Study Of Cummins

Mr. Debasis
Guided By : ISB 5.9 BS III
Mohanty, Engine
Customer Support Manager, Tata &
Sales & Service Tr o u b l e s h o o t i n g

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Group Members

 Ritesh Ranjan Patra (140301MER059)

 Aishwarya Jena (140301MER201)
 Ashutosh Samantaray (140301MER055)

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Engine Overview
 Cummins ISB 5.9 is an electronic engine that
has displacement of 5.9 liters with 24 valve
cylinder head, front gear train and a high
pressure common rail system.
 The ISB 5.9 offers a choice from 180 hp to 230
hp for BS III and from 130 hp to 230 hp for BS
IV OBD II emission norms for various
commercial vehicle operations.
 Available for Medium/Heavy Duty Trucks,
Tippers and Bus applications.

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Engine Specification
 Name – Cummins ISB5.9 BSIII
 No. of Cylinders – 6 inline
 Swept Volume – 5883 cc
 Compression Ratio – 17.2:1
 Max. Power – 329hp@2900 rpm
 Max. Torque – 827Nm@1600 rpm
 Bore x Stroke – 102mm x 120mm
 Main Journal – 83mm (RS1- 82.75 mm ,RS2- 82.50 mm)
 Big End Journal – 69mm (RS1- 68.75 mm,RS2- 68.50 mm)

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Engine Specification (Contd.)

 Valvetrain – 4 valves per cylinder

 Camshaft Drive – Gear Driven
 Fuel System – Direct Injection
 Fuel Type - Diesel
 Turbocharger – Holset Engineering
 Cooling System – Water-cooled
 Oil System – Wet Sump
 Dry Weight – 499 kg.
 Oil System Capacity – 15 litres

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Components of Engine
 Crankshaft
The function of
crankshaft is to translate
the linear reciprocating
motion of pistons into
rotational motion
required by the
automobile.

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Components of Engine (Contd.)
 Camshaft
The camshaft is used
to operate poppet
valves. It consists of a
cylindrical rod running
the length of the
cylinder bank with a
number of oblong
lobes protruding from
it, one for each valve.
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Components of Engine (Contd.)
◦ Cylinder head
It has passages called
ports or tracts for the
fuel/air mixture to
travel to the inlet
valves from the intake
manifold, and for
exhaust gases to travel
from the exhaust
valves to the exhaust
manifold.

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Components of Engine (Contd.)
 Flywheel
A flywheel is a
rotating mechanical
device that is used to
store rotational
energy.It stores the
torque.

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Components of Engine (Contd.)
 Cylinder block
The cylinder block is the
portion of the engine
between the cylinder head
and sump (oil pan)
and is the supporting
structure for the entire
engine. All the engine parts
are mounted on it or
in it and this holds the
parts in alignment.

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Components of Engine (Contd.)
 Piston
Its purpose is to
transfer force from
expanding gas in the
cylinder to the
crankshaft via
a piston rod or
connecting rod.

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Components of Engine (Contd.)
 Connecting Rod
A rod connecting two
moving parts in a
mechanism, especially
that between the piston
and the crankpin (or
equivalent parts) in an
engine or pump.

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Components of Engine (Contd.)
 Valves
Intake Valves permit
intake of fuel and air.
Exhaust Valves
permit the burnt
gases to leave the
combustion
chamber.Valves also
seal the compression.
(4 Valves per cylinder arrangement)
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Components of Engine (Contd.)
 Inlet Manifold
It is the part of the
engine that supplies
fuel or air to the
cylinders.
 Exhaust Manifold
It is the part of the
engine through which
the burnt gases come
out of the cylinders.
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Components of Engine (Contd.)
 Waterpump
The purpose of a water
pump is to push coolant
through the engine block,
radiator and hoses.
 Oil Pump
It circulates engine oil
under pressure to the
rotating bearings, the
sliding pistons and the
camshaft of the engine.

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Components of Engine (Contd.)
 Viscous Fan
The cooling fan has to be
controlled so that it allows the
engine to maintain a constant
temperature.

 Fuel Injection Pump

Function of fuel injection
pumps. To supply accurate
metered amount of fuel with
sufficient pressure to open fuel
injector in correct timing

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Components of Engine (Contd.)
 Thermostat

The thermostat is used to keep the engine cool as

it warms up. The rod in the valve of the
thermostat is pressed into a material such as wax
which starts melting at temp around 80 degree
Celsius. Its melting causes the valve to open
which lets coolant mixture to flow in the
radiator. In this way, engine gets cooled.

