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1. English – Original Instructions 5-2010 A030D088 (Issue 3)
X1.3 Engine
Engine Service Manual

2. FOREWORD
3
Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1

3. CONTENTS
Section Description Page No.
A GENERAL INFORMATION … 7
B ENGINE VIEW … 8
ENGINE NUMBER LOCATION … 10
C TECHNICAL DATA … 11
MANUFACTURING DATA AND DIMENSIONS … 12
THREADS AND TORQUE SPECIFICATION … 18
D OPERATION AND MAINTENANCE … 19
E FUEL SYSTEM … 23
F COOLING SYSTEM – WATER PUMP … 46
G FRONT OIL SEAL … 47
H FLY WHEEL AND REAR END OIL SEAL … 51
I BALANCER UNIT AND OIL PUMP … 54
J CYLINDER HEAD … 57
K TIMING CASE AND GEAR DRIVE … 66
L PISTONS AND CONNECTING RODS … 70
M CRANKSHAFT ASSEMBLY AND MAIN BEARINGS… 74
N CYLINDER BLOCK AND LINERS … 77
O LUBRICATING SYSTEM … 79
APPROVED LUBRICATING OILS … 80
P ELECTRICAL EQUIPMENT … 82
Q TROUBLE SHOOTING … 83
R SERVICE TOOLS … 92
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4. Section A
GENERAL INFORMATION
SAFETY
The safety measures that always should be
performed in order to avoid risks that is always
present.
All servicing normally be carried out with the engine
stationary.
Do not approach the running engine with loose cloth
or long hair.
Be careful of hot surfaces.
Do not open the radiator filler cap when the engine
is hot.
Avoid skin contact with oil, fuel or chemicals that
can cause burn. Long term contact with oil can lead
to the skin problem.
Run the engine only in a well-ventilated area.
When lifting the engine use the lifting eyes that are
fitted to the engine.
Never work alone when removing heavy parts.
When cleaning the engine with high-pressure water,
never direct the jet at seals, rubber hoses or
electrical components.
Always prevent diesel or oil from contacting rubber
parts or tubing
CAUTION: Warns of a risk of injury, serious
damagetotheproductorseriousmalfunctions
Important: Is used to draw attention to things that
could cause damage to or malfunction of the
product.
TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and
equipments are available before starting work.
Use special tools where they are specified.
Never drop the tools
Use correct tools as specified.
REMOVAL OF PARTS:
First find the cause of the problem and then
determine whether removal or disassembly is
required before starting the job.
INSPECTION OF PARTS:
Each part when removed should be carefully
inspected for malfunction, deformation, damage and
other problems.
All disassembled parts required for reassembling
should be carefully stored.
Ensure to separate and correctly identify the parts
to be replaced from those that will be used again.
CLEANING OF PARTS FOR REUSE:
All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method.
PARTS
When replacing parts, use genuine parts.
Oil seals, Gaskets, O-rings, Lock washers, split
pins and plastic nuts should always be replaced
with new ones.
Standard values such as torque and adjustments
must be strictly observed in the reassembly of all
parts.
FITMENT
Use correct tools, gauges and testers for correct
fitment of the parts to standard value.
ELECTRICAL SYSTEM
Be sure to disconnect the battery cables from the
negative terminal of the battery
Never pull on the wires when disconnecting
connectors.
could occur if the instruction is not followed.
or handling.
Note : It is used to draw attention to important
important information to facilitate procedure
WARNING : Guarding should not be removed
when the engine is is running condition.
Note :

5. Section B
ENGINE VIEW
FUEL INJECTION PUMP SIDE
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Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1

6. ENGINE VIEW
CAM SHAFT SIDE
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7. Engine Identification Plate
Each engine is p rovided with a Data Plate as show n
below. This provides information unique to the engine.
The engine data plate shows specific information about
your engine.
The Engine Serial Number (ESN) (1) and Control Parts
List (CPL) provide infor mation for or dering p arts and
service needs.
