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7/28/2019 C-300 Tata Motors
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
C Series Engine
FamiliarizationFor – TATA Motors Ltd.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
1. C Series Engine Familiarization
Invented in 1985 at CDC RockymountUSA, with a mission of light weight/fuel
efficient/cost effective engine which will
cater wide range of applications like Auto/
Pg/ Industrial/ Ag/ Defence.
Extensive product validation by durability
testing, 100 Engines were employed with
40,000 durability test hours in addition to1.3 Million vehicle miles.
CSS&S Product Division has shipped first
engine in July 2003.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
2. The purpose of this program
is to familiarize you with the
CUMMINS C SERIES DIESEL
ENGINE. First, we'll discuss the
general specifications and
applications, design features andserviceability aspects. We will
then describe the engine systems
and some of the optionalhardware.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
3. The C Series engine is a
heavy-duty diesel engine
featuring many of the B
Series design concepts for simplicity and compactness.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
4.The engine incorporates,in one design, all the
important features and
advantages of modern dieseltechnology.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
5. It's designed to metric
specifications throughout. The only
deviation from these specifications isthe use of SAE standard pipe fittings
and plugs. Unit specifications for
optional accessory equipment willvary with the supplier. The service
publications list metric values along
with their SAE equivalents for
comparison.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
Data Plate :CDS&S Product Division on behalf of
Cummins India Limited.
CID/L – 8.3 Series – C CPL – 8739ESN – 2575 XXXX Model – C 300 20
Valve Lash ( Cold) IN EXHmm 0.30 0.558
Firing Order : 1-5-3-6-2-4 Low Idle RPM : 700
Mfg. Date : MM/YYYYCust.Spec – 41045 Rated HP – 296 @ 2200 RPM
Fuel Rate at Rated HP : 156 mm3/ stroke
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
9.For automotive engines, thefirst character denotes engine
series, followed by engine
displacement. The remaining
numbers indicate the rated
horsepower.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
10. The engine displacement
is 8.27 liters (504.5 cu. in.),
the bore is 114 mm (4.49
in.) and the stroke is 135
mm (5.32 in.). The engine
firing order is the same as allother Cummins in-Iine six-
cylinder engines,
1-5-3-6-2-4.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
11. The engine is designed
as a turbocharged engine, but it is available as a
naturally aspirated engine
for industrial applications.
Now let's discuss the design
features of the C Series
engine starting at the front
of the engine.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
12. Rubber-core and
viscous dampers are used to
dampen torsional vibrations. A
wide variation of options are
available on the engine for
automotive, industrial and
construction applications. Anautomatic belt tensioner
maintains proper belt tension.
This view illustrates a belt-driven fan hub.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
13. This is the gear train
layout of the engine. All the
gears are hardened and have
helical-tooth form for strength
and quiet operation. Timing-
mark alignment is used
between the crankshaft andcamshaft gears. The fuel pump
drive gear does not require an
alignment keyway or timingmarks.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
14. The drive shaft diameter of
the Bosch PES.A, PES.MW,
and PES.P pumps are
different. Three unique pump
gears are required.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
15. The higher horsepower
rated engines require that theintake air be cooled.
Industrial engines typically
use traditional engine coolant
aftercooling, while
automotive engines typically
use charge air cooling.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
16. The cylinder head is a
one-piece, cross flow design
with two valves per cylinder.
This design preserves
exhaust energy by slightlycooling the short exhaust
ports.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
17. A pulse type exhaust
manifold with a divided entry
passage is used with a dual-entry
turbine housing to improve
engine efficiency. Naturally
aspirated engines also use the
pulse-type manifold for parts
commonality.
C Series Engines use a
turbocharger manufactured by
Holset Engineering Co., Ltd., a
wholly-owned subsidiary of
Cummins Engine Company, Inc.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
18. The cylinder head designfeatures include:
integral intake manifold
integral fuel filter head
This design minimizes the
potential for air and fuel
leaks.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
19. The valve guides and seats
are replaceable.
The integral valve stem seal
combines the valve springguide and the valve stem seal
as one part.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
20. The valve train consists of
the camshaft, tappets, push
rods and the rocker lever
assembly. In addition to the
intake and exhaust valve
lobes, the camshaft has a provision for driving the fuel
transfer pump. A, P pump and
MW pump use a chilled-ironcamshaft.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
21. Replaceable bushings are
used in each of the camshaft
block bores. Oversized
bushings are available for servicing damaged bores.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
22. The cylinder block has many
innovative design features. The
block casting includes provisionsfor:
• oil cooler housing
• thermostat seats
• coolant bypass line
• water pump volute
• oil pump housing
• water pump inlet
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
23. The engine has replaceable wet
cylinder liners. The mid- stop design is
used to "locate" the liner in the block. A
press fit between the liner and the block
aligns the top of the liner in the block
bore with the cylinder head gasket
providing the coolant seal. A band seal is
used for coolant sealing at the mid-stop.
