Vacuum Truck Manual

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OPERATION AND MAINTENANGE MANUAL
I FOR
]-t
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sxrD M',NTED vAcuu' sysrEM
'LEANING
tr MoDEL -TPs-vAcrRUGK-GxD'9ooP
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!i cr rr\r :- sARCHANDRABNvtRoNS,LUTI.NS
a- . rvT.LTD.KAKINADA (A.P.)
L. PRODUCT - SKID MOUNTED VACUUM CLEANIN(;
L. :
SYSTEM
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kr, TPS INFRASTRUCTURE LTD.

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84-M BLOCK, COMMERCIAL COMPLEX
GREATER KAILASH _II. NEW DELHI.I1OO48
PHONE: 9 1 -l l -2921210 l, 2921 4007, 5 1 638293
E-MAIL: tps@airtelbroadband.in, tps@tpsmfg.net

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SPECIFICATIONS
INTRODUCTION & TECHNICAL

GENERAL ARRANGEMENT

USING INSTRUCTIONS

I
\ SAFETY PRECAUTTONS
I
\ LIST
MAINTENANCE / SERVICE CHECK
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t TROUBLE SHOOTINGS
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t ELECTRICAL ARRANGEMENT
t RECOMMENDED SPARES
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OF BOUGHT OUT
t O&M MANUAL AND CATALOGUES
t ITEM
I ENGINE
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L NTRODUCTION
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TEC HNlICAL
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l- SPECI FIC ATION
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t The machine is a heavy-duty vacuum
in al1 aspects and is suitali.'i.,
-""*a
loader' Th-e machine is seif-contained
.""ii".irg free flowing sludge and slurry in
containers' The above machine is
E coniunction with truck
"V"fonic machine of its kind available in the
one of the most efficien' p"*Jll f"l1
E "J state of art filter systems' positive
tf international market' flrt"tiit"'ir-rf
displacen.rent vacuum
the fallowing features;
pu*p u"a cJntrol systems' the offered machine has

l:' 01. VACCUMPUMP SYSTpl4 : flir hontll"'s capac'[1'ahofi)t'r'


t- an Air - cooled positive
t: The vacuuu pump system incorporates vacuum
displacement Vacuum purnp developing
maxirnutn up ro 8000 \4M
t- DaPa (water t*ii"i This vacuum pump is driven by a
t- moLrnted on a
"oturrr";'i'fiig
separate Diesel engine
Frame
*;;teE o"-tt'" 'outtline
with vibration dampeners
skid' The entire assembly is

L.
t- 02. CYCLONIC SEPARATION CHAMBER
t:
t: Thevacuumloaderhasanin_builtcyclonicseparationchamber

t* 03. FILTTER SYSTEM


L ltration stages:
L The machine incorpolate two-fi
i,ug" - I - high etficiency cyclonic sepalator'

L Stage - ll - higtr pelformance. catlridge filter


tttt co'itpresscd ail jct blolvlng'
with automatic

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.l.mng

04.
,"yr,-tn r'r'itl'r

DIESEL E,NGINE
"t

l-. The high pressure jetting pump is driven by an auxiliary diesel engine model
lJ. Ashok Leyland q80-rd l;i'' is l3; !f ls00 RPM on continues basis
l- (n.rarirnum Rating 22iP;';JzOo'npul
aspirated and is watel m"f"J
tr* oi"i"t engine is naturallv
*itf-t direct injection four stroke in line
1-- cvlindels. The diesel tngint i' with
all nec-essary standards accessories like
l* ;J:il**. t;"; ;i;;; r;?;;; p'n'f
"'tion
Line' instrument paner with RPM

1- indicator-cutn-hout' tot'it"t]'';;t1;t' stafter button' oi1 pressure gauge


and

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water temperature gauge, the .adiator is industrial type
with air blast, heavy
duty type air cleaner. The diesel engine has arl standard features /
protections, with are required in the satisfactory operation and.
Perlormance of the machine.

05. COMPRESSED AIR SYSTEM

The machine has in - built air cornpressor with requisite capacities to


nleet compressed air requirements for different system, the compr.essed air
svstem incorporates air receivers, solenoid valves with timer arrangement
,
purging system etc, the controls are pLC controlled

06. CONTROLDEVICES

The vacuum loader has the fallowing control devices

1 . Automatic cut off diesel engine when the temperature of vacuum


purnp exceed the design parameters.
2. Level controlling system for ensuring that the level in the cyclonic
chamber does not exceed the requisite capacity .as soon as ihis level
is achieved tl.re diesel engine is automatically cut off with an
indication on the control panel.
3. Vacuum release valve
4. Non return valve is provided to prevent counter r.otation of the
vacuull pr-u-r-rp when stopped under vacuum.

07. MACHINE BODY

The entiie bocy of tlie machi,e cha,rber is with souncl proofing cover
and with fucility for locking arangement.
CARTRIDGE FILTER DETAILS

CARTRIDGE FILTER

I. EfficiencY 99.9%
2. lr,laterial German Cellulose Filter Media
3. Out going Particle size 5 Microns
4. Total Area 40 nt2
5. No. of Carlridge 4
6. Cleaning Mecl.ranism
Pulse Jet Cleaning System with Timer and Solenoid
Valve
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l-- FI
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GENERAL ARRANGEMENT
pmr nrrarr,s
Me-csrNs cHAMBER

IE TOF EXHA-STIILENqEB
va.cuuu puup
PNg NqT-BT SILENCER

tE NONnerum v4!vE
coot tNc SILENCER
e===-rn
ffinroCc FILTEB
E HOPPER

l. OIESEI ENGINE
eNT=-wteRAnoN PAD
E.
L SSBELLOW
VERTICAL SILENCER

L flr-neeneellqw:-ryqNE
f- pui-r-pv ron EXGn{E

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l. .IOCTTY PULLE,Y

l. buerFrr,ru--Pro Hq3IEB
l.. Hoiuzer'mql sIIENgEB

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f- Sr-lcrtoN nqr-er

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T]SING
INSTRUCTIONS
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following characteristics
) Do not suck material with
T o
o
Inflamn-rable
\- ExPlosive
. ChenicallYaggressl\'e
l\- . Dangerous to Health
t: P
' Make sure that sucked
matelials such as unslaked lime and
water' or naphthalene

L-- ;;;;;;"" do not react clre',icallY'


t{ ! After suction work, empty.and
clean collector body/i,tercept hoppers
and filter

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compal tnlent 1o avoid
nttxttlg'

L: ., tI"t:91:'*"1::[#ittffi::l';t'
\\rrh ternpcrar'irlet

L ' Do not suck rttatcrials


Iln."i.,ti r'""t dissipatiorr' we recotntrtend
to cool the air
employrrlg
stream'

L H;';;;il;iplp"tin"
n-raterials to avoid blocking
of flaps

L )- Immediately discharge
hygrosglnil
to tcsidues'
or sticky

L seals due
^,ra'f".fti"* "f

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1-.
Suction Unit

For optirntrm perlbrmance'


make sure that during
suctr;;i,:':fJ'fli;;::*i"':'

l-. :w:ll':--,1:f ,:ff ,"f '.f; i:tll'ij:i::J'ilffi::::il;''*n"


l- Ambicnt conditions
l-- at which the plant
works is from l0' C to 40"C'

l-- Average ambietrt ternperature

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ATTDN'IIONI

After rvorking for witl.r


high vacuum of more
tryl5O MMHG
by exposing suction hose
to
foL about 25

z-J,l,inu*t'
l- minutes, fiee air must
u" *t"*j'?i'

l{. atmosPhere'
Clogged suction line

la closBineof suction,'l:T'Jl[,TJ;;:J:lrt;1,*,.""11Tilil"]il:;T[illi;i]"
l-- loosen the cloggilg
bI
srvitch off stLctioti ttllit'
'lll'li;..;
dtsco f,"l"r."a clean by sti'ring/poking'
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HosesandtubesshouldleadtothesuctionpointaSstraightasposs.ible.Radius'of
of pipe)'Please note there is substantial
bends should be u, lurg" u, poiti-J1"'1n=iO*aiu
against gravity and at the bends in the
vacuum loss with increase i" p"ip"'f-"ngtt" t'ction
pipeline.
or steps' as this will damage the hose'
Do not pull hose over sharp edges, railings
f-
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l.. FINAL INSPECTION & START- UP

l- Make sure all bag clamps and access


doors are tightly fastened'

l. Check atl Compressed air piping for


leaks' start the system'

l-- Maintenance
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Inspect Cartridge filter at least once
irlter. Verifl, that all solenoid #"'l*
Carlridge filter.
in a month' Replace any faulty Cartridge

"ptt"ting'
as this ii the key to cleaning of
the

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Ensure that the air used for cleaning
Cartridge filter is clean and free of moisture and oil'

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la After working with high vacuurn of
more than 450mmhg' free air must
be sucked

lor 2-3 nrin. for Machine stopping'


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In case of sticky suction material' suck
in water lor cleaning the suction line'

After sucking liquids, dry filters by sucking


dry air for some minutes'

L. Immediately discharge hygroscopic


or sticky suction material and clean
collection

L. container and seals.

L. Check V-belt tension'

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TPS ilanufaeturin$ &Jonstruction

Esoolru:uo, 26b mm'-


{rwroq:e
lnl€.cept hoPP€( ol sny de6lgn
(s!s s€P€/6lo los.rlet)

suclon uru-l
V CTRALERvacuum
U-coJPlhg

H
ll-q
iranspod L'ail6r
al cholce Cca.,1ectlcn hose \aiL\
2 1,1 cc Jplings

C6necl,on
v end M
flo56 xllrl
c.uplhg

H
fht
Si/aj-chl m€lal rlPo
wdlr '/ ?,'rd M €uplll.,g

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f\-f Cc.rtedt:.l L5€ willl
V a..d M -rJpllg
A.-. VB v llBrrblo
'{!.i
SLrll- fEss
e!9ih0
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}.1

%
'xn 9'-'q "
-.-:1 -?
.'1=-:1:'

fT a:. _ ij;-cre i.-n


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-ls.|--.:e': i

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- --: : ':r...:.-i' j1 nc j:+ , : a'ixl-'la :.:r'a
c'r-Jtli'c :^':i.. '"l:crjl:'u:

:::-:ran:nlelci cur va:'..i!:-: icaCeas '-a:!e]'t aa all in(ef!:ct ncccer: c12':iac:u:t:''r?"'2'2


:_.1.:': ::::as? al a\/ caaaliaa. Aaaatat. -i't. c:i,'reen va'''u'''l lcac:l anc 5::rc:ti
rc;'El z
r19

:::-:::::r:-"- ,,,/
lh 2 ::L:li.Cs
\,1 ,!ii1 ..:aa::ttla.
a.\ll IIAINTIN 45CIt }{.']'f{I.''tI

N
OPEruTION
Lt: Cornpany'PYt. LtiL
l
rt pipework system with K and-SK suction tools and EH piping elemenis
rl

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tb ,,".c co.necltcn

tr ,t to *_-o *,n-,
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ComPanY P\ILLtd
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GENERAL INSTRUETION5

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Kaep a min. dislanae 0l 0.5 m L:lween suclion intel
and humans or an:m;ls.

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E. A suclion nczzte wiih;aiusiabLe air inlel shouid ure us:'d

E. I suciionrng is ver|:al[1i up, a itu:dizin-o nozzie musi be usec.

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kk OPEILITIO); .d\D \LUts*rEN,\.,\CE lL\-.,\Urr i
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S<
ou

condensole droin

lilter canridge

L- c3niel.]sate Cralil

I.- i

t--
,,va te

ccerale inaiuali/

F
l-,
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li ccni:mirrciei tr'/ cil'
Chec!. rubber sec i'
Llse sccp wcier ( I cle'r'irrq ::i;ci'

cir ircri inside ic ci / cncj c)'e'" '


h c ariSr=ssed
.'Yii

l--= SLovr:ii ccfirii-ce


)^aFlcaa ccriiiige cr'ce ir': "'=cr
l-,-'
r-- ,
l-g
l-- " offi ox .lrrp MArft"Tn\ialicE Srti\-uar
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LI SAFETY
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L] PRECAT]TIONS
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L . Observe all safety methods as required for working in polluted areas'and
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i. f."p a minimuni distance of 500 MM between suction nozzle inlet

tj
l.ruman/animals.
3. Keep clear from the 'V' Belts drive system during operation'

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5.
Do not exceed the leading capacity ofthe collecting hopper
In case the vacuum is continuousty above 450MMHG'
checked for choking in pipeline or choking offilters'
Do not pull hose over sharp edges This rnay damage the hose'
The
machine'
suction line should be

r- 6.
i. Do ,-rot suck inflammable, explosive, chemically aggressive
material dangerous to

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8.
g.
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health.
Do not suck hot material more than 45"C'
l,rute sure rhat sucked rnaterials do not tend to chernically react
lime'
with the-
Napthalene and
of the rnachine l-Ience' materials like unslaked
L. ""rnp-r.r,
Ber-,ier-,e etc.should be inlmediately discharged from
the container of the machine

f-- if suctioned by mistake, and the machine should be


cleaned.
thoroughly checked and

f-- f O. i-rn"Jlut"ty discharge hygroscopic and li'ee flowing wet material


to avoid

f-. blocking of flaP.