Note: The engine data plate must not be changed unless approved by
Cummins Engine Company Inc.
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Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1

8. Section C
TECHNICAL DATA
Engine Type : 2 Cylinder. 4 Stroke. Inline Type. Water Cooled
Aspiration : Naturally Aspirated
Combustion : Direct Injection
Bore (Nominal dia.) : 3.740 inch (95.0 mm)
Stroke : 3.58 inch (91 mm)
Cubic Capacity : 78.7 cu.inch (1.29 Lts.)
Compression ratio : 18.1 : 1
Rotation : Anti-clock wise from the flywheel end
Firing order : 1, 2
Valve Tip Clearance : 0.010 inch (0.25 mm) for inlet value and 0.012 inch
(0.30 mm) for exhaust value)
Atomiser setting pressure : 250 bar (5 Spray Nozzle)
Inlet valve opens : 12° B.T.D.C.*
Exhaust valve closes : 12° A.T.D.C.**
Total inlet open period : 232°
Total exhaust open period : 236°
Fuel Injection Pump : Cambox type fuel injection pump, mechanical
governor
Injection timing : 10° B.T.D.C
When No.1 piston at TDC compression stroke.
Fuel feed pump : Plunger type pump located on cam tunnel.
Driven by engine camshaft
Application : Genset
DE-RATING FOR ALTITUDE :
Where engines are called upon to operate in very high atmospheres occasioned by altitude. such engines
should be derated.
APPROXIMATE ENGINE WEIGHTS :
Basic weight (with starter motor & flywheel) : Approximate 148 kg
ENGINE DIMENSION :
Height : 635 Length : 565 Width : 470
* B.T.D.C. – Before Top Dead Center ** A.T.D.C. – After Top Dead Center
/Electronic governor.
Engine Model Lube Oil Filter Coolant Element Air Fuel Filter
Capacity Part No Capacity Cleaner Element
(Ltr) (Ltr) Part No Part No
X1.3G2 4.5 0122-0961 4.65 0140-4088 0149-2952
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10. MANUFACTURING DATA AND DIMENSIONS
The following data of clearances and tolerances are given as a guide for personnel engaged in major overhauls
and the figures are those used in the factory for production purposes.
Cylinder Block
Height of cylinder block (Top to bottom faces) … 12.498 / 12.501 inch (317.45 / 317.55 mm)
Parent bore dia. for Cylinder Liner … 3.740 / 3.741 inch (95.00 / 95.02 mm)
Main bearing parent bore … 2.440 / 2.442 inch (62.00 / 62.03 mm)
No. 1 Bore for Camshaft … 1.930 / 1.931 inch (49.025 / 49.050 mm)
No. 2 Bore for Camshaft … 1.939 / 1.949 inch (49.25 / 49.50 mm)
No. 3 Bore for Camshaft … 1.939 / 1.949 inch (49.25 / 49.50 mm)
Balancer Shaft Bore Dia 1 and 2 ... 1.023 / 1.024 inch (26.00 / 26.02 mm)
Pistons :
Type … Pistons are of special light aluminium alloy with a re-
entrant bowl in the crown. Offset of combustion bowl in
piston crown should be to the FI Pump side while
assembling piston in engine. An arrow mark is stamped
on piston top surface for identification. Arrow should face
front of Engine.