Worn or damaged liner seats can be
machined. Service shims are used to
assemble the liner to the specified
protrusion after machining.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
24. The power components in
the engine (piston, rod, and
crankshaft) also offer distinctivedesign features.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
25. The connecting rod is the
heavy-duty Cummins design.The pin bore bushing is splash
lubricated by dual piston-
cooling nozzle spray. The rod bearings are steel with an
aluminum overlay or tri-metal.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
26. These engines use three-ring-grooved pistons. A dual Ni- resist insert with a
keystone profile provides better wear
characteristics to the top two ring grooves.
Other piston features include: a full floating
piston pin held in by retaining rings. and a
forged aluminum body. The combustion bowls
for turbocharged and naturally aspirated
engines are similar in appearance. Higher
rated turbocharged engines use an anodized
coating on the piston face and bowl to increase
durability.
Always check the part number to be sure the
correct configuration is being used during
piston replacement.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
27. The crankshaft is a forged-steel, full-fillet-hardened,
integrally balanced unit. The
crankshaft thrust is controlled by
a flanged, upper bearing shell,
which is located in the number 4
main bearing. Oversized rod and
main service bearings areavailable for use with reground
crankshafts. An oversized,
flanged upper shell will also beavailable to permit clean-up of
the thrust surface.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
28. The overall design objectives
include simplicity for service. Only
three special tools are needed for overhaul: the Cummins universal
liner puller. liner driver and liner
hold- down clamps. The cam
bushings can be removed and
installed with a universal
automotive tool. A liner seat cutting
tool is available if needed.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
29. Now let's discuss thefour systems, starting with
the LUBRICATING OIL
SYSTEM.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
30. This schematic illustrates the
oil flow through the entire engine
system. We'll trace this flow
section by section as it progresses through the engine
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
31. The lubricating oil flow begins as the higher capacity
gerotor pump draws oil from
the pan through the rigid,internal suction tube.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
32. The pump then delivers the oilthrough an internal drilling in the
cylinder block to the bottom of the
oil cooler. Through the inner
channels of the cover the oil flows
to the top of the oil cooler.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
33. At the top of the oil cooler,the oil flows by the
thermostat. If the oil is cold,
the thermostat will be open,allowing some oil to bypass
the cooler and flow to the
filter. As the temperature of
the oil increases, the
thermostat will close and force
the oil flow through the cooler
element, thereby regulatingthe oil temperature to the
engine.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
34.Coolant which passes around
the plates of the element cools the
oil. From the cooler, the oil flows
to the combination oil filter, filter
bypass valve, and the pressure
regulator.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
35. The regulator valveremains closed until the main
oil rifle pressure is
approximately 345 kPa (50 psi). At high pressure, the
responsive regulator plunger
moves toward the plug,
allowing some oil to return to
the pan. The tapered shoulder
on the regulator plunger creates
a variable opening to regulate pressure.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
36. The turbocharger is
lubricated by filtered engine
oil. Oil under pressure issupplied to the bearing
journals and the thrust
bearing. Once the oil has
passed through the bearings, it
is no longer under pressure,
and flows under gravity, back
into the engine oil pan sump.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
37. A combination oil filter isused on the C Series engine. The
upper section of the filter
contains the full flow filter element while the lower section
contains the bypass element. Oil
which flows through the full
flow portion of the oil filter
flows to the main oil rifle. Oil
which flows through the bypass
portion of the filter, returns tothe oil pan.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
38. During normal engine
operation, oil circulates through
the full flow section of the
combination filter and into themain oil rifle. If the full flow
section becomes plugged to the
point that a 137 kPa (20 psi)
pressure difference exists between filter-in and filter-out,
the bypass valve opens in the
oil filter head and routes
unfiltered oil to the main oilrifle.
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Service Training School
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39.To measure the pressuredifference between filter-in
and filter-out, a filter-in
pressure port and a filter-out
pressure port are integral
parts of the filter head.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
40. Once the oil has been
cooled and filtered, a
drilling over the number 3main bearing carries it
across the block to the main
oil rifle. The main oil rifle
runs the length of the block
and carries oil to the
overhead and lower end
through individual drillings.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
41. The transfer drilling from themain oil rifle intersects a drilling
between the main bearing bore
and the camshaft bushing bore.
These drillings supply oil to the
cam bushing and main bearing.