• Oil Pan

It's at the bottom section of the crankcase

of an internal combustion engine, serving
as the reservoir for its lubricating oil.
It is otherwise called as sump tank.

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Components of Engine (Contd.)
 Timing Belt
It synchronizes the
rotation of the
crankshaft and the
camshaft so that the
engine's valves open
and close at the proper
times during each
cylinder's intake and
exhaust strokes.
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Components of Engine (Contd.)
 Apart from these components there are also
some integral components like Injectors, High
pressure line, Push rods, Bearings, Valve guide,
Dipstick, Alternator etc. in the engine.

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(Go Ahead…)

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 Engine does not start for Fuel
System
Problem: Solution:
1. Empty fuel tank 1. Fill up the fuel tank
2. Fuel is old, dirty, 2. Change the fuel
contaminated 3. Check and repair
3. Faulty wiring and 4. Service the pump
connection problems in
5. Repair or replace
fuel systems
4. Fuel pump not working
5. Fuel supply hose damaged,
distorted

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 Engine does not start for Ignition
System
Problem:
1. Battery is undercharged
2. Ignition switch is faulty
3. Ignition coil not functional
4. Loose plug wires
5. Faulty spark plugs
6. High tension lead faulty
7. Distributor not functional
Solution:
1. Recharge the battery
2. Ignition switch repair
3. Ignition coil replace
4. Replace the high tension lead
5. Check and repair
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 Engine does not start for Starting
System
Problem: Solution:
1. Battery is uncharged 1. Charge the battery
2. Starting motor not working 2. Repair the motor
3. Starter solenoid not 3. Repair the solenoid
working 4. Change the starter relay
4. Starter relay not working 5. Change the wire
5. Loose wire connection connection

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 Engine does not start for
Lubrication System
Problem: Solution:
1. Main oil pump not 1. Oil pump change
working 2. Oil filter change
2. Oil filter is faulty 3. Oil gauge change
3. Engine oil pressure gauge 4. Change oil
not working
4. Low quality oil

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 Engine can be cranked, but fails to
start
Problems: Solution:
1. Fuel supply hose damaged or 1. Change fuel supply hose
distorted 2. Fill up the fuel tank
2. Fuel tank empty 3. Change the filter
3. Fuel filter is clogged up 4. Change the fuel
4. Fuel is old,dirty and 5. Service the fuel system
contaminated
6. Clear the vent
5. Closed fuel tank vent
7. Change of sparkplug
6. Wrong engine oil
7. Inoperative or clogged
thermostat
8. Sparkplugs defective,
plugged
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 Engine starts but does not run
smoothly
Problem: Solution:
1. Compression leak 1. Change the compression
2. Enginehead gasket leak ring
3. Piston ring defect 2. Change head asket
4. Ignition coil defect 3. Change piston ring
5. Spark plug defect 4. Change ignition coil
6. Injector defect 5. Change air filter
7. Air filter faulty 6. Change injector

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 Engine knocks
Problem:
1. Faulty ignition distributor
2. Plugged fuel injectors
3. Faulty valve timing
4. Loose timing belt
tensioner
5. Lean air-fuel mixture
Solution:
1. Change the distributor
2. Change injector
3. Adjust timing belt setting
4. Adjust idle speed setting
5. Change the fuel
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 Engine knocks (Contd.)
Problem:
1. Anti knock sensors
malfunction
2. Engine is too hot
3. Carbon deposit in the
combustion chamber
4. Faulty main crankshaft
bearings
5. Water pump bearing is worn
out
6. Flywheel is broken or has
cracks
Solution:
1. Change the sensor
2. Check the thermostat
3. Clean carbon from
combustion chamber
4. Change the main bearing
5. Change waterpump bearing
6. Change the flywheel
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 Engine smokes
Problem:
1. Engine is burning oil
2. Worn or broken piston
rings
3. Worn valve guide or seals
4. Faulty head gasket
5. Broken or cracked engine
head
6. Leaky fuel injector
7. Air-fuel mixture is too rich
Solution:
1. Change the oil grade
2. Change piston ring
3. Change valve guide or
seals
4. Change head gasket
5. Change the engine head
6. Change injector
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