in Cable : CUMDIZ PATNA PHUNTSHOLING (BHUTAN) Deki Corporation PBNo 73, Industrial Estate, Phuentsholing (Bhutan) Phone : (00975-5)252344 (O) / 252227 (R) Fax : (00975)252707 Cont. : HRP Ashi Deki Cable : DEKI PHUNTSHOLING BHUTAN RANCHI Prime Power Services Bagroy Market ,(Opp.Shanti Petrol Pump) Main Road , Ranchi -834001 (Jharkhand) Phone : (0651) 209015,300722 (O) Fax : (0651) 300722 Cont. : P B Luktuke / R R Luktuke E-Mail : ppservic@dte.vsnl.net.in

SHILLONG Stanley Roy Construction Mawlai GS Rd, Shillong 793008 (Meghalaya) Phone : (0364) 241490, 241644, 241075 (O) 241071 (R) Fax : (0364) 241644 Cont. : S R Thangkhiew / K S Kharkongor E-Mail : stancon@dte.vsnl.net.in Cable : STANCON SHILLONG SILCHAR Eastern Diesel Sales & Service Sonai Road P O Link Road, Post Box No.49 Silchar -788001 (Assam).

Phone : (03842) 25100, 25900 (R) Fax : (03842) 25853 Cont. : P P John / P A Davis/ P O Polson E-Mail : johnsons@dte.vsnl.net.in Cable : EDEESS SILCHAR SILIGURI Himalayan Services Saibal Mansion, 2nd Floor, Hill Cart Road Siliguri- 734401 (West Bengal).

Phone : (0353) 431206, 534314 (O) 514359 (AKB) 514358 (BM) (R) Fax : (0353) 534314 Cont. : B B Mukherjee / A K Barman E-Mail : suddha@dte.vsnl.net.in Cable : HIMSER SILIGURI

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TEZPUR San Engineering Extension Police Line, Opposite IT Housing Complex, PO.Tezpur -784001 (Assam).

Phone : (03712) 20936, (O)/21079 (SNB) (R) Fax : (03712)21079 Cont. : S N Bagchi / K R Pal Chaudhary E-Mail : snbagchi@sancharnet.in Cable : SAN TEZPUR TINSUKIA Saurav Diesel Sales & Service Pvt.Ltd Gillapukhuri Road, Bordoli Nagar, Tinsukia - 786 125 Phone : (0374) 340878, 339806 (O) (0361) 524352 (R) JS Fax : (0374) 335343 Mobile : 9864024212 E-mail : sauravgroup@satyam.net.in Cont. : Sauravi Sharma / Jayanta Sharma Cable : SUNDIESEL SIBSAGAR

ZONAL/REGIONAL/AREA SERVICE OFFICES (SOUTH ZONE) Cummins Diesel Sales & Service (India) Limited BANGALORE (ZONAL OFFICE) 24,9 th Main Rajmahal Vilas Extension, Bngalore-560080 Phone : O : (080)3343831/3341958/3460160 R : (080)3343831 Fax : (080)3344552 Telex : (0845)2507 Mobile : 9844027417 Office Incharge : Zonal Manager (South) : S K Saigal Area Service Manager : V.K. Tagade Area Marketing Manager : M.R.Shah Area Parts Manager : U.R. Shrivastava E-Mail : cdss.bang@vsnl.com HYDERABAD (REGIONAL OFFICE) 3-6-482 ,Street No.6 ,Hardikar Bagh, Himayat Nagar , Hyderabad-500029 (AP) Phone : O : (040) 7678891/7678892/6612932 R : (040) 7605096 VND (040) 234923 MLR Fax : (040) 7678892, 3226627 Telex : (0425) 2223 Office Incharge : Zonal Manager : V N Deshmukh Area Service Manager : M L Rego Area Marketing Manager : G S Kadam E-Mail : cdss_hyd@satyam.net.in