The groove in the main bearing
upper shell guides oil flow to thedual piston cooling nozzles,
which are seated in the upper
main bearing saddle. The piston
pin is splash lubricated by thespray from the piston cooling
nozzles.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
42. From the main bearings, oil
enters the crankshaft and
lubricates the rod bearings
through internal cross drillings.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
43. Drillings in the block
and gear housing connect to
the external groove on thenumber one cam bushing to
provide oil to the injection
pump. An overflow holeabove the pump shaft
allows oil to return to the oil
pan.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
44. Oil to the overhead is
carried to the cylinder head by a vertical drilling that
intersects the external
groove in the number seven
camshaft bushing. The main
oil rifle supplies oil to the
cam bushing.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
45. The oil then flows to anangle drilling in the cylinder
head. From the angle drilling,
the oil flows through an oil
transfer tube. which supplies
the oil to the rocker lever
assemblies. The rocker lever
supports are installed over thetransfer tube. From a hole in
the transfer tube the oil is
transferred to the rocker
support capscrews by therelieved area in the base.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
46. Oil flows around the
capscrews to the rocker shaft.
Oil continues to flow into theinside diameter of the shaft
and along its length. The ends
are sealed by cup plugs.
Drillings allow oil to flow
from the inside diameter of
the shaft to the intake and
exhaust rocker lever bores.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
47. The rocker lever has a
short drilling that carries oilfrom the rocker lever bore
up to a trough on top of the
lever. Oil flows down each
side of the lever to lubricate
the push rod socket and the
valve stem.
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
48. The front gear train
assembly receives
lubrication from oil splashand a drain hole above the
fuel pump drive shaft. The
oil pump idler gear is pressure-Iubricated. After
lubricating the front gear
train, the oil drains back tothe pan for recirculation
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Service Training School
Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
49. Oil pan capacity for the C
Series is 19 liters (20 U.S.
quarts). At normal operating
temperature, minimum oil
pressure at low idle is 69 kPa
(10 psi). At rated speed,
minimum pressure is 207 kPa(30 psi). ( L-16 liters / H-21
liters). System Capacity – 22.4
liters.
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50. Now let's take a look at
the COOLING SYSTEM
design and operation.
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From the cooler cavity, coolant flows into the lower water manifold
cavity. A portion of the coolant flows through the coolant filter and
returns to the upper manifold.
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Coolant from cylinder head enters into cylinder block
upper manifold through six cast opening.
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When the engine is belowoperating temperature, the
thermostats are closed, and
coolant is by passed to the
water pump inlet. As thecoolant temperature increases
to the intermediate range,
thermostat will start to openand coolant flow to the bypass
will start to be restricted. At
engine operating temperature
the thermostat will be openand bypass will be closed.
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S i T i i S h l
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64. On charge air cooled
engines, the intake air is drawn
through the air cleaner into the
compressor side of the
turbocharger. The air then
flows through a large pipe,
around the fins of the charge air cooler, and through another
large pipe into the intake
manifold.
S i T i i S h l
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65. Air flow continues through
the inlet ports and into the
combustion chambers. After
combustion, the exhaust gases
flow out the opposite side of the
cylinder head. This flow patternacross the cylinder head defines a
"cross-flow" cylinder head.
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72. The timing feature prevents
rotation during pump installation.
A protruding internal tang
indirectly attached to the pumpshaft locates the pump shaft for
correct timing to the engine. A pin
behind the access nut is fitted over the tang to prevent rotation.
After pump installation, the pin
must be removed and installed in
the reverse position for storage
behind the access nut.
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77. When the high-pressure fuel
reaches the injector, the pressure
lifts the needle valve against thespring tension to allow fuel to
enter the combustion chamber.
Leakage past the needle valve
enters the fuel drain manifold. Thefuel drain manifold routes leakage
from the injectors to the inlet
fitting on the intake port of the
fuel filter head.
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79. SAE #1, #2, and #3 flywheel
housings (both wet and dry) are
available with arm or pad mounting
arrangements. When used with theoptional variety of flywheels,
flexplates, torque converters and
clutches, transmission mounting
requirements for both automotiveand industrial markets are satisfied.
A barring mechanism is optional
with the flywheel housings (both
wet and dry).
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87. Multiple turbocharger
locations are also available to suit
space constraints of various
installations. Several locations are
offered:
• a high-center mounting (front
exhaust outlet)• a high-center mounting (rear
exhaust outlet)
• a low-mounting
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88. This concludes the C
Series engine familiarization
program.
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Cummins Diesel Sales & Service (India) Ltd. ‘C’ Series Engine Familiarization – Tata Motors Ltd.
C Series Engine Maintenance Schedule :Every 36000 kms
• Drive belt tension
• Valve clearance
• Electricals
Every 72000 kms
• Vibration damper • Battery
This is on High Way specification. Off- High way Oil & Filter change interval
is 9000 kms or 250 Hrs of operation whichever occurs first.
Flush cooling system and fill fresh coolant at every 2 years or 3,20,000 km.
whichever occurs first.
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Troubleshooting : Major Troubles
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