Piston Height in relation to cyl. block top face… 0.0138 inch (0.35 mm) / 0.0019” (0.050 mm) Above block
surface
Bore Dia. for Gudgeon Pin … 1.1025 / 1.1027 inch (28.005 / 28.01) mm
Top ring Groove Width … 0.102 / 0.103 inch (2.59 / 2.61 mm)
2nd ring Groove Width … 0.1 / 0.100 inch (2.54 / 2.56 mm)
3rd ring Groove Width … 0.119 / 0.120 inch (3.03 / 3.05 mm)
Piston Rings
Top Compression … Chromium inlaid. Half Keystone
(Symetric barrel on periphery)
2nd Compression … Cast Iron. Taper land
3rd Oil Control … Conformable oil control ring
Piston Ring Width
Top and 2nd ring width ... 0.097 / 0.098 inch (2.47 / 2.49 mm)
3rd ring width … 0.117 / 0.118 inch (2.97 / 2.99 mm)
Ring clearance in Piston Groove :
Top ring clearance in Groove … 0.0039 / 0.0055 inch ( 0.10 / 0.14 mm)
2nd ring clearance in Groove … 0.0019 / 0.0035 inch (0.05 / 0.09 mm)
3rd ring clearance in Groove … 0.0015 / 0.0031 inch (0.04 / 0.08 mm)
Ring Gaps
Ring Gap – Top … 0.012 / 0.020 inch (0.30 / 0.50 mm)
Ring Gap – 2nd … 0.025 / 0.037 inch (0.65 / 0.95 mm)
Ring Gap – 3rd … 0.010 / 0.018 inch (0.25 / 0.45 mm)
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Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1

11. NOTE :The ring gaps given above are for when checking in the unworn portion of the cylinder bore.
Gudgeon Pin
Type … Fully Floating
Outside dia. of gudgeon pin … 1.102 / 1.1025 inch (27.995 / 28.00 mm)
Fit in piston boss … Transition
Clearance fit in Small end Bush … 0.0011 / 0.0019 inch (0.03 / 0.05 mm)
Small End Bush
Type … ci Steel Backed. Lead Bronze Lined
Outside Dia … 1.220 inch (31.00 mm)
Length … 1.378 inch (35.00 mm)
Inside Dia after reaming … 1.151 / 1.155 inch (29.35 /29.35 mm)
Connecting Rod
Type … “I” Section
Big end Parent Bore Dia … 2.008 / 2.0086 inch (51.006 / 51.019 mm)
Small end Parent Bore Dia … 1.220 / 1.221 inch (31.00 / 31.25 mm)
Big end Width … 1.244 / 1.248 inch (31.60 / 31.70 mm)
Big end side clearance on Crankpin … 0.012 / 0.020 inch (0.3 / 0.5 mm)
Length between bore centers … 5.825 / 5.827 inch (147.975 / 148.025 mm)
NOTE :The numbered side of connecting rod and cap should be on the fuel injection pump side.
Connecting Rod Bearings
Type … Pre-finished. Steel Backed low carbon steel
AluminiumTin/Silicon
Inside Dia. (Big end bearing) … 1.949 / 1.950 inch (49.53 / 49.52 mm)
Bearing Running Clearance … 0.0015 / 0.003 inch (0.04 / 0.079 mm)
Recommended sizes in service … 0.010" (0.25 mm); 0.020" (0.51 mm); 0.030" (0.76 mm)
Crankshaft
Material ... Chromium molybdenum alloy steel forging. Statically
balanced. Main journals and crank pins are induction
hardened.