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CHECKLIST
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Daily check list

l. Check pressure droP.


2. Observe stack (visuallY) (audible
an'v malfunction in the operation
3. Walk through the system, Iistening for
)
Ieaks, Cartridge cleaning system' etc
in the plocess being \ entilaled'
4. Note any unusual occurence
5. Check comPressed air Pressure'

l: 6. ,qssure that'dust is being removed from


the system'

l: WeeklY check list

l* 1. Check Packing glands


li 2. Check compressed ui'lin"t' including
line oilers and filters'
to ensure all valve are operating

L 3. Check Cartridge filter-cleaning sequence


ProPerlY.

L 4. High-temperature application -veriff


accuracy of temperature indicating

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l.
equiPment.
5 LiJk;;,ure drop indicating equipment for plugged
lines'

MonthlY checklist

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r. 1.
2.
Inspect and lubricate appropriate
item'
Check for cartridge filter cleaning'

l* 3.
4.
Check all clamPs'
lnsPect housing lor corrosion'

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1* QuarterlY checklist

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1-.
1. lnsPect baffle Plate for wear'
2. Thoroughly inspect Cartridge lilter'
3. Check duct for dust build-uP'
l.- 4. InsPect Paint'

l-- Annual checklist

l- 1. Check all bolts

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l-
2.
3.
Check welds
hrsPect hoPPer for wear'

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TPS Infrastructure Ltd'


t- C-7, South slae of C'f Road Indltstrial
Area' Ghaziabad

SERVICE CHECK LIST


i' Date:
- Client:
Machine Model :

L
t: VACUUN{ PUN'IP
Seruo sYstem12o or
L- oilGueilloC

L- Oil Changed First change (60

L-
L*
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l--
DIESEL ENCINE

1-
l-- En ei n;-oI
i F i it.,
Diesel Filter Condition
c ond it i on

l-- V Belt Tension


PTO Condition

l-- .ARTRIDGE FILTERS


l-- [--"r.rre J.iglott*g Time lnterval

l- SoG,roid Valvc oPeration Timi

l-- Punctio,rine of all Indi

r-_ B
C
MiiV".*u',, A.t,Iq!g!
f,-- D

L.
05
oI Release Valve
"""rrtl-t

L. B
C Alft.kLscffirum loss from rubber

L.
f--
D
E
of flllinq level Probe
ine of ull Nuts o,d bolts
acstxe srABT u!
L.
06
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B
C G;G; Fiitt O,""b"I closed r'rain
O;rt rmilt, H"** main Filter door

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frilu"cl.,u,l', at relief valve

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I i7 Trprxc exo sucrloN vALvE/


nrrn
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^^rrNErr-TIrlNc
B To check temP. , Pressure rn closeo
sYstem,
i

SERVICE ENGINEER
I CUSTOMER
I
DATE:
DATE:
a

L.
f..
f-- Check level TYPE OF OIL

I{ Hrs (500) or 5 Energol CS Energol CS

l{. times a Years 300 (-1s') 220 (-12")

rJ, Note: If oil becomes stuggy, the oil


shor'rld be changed irrespective ofthe
period'

l...
L. FILTER CLEANING/CHANGE

L. Vacuum SYstem
Suf"ty fiIt"r (Cartridge
L,
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Moistu.e seParator fi lter

earlier if the machine is working under


f-- . It is recomtnended to change the filter
dusty cor.rditions.

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LI TROT]BLE
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L] SHOOTINGS
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TROUBLE - SHOOTING FOR ENGINE

rj FAILURES POSSIBLE CAUSES REMEDY

l{ ENGINE
lJ, Contact on: Engine Not Battery discharged. Recharge or change

l..- Cranking Cables cut


connected
or terminal bad11' battery.
Repair or Clean Battery
I*- Terminal Check Starter

L. Re-push stop control

L
L.
Engine Fails to Stat Shut-down control not Pushed
hack (drawback sPring broken)

Diesel Tank empty


(replace spring)

Top up, bleed and Prime

L. fuel supply lines.

f-- Feed oumo filter clogged Clean it

I-. Change Cartridge and

L. Filter cartridge clogged


bleed fuel suPPlY lines

L. Leakage or Pressure of air in Check lor leak and rectifY

L. fuel supply lines

L. Engine is hard to stafi


Check BatterY, Clean

L. Battery CaPacitY too weak,


Terminals loose or rust) .
Terminals & Lubricate
them

L. ulei!4e!1e!r]-
L. In winter, oil too viscotts
Clean feed PurnP. tilter

L. Insulfi cient luel intake and change filter

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--'_---
Leakage or Presencc 01 alr
fuel supplY lines
1l)
cartridge.
Check and tighten all
connections.

L.
f--
Air Filter Clogged Clean Filter

Contact Er.rgine

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The engine does tlot run
smoothly and does not
gile top power
113ry111 Manulacturer

Contact Engine

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L Erhaust smokes heavilY
Iniector needle seized

Excessive engine oil level


Manufacturer

Reduce level to maximum


mark on diPstick

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L. Contact Engine

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Piston fungs seized or broken

Radiator fins diry


Manufacturer

Clean fins wit water jet

lJ. Defective Injector Contact Engine

L. Manufacturer

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L.
Engine becomes too hot
lnjection PumP DeliverY Off
Set
Contact
Manufagqlgr ==_-
Engine

L. I Replace Belt.

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Fan Belt Broken

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L. NOTE: The user should read the Engine Manufacturer's
the instructions gi'"' t'f**' Tt'e details
Manual carefully and follow
given in this chapter are not complete

f-- and are onf v to a'u*'ihe attention oi the Machine


user to some of the

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important checks to be carried out'

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IJ FAULT CAUSE
l{ VBCUUNA PUMP TOO HOT
Do not run at max.vacuum without

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Pun.rp being run at max.vacuum over
interruption. Check reasons like choked
pipeline or filters for high vacuum
operation. Normally duril.rg suction-

L
L Oil level in Vacuun.t too h igh or low
application the vacuum gauge rvill be
deviatins betrveen 250 to 35
s"---t
tt.,. oit i.""t on the correct level
D*i, ond t"plu"e the oi1. See in tl.re
l* Wrong oil in vacuum Put.tlP
Chaoter "Maintenance of Vaclvqf ump]

IJ Vacuut" .el"'ase-alve r.r.risadjusted Clrei'L' lte


"a."um
release valve and

lJ. A16,""rAp-6d ".tor or tensiort of Cii..k-tl,e otign'renr utd tension ol'the

l-_ belt rnay be mis-adjusted


M^i,,r fttt"t ."rtridge filters rray be Cle- G -a- ittte. bY ComPressed air
l--- chocked
"t 3 minutes'
purging system lbr 2 to
'Cort.iag"

f- filter may be removed and


cleuned by compressed air as explained in

L
L
L
Scked material or air too itot
OIL IN V-,q,
c uu Iu P u M P ExH Au s
Oil level in vacuum Pum 9e
r AIR
IerIC
"rateriat
Adrust the oil level
to be suctioned cool off'

Ct ..t tt . vacuum PumP seals

L.
L. Excessive bearing clearances
Roturv Van"s torch chambe| walls or eacl]
Rebuild vacltum PumP

L. othet'

L. Excessive backlash ot gears

L
L
RotarY Vanes out of balance'

SLICTION FORCE NOT SUFFICIENT


Cheffim"rg speed & soiution direction et ect tt e treit tension & electrical

L
L.
of vacuttn't
Muin fiIt", and cartrid filter chocked
Vrauun, release valte o too soon
Clean both filters
Clr.ck a"d th" ,"cuum,lelease r3!re'

L.
"di,rst
Tai leaks
Check the belt tension.

L.
L.
Belt drive Slacks
D,...Lr-tl*"tion hose too small
Vac** iltt *er itll.d, naterial in main
e the suction hose.
E;pty.;G,"et. clreck the material level

L
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filter.
E"d .orr..tio" ,rlves on cet.ttralized
ineline
Close the valves.

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LI SPARES
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RECOMMENDED SPARES LIST

SL DtrSCRIPTION
DTA,I (I'S T' Ur( IYIAUHIN I{
I QTY IPARTNO
I Cartridge filter from imported German FilteiMedia 4 Nos. 900Pol
2 Solenoid valve (24VDC) for purging- 7 Nos. 900P02
J Temperature controller \\'ith RTD (24 VDO 01No. 900P03
4 Sequential timer 24VDC 01No. 900P04
5 Vrg!]]l€gli" _-- 01No. 900P0s
6 V-Belt I Set 900P06
7 Rr"rbber sealing for cord round ,&ectangulat. for cloor etc. 50 meter 900P07
8Moisture separator/air cffi 01No. 900P08
9 SS bellow 0l No. 900P09
10 Idler nrrller. l Set 900P 10
tl Engine stopping solenoiF 2No 900P l I
12 Tachon.reter Cable 2No 900P I 2
l3 5port 4 rvay solenoid directior.r control valve 2 Nos. 900P 1 4
14 Rubber bellorv 01No. 900P 15
SPA rurs ! 01{ P't'o
18 I HB Plate INo 900P 1 6
\. t9 Center Plate 1No 900P17
t0 D[txrs Plate 4 Nos
\r 21 Sliding Sleeve 2Nos
900P 1 8
900P 1 9
22 Lever [,ink 16Nos 900P20
- l3 Catar'Ass",rbly 2 Nos I 900P21
\r 2,+ Flexible Hose Assernbly 2 Nos I 900P22
5rA I (I!S -t L'It AUXTALII{Y ENGINIT
\r
t5 J- rrg ine Air I iltel Elernerrt 1No. I qOOPli
t6 Frrgine PlinraD, Fuel Filrer -2 Nos. I 900P24
- :1 t.!sLnslg!91!e!_I!9LUq 2 Nos- 900P2s
x Ensine Oil Filter 2 Nos. 900P26
rAl(tls I uK ul-[,u l t{lcAl
:9 MCB -32 A l Nos. 900P27
rr .(l MCIJ- 2 A Nos-
1 900P28
:r Control Rela] 1Nos. 900P29
- MCB 16A 1 Nos 900P:10
: S.l."trf,*ir.h I 1\OS 900P31
rra l, uutton
usl.r 2nos 900P32
5electol bwrtch/Push tsutton Elemen
rrr 1NO 5 Nos 900P33
1NC 5 Nos
: Indicatins Lisht 2 Nos 900P34
r- _' 1emp. Ciauge i
Nos 900P3s
:! Oil Pressure Gause 1 Nos 900P36
: * Hour Meter 1 Nos 900P37
:
:
rt
RECOMMENDED SPARES LIST

SL
DTAIU'S T' UI( IYIAUHIN I{
DESCRIPTION I QTY IPARTNO
I Cartridge filter from importeC G".,nan Filte. Ir4eaiu 4 Nos. 900P01
2 Solenoid valve (24VDCJ for purginE- 7 Nos. 900P02
J Temperatrire controller \\'ith RTD (24 VDO 0lNo. 900P03
4 Sequential timer 24VDC 01No. 900P04
5 VrS!t!! Cg!i" __- 01No. 900P0s
6 V-Belt I Set 900P06
7 Rubber sealing for cord round ,&ectangular for cloor etc. 50 meter 900P07
8 lYor!! L'11 lqpelele!/all_e lsqllr 0l No. 900P08
9 SS bellow 0l No. 900P09
10 lo Ier pu lley l Set 900P 10
1l Er.rgine stopping solenoid 2No 900P l I
12 Tachor.neter Cable 2No 900P I 2
l3 5por1 4 way solenoid directior.r control valve 2 Nos. 900P 1 4
14 Rubber bellorv 01No. 900P I 5
SPA] iTI'S FOR PTO
18 HB Plate INo 900P 1 6
\ t9 Center Plate 1No 900P17
t0 D[txrs Plate 4 Nos
\r 21 Sliding Sleeve 2Nos
900P 1 8
900P 1 9
\r. 22 Lever Link 16Nos 900P20
23 Cotilss",rbly 2 Nos I 900P21
\r 2,+ Flexible Hose Assetnbly 2 Nos I 900P22
5rA l. (I!S -I L'It AUXIALIITY ENGINIi
t5 l- rrg ine Air Iillel Elernerrt 1No. I qOOPli
t6 Frrgine Plinraly Fuel Fiirer
-2 Nos. I 900P24
- )7 Iin_qine Secoldar) Fuel I tlrer 2 Nos. 900P2s
t8 Engine Oil Filter 2 Nos. 900P26
r.{lr IU5 I'OI{ T'L[,CTRICAL
ts N4CB -32 A l Nos. 900P27
.{l MCTJ- 2 A I Nos- 900P28
-l Control Rela] 1Nos. 900P29
: MCB 16A 1 Nos 900P:10
: Selectorf,witch 2 Nos 900P31
rra ilsl.r ut"ttton
l,
2nos 900P32
5elector Swrtch/Push tsutton Elen]en
t 1NO 5 Nos 900P33
1NC 5 Nos
: Indicatins Lisht 2 Nos 900P34
r- Ten.rp. Gauge Nos
1 900P3s
Oi1 Pressure Ga 1 Nos 900P36
* Hour Meter 1 Nos 900P37
:
:
\
40 RPM Meter Gauge 1 Nos. 900P38
4t Temp Sensor I Nos. 900P39
42 Oil Pressure Transducer I Nos. 900P40
43 Engine Water Safety I Nos. 900P41
44 Ensine Oil Safety 1No. 900P42
45 Battery Terminal 10Nos 900P43
LIST OF ACCESSORIES