SERVICE DEALERS BANGALORE Ajax Engineering Pvt. Ltd. 148/25, Industrial Suburb, Yeshwantpur Bangalore - 560 022 (Kn.) Phone : (080) 3373439 / 3372977 / 3377490 (O) (080) 5257562 AKS, 5483008 TJ Fax : (080) 3379510 Mobile : 9845015828 AKS 9845040628 SARLA K E-mail : ajax@bgl.vsnl.net.in Telex : 0845-2312 AJAX IN Cont. : A.K. Singh Col (Retd.) T. John Power Devices 14/2, 1st Floor, Krishna Manere Wood Street, Richmond Road, Bangalore - 560 025 (Kn.) Phone : (080) 5574141/5573111/6681550 (O) SP Fax : (080) 5578214 Mobile : 9845001551 SP 9845188193 HNR SARLA K E-mail : powerdev@bgl.vsnl.net.in Telex : 0845-22692 PEDE IN Cable : PAVDEE BANGALORE Cont. : Mrs. Saraswati Jaiprakash, HN Raju CHENNAI Fourstroke Diesels 1/53G, II Street, Sripuram Col., St.Thomas Mount, Chennai-600016 (Tamil Nadu).

Phone : (044)2335897/2346644/2345067(O) (044)2335908 (KPS),4900200 (Venkat) Fax : (044) 2346134 Cont. : K P Shankar / NV Venkatraman E-Mail : fourstro@md3.vsnl.net.in Cable : FOURSTROKE CHENNAI

CHENNAI (REGIONAL OFFICE) No.3,Third Avenue,Indira Nagar, Chennai-600020(TN) Phone : O : (044)4401073/4416429 / 4423412 R : (044)4424203 S Haridas (044)4416429 U.V. Shenoy Fax : (044)4911120 Office Incharge : Zonal Manager : R P Das Area Service Manager : S. Haridas Area Marketing Manager : K Balasubramanian E-Mail : cumminschen@vsnl.net COIMBATORE (AREA OFFICE) 1,Ramalinga Nagar,Cross Road No.2, 3rd Layout ,Saibaba Mission Post, Coimbatore-641011(TN) Phone : O : (0422)430197 R : (0422)447851 Fax : (0422)445904 Telex : (0855)8596 Office Inchage : Area Service Manager : P N Amarnath E-Mail : cdsscbe@md3.vsnl.net.in Pager : 9622766091(KK)

HUBLI (AREA OFFICE) II nd Floor,Srinivasa Building, Near Old Income Tax Office Building, Vidyanagar,Hubli-580021 Phone : O : (0836)373840/376714 R : (0836)250331 Fax : (0836)375556 Office Incharge : Area Service Manager : G M Dinesh E-Mail : cdss_hubli@satyam.net.in MADURAI (AREA OFFICE) Plot No.357, Anna Nagar, Madurai-6250020 (TN) Phone : O : (0452)533887 R : (0452)654196 Fax : (0452)521930 Telex : (0445)403 Office Incharge : Area Service Manager : S Muthuswamy E-Mail : cdssmadurai@satyammail.com

KOTHAGUDEM (AREA OFFICE) 5-3-32,Babu Camp Kothagudem-507101 (AP) Phone : O : (08744)46110/42058 R : (08744)44661 Fax : (08744)46608 Telex : (0423)209 Office Incharge : Area Service Manager - Ramesh Acharya E-Mail : cummins@hd2.dot.net.in CHENNAI S.P. Sales and Services W-7 Block, 9th Street, 3rd Main Road, Near Tower Gate, Anna Nagar, Chennai 600 040 (Tamil Nadu) Phone : (044)6211684 / 6212279(O), (044)4851376-MPS Fax : (044)6215379 Cont. : MP Sukumaran / PJ Ganeshan E-Mail : spsales@giasmd01.vsnl.net.in Telex : 041-23393 STCO IN Cable : PLUNGER CHENNAI Pager : 9632705566 (P) Vishvadevi Engineering Enterprises 14 Jayammal Street,Teynampet, Chennai - 600018 (Tamil Nadu ).

Phone : (044)4344875/4321692/4321074(O) (044)6424026 MPV, (044)2347423 PDB Fax : (044)4344875 Cont. : MP Viswanathan / PD Barnabas E-Mail : vupusaki@md2.vsnl.net.in veevellore@vsnl.net Telex : 041-23393 STCO IN Cable : SHANKIRCUM CHENNAI COCHIN Sunitha Diesel Sales & Service Building No. XIX/172, P. Box No. 20, Near Railway Over Bridge, Tripunithura, P.O. Cochin - 682 301 Phone : (0484) 775760, 775761, 777177, 780047 (O) SC (0484) 776770, 776770 (R) pnj Fax : (0484) 775900 E-mail : compower@md3.vsnl.net.in Mobile : 9847052777 PNJ Cable : CUMPOWER ERNAKULAM Cont. : P.N. Job

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COIMBATORE Maniranjan Diesel Sales & Service 101 Shastri Nagar, Opp. Kovai Medical Center, Aerodrome, P.O. Coimbatore - 641 014.