Main Journal Dia. (Std.) … 2.282 / 2.283 inch (57.98 / 58.00 mm)
Crank pin Dia. (Std.) … 1.889 / 1.890 inch (47.98 / 48.00 mm)
Main Journal length - Nos.1 … 1.311 / 1.326 inch (33.30 / 33.70 mm)
Main Journal Length – No.2 … 1.338 / 1.341 inch (34.01 / 34.08 mm)
Main Journal Length – No.3 … 1.330 / 1.346 inch (33.80 / 34.20 mm)
Crankpin length … 1.260 / 1.264 inch (32.00 / 32.10 mm)
Main Journal fillet radii Nos. 1 … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Main Journal fillet radious No. 2 and 3 … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Crankpin fillet radii … 0.098 / 0.118 inch (2.50 / 3.00 mm)
Surface finish (all Pins and Journals) … 0.4 microns (Maximum)
Crankshaft end Float … 0.003 / 0.006 inch (0.07 / 0.15 mm)
Crankshaft rear end Seal … Lip Type
Regrind Under sizes. Main Journal
and Crank Pins … 0.010" (0.25 mm) ;0.020" (0.51 mm) ;0.030" (0.76 mm)
When checking ring gaps in a worn bore. 0.003’’ (0.076 mm) should be added to these ring gaps for
every 0.011 inch (0.03 mm) increase in bore diameter
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12. NOTE: When regrinding the crank pin length should not exceed 1.5748 inch (40.00 mm) and the
Crankshaft Thrust Washers
Type … Steel Back - Low carbon steel - 1.8 mm incl. Aluminium
Tin (or) Copper Lead
Position in engine … Cylinder Block Centre Main Bearing Housing
Thickness-Standard Size … 0.105 / 0.107 inch (2.67 / 2.72 mm)
Thickness-Oversize … 0.1283 / 0.1303 inch (3.26 / 3.31 mm)
NOTE :
Main Bearings
Type … Pre-finished. Steel Back low carbon steel. AluminiumTin/
Silicon or Copper Lead
Inside Dia. (fitted) … 2.362 / 2.363 inch (60.02 / 60.03 mm)
Running clearance … 0.0015 / 0.003 inch (0.04 / 0.079 mm)
Recommended size in service … 0.010" (0.25 mm) ;0.020" (0.51 mm) ;0.030" (0.76 mm)
Camshaft
Type … Chilled cast iron
No. 1 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)
No. 2 Journal Dia. … 1.927 / 1.928 inch (48.95 / 48.975 mm)
No. 3 Journal Dia … 1.927 / 1.928 inch (48.95 / 48.975 mm)
Running Clearance – All Camshaft Journals … 0.002 / 0.004 inch (0.05 / 0.10 mm)
Oil way for cam shaft lubrication … From main oil gallary to centre cam journal
Cam Lift - Inlet … 0.393 inch (10 mm)
- Exhaust … 0.393 inch (10 mm)
Camshaft end float … 0.004 / 0.014 inch (0.10 / 0.35 mm)
Cylinder Head
Cylinder head total height … 4.410 inch (112 mm)
Leak Test … 4 Bar for 1 minute
Valve seat angle … Inlet 45° / Exhaust 45°
Permissible cylinder head bow
Transverse and Longitudinal … 0.001 / 0.002 inch (0.03 / 0.05 mm)
Valve Layout ... E, I, E, I
NOTE :Valve stem seal (with Sintered metal insert) is fitted in both inlet and exhaust valves.
block and the rear main bearing cap.
While locating the Thrust Washers ensure that the plain surfaceSteel back is towards the
rear main journal length should not exceed 1.8610 inch (47.27 mm) and Nos.2 and 4 main Journals
width should not exceed 1.2275 inch (31.1785 mm) maximum. The maximum permissible
undersize is 0.029 9 inch (0.76 mm)
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Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1

13. Inlet and Exhaust Valves
Valve Stem Dia (Inlet) … 0.273 / 0.274 inch (6.95 / 6.97 mm)
Valve Stem Dia. (Exhaust) … 0.272 / 0.273 inch (6.93 / 6.95 mm)
Clearance fit of valve in guide (Inlet) … 0.0004 / 0.0015 inch (0.01 / 0.04 mm)
Valve face Angle (Inlet) … 45°
Valve face Angle (Exhaust) … 45°