L
rJ
S.No.
i
DESCRIPTION
WIRE BR.AIDED RUBBER HOSES
7.5M LONG
SIZE
lOONB
QTY
I

TJ 2 WIRE BRAIDED RUBBER HOSES


7.5M LONG
125N8 i

rJ J WIRE BRAIDED RUBBER HOSES I5ONB

IJ 4
7.5M LONG
COUPLING SET l5ONB
IJ
2

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EDITION :3HVp_2001 OPERAIING INSTRUCilONS
r! FOB
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-
,

Tri Lobe Vacuurn pump

)
)
i

a
a
t
t
TRT LOBES
I ROTARY TRt LOBE
VACUUM PUMP
t

INSTALLATION
OPERATION

II4AINTENANCE
IIIANUAL qm
SERIES

An rso sooi certiried


@ company
Khqleek C-e-tlr<-, r+e lr+g noqliEtq (oo-J.
g?rnor,e . Che..rnqi 600 oog.
-
phr 8Ss+83?/ 3y5-4e8/.
Errr"t) I ko.1 r*rtt@trd g.Vsrat, opF'Jn
@ bal. v3hl . 'a,e*,iu
INDEX
PAGE NO.

CONTENTS (i)

(ii)
MESSAGE

INTRODUCTION

GENERAL

STORAGE 1

INSTAL
3.1 ffi
PIPINGS
I
2
2
2
J.J DRIVE COUPLING 3
3.3.1. DIRECT DRIVE THROUGH
3.3.2 BELT DRIVE
3.3.3 DIRECTION OF ROTATION 6
6
a,-ccessonteq 6
4.1 RELIEF VALVE
6
SILENCER
^') Fll TER AT INJECTION L
INE 6
-o"o
^; P.INT 6
,*ar*uMeN r r'cPPlNG
'o'o ti*t^,ttt *uuuER sLEEVE
(BELLow) 6
6
MANIFOLD ASSEMBLY
^A OIL CIRCUIT MONITORING
O'
8
purnNc INED!EB4r!9I
8
51 rt t ntel SrnRrtUO
uI,, SUBSEQUENTSTARTING
8
r_Uenrc{qN I
6.1 Rf COt'llUeNOeO Otr 9

:.: SllSHiNIII.EO'ENCY 9.
I
9
7.1
o,.,'?*,153i"RU"no*"*
7.2 ,i'*,-+-f-ffi

TROUBLE
83rga, PARTS
s7,#
1.(unri
ceGssecrtgut' 14
Sanoelc
lel 226:.
Fax:oBC 10. 15
+ma l: k.
-I
11.
I
-I
r.
L.
l;,
l:
t:
t;
It: MESSAGE

t: Dear KaY Customer,

L; Thank you for buYing a KaY Positive


t: Displacement RotarY Tri Lobe

t.
l;
Vacuum PumP. We believe that You
have bought the best.

t* Kav lnternational Limited has the

t- tSO SOOr certification for Marketing


& Sales, DeveloPment & Production

t* of Tri Lobe Vacuum PumP Each


component of the KaY Vacuum
l* Pump undergoes stringent qualitY
control checks to ensure an international
standard end product'
l-.
l; Thisinstallation,Operation&MaintenanceManUalContainsinformationaboutyournew
equipment & its operating a1"t'i"" '"q'irements'
Please take a few minutes to read it
1-
t-
1-
caref ullY.

lf, {or any reason, any of our products


do not meet your performance expectations' we
wouldliketohearfromyou.'AtKaywebelievethatourbestsalesforceisyou,our
l-. customer, & we want you to be satisfied

l-. forward to providing you prompt

r.
L.
We appreciate your purchase of a Kay ?rod':t l-!:l
,i["llf & catering to your future equipment needs.
""-."r"ice

r.
f-.
Yours trulY,

L
r-
Sd. xxx
K. L.Arora
Chairman Cum Managing Director

L.
L.
L.
L.
L (i)
INTRODUCTION
designed'
Rotary Tri-lobe Vacuum Pumps are
Kay
t according to
& provided maintenance
nllnrtu"trr"O
t ,aO nOO,1 KAY is dedicated to quality'
through I
performance of their I
t of their people and
"*"utt"n"u equiPment'
production I
that goes into a KAY vacuum
pump I
Each component
;;;"*"". stringent quality control
finally
be{ore being i
rotating parts are dynamically I
fitted. Also, all the loads'
and lower bearing I
orl.""o for smooth running
l
vacuum pumps are
tested on i
All manuf actu red KAY
where
benches according to BS: 1571 ' PART-Il'
test
same as in actual servlce
the load applied is the pump duly
(required by client) Each vacuum
conditions
boxes is ready {or
0","*O and packed in wooden'
destination'
shipment to required

Ean93t
307, Ah -
1.(unti L,
&n,oeic
Iel:2261
-l
Far:08C
*maitk 1

LTi
+
ql

t-
L 1 GENERAL

t* All the Vacuum Pumps undergoes a complete approved testing process before delivery. The test records are
kept for'10 years for record and may be sent on request or consultation. The Oil is drained out after the test
L
NoTE: - The Vacuum Pump is dellvered without oil Filling.
L
L Each Vacuum Pump is provided wiih a Name Plate Comprising, Type of Vacuum Pump and Machine Serial
Number.
L
I ln case any major repair and modification done by Customer without authorisation of manufacturer during
l-- installatron or operation, it will involve the only responsibility of the customer and will cancel any right due to
guarantee'
L
|.-] 2. sroRAGE

L The Vacuum Pump and accessories shall be stored in a dry and suitable protected place. The rust preventive
Ih- coatinq or oil shall be renewed or changed, if required.

1- 3. INSTALLATIoN

l- 3.1 oN FouNDATIoN
'NSTALLAT',N
Ih- o Durinq concrete foundation preparation all care should be taken for solid, leveled and smooth
r loun0atlon.

F . Before setting the machine on the foundation care should be taken that pans in contact with concrete
1- shall be cleaned of any oil or grease traces to get a good concrete setti']g.

lJ . Uneven suTface of concrete in contact with base plate can be avoided by putting shims in between
il required
L . After alignment, grout the anchor bolt and tighten them after setting of the grouting compound.
E -
CAUTION: Never insert shims between Vacuum Pump and Base Plate to correct any leveiing defects.
l_
Nlaximum Horizontal Deviation: 0.2 mm/m
l_.
Vacuum pump unit, never use the inresrai cast tuss on the vacuum Pump side
l: l,fi: I;:rJ:r#e
!- rNsrALLATroN oF vAcuuM puMp wrrH ELAST'. suppo*T
L
i - Under the base plate legs an elaslic supports (i.e. Anti-vibration Pads) is provided which should be fitted
1- , to lhe Base Plale using bolts and Nuts. Lower the Vacuum Pump unit on foundation, taking care that
the hole of Anti-vibration Pad, Base Frame mounling hole coincide with the foundation bolt.
f_-
r-.
L.
r-
L
L.
L.
r-
FOUNDATION BOLT

PAD)
MOUNTING ON ANTI-VIBRATION
Fig.-1 (BASE FRAME
compensz:
must well set elastic supports are not for any -{
Pads)
The elastic suppons (Anti-vibration
ol unevenness ol foundatlon
orunevennessorroundation
Anv r r rdlur
'The

^"",;i#:ffi;;::::::::lfy:l*:""XHJgXTil:o:$:',':[*"
of insert solid block between base
and the concrete ' i
ot Anti Vibration Pad ln case
'n"'"nn""t
3.2 PIPINGS
wedges il
material such as wood
thoroughly cleaned Remov: anJ.lo-:?:Si
The piping shall be
matter in the compression chamber'
check that there is no torelgn
rotation of rotor and
S""rr" f,""
Pump flange'
piping shall not exerl any strains or loads on the Vacuum
The {
3.3 DRIVE {
Preparation: -,{
which should be
coated with protective layer of anticonosive element' "'"Yff;:l{
Drive Shafl end is
for pulrey / coupting f itment and w
ilrv ,,r.qurt" tools
instalarion of the coupring "|. orl;;;;;
Oef{
To make the mounting easy
and to avoid any scratch mark on the shaft use lubricant
on the
'nun
J
hammer blow
::Ir1, - *"u". 'ount the couplins / Pullev with {
3.3.1 DrREcr DRIvE rHRoucH
couPLlNG {
level and atignmiJ
shalr be placed at the correct
the pump shaft axis. tne motor dimens]1
For datum axis. colsider
J'H il;;"ior reg' si'e ol tn'"
shoutd be as per leg
should be done by inserling
,r"[r"J,, larger than leg area . J
,n"
"0u""
between botn couprins
tolerance
l']*'
'"^':T:]: T:ll:Ji".':X::il";l'J:lIJffi:,X"::"il:I
procedure must be exactly as per recommen -
a'so the alignmert '"nol'irntnt I
manufacturer. .-
a" p"l'O?l??l{
mounling
be done ior couplingas it is a major{actor for drive
inspection must is by
Alignment
t""o"JnitJ orsuigested one most common method of inspection
inspectlon procedure as J
indicator.
be checked as follows' J
J
Ban(
fi1,,
the dial indicator method' lhe shafl coupling alignment shall
When using
lK'
J
B.
ban0
tot i: 3L 1. Check the face run out of coupling
out of coupling
2. Check the lateral and longitudinal run
I
tax I
efitai
O-

J
J
Fa:

.J
n
t-
t:
L:
L;
u
ti
LJ
1-
tJ
t:
H
tJ.
l.. Fig.-2 (CHECKING THE ALIGNMENT OF COUPLING)

l-. COUPLING ALIGNMENT TOLERENCE: -

l- For radial alignment max 0.05mm.

l* For axial alignment max 0.05mm

1* 3.3.2 BELT DRIVE

l* The pulley alignment shall be carried out by using an appropriate media


such as (thread or a rule) The

l* shafi parallelism is confirmed when the thread or a rule is in contacl with the pulley at points A, B, C & D'

L-
l*
l*.
L
L.
L.
L.
r-
L.
r-
L.
L.
L.
L.
L
Fig.-3 (CHECKING THE MOTOR PULELY & VACUUM PUMP PULLEY ALIGNMENT)
Belt tensioning

TherecommendedbelttensionistabulatedandthetensiongiVenShouldbestrictlyaSperrecommenC=:
De{lection for each 100mm
Test force't' Per belt -(kP)
o{ center distance 'E' - (mm)

> 63-71 2.00


SPZ-3V 1.75
> 71-90
1 .45
> 90-1 25
1 .30
> 125
> 90-100 2.75

> 100-140 2.30

> 1 40-200 2.10

> 200 2.00

> 140-160 2.00


SPB/5V 1.55
> 160-224
1 .20
> 224-355
1 .10
> 355

> 224-250 2.10

> 250-355
1.60

> 355-560 1.60


1.3f,
> 560

-testing devlce)
belt tension (Using
There is also a procedure for cl-recking

{
{
{
{
Fig.-a (BELT TENSIONING) {
should not be less than {
both shali' The total de{lection
Press the belt at the mid of
{
Ea.=E.e
Bi 100 {
eaih 100mm of center distance
3t
E = recommended deflection
for
t' {
e = Center distance
Tel

Fa;
{
en
{
-I
I
l-
l: Ea= Tension the belt till its total calculated deflection E reached

tr, f = Test Force

L First check of belt tension should be carried out after 30 min. and then second check after 24 hrs. of
continuous running. 'l-ighten the belts, if required.
r* 3.3.3 DIRECTION OF ROTATION
1*
L IN EVENT OF ANTICLOCK WISE DIBECTION

L Z-r-\
L
L >
lnjection
B
Das.<
I la-l
--@--
- -i-.-
I
Suction
a
1; lnjection I : l.