Phone : (0422) 627530, 629165 (O) (0422) 627156 (R) CND Fax : (0422) 827156 Mobile : 9843017531 NDT, 9843017530 CD E-mail : mrdss@md3.vsnl.net.in Cont. : N.D. Thakur, CN Deshmukh CUDDAPAH Naveen Diesels CPVR Towers, Near RTC Bust Stand, R.S. Road, Cuddapah - 516 001 (AP) Phone : (08562) 45057, 45157, 45257 (O) SC (08562) 45267 (R) EKB, 45077 Prashant Fax : (08562) 45107 E-mail : ekbabu@hd2.vsnl.net.in Telex : 0483-207 NAVE IN Cable : NAVDIESEL CUDDAPAH Cont. : E.K. Babu, P.D. Sanjeev GULBARGA A K Engineering Services H. No. 1-435/36/1, Opp. Kothari Bhavan, Jewargi Road, P. B. No. 71, Gulbarga - 585 103 (Kn.) Phone : (08472) 422713, 421494, 23321 (O) SC (08472) 21494 AKV, 23221 MV (R) (044) 2347423 PDB Fax : (08472) 22713, 21494 Mobile : 9844054064 E-mail : akengg@blr.vsnl.net.in Cable : DIESELPOWER GULBARGA Cont. : A.K. Varadpande, M. Varadpande

HOSPET Comtech Door No.212 IV Wrad Station Road, Hospet-583201. (Karnataka).

Phone : (08394) 28794, 27394 (O) 27238 (AKG), 27193/24108(DAG)(R) Fax : (08394)27082 Cont. : A K Garde / D A Gadgil E-Mail : com.tech@gnblr.global.net.in Telex : 0818-206 COMT IN Cable : DAGGER HOSPET Mobile : 9844087193 DAG Vijayshree Diesel Sales & Services Near Bust Stand, K.R. Road, Ranipet, Hospet 583201 (Karnataka) Phone : (08394) (O) HUBLI Ghatge Patil & Sons Shantiniketan Hsg. Project, Commercial Complex, Opp. APMC Yard, Bhandevarkoppe, PB Road, Hubli - 580 025 (Karnataka) Phone : (0836) 322194, 323028 (O) (0836) 370397 (R) GSW Fax : (0836) 322194 Mobile : 9844057883 E-mail : patil_sons@satyam.net.in Cont. : U.D. Kulkarni HYDERABAD Srinivasa Diesel Corporation 3-5-170 / 1 / 11&12, Narayanaguda, Hyderabad - 500029(AP) Phone : (040) 3220009,3221492,3223445, 6182007(SC) (O) / 4751869 (KR) (R) Fax : (040) 3227460 Cont. : K Ramakrishna E-Mail : sdchyd@hd2.dot.net.in Telex : 0425-2365 SDC IN Cable : MITRAGENCY HYDERABAD MADURAI Madurai Diesel Sales & Service Devidattam Paramasamy ThevarNagar, Narayanapuram, Madurai - 625 014 (Tamilnadu).

Phone : (0452)681765 / 680001 (O), (0452)680557 MJ/681418(A SUDHIR) Fax : (0452)681515 Cont. : M Janardanan / A Sudhir E-Mail : maduraidiesel@vsnl.com Telex : 0445-398 MDSS IN Cable : CUMPOWER MADURAI MYSORE Dyna Diesels 30 Industrial Area Bannimantap ‘A’ Layout , Mysore 570015 (Karnataka).

Phone : (0821)496290/492006(O), (0821)490715 WAK Fax : (0821)498367 Cont. : WA KHAN / Mrs.WA KHAN E-Mail : dynadsl@bgl.vsnl.net.in Telex : 0846-346 DYNA IN Cable : DIESELICA MYSORE Mobile : 9844069052

PALGHAT Palghat Diesel Sales & Service.

5/873, Kuppiyode, Koottupatha, Chandranagar P O, Palakkad - 678007 (Kerala).

Phone : (0491)573022/3 (O), Fax : (0491)573024 Cont. : PV WILSON E-Mail : pdss@md3.vsnl.net.in Cable : STALLION PALAKKAD PONDICHERRY Lignite Diesel Sales & Service.

Plot No. 37 & 38, 100 Feet Road, Cholan Nagar, O.K. Palagam, Pondicherry - 605001.

Phone : (0413)335981/338396(O), (0413)337650/339118 AR, (0413)357014/358928 NG Fax : (0413)341640 Cont. : A Rajgopal / N GNANASEGARAN E-Mail : lignitediesel@vsnl.com Telex : 0469-234 LDSS IN Cable : LIGDIESEL PONDICHERY PORT BLAIR Sunny Diesel Sales & Service.

27, Dasmesh Market , Dr.DiwanSingh Gurudwara Opp Andhra Asson.

Abardeen Port Blair 744101 Phone : (03192)31558/30698(O), (03192)50558 VT Fax : (03192)30572 Cont. : V Thiagarajan E-Mail : sdss@cal3.vsnl.net.in Cable : Powerplus Portblair SALEM K J Diesels Plot No.50 Dayanand Avenue, New Fairland Extn, Salem - 636016 (TN).

Phone : (0427)445231 / 331131(O), Cont. : K NAGRAJAN / K MAYURNATHAN E-Mail : kjdiesel@vsnl.com Cable : POWER SALEM SHIMOGA The primemovers Plot No.42 & 43 Mandli - Kallur Ind.Estate, Shimoga-577202 Phone : (08182)23412(O),(08182)55973(SC), (08182)71172 KRR/ 57132 BVS Fax : (08182)71187, 20615 Cont. : KR Rajasekhar/Mrs.R.Shamanthaka E-Mail : primemovers@vsnl.com Telex : 0831-223 TPMS IN Cable : PROVERS SHIMOGA Mobile : 9844028421 KRR / 9844028412 (O) THIRUVANANTHAPURAM Karthik Diesel Sales & Service T.C. 11 / 237, Ram Nivas, No.A - 28, Kanaka Nagar, Kawadiar P.O, Thiruvananthapuram 695003 Phone : (0471)313628 / 313826 (O), (0471)320171 KJ / CVG Fax : (0471)313972 E-Mail : kdsstvm@md4.vsnl.net.in Telex : 0435-6462 DEVI IN Cable : CUMPOWERTHRIUVANANTHAPURAM Mobile : 9847053777(KJ/CG) Pager : 96523304457 Cont. : Mrs.Kalpana Job / CV Ganesh

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TIRUNELVELI Diesel Care Mangammal Salai, Opp:KTC Nagar, Tuticorin Road, V.M. Chattram, Tirunelveli 627011 Phone : (0462)573006/572884(O), (0462)572839 VGS ,579428 VLA Fax : (0462)578667 Cont. : VG Shivasubramanian/VL Anantharaman E-Mail : dcare@md3.vsnl.net.in Telex : 0433-263 CARE IN Cable : CUMPOWER TIRUNELVELI Mobile : 09843057726 (VGS) 09843058667 (VLA) 09843062445 (GC) Pager : 9652260304/9652290006 9652260104 TRICHY Caveri Diesel Sales & Service.

PB No.180 , No.2,Birds Road,Cantonment, Tiruchirapally - 620001. (Tamil Nadu).

Phone : (0431)418265(O) Fax : (0431) 464265 / 418265 Cont. : V Naganathan/R Aramuthan/S Harikumar E-Mail : caveritr@satyam.net.in Cable : CEEDYESES TRICHY Mobile : 9843055265(VN)/9843054385 (O) Pager : 9652852466 (RA) VIJAYAWADA The Mithra Agencies PB No.357 , Gudavallivari Street, Governorpet, Vijayawada-520002 (AP.) Phone : (0866)574607/575877/576806 577815(O), (0866)474277 M Subrahmanyam 573179/477823 M Chandrasekharam Fax : (0866)575335 Cont. : M Subrahmanyam / M Chandrasekharam E-Mail : mithraa@hotmail.com Telex : 0475-6204 TMA IN Cable : MITHRAGENCY VIJAYWADA VISAKHAPATNAM Hamsa Diesel Corporation.

10-50-57 Ramnagar Waltair,Main Road , Vishakhapatanam- 530002 (AP.) Phone : (0891)563427/576255, 525794,549735 (O), (0891)538083 PLNS Fax : (0891)551484 Cont. : M Bhaskar Murthy / PLN Sarma E-Mail : hamsamithra@rmc.sprintrpg.ems.vsnl.net.in Telex : 0495-426 HDC IN Cable : HAMSA VISAKHAPATNAM