Valve depth below cylinder head face … 0.015 inch (0.4mm)
Valve head Dia. Inlet … 1.590 / 1.598 inch (40.40 / 40.60 mm)
Valve head Dia. Exhaust … 1.492 / 1.500 inch (37.90 / 38.10 mm)
Valve Spring
Free length … 1.968 inch (50 mm)
Fitted length … 1.102 inch (28 mm)
Load at fitted length … 250 N (25 kg)
Tappet
Outside Dia. of Shank … 1.061 / 1.063 inch (26.96 / 27.00 mm)
Rocker Shaft
Outside Diameter … 0.629 / 0.630 inch (15.976 / 15.984 mm)
Rocker Lever
Bush Bore Diameter … 0.787 / 0.788 inch (20.00 / 20.02 mm)
Running clearance of Bush on Shaft … 0.011 / 0.002 inch (0.022 / 0.048 mm)
Timing Gears
Crankshaft gear … 20 Teeth
Idler gear … 25 Teeth
Camshaft gear … 40 Teeth
Fuel Pump gear … 40 Teeth
Balancershaft gear … 20 Teeth
Camshaft Gear
Gear Bore Diameter … 0.944 / 0.945 inch (24.00 / 24.013 mm)
Clearance fit of Gear on Spigot … 0.000 / 0.0019 inch (0.00 / 0.05 mm)
Idler Gear and Hub
Bore Dia of gear … 1.025 / 1.026 inch (26.040 / 26.061 mm)
Diameter of hub … 0.984 / 1.024 inch (25.00 / 26.00 mm)
Clearance of gear on hub … 0.002 / 0.003 inch (0.040 / 0.082 mm)
Gear Hub Width … 0.659 / 0.661 inch (16.75 / 16.80 mm)
Bearing length of hub … 1.6019 / 1.5940 inch (40.69 / 40.49 mm)
Gear end-float … 0.002 / 0.006 inch (0.060 / 0.140 mm)
NOTE :The bore and faces of bushes should be finished to the specified dimensions by
machining after pressing the bushes in the gear bore.
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14. Crankshaft Gear
Diameter of Bore … 1.4996 / 1.5011 inch (38.090 / 38.13 mm)
Spigot Dia of crankshaft … 1.5005 / 1.5000 inch (38.113 / 38.10 mm)
Transition fit of Gear on Crankshaft … 0.011 / 0.0015 inch (0.03 / 0.04 mm)
Fuel Pump Gear
Diameter of Bore … 20 mm with taper bore
Pump adaptor Dia. … 1.8897 / 1.8887 inch (48.000 / 47.975 mm)
Clearance fit of gear on spigot … 0.0039 / 0.0022 inch (0.100 / 0.056 mm)
Timing Gear Backlash
All Gears … 0.002 / 0.005 inch (0.06 / 0.14 mm) (min.)
Lubricating Oil Pump
Oil Pump type … Lobe type
Number of inner rotor lobes … 9
Number of outer rotor lobes … 10
Balancer Shaft end float ... 0.003 / 0.006 inch (0.075 / 0.150 mm)
Lubricating Oil Pump Clearances
Inner Lobe to Outer Lobe … 0.0005 / 0.0025 inch (0.01 / 0.06 mm)
Inner Lobe end clearance … 0.0015 / 0.003 inch (0.04 / 0.08 mm)
Outer Lobe end clearance … 0.0005 / 0.0025 inch (0.01 / 0.06 mm)
Outer Lobe to Pump Body … 0.011 / 0.013 inch (0.28 / 0.33 mm)
Lubricating Oil Pressure at maximum engine
speed and normal working temperature … 3.5 kgf
Lubricating Oil Relief Valve
Type … Spring Loaded Plunger
Pressure Setting … 3.569 kgf / cm1
Lubricating Oil Filter
Type … Spin on
Element … Replaceable Paper / Canister
By-pass Valve Setting … 12.94 / 17.06 psi (0.91 / 1.20 kg/ cm²)
Sump Capacity … 4.391 lts. Sump capacity vary according to application
Cooling System
Type … Water cooled
Coolant capacity–Engine only … 4 lts. (approximate)
Thermostat
Type … Wax
Opening temperature … 73° ± 2°C
Fully open … 83° ± 2°C
Water Pump
Type … Centrifugal
Pulley bore dia … 0.944 inch (24 mm)
Interference fit of pulley on shaft … 0.005 inch (0.121 mm)
Clearance between impeller blades and body ... 0.008 / 0.020 inch (0.2 / 0.5 mm)
Distance between impeller rear face to body … 3.929 inch (99.80 mm)
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Publication 0983-0506
Issue 6 – 6-2010
Service Manual
Engine Model X3.3
Page 1