1;
r.
POSITION V

L
L
\ l ,l tr"t".
f

1-
L
l{. ,r"t"" l POSt_flON H
nFnon /'
A Y
\ """''"

l-- IN EVENT OF CLOCK WISE DIRECTION

L. z::R
t-- - lniection

l-
lniection
\ ?
<
.strl_Y_l)
r-
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Dis.

lnjection
--v
-<
SLlction
[[ -,-/J
\+/
>
.:
Dis.

lnjection

t- POSITION V

r,
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lnlection
\
\ A
/
V
rnjection

--l
f.-. f".!tfl
f- \-q-t-
{--rl )
I

L. Y
\,r*,.. *",..l
f-- ^n"*"f Dis.

l-
POSITION H

L. Fig.-5

L.
suction
Normally the direction of rotation is anticlockwise with top ?."d ?'tii *:ii:q:.i.,1::T: :
Viewedfromdriveend.simultaneouslywithVerticalmodeofmoUnlingthedirectionofrotalionWillr:.l'-
same with horizontal ilow direction'
the configuration may be changed to s:: ;
ln case of any specific requirement of direction of rotation
customer requirement.
direction in any of the specified configur::l
Note:- This Machine is not designed lo rotate ln the reverse
indicated above

{
4. ACCESSORIES
{
4.1

:il:: :::::ucrion side & a very essenriar saf ety device for the equipment. u must
be
"r,""r"0
r.
{
f unclioning Pe riod icallY. {
4.2 SILENCEH {
ThisVacuumPumphasaSpecialConfigurationwiththreeworkingporti.e.SUction,Dischargeandln]::.

::l;,".m:"iE:::il::::,,";f ;"""iil:":';,:lilJtT:31".::15:H::"."#i,il:::ruq
{
4.3 FILTER AT INJECTION LINE
ln a dusty environment, the air inJeclion systern
must be fitted with filter' CaLrtion will be taken,nu, {
loss across the filter must be as low as possible' {

4.4 INSTRUMENT TAPPING POINT


J
FormonitoringVacuumatsuctionnozzleandPressureatdischa(genozzleofmachine'threadedn' {
provided for instrument mounting or a separale plpe line may be proi
at suction and discharge are

4.5
formountingallmon]toringinstrumentsaswellassafetydevice(SUChaSSafetvreliefValve)

FLEXIBLE RUBBER SLEEVE (BELLOW)


J
[/anufacturercanprovideitaSandWhenrequiredbythecustomer.lthasfollowingadvantages. j
-{
a
r
Absorb any vibration due to solid born sound transmission
Compensate slight mis-alignment up to tolerance
recommended by rnanufacturer' j
r
o
Should not be fitted dlrectly lo the machrne flange but
in no case it shouic be used to compensate any excessive
after the silencer'
or insufficient Iength of the pipi
J
4.6 MANIFOLD ASSEMBLY :{-
isolate discharge and injection port and has fla
It is a specially designed adaptor fitted to body to
{
connection to mount discharge silencer and injection silencer'
The sudace of manifolcl facing to body counier conneclion side
has special connection plate'
J
4.7 oll ctRCUtr MoNtroBlNG {
VaCUum PUmp iS provided With splash Iubricatior..{
For Vacuum PUmp Series 3HVP(H) and 3HVP(V),

Br

1,
gl
:; :1m, ru:; ::j:[,:1:"il1 ilff ifl
cf oil circulation on the both sides of pump
":,T
:::;::,", "e
nd ca, .n .,
","
una,un",
i J
{
e-ll
6r l
r-
l-
]: P UII]NG INIO-oEEBAII ON
1:
t:
l: INJECTION

e
SUCTION

t: orscHAnGE
INJECTION

L:
L:
l: A.
B-
OIL FILLING PLUG
OIL DRAIN PLUG
L: c. OIL LEVEL INDICATOB

t;
t;
D.
E,
PLUG FOR CLEANING THE COMPRESSION CHAMBER AND
CASING DRAIN PLUG
ROTORS

Fig.-6 (SKETCH OF 3HVP(V) VACUUM PUMP)

t*
t*, INJECTION

L
r..
L
4

L
,|

1- 7

l- 9

l-
l--
l-
l-..
l- Fig.-7(GENEBAL ARBANGEMENT DRAWING)

L. PABTS NAME

f-. S. No. PAHTS NAME S. No.

BASE FBAME

f-. VACUUN/ PUIV]P 6

r- MANIFOLD 7 l\ilOTO B
2
V. BELT

r-
SUCTION SILENCEB B
3

4 IN.]ECTION SILENCER I SLIDE RAIL

L. DISCHAHGE SILENCER 10 FILTER


5

L.
L.
t--
h
t,
I

I
{

II
{

{
Fig.-8 (FOUNDATION PLAN)
{
lNlTlAL STARTING {
5.1 on .,,ntinn ctiscl
anrl discharge
suction and src=
exeds no strain on the machine llange' both
D Check that the piping {
tr Check the tightness of oil indicator' at c :{
as well as rubber sealing
Gasket sealing at suction and discharge flange
tr Check all the
{
J
plug'
indicator, breather plug & drain
Marked level in the oil indicator'
tr Fill the oil casing up to Red
mounting o{ drive (i e couplin
of Vacuum Pump shaft before and after
tr Check the tree movernent
{
machl'
then-011"::::' rotation as per construction or {
::::'-",',:supplv voltase lor motor and 3'
of rotation as per point No 3 3
" and its recommended iirection {
trChecktheoetttensionanaalignmentorthecouplingalignmentaSperpointNo.3.3.l&3'3.2,
before putting it into operation
valve and it's opening J
tr Check the funciioning of check
As far as possible try to mount
check valve in Horizontal
position'
J
-
CAUTION: Never operate machine in close position of valve in either
suction or discharge llne
J
5.2 SUBSEOUENT STARTING J
o Check the oil level -{
Ql\,4akesurethatonSuctionlinewhenoperatingnoValveisClosed.
the selected Vacuum
on suction line to obtain J
tr Set the Relief valve mounted
J
t. LU B RICATION
J
6.1 RECOMMENDED OIL
in'extreme pressure oil of Indian
Oil namely Servo-mesh SP-320' --l
Lubricating oil recommended
equivalent to SP-320 oil can be used but
the oil propeny must match with
J
J
ln case of non-availability
of SP-320
below mentioned properties
CHARACTERISTICS
At 4OO'C {
Kil.IEMATrc VS.OSITY CSi,
VISCOSITY INDEX, Min'
ir-RsH potrur, (coc),'c
-l
J
l0
l,l
la POUR POINT, ' C J
fel

)'m
COLOUR (ASTM)
nffiresr (D-665 A&8,24 Hril
J_J
.J
r!
E
f (in liters)

tE
o.z OIL OUANTITY

3HVP(H)

E DBIVE SIDE
NON-DRIVE SIDE
t: 3HvP(v)
t: DBIVE SIDE
NON.DRIVE SIDE
t:
li- 6.3 OIL CHANGE FREOUENCY
.Cleanthedrainplug'fillingplug,oitindicatorandrenewthesealingbymeansofTellonorSimilar
t- sealing element on occasion of every
oil change'

t: rThetirstoilChangeshouldbeConductedatler2oohrs'ofoperation.Followedbyoilchangeat
everY 10oO hrs of operation'
L; .CorrectoillevelWiltbeconsideredonlyWhentheoi|leve|isonthetopoftheredmarkWhenthe
t* machine is in stopped condition'

IL; 7. PREVENTIVEMAINTENANCE
The maintenance operation shall be
limited to routine inspection of oil level and
periodical oil change'

t;
Ir.
safety valve functioning check and
checking of belt tension'
cleaning of oil chamber by draining out
old oil, cleaning of filter &

t;
rj
7.1 CLEANING OF COMPRESSION
A plug is provided at the bottom of
draining out any condensate or any
CHAMBER
the casing of the Vacuum Pump when operating
other accumulated dust particles at bottom
in vertical mode for
ol casing'

lJ. 7.2 INJECTION FILTER CHOCKING


1- Afoulingindicator(IilterChockingindicator)maybeprovidedoninjectionlinetomonitorfilterchocking,

L
l-
Wn.n ,Jo piston comes to bottom line' filter

Use compressed air for filter cleaning


is supposed to be chocked'

Filter cleaning must be clone atleast once


in a week time'

l-
L.
r.
l-
L.
L.
L.
L.
L.
L.
r--
ffiune oF TRoUBLE 'the
at ClrecX tne condition of
The machine does
J rn" ,o,or. rub against.each rotors & casing and
check the i-
not stad or gets jammed
other or against the caslng' and adjust it require:' -
"l"arrn"""
b) Check vacuum &

ffi
is
b) A heavy over load re '
temPeratu
imposed to the vacuum PUmP'

c) The PumP casing


ts
,;"-:;il" of rotors & cas r{
distoded bY excess stress
& ad;ust clearance'
lf requirec - -
or due
exerted bY the PiPing
to uneven foundation'
d) The machine must
be J
d) A foreign matter
has
entered into the Vacuum
overhauled.
I
{
e) The machine is
contaminated'
e) Clean the machine'
J
checr5l.l
a) Friction / Touching of
the liE,"n[u'" to be

Abnormal runnlng with and adjust if required


rotor with each other
or J
n oise.

b) Change the gear'


b) Too much gear backlash'
J Chung" the bearing'
[Too rrign bearing clearance'
to d The machine must be
di Roto' unbalanced due overhauled.

a Clean or change the


filt3'J
a) Filter choked
cn""x,r," inj""t'ot fill1J
ol-,
Ll Air inlection is insufficient
CLr.g" tYPe or corre'::l
c) Oil level & oil viscoslty "level. "if
are too high -:
P-
d) The clea rance belween
rotors and between rotor
CrOverhaul the Vacuum
J
& casing too high'
rePl:l
-l
,'LiD oil seal must be
a) Oil leaks at sha{t Passage
due to LiP oil seal damage'
or
D) Tighten the indicator
b) Oil leakage f rom oil
change the sealing
level indicator'
ir :) Overhaul the Vacuum
P:-l
I
I
c) Oil leakage f rom
due or drain off excess
orr
comoression chamber J
or
to sealing are worn out
: oil ievel too high '
I

-.=,===-'J
I
't
L-
L.
r;
L
l;
S.NO. NATURE OF TROUBLE

The suction capacity


CAUSE

a) Excessive vacuum at
R EMEDY

a) Check the gas / air system

t;
is too low suction side
b) The clearances are too high b) Overhaul the Vacuum Pump

1; c) Filter may be chocked. c) Clean the filter.

lj d) The operatino condition d) Check the operating

L
L 6. Too high power input.
do not complies with the data
given on specifications

a) The operating data differ


condition

a) Check the operating data &

f*. from the data specified on


the purchase order.
compare with purchase order

l;
data. check the lntake
resistance due to filter chocktng

H. b) High vacuum at suction b) Check the vacuum valve

l* side at suction side.

l- Note: - As & when required in case of any major trouble and their maintenance KAY SERVICING TEAM

l- will be at your disposal to give you advise & to study the best possjble solution.

O
la
Bepair in the field by our specialists.
Q Complete guaranteed overhaul.

L. f, Repair / Replacement at works.

l-
L.
L.
L,
L.
L.
L.
L,
r,
L.
L.
L.
L.
r.
L.
s
\.
't1
9. CROSS SECTIONAL DRAWING & SPARE PARTS LIST
FOR TRI-LOBE VACUUM PUMP SERIES 3HVP

I
I

.jI

<
I

{
I

:
:
l--
1- (List of Spares)

L SL. NO. OUANTITY DESCRIPTION PART SYMBOL

L
1-
01 01 CASING ( D

t- 02 02 SIDE PLATE

lj 03 01 DRIVE SHAFT FITTED WITH LOBE

L
L
a4 0'1 DRIVEN SHAFT FITTED WITH LOBE

L 05 o2 BEARING HOUSING AT NON DRIVE SIDE


)@_
IJ
l;
06 01 OIL COVER FOR DRIVE SIDE
@_
HELICAL GEAR FOR DRIVE SHAFT
@
l- 07 01

E::
l* 08 01 HELICAL GEAR FOR DRIVEN SHAFT G. h1/
r* 09 01 HUB FOR DRIVEN GEAR /ffi)
aN4/

l* 10 02 BEARING COVER AT NON DRIVE END t0)


l-.. i@
l*. 11 03 THURST PLATE
r ---i _]
l; 12 o4 PISTON RING BUSH WITH PISTON RING
L...* ___..1i

l* 01 OIL SEAL BUSH


t_J
l;
13

f-" 14 02 BEARINGS AT NON DRIVE END i]I


f- '15 o2 BEARINGS AT DRIVE END @
L. '16 01 BEARING AT SHAFT END i@
L.
L. 17 01 OIL SEAL

L.
f-.
18 01 OIL FLINGER

r-
L.
'19

20
o4

04
OIL PREVENTING DISK

SIDE PLATE BUSH

L. 21 o1 OIL COVER FOR NON DRIVE END


w
L.
f--
22 01 OIL SEAL HOUSING

r- 13
-

Iil
FOR ANNUAL N{AINTENANCE CONTRACT
10. FORN{AT FOR OFFER REQLEST

To
f)ate:
N,I/s Kay International Limited
205-206, Lusa Tower
Azadpur,
Delhi-110 033
{
FOIT DRY \NCUUM PUMP'SERIES - 3HVP
SUI] : ANNUAL N'IAIN,I,EN,{NCE CO\TRACT {
{
itr our plant are given her:
Wcwotrld]ikctoel]telil]toilllAnl]uirlNlaintenarlceCorltlactwith}'otl.Kindlr,subrrrityourd.:taileclofferrr,iti:
oi;,,.r;.. The cletlils of Vacuum Pump lunning
ter.ms and conditions io. -"in,"nr,l.. {
belou':-
{
t. ComPanY Nanrc {
7. Cor.nPanY Adclress {
Contlct Per son/Designation {
{
4.

5
Telephone No.

Fax No.
ii
6. Details o1' Vtcuttm PunlP
{
PI]MP {
\ACUUM PUMP NIODEL APPI-ICATION OF IACUUM
{
{
{
{
{
:{
J
J
{
{
J
I
(Authorised Signirtory) J
t
J
14
J
-r
l--
r; II. FORIVIAT FOR DEMANDING SPARES

li
li
l; X International Limited
I/s Kay
Date :

1; 205-206, Lusa Tou er


AzadPur,

IJ Dclhi-ll0 033

l-
l;l- Kinrl Attn. : IVlarketing Ilanager

Sub: Spare parts for Ka1' Vacuum PunrP'


l;l.l (iVlodcl r'o. --..... -..._-.- PumP Sr' No'

r;
l;
Dcur Sir-.

Plcrse sencl us the quotation tbr-followrng spare Parts


:

l;
r;
r;
l*
L.
L.
L.
L.
L. Thunking 1'ott

L.
f-
\.rLrrs l'aithl ull!

L.
L. .\uthorised S ignator) )

f-.
\.utre
Jc:ignation

L.
L.
-\JLltcss
...,|,:

L.
t- .1\ :

, -,litil :

L.
f Note : To be lilled lbr cach vxclluln purrlp separately

15
t-

1
,{,

II
{

{
{
{

:{
J
{
{
J
J
J
J
{
J
J
J
J
J
*:friih J
{
"S!,tY
J
K,trL jil" ::,t'IJl|fl',:T'' " =
J
--" .-"r"r.,
CORPORATE
Delhi-110033 (lndia)
HEAD OUARTERi :205'206' Lusa To"ver' AzaclpuJ' 7220491
7249051'52.7222941 1223035 Fax: 91-11'72496A3'
com
e ma : kayintl@vsnl'com Website : w$/w'kayblowers Sonepat (Haryana)
JJ
pu'r"p
PO - StuOi"
Village-Ba-dmalik'
Works -' Beeswan l"4eel, .Distt

]-l
,)
,r Begd' Office ; D 8' lModel Town' Delhi-'! 10
009

chennal Kolkala i'lumbai Bourkela

59, Benlinck Streel ilH.r:r;r*


I gangalore 3E 3rd Floor , Shree Complex
iii;or; ,t. oo *'
4 17, Beheia cl2obers
o
BehindCanaG Baik
: 307 AhujaCh:-bers
;;,;;;;.j;; K-kara.'70r06s 2r3 NarimanPrnt
UdLlNalar, Rou(ea 769012
I 1. KumataKL:iFoad,
ii"iis. M;;[,n n.ri, T.].r2371e43 r'lrnbal-40002.
Bangalore'sir: :01
,".l. il],, ", O.*U 1,,ojldB-r7oq r ?d4r/9r - 15--J.2834500 Ie1511241 502202
$rtiiiri:ii"'J
Tel:2265811 1286229
ht: A8l'228a29 2265811
a ru L:kayifl e,llvsnl.nelin
il' :.ilj; -;;;r
Fax C44-8554231
'
L:d rdl.'. oro.
Iavlnll6 mc1. snl.n-
i":0"283r't
€-nail:kay nle:'n2 vsn 'f!t n
Fax:0661 5039C6
e-ma I : rkl ashoklale sancharnel.ln
:1,:1?ili':';,,.. 'J
INSTALLATION & MAiNTEI{A NGE
INSTHUCTIONS
CAT:LC G UE IiO'S
:-,'/AY OlAFHnAGl.l i-)/P5 SOLEI''lC VALVE: sc=:5:.;r
:rJrcK oPEl{l}iG - G:.'i"ANO Gl ACa.lga 22e ice:s:.-::
. NORI.!; LL'/ C LOS ED OPEN;TJCI]

:.l-ic- :'oi'AC . i:... For : : Yoltr!. :Jl ;:.:r '- :cc\ f.. clos!cj .,i:j llolc
ON or rc.: rii,ehrfgr: 155c::r.ltr. :..rl3c:
sCEiji a:-w3: :"r:rrlly cloi"
is r:rc::itrc:rt duti::rir lsvc b.:::-a%.choscr_
3.:i:rivc dury tin:c .l); ior DC Th:5 pirlr r:ri:rc wo.ir cr o:::::a.. -irh r
.rn tlpc vl-!vc' d.::3:'d for qursl: corn;..:. Sparc Pr:5 K:r acr..:r r.-
-.rla'it"sing. Th: ;::rc bodY r::c ..::; lj_-s (:rtforLa'j :c:<i.r? : Ili0'i\
ire oi alurniniu- '!nst'uctroi :: :::.st :. t:flEs r:.:::::5L:d t.-.: lU&\. 5 ulLs

ialvashsvc ro cPc:r fr3mc sol'- .,.r8:i:cc limc far DC ll min. 'vhcn th.
'il:rtor l)'l i :.i:.cic 5 .icrSi:::r ic: th. r:'i. rUou- ii:..\s-
bid of rfc pt's-on so:kc: :... .ic.ri:.C lir:]: r]i. rol.ioij :.com€5
.lv6 wirhprc:ir WP (lf :' l rr' Pronc-'
'-i6J0) r: l :.t lid c:1n bc tcr-::.3 )e l11. -:.d onl:--
r. pl,:g-on.cnnc.:or -
!!,5kc'-' :::::-r.. :i:r'.r:r -,i: :i:tr:::r '1iil b.
OPER,\TlOir
,NorI!JlvCIoi.j: :Iif:is: -::r ri::1!c l
Baoid is de-<ncrg=.1 3c 1':': i rn'n so'l I, r..,.:-.;rgs.r^-c:
-.i,1R:l\C:Turi,.1:.:.ca1. -crsuP_
ALLATION : | :.d c.?r.ssu.:: :a i :.ac:: :::akjn:
carxlogu. numb.t, ; :.::!.'. 7ol(;!' ::::r::. i: is;rol i . i I : i : .r' o . : . : i ! c th3
I

scdic.. Inionnstion :::;:rrcd on cci' ::::c rror thc Pip. tr.. i.r r.p:r::
C::].\NI \ C
: ;.icci.c:c1nir,t .'-...o.cj:o - .!vcsie

ls
oNr\c
rlvc mrY b< -:':ounrcJ.. ".' :::irr!lc. 'i-nc tiurc :.:r... clc:-i ::js wilj

rrj
Positroi
. :,-. . c.c::dirgon i..r: ria '.. :.. con-
lhoush uprisr: posirion 1 _:i5 gulr3r'
b6t p.rfcri:3rc..
.: ::-:c:. :1u-r:ish :,,. .;.r.r::1 :rc:5-
.. .:-i:::. orici:. ' .: :i::r:. .:c:."_

l;
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f'-.
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Ll': t )l:.

L.
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ku
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F.s,66t :ro ' -------:=+/ G!r'.r 5iu, co.^drr'

F pt,c ccn"erot

tnl
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t-//
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5.rb.r. ru3 Li.h.rrr


:

idr !....: 'r* IaJ

r.t:rlh

Mr/rLnq -rHlS SIO: CJ- dn oraonrat:

3le.d nor. 'n


d'3::i!f,
ar'g^h..r Eih c:Y.s 'n _
e,rcm:tcc"tcu,::ll:
.tat^t.i^ lttef: r...'
ano bon..l fiU5:.: |n Jl.? ,
I

OFEF;IIO{\I

dlve S
io the top ol the
is becoming doses the mai.a o.;:ice ir oIa
fust lke the seco.d saving el;ens,r'e
in.lLrsures. Sl.le a?. Tie exhaust air ncis-. kePl
ol pallicle c,own by siiencers wniah cerd
buiil-in with lhe Y.- anc r'
s nowaoays ls
pment as
- Hj"',,i"i'"r"'i"J1 13.'ryy*' I ;*
znd

f :l.lELEC for ha-zardous locati.o-<


'C.c.nJj 6 ru.€ l..Ert : .:.crding EN 50 O14 aod EN 9J Orr
Ihward Valve parts In contact with r.nedia S:'.ty code E=: d ll8; use p.efu
the bag a6ainst i}Ie hrq-, quzr:l'y Fb4re | (i-l Efd nylc.. S:'ely code Eax d ilc; use prell NF.=1.
iesrrlts io acditicnal reinfcrcad Necprene ..1) ar;cf/acm: :. ::eased Safen//Special kotecicn
e-ae '.v€:I resi:iant ar: cr:rantoi:
long cce|ating lrie. e...i rnder h:rsil s: ancij opereicrs ict hezarcavs
a dust collecicr is l.-:iicns conlcrinrng to \,CE OI;;.
on the r:qht ccnditlc:s. lIlaar can :,-. aaaa.i)ea z:
wnici are generated by an optjcr (.s ix V). - ::cry mOUlCea corl ..vrih a 3 in:c..
ui,-
: ':Ot,/ cable -! s). rrss t.e,ix'/E!
ano alcsinq diaphracm
pulse ciachraErn
- .-=i ,alercrc:j :nclcs -rre .rli
: :rv iermrna :ail iEy :s). -._
ces;gne.J ior ihra "alves .. t '/=.

exremeli iasi coeoina ic E. -:.iIra l


lo p(cduc: re,ritle an acre.r:_ieaii:Irls ar- :- ;,.. :r. .l: --..c /aliac::
,oeiaiian
--
;he cie-r:ai a. :miniu:- a a., -a."-::a r,- r -' ::: :.1. -i 1 : ::C. :- - trts
is _occo :ai;c5r_.n resr:::._ taa :i
jrlrerne '.: i .ano,l - '-. _ .' := . ec'c .=auc1:
:lgt ilc.,v. enq.: i,;e 3ccj.: . 3Y :rCCr :a;:rr a a( a!..-a -^a a. _:- . ttlaat:ees
lta t=:::.: : t:_:,:i: ::
wdh ::e :ce.aal lri.. 'vni(:a :r': :i., -aa;aa.. :' --, '1 'c:: ',cr;;: z: tctiag.
::aer'ra ,e: -arve il.e _:t Ctre agcticeit.. , -a.suri .: .a - 'C' -ta, .Cm|na iclaee .tlaa a-
).C.
:;ge::Tc re3tL-'te. ,a:,.r re3 icr iirS
StanCarc scienoids :ei ::i.
lacry :r,c.. cat:) aaece ,, .a...:a a Ter-a::eiures
;.a55 ; -'. .. '..'orn-c :.,12 - i-, amaEa atc ia-:t\:(a-.
nsialled tj .,..r ai16. -,,; I , t :l
:,1ecail . : -'rcanc:... [- _
::r '-.'recrr-' ::iicE,- -i:s -:.-
:e-cuiaiicna ::,J i_sn ae ,.rs: ea -! 125' sa:a]lv'/;1.r.
i3: daai: e ala- .' :. : :' Inst: Eiicn
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l- GENSETIIVTAR! NE ENGE E\$ ffi
l- Service Manual
L ALGP68OTC,EAI1
IJ ALMUTC6SO/'i
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GENSET/MARINE ENGINE
Service Mamual
ALGP68OTC.E4i,I

"'xI,I$ffi3i;
f-
L. FOREWORD

L.
L. This Service Manual has been preparec to acquaint you with the operarion,
maintenance and overhauling of Ashok Leyland AL680 Series Genset & Marine
L
L
Engines. This manual contains technical specifications, service data and instrucrions
on the correct methods of carrying out maintenance and repair work.

L
L.
Chapter - I gives Technical specifications, Preservation & pre-commissioning
procedure, Genset installation & Testing, Marine Engine lnstallation, lnstruments &

L
L
Control, Operating lnstructions, Maintenance Schedule, Filling Capaciries,
Recommended coolant/Lu b r icant Tables & Tightening Torques for AL6g0 series

r+- Genset & Marine Engines.

Chapter- 2 is provided with necessary maintenance and overhauling procedure.


L. Representative diagrams of exploded/cur-section views of the Engine aggregare

L,
L.
assemblies are added wherever necessary. special Maintenance Tools and
applications are provided wherever required, The contents have been indexed with
a clear section numbering system which helps in rapid reference.
lJJ.
L. Chapter - 3 givs5 Maintenance & Overhauling procedure of Marine Accessories.

k,
f,
ln accordance with Ashok Leyland Limited (the company's) policy of continuous
product improvements, the company reserves the right to change the procedures,

f,
f,
material, specifications, dimensions or design referred to in this Booklet, at any
time and without prior notice. Relevant changes would be updated through our

L
r.
service circulars, if found necessaD/.

care has been taken to include as much useful information as possible. Every

L.
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reasonable effort has been made to ensure that this booklet is accurate. The
lnformations, Data and Procedures given in this manual are indicative in nature

r,
and
not binding.

L.
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operators are strongly advised to get the service and repairs done at the
workshops of Ashok Leyland authorised Dealers / Service centres and use genuine

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L.
spare parts. lf you are in doubt on any point, please seek the advice of the nearest
Ashok Leyland representative or dealer. should you need any further information
please write to :

fE. Technical Service Group


Ashok Leyland Limited
Marketing Division
\.
480, Anna Salai, Nandanam,
\ /-k LAn )C
L.
L. GENSET/HARINE ENGINE SERVICE MANUAL .

L.
l-- CONTENTS

L.
rr GENSET/MARINE ENGINE SERVICE MANUAL

rf-- Serial No. Chapter Name Chapter No.

rf-. General

rf; AL5B0 Series Engine

L. Marin e Accessories

L. r Network
L.
Deale

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L.
f.
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E Ghapter - o{
GENERAL
f.-,-
f- GENERAL OI.OI

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CONTENTS

- OI
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CHAPTER
I

GENERAL
f 'r"..,on--*1...-
Section bject5u Page No.

S o,.r- ;;."n o*n.". 0t.03


01.03
f] ll 0., Free service 0 t .03
power Unir Regisrrarion
E i'troz 0 t.04
Engine rdentification Plate 0 t.05
Ir: r:l:l
!0104 Levp:r-ts ""'" ' 0 t.06
E
0t.07

at.7. preservarionandpre-comnrissioningprocedure........
0t.08
f
0l I Genset tnstaltation and resting""""""" 0t.
H

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01
ot.4

5
Marine Engines lnstallation lnstructions

Instrument Panel and controls for Genset and M:rine Fnoina<


0t.t5

0t.19
01.t9
01.21

ol 6 Engine Failsafe system for AL 680 Series Genset Engine.


L: 0l .22
I- ut.r Before Starting the Engine 0t.24
E

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0

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l'9
Maintenance schedure ..................

Filling caPacitv
0 t.26

0l .29

or.ro Recommended coorant o1.29


[1
f-- ul.ll RecommendedLubricants............

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L.
01.12 Tightening Torques
0

0
t.10

t.30
I
L-
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L ]OI.O ATTENTION OWNERS
GENERAL O I .03

L. 8. The warranty sh: I become nuJi and voii:

rf i 01.0.0 Warranty
- ):OK LEYLAND L '1ITED (AL) warrants each
.-,.-: soid by it to be fi-ee from defects in n.rateria
lf the engine is used in ways na:
recommenCed by the Company, if
features oi the engine are modified.
an/

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' :-: ;. orkmanship subject to the follo,a,,ing terms and the engine rs repaired or disassembled,
::_ficns: even parti:lll, by persons not belonging
re period of war.ranty shall be to AL's authorised workshop, if the
:
entrne i: loaded beyond power
:l 2.1 months ,a-om the date of .,espatch oi permissible or if the instalJation of

L ergine from AL works or l0C0 hours oi the


e^r ne ,.' 1Ot ds pe. t.le
oDe13tion ,,rhichever is earlier for ensine recommenc:irons of Al

L L ..,
:cld fcr Genset app lication.
)g months i-om the date of despatch ci lf ihe fu: injection pump ca braticn
trgur-esare titered or the relatrre seals

rr,
engine lrom AL rvorks or 2,5CC hour: of
tan-pered ... ith, il unsuitable luor-icants,
operation, ,.,hrchever is earlter lor othe.
luels or cc:lants are employed cr non
applrcations.
genurne spl-e pafts are {ltted.
- the event ci transfer or an) alienatrci.
::-er.,.,i:e of the ensine during the ,,r,ar.ranr,. lf t"e Free Sl.,,ices are not rarn:J out

f; :.:-rcd menironeC r Clause I abo,,: ,,.,arrant..


-.1 o L-r ^
..,eJ u1,-:S pr
- lf tie recol.rtended
is nct lollcr..:d
matntenance practice

L, :'-ten: fI A:hok Lailand is obtained.


. l:.

f- - :. 'c e\,,ent oi :ry defeit bcrng Ci:co,.


. :- r if e per.ic.J n,:nlrcneC in ll:u:: I
erac
9. When a :.r1 i; .:placed under the t.r.rrs of
warflntl Ile bc-:fits ol the lvarraf:,, 5hil
1DD..
L.
:bo,.,:. _a e ., pl._.
:- : ::;.:iLl,, e plr-i : .etL| ned to ti)e .:.l,r.ri
A- rernrlnCcr tI tl.. y731-13^1, p:r]oij :1:ite,J
:: :. .,. crkihop ;eight pald, i",,rrhrn I d:) s
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clau;e I ::c,, e

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- : c:igatron un::r ,rarranty shril
b: imlred 10
.:-:- ":pairing or .eplaring lree of :h.rrge suclr
: ci the er::-ra a: are deenn:rj :o be
,:: ii.e rn the JDinion of ,AL .rnd shal nor
I 0 AL reser,, :: ihe , .lht to mcd,f) the i:.ahnri.ri
specificaticns ol :.. introduce impro,,eI,rent
its engine: at :^. time and rs u,.r:ter nc
cbligation lo a.ll/ such nrodificatr.:ns
to

or

l-. . -:-r ic conseqLajrtial losses Ail


--:i:ciive pafts ihat have been the drnraeed
replaced siall
r-fproventaiis to a.qt.es oroduced al .tn
Cate.
ea.iy

l-. ::: tire the propert,, of A;hok Le;land I I


This warr:nty is r lieu of and exclujes

L
all
' lr-cDrietlr) p:r-ts not manufactured by AL aondjttons \r,/aTra:::res Iabiirties expre;s
or
r. F ,:1 t' "o I ou,p-.., r L -ctr .a implred, r,,hether 1 rommon law stJt!ie

l-
or
. _, :.rr:nt, f'larine gearbox, pTO. Tur-bocharger. otherwise rn relailn to all engines, \,,hether
.-..:. Alternator etc. the warranty terms of the
r;
covered b,, lvarran:. or noi.
. :::t .e suppirer :hali be applicable. 12. Any ciaim c. dpp a,ition in connectron u th th.

l; .r' <ndr. Lc - -o o her I gtt e.(ept ,ho-o saie, of Ashok Le; :nd engines shall
be ,ubject

u
: - _.::.. stated he-ern and have rn parlicuar no io the jurisJiction :i Courls in l.ladras onlv
-:-: :l .epudiate ihe sale. or any agreement or
'. : - any reduction in the

l- ''. :-3,ne or to demand purchase price of


any damages or
: --::-;ation for losses, consequential or
01.0.1 Free Service
AL Customers can avail cf lree
l.- '-:-.. ;e. incurred cr accrued. senrices oflered by
AL in any authoriled dear:r.5 w6r[516p on proo.lctio/t
of the Free Service Coupcr Book.
l- : : -;:cmer will be responsible for
:.e cost ci non-durable materials pe' odrc;.\ -. tree Sen,, es is g .en
L, rorrcarts, fuel filters, rubber items etc.) l-t ?11,,
the ":oappearing
schedule
in

t;
blltw.
:ie coit of maintenance and lubrication
)er dt ln.
Model lnstallation Hrs
l; :-e ccst ol repairs made necessary b7 lndustrial Yes
50 200 Hrs 400 Hrs.

u
- l:-t-a! wear & tear, Yes Yes Yes
accidents o;
-:.:le. use not authorised by AL or by Yarine yes Yes Yes Nlo
- - -)l:. sto tde or negligence.
l* :-. ao;t of repairs, caused by damage Checks to be
o,\ia^ ;^ +h.A E-^^ c^-:,
carned out during each lree.seryice are
. , , ',
-
01.04 G E NERAL

0 t .0.2 Power Unit Registration

(AL) works
Tlr: po,,:r- un t Registration folder s suPPl ed ,,ih every e.g,ne despatched from Ashok Leyland
, nc / cc ,e t the -d -1e. Lhe sDe i.'rcr copies are g ..en below f:r your ready reference (for lndustrial & l'larine it is
d ff,er-ent).

Ccpres

L
ci PURF are to be mailed tc

AL Ingine Salt,. Nandanam Cl :r ra

AL legiona O--ce
600 il15. I
{
of
{
AL Service D--':]cr - ( io be aclreilci to f-i-: conce|nea Senvice Dealer and End Uiers Locatlon n case
{
doubr. This c.Dy .an a to be s:nt to ihe n::i.e:r Re{io.i Oflce of AL).
{
ioldcr is s-pp ea io lt: ndu;l'il =n3ine ieraice dealers through our Regcnal
Ofl:ces
l-h: fi ce iSrV!ie CCnPOn
-';1 out Free
{
for car
sCplratei,. On re[.] lrl oi PURF at :.L iegonal 'lific:s rc5pe:ti"e c::lors 'v I be intimated
i;'.q Fr.c Se..:a and .Vlr-rai.rt)'ceneflts ofiered by A'h:k Leyla:d' {
5,r.. ce: ?cceipt c' P'iP,F s rnitndatlr^, f6, .l',3
{

@ ,"orat",oa to*aR
INDUSTRIAL ENGINE POWER

uNlr REGN. FoBM 1/


UNIT REGN'
r cx vrt' cur,trn s A'?LlcAB!:
FORM

COPY FOR AL ENGINE SAi.E-i NANDAi']\M


-l
J
ENGINE N'
NAMI OF OE MFR.]DEALER

J
ENGINE [iODEL

]NVO CE \O & DT J
CUSTOMEtr CODE
J
CATEGOaYOF INSTALLAI'1ON: 1) llEW
J
tr
l
4)s -, r-, I D 5)CENTnAL

J
J
NAN,E OF OE END USEB
1)ENGG, D 5I CONSTN. 8) TRANSPORI f :

2) TEXTILE N 6r MINING tr e) FOOD tr AODRESS

3) LEATHER E
n
7) CHEM CAL t-- Io) OTHET' I

J
-ar
co5
4 frosPrraL
4) ;ENSET I PIN CODE J
;ircl
UJ
1r COtuIPRESSoF

2r HARVESTOR COMAIIiE s) DRILLTNG RIGS


6) PUMPS
I
n
- J
.-l
6>
Our
FO
FAULTS OBSEI . rr WHILE COMMISSION NG J
J
NOTE] THE ENGINE WARRANTY WILL BE APPLICABLE
SIGNATURE OF OE MFB/DEALEN
WITH SEA1 J
ONLY lF THIS lS COMPLETED & RETURNED TO:-
AL ENGINE SALES J
AL REGTONAL OFFICE
AL SEBVICE DEALER DATE:
-l
. PLEASE PFOVIOE USER'S WITHOUT

-l
--l
.I
-l
q

I*
rl-- MARINE POWER UNIT REGISTRATION FORM
MARINE POWER UNIT REGISTFATION FORM
GENERAL

AL ENGINE SALES, NANDANAM


O I .05

l.. rO BE FILLED BY DEALEH

ri
TO BE FILLED BY ASHOK LEYLAND LTD,

NAME OF NAME OF END USER :

lj AD DFi ESS
ADDRESS:

L
L CUSTOMER CODE

L AI ENGINE I\4ODEL
DA-E ]F SALE BY DEALER

L ESCRIPTION OF EQPI

L
BEING POWERED

r. E
FAI]LTS OBSERVED WHILE COI'4M ISSIO^''NG NEW INSIALLATION

REPLACEMENT tr

L.
L. z PBOP NIAKE
OTHERS"
(PLEASE SP EC FY) .

L. Qa
PLEASE USE THIS SPACE TO

L.
tllAF. GEi ISET
GIVE DETAILS OF OTHSRS
..J
oo LIJ

L
C!

kL 'rCiZ THE WAiFAf;ii Vr'll! BE A;"LlaABLE ON:_Y 1F TtslS S CSMP_iTED a FETURUEO TQ ASPOK LEYLANO
=ilGNE
T CK WH CHEVER IS APPLICABLE SIGNATURE OF DEALER WITH SEAL
DATE

L.
L. ASHOK LEYLAND LTD.

L.
L.
@ cro l= xxxx l

rr, xffil
rrpr
ro|@
ENGINE

sHp[--
MAX. CONT

*r*f--*l
)oo(-

L.
L.
N,EA4E P!A7E SAMPIE

the io quote

L. relerring to any problems or while ordering sPare Pads, operators are requested alwaYS

type and Cl'1O number to effect correct suPP Y of Parts.

I
E.
L.
r.
r.-
01.0.4 Leyparts
Leypan: is the brand nanre for Ashck Leyiand

Genuine SPare Parts

Leyparts
c? Srands for qu3llty, re iabr ity, reaCy fitment and
long term e.orcnly.
5r; Js'o' :o^ -\"chen...' -ante :j a n,.ri're sDa'e
paris for ;shc< Leyland applicati:ns "equired for
aft=| sales supicrl.
ci Or-ers oetter '.:lue lor r:oney
c? O'=rs dedic:::d pans suppc -! :rrough its

Yen cle Oii Ro:d Senvice

c:' Oi':rs comrre-:nsive r-e;rir kits


ci ls -.ad: a. arla:le throug. a wide nei.,'ork across
lnc : aonS ;t nS Jf
i Oi er- | J0 reta le. out ets
-<

,. Cr':r 25J AL De:l:r /' Di: -.ih',ior orrt et5


,, Or:r- l:l AL Auiro :ed ::r" :a Cenircs
. 5 -rL ..:rehouse:
; \L P,eg:nal / Area offices
5e re lble eii: e^t and e:?non-ric cp:r-ation of a
.:hiale japelrci: cn :he sounc.ess of :'le aomponenls
...rtah <l i.:l i-53 -ra<iNJ o: 1 LeTparr, :arries the
',:rne OI S'rariarc; with r::Pect tc i'rlnuiacturing
F:-ocess3s. iYsteri: . d merslons, str:ngth and
t:leranc:s Sin:e. "What We Fit is What \A/e
Sell"
lr is ve]) li(ely tha: spare p:rts othe- th.rn LeyParls
'.. tuld r ot iarr-, ali quality aspects m:1,ch
.g LeyPlrls.
Tnerefo-e n a] l,ke.-hood usage of tlose sPare parls
v.ill noi Tied ihe 'equired reliability eiiciency and
eaonorn/ of the .:hicle irrespective of the rePair
v.orkma,lship Ilor. so the parls siiPp led to the
market by the OE approved vendors ma/ not carry
II
ine OE spe.ificatio.s as in Leyparts. A lso for meeting
safeiy and emissior requirements use of LeyPafts is
r3comrrended. Fo, guaranteed geruirre LeyParts
II
aways Duy from aJthorised Dealers/Sen'ce Centres
I
o'Reta,lers.
I
Always demand usage of LeyParts v'henever rePair
\york is carried cut. To ensure lhis, enirusl repair jobs
to Ashck Leyland Dealers and Authorr:ed Service
II
Centres (ASC) so aj to avail advantates of LeyParts
I
I
t-t
It' 6 GENERAL O I .O7

E 0l.l MODEL COVERAGE


lJ: odel ALGP68OTC.E4lI ALM UTC68O/ I ALMU6SO/7
T: M
Genset Engine Turbocharged Marine Engine
ll: Marine Engine

ll: General Data


ll: Dlrect lnlection 57stem
ll: Combustion s) slem

l(
IL
Cylin<Jer bore r siroke )l lilin ^ lic

I lOqS cc (680 C r. in.)


nr an

P ston displacen-rent

H
r,
L
Compressiorr r3tio

Frring order
r5B:

t-5-3,6-2--1

L.
r;
k
Direction

Output Data
of rotation A nti-clock.rise fi-orn tr, ,vhee side

r{ I'ra. 3'l ' I 15 DS':t lo., D n,. ,ru - ,O.y l /t PSma...u,t00rpr


lj I r50Orm)'r"! I l1l<o PS co ' Q ))00 'o'nr

IJ Ii
l15 vA,drP /.tt
10,'1, overlcaJ

lj
lj Rating Standard 8S55.1 BS55 t4 8S649

IJ
rr Recommended
Alternator range (KVA)

Electrical Systern
I75 KVA

)4V

L
r,
L.
flanne Heat

lYarin-- Oil Cooler


E. changer A sian Radiator l'1ake

Asian Radiator Make

L.
L
Engine Rear End SAE L flywheel housing
with SAE l4 fl7v;heel
SAE
Suitable
I flywheel housing with SAE 14 flywheel
to gear- box make such as Chatge Patil

L
suitable for single

rr Sea \ /ater Pump


bearing alternator

Johnson Sea Water Pump SL 1003

LL. IYarine PTO Chalge Patrl Make, Cll0 PTO


O I .08 GENERAL
AND PRE. Pre-commissioning Hint:
O I.2 PRESERVATIO N
COMMISSIONING PROCEDURE De-preservaricr P'c:ec'r:e
De-preserve the engine os
p't l't".'.!
Storage of Engines at Normal
given below:
Ambient TemPerature
Whenever engines are kePt in storage Ll Crrn 1 -.-"1 '1 . l:-.: :
proPer care should be taken as detailed i:e Jet ol a' 'o '-* .' , ' C ":
below: 11 Uncover a I oPen ngs a'd al:'::- ''1
a.rrnections shoulC be nrade'
lf stored ior a shorrer Period: - -.
to ! Remove ihe ttrPei ft-onr fLri :
.") The engine should be thoroughly washed' r-e e d I ,r I
Ten.rove any deposits of muC r"hiclr
r:r:') be
PUMP'
salt laden. -
I the taPe from the ou--:-- -'
Rennove

lb) The engine should be stored in a co"ered 1 e b--alhe, Dpe.


area, on P ain hard suriace' 3 F--mo',,e fuel {lllers and fit nei' cnes'

(:) Disconnect batiery termlnals' 1.4 F.enrove injeators :nd check for- co'i:::
cpening pres:ure anC rellt as io lo'nis:
Once a ' eek the engine should be
strrled
(C)
I Loosen hi3h Pressure P:=
and run for a few minutes'
conncctrcn5 3t PUmP and injeci:
:nd ard t tir :'.'c. Also renro\'e :- -
lf stored for longer Periods:
inicctor le:k cl'f PiPe'

The bltier ies should be reilro'"ed :rd a Extract the irle.tor-' Plug the ini'::
plepared ior- storage in a dr7 pl:ce
Top |,. o|,PCrr'l "r,l Po'c rr'
"nd
up with dlstilled ,;ater and charge iul y ,,p /.P: o'c''' 1d loo:-r
before storage Check and charqe
at reqular carbon from injector \\ l.h a cloth'
inlervals dJring storage' I Conneat injeator tc the nozz:
the
Remove ihe n1ectors and spral 20
ti of tester. OPerate the hand ever c
I SAE l0 the tester for about 0 12 stroke:
engine innibitine oil (Shell Ensis o :n a u'
lhe rozzle scould Prav
Ca-strol stor-age oil 30' Servo preserre
30)
the for atomlsed form.
through injector hole. Crank engine
about l0 second s. Then it ba'k the I For checking the opening pressure

injectors. depress the hand lever until the nozzl:i


ejects the test oil and the p"essule{
Spray liber'allY anti-corrosive oil over rocker gauge reading suddenlY droPs'
levers, Push rods, FIP Plunger sPrrngs and : j.j.. r . lr. relor'lq dl .r ,tai {
tap Pets.
;::'"^'..;J"" 'o,'-T;['*'"'":::{
Drain the lubricating sYStem and replenish
1i.;.1a-.. ni;r.'-hin.:.
I
the same with engine inhibiting oils.

It is ad"isable to drain the coollng system'


!
:J: ;":'::1,[",:]: :' J:"::,il:{
A bod a 's to De hung or thc engine
indicating that cooling system has
been ]1"" ;:"T.;"'i:: ":'i'":::""i;t!
uli|,,"., "." " nc'. f-'17,t'gn',tn1{
;{
of
.lrained cut to avoid accidental starlinB
the engine.
::'J;". '',^::"'J"; H]:'
It is advisable to drain the fuel tank as well .ertared. TiPhlen the nozzle clamol-I
as the fuel filters to avoid formation
of gum to the recommended torque o'
deposits and the Possibility of difficult io o.uo ,r-. F Jsh the
i:t f'l
startinS later. t'tn"".,o,]' o'2'otl,l'".,
ili..i
Completely seal with masking tape
engine intake, exhaust tail
hole of the fuel tank.
PiPe and the vent
the

).
::".,'"Y:,.
leak off PiPes to the injector'
No\^, the engine is ready for installation
r.
rrl
Lr
fl GENERAL OI .O9

EI lf the engine is stored beYond one f While reiltting the injector, check a.:
clean the bore in the engine. t::
rrt year, represervation and rePacking

ri
Lrl
must be carried out
lf the period of Preservation exceeds one
year - Represervation must be carried out
sealing washer originally fitted can be
made use of since the injectors were
not fully tightened earlier. lf they are
indented or damaged they should be
during lhe l2th mo1th. The date of
[{i Represeruation must be entered in a label
replaced. Tighten the nozzle clamp
to the recommended torque. F ush
tI attached to the engine. Cancel the label the high pressure pipes thoroughly

t: showing the first preservation. This rnust be


repea:ed e'.,ery l2 mcnths, if the period of
storag: excceds a pcriod of one
and connect to injector. Conoe.t
r ,- t, r o{ n. - lo.i,A i ie/ o

E
year.
3. Run the engine lor l5 minutes with the
The engine must prepared for
l. Represervation.
be lollowing r ust Dre!enlive agenls:
a) Fill et w'tn wdler cor'ta -in8
L.
ldcl
^ater
Clean al external Parts, thoroughly. Direct l% shell bocut cutting comPound or

l; the jei of air to remove all dust. any water soluble cutting compound

r, Unco,:r all ooenir6, a^d


conneclions should be made.
dPD.oPr:1e b) Connect fuel feed pump to a
mixlure of diesel and l0% flushng

E. r Remove the tapes from iuel tnlet to oil such as lubrex or equivalent.

r,
lJ. Remo',
the feed pump of the luel
;ump and outlet of tlre breather.
e lue filters and fit new ones.
iniector c)

d)
Fill engine sump with Servo Prese:ve
SAE - 40 or eqlrrvalent.
After l5 minutes disconnect the fue
I{,
r]i, Remo'.e injectors and check for correct line and allow the engine to run so
opening pressure and refit. that the fuel in the filter and pur"np
are exhausted.
I .oosen l-gr pr--55u16 ooe ronnection.
at pump and injector end. and lr Stop engine and remove

E .emove. Also remove the injector a) Air cleaner and cylinder head cover

r;
r{.
I
leak off pipe.
Using special tool, extract lhe injector.
Plug the inlet and leak off opening
b)
c)
lnjectors

Fuel pump inspection cover

r,
r
with protect on caPs. Wipe off dlrt
and loosen carbon from injector with
a cloth.
Crank engine with starter motor.
During cranking spray l0 cc of rust

rr
preventive oil (Serwo Preserve SAE - 40)
I Connect the injector to the nozzle into each injector hole in the cylinder head
tester. Connect the pressure Sauge to and 20 cc through the inlet manifold.
the nozzle tester to the injectom.

r.
Stop cranking after spraying oil into the
Operate the hand lever of the tester
cylinders and manifold.
for about l0 - 12 nrokes. The Nozzle

I;. r
shouid spray in a well atomised form.

For (hecLing the opening pressu-e


Spray
a)
oil (Servo Preserve (SAE 40) on
Rocker assembly

E. depress the hand lever until the nozzle b) Fuel pump plunger springs and tapPets

ri
Ii
ejects the test oil and Pressure gauge
reading suddenly drops. Note down
the readin8 al this stage. lf the
3.7 Replace all components and seal
openings:
a) Air
all

E
cleaner
reading differs from the prescribed

r
A-t
L )r
value adjust by changing the total
thickness of the shims.
b)
c)
d)
\A/ater
Fuel inlet
Breather
- inlet and outlet
O I.I O GENERAL
Drain
a) Water from water iacket
b) Oil from FIP
Attach a label showing 'NO OIL' and
dale

of Preservation.
Repacking
sheet and
Cover the engine with PolYthene
Close the
place inside the packing case.
case and keeP in an area free
of moisture
must be
After a long storagc the engine
(remo'red
.n".*i ."i gastJs and seals
and fitted back during rePreservation)
l"- ."fru."a, along with fuel. and oil
n]ust
filter rr
The bepresenvation Procedure u
"Lrn"n,t
must be strictly adhered'
]I
To start the engine after a
storage
long
II
ll
Reilll
Flush the cooling system completely'
ifr-" .oofing tyt*' Add anticorrosl're oil
1",, fr-eeze contpound as the
climatic
""1 Jl
Ilt
conditions warrant
rron" tho ^nqire
Rcmove na<ktng l'lPec
and the vent
intate, the exhaust manifold
hole of the fuel tank
Drain the oil from the engine
sump F ll the
the recommended engine oil to ll
,u-p *ltf,
the required level ll
Clean the fuel filter elements

. harac
Check the
rnlectors thoroughly for correct
terislrcs and Pressure settrnS'
sPray Ilt
Check the comPlete electrical
charging circuit'
solenoid Point and battery I
Clean starter
J.-,"r0. Also check sta'ter motor with
utt..nrtoa bushes for ProPer
the commutator'
contact
and
II
(f) Crank the engine until the
oil Pressure builds
I
uP.

Start the engine and ensure


that the
I
(e)
recommended oil pressure
ls atiained
f
Running'in Period
h will be advantageous if the
engtne ts I
attended to with sPecial care
to
and attentron
I
I
ensure proPer
when all Parts are new'
i"Jl'"g i"l. lf the following recommendations
,- "af"."O to during the first
.p"*,.^, it will asslst proper
200 hrs of
"bedding-in"' l
WARNTNG: Avoid
the engine to very
accelerating I
high sPeeds withod load
OPerate

the engine a two third of its


.- l^..1
l\
5r
g-i GENERAL O I.I I

rt 01.3 GENSET
TESTING
INSTALLATION

Lrl lnstallation Procedure for Engine


L^( i Coupling to Alternator
UI The instaliation procedure need to be strictly
[r' adhered to achieve proper oPeration of the

t: Diesel Genset.

The englne ls to be placed on level ground


t- resting on its mounting brackets The
t: flywheel and flyrvheel housing should be
cleaned and made free from nlcks and burrs,

lj on the sPiSot bores and fitting faces' This s


to ensure srnooth track for d al probe'
lj Ftywheel Housing Alignment
lJ.
l- Face out

lj Mount the dial indicator on the fly'wheel a;

l- close to the flywheel housing as poss ble'

IJ Set the indicator perpendicular to


housing with the probe touching on the
the
face

lJ, of flywheel housing

IJ Rotate the flywheel and record the faceout

L on the flywheel housing

L Care to be taken to avoid


over mounting holes on the
the probe
face
riding

L
f--
The mirror may be used to check the dial
reading at the bottom when the flywheel is

L.
rotated.

L. Runout

L Similarly set
the
the indicator so that the stern
bore of the flywheel housing
is

L.
riding on

L.
f--
Rotate the flywheel and record the runout of
the bore.

Flywheel Alignment

L.
I
Faceout
FACEOUT. FLYWEEL T FLYV'IEEL TISG.

SA€ 1 DRIVE ENO = 0.01? MAX


SAE2 ORIVE ENO '001? r' t
H )(

r,
SAE 3 ORrvE END = 0.06

Mount the dial indicator on the flywheel

r
L.
housing and set the indicator perpendicular
to the flywheel face with the stem riding on
the face.

s Rotate the flywheel and record the flywheel


faceout.
r,
E GE N SET INSTALLATION
GENERAL OI.II

l- TESTING

u
l{
lnstallation Procedure for
Coupling to Alternator
Engine

The installation procedure need to be strictly


Li adhered to achieve proper operation of the

l. Diesel Genset.

L
l*
The engine is to be placed on level ground
resiing on its mounting brackets.
flyra.,hee and flyv,,heel housing should be
The

f- cleaned and made free from nicks and burrs,


on the spigot bores and fitting faces. This is
to ensure smooth track for dial probe.
L.
r.
L.
Flywheel Housing,Alignment

Face out

L. llount the dlal indicator on the fly,whee1 as

L. closeto the fly,"vheel housing as pos: ble

L. Set the indlcator perpendicular to


housrng with the probe touching on the
the
face

L. of flywheel housing

L. Rotate the flywheel and record the faceout

L. on ihe flywheel housing.

L. Care to be taken to avord the probe riding


o\er mo-nLng l'ole; on the faee.

L. The mirror may be used to check the dial

L. reading at the bottom when the flywheel is

L.
rotated.

L. Runout

Lr Similarly set the indicator so that the stem

L.
riding on the bore of the fly"wheel housing.

L. Rotate the flywheel and record the runout of


the bore.

LI
rr-r Flywheel Alignment

Faceout

['1ount the dial indicator on the


FACEOUT - FLYffi€EL A FLYYIIEEL TISG.

SAE 1 ORIVE ENO = 0.012 MA)(


SAE 2 DRrVE END.0.01? UA)(
SAE 3 DRfvE ENO = 0.0(tr r,lAX

r-r
flywheel
housing and set the indicator perpendicular

Lr to the
the
flyvvheel face with
face.
the stem riding on

LJ
l-l
Rotate the flywheel and record the flywheel
faceout-
OI.I2 GENERAL
Runout
- Similarly set the indicator so that the stem is
FLYW}iEEL E FLY\/+EEL HSC1
RI,!{OUT -
.iding on the fl;wheel flex - plate sPiSot bore'
SAE 1 ORIVE EllO = O.OIZ M X
Rotate the flyrvheel and record the runoLrt' sAE 2 o{lt\J'E E:l{o = 0.012 uax
MAX
s^E 3 ORiVE ENO '0.06
Fig-2
Reler Fig I & 2 for the runoui and faceout
value of flywheelwith reference to flywhee
housing and viceversa.
A l"leasure the distance bet"'een flylvhcel
and fly" heel housing mo'rnting using a

stra ght edge and dcPth


"ernier'
B. l'leasure the distance between flex
plate and alternator mounting face
Note: The above measurements need to be equa '
lf not, adlust the alternator height as Per the
recommendation of alternatorI.i-lanufacturer
The varlation between A & 3 should not
exceed 0.05 nrm
the SAE star I rr d --.'- o80 e 't : is aJ e 8' ''1
below.
Engine TYPe ; -L680 Series
Flywheel H ousing : SAE I

Flywheel : 5.-. E l4
Crankshaft End Float
The crankshaft end float need io be checked
and recorded before assembly cf alternator
The dial to be placed at the damPer slde
on the riSid Pcrlion of PulleY.
LonS bar lo oe r^se-led or rhe opening
g,ren o" th" fl/wheel housinA so rhat lhe
flywheel is pushed to one end
f
By pushing the flyv','heel to other end, the end
float can be measured using the dial gauge' f
The value should be within 0.002" to 0 01 0"
f
Any value obtained is nol within
recommended limits given abo'/e need to ce
the
I
corrected before installation of alternator'
The alternator flex drive need to be flat and
free from burrs, clean the sur{ace of the flex
II
drive housing flange before fitment of the
altemator.
tr T
The alternator is supPorted using a hoist
and the machine is moved horizontally J
towards the engine flPvheel.
J
Ensure that the flex discs are properly
seated within the drive disc recess in the I
engine flywheel.
The atternator mounting fastene6 and flex Plate
I
mounting fasteners to be tightened in such a
J
way that there is no strain on the flex Plate'
This can be done through tightening of
opposite bohs as Per lhe figure'
J
Fis-l tr
GENERAL OI.I3

to the The engine to be tested in the r.''eil-


ine botts to be torque tiShtenedalternalor ventilated room so that the air intake
specified value as Per the LemDe.atLre does not rncrease by more

ilr manufacturer's recommendation

Ensure the end float after assembly which


rhan 5'C above the ambient The loaorng
of the generator to be done preferably by

ilEI a be similar to that of before heaters ensuring Po''ver factor closed to


"""0
arre.UtY ,"tue The minimum
end float one. Ensure the voltage across phases is
need to be 0.002" as Der Lne Spec ard the varratio.] between
'f
rhe Dhases is with r .he limrl; nol
:n Auton
adrustmer i Lo be rrade
Ll^6 dtrL
Genset Mounting Details:
needs to VorLrge oeguraLor a( Per rno allerraLo'
The alternator along with engine
EI b" n,ount"d on the frame through flexible manufactureT's recommendation

El mounts suci-l as Cor-i B ubber'


,rr".Ufy ul."g with mounts to be
The e nirre
mounted
Set the f,yuP sPeed to 1550 - 1567 rPm.
ioad the engine at 25% for about l0
tst on ir,"'u"t" irrnr"' The base frame need minutes and increase the load to 50%
for

trl
:s
io i" .-'g'a enouSh to aroio oex:rg' '1. another l0 minutes Ensure water
fle^ -noLnt 19 temperature reaches 80'C Then
load the
."ao",a',"ndad to use indtvrduai

trI to take care of adequate end float durng ene,Te lo 75a/"lor 'O mrnules' r'1ally load
for rdied toad of ro r9o fo- tO

rtl higher oPerating temPeratures

The radiator mounting needs to be


checked
t,lJ
"ngn.
minutes.

li so that 2/lrd of the Projected


outside the cowl The
fan
radial
width is

clearance

U"t*""n hn tip and radial cowl should


be
lf speed hunting s observei during
testing, the same can be corrected
by

adjusting supplementary idLinS scre""'


&
Lr. minimum I mrn The radlator hose resett;n! of max speed stoP screw for

1l connection lirhtness to be checked'

The electriaal uiiring for engine installatron


required ilYuP sPeed'
The electrcaL checks to be dore as
per
1r panel and aternator to be ensured without alternator manulacture. recommendation'

L! any loose connection' l0% overloading is permissible for a


tt Ensure that the frame is on a flat sur-face ."^i*u. PerioJ of I hour for every 12
hrs of continuous oPeration A specimen

u
IJ
before starting the engine'
24v two no' o'
5\ste'n vo,tlge wrll be
,iv u*t"r.", are used for tl^e e gr-e
electrical system' The battery
to
cable need
copy of the Load Test Report ]s given
reference.
lor

be of shorter length to avoid resistance loss'


lJ.
rr Water and oil level
starting the engine'
to be checked before

l-. The recommended grade of oil


to be used'

I- Clean fuel suPPlY to be ensured'


out of the
I*- The exhaust PiPing to be taken
tesling room so lhal re-crr(ulation
o'ezhalst

t*- gas is minimLsed / avoided

fr
f-
Ensure lan belt tightness'

Genset Testing

f- Start the engine and ldle the engine


minutes and check the oil pressure'
for 2-3
ammeter'

I.r unJ-i".p".r,,t" gauge functioning Checklt


io. oil pr"rru." on the gauge at idling
rL need to be above l 5 kg/cm'
pressure'
for. abnormal noise / metallic sound'
rL
l.r.
Ct
".t note that alternator outPUt 10 be
Pleas.
connected only when rated engine
speed is

Ir- achieved.
OI.I4 GENERAL
LOAD TEST REPORT
shift:
Set No :

Type of Set : STD/RTU


lob Card No. :

Test Date :

Genset Rating :

<W
eF
II
rl
'u
iu
Type : Slip Ring/Brushless ltr
i!
lnsulatioo Resrstance (i-se 500 V DC llegqer);
dJ
[.J
Test Condition : Resisl:nc: Load Bank at lJnity P F
U
Ambient TemP : "C
u
LOAO AMPS VOLTS HZ RPM
TIME
(MrN.)
OIL
(ksc)
PR. WATER
TEMP'C
VIBRATION
MICRONS u
U
o%
U
)594
u
50% EJ
15% U
U
t00%
U
I t0%
u
Note: lo% overloading is permissible for a maximum period of I hourfor every

Remarks if anY:
l2 hours ofcontinuous operation'
u
u
All control functions oPerating according to specification: Yes/No
u
Itt
Battery charging : Ok/Not ok.
u
Comments:

Test Pass/Fail
Testing Engineer Name
u
]IJ
Lr
!
tl r

MARINE ENGINES TNSTALLATION


GENERAL OI.I5

rl
ol.4
INSTRUCTIONS
I
General

rl Normally, ln marine engines the engine


{i I

flywheel housirg has an adaptcr flange fitted

rl I

I
on it. A icnward reverse Ghatge Patil/
M echan lc al/PRl'1 hydraulic Cear Box is boLred

.!.i I
on to this fla^ge. The gearbox input shaft
is located in the :Pigot bearing r'vhich is
.i.i housec t^ Lhe l7'r'vh'el 'loJsi' g lor con 'F tr
,i:i
I

locatlon. Dri'.e lrom the engne to the rear

rrl
I
l+'I I
stern gear is t.ken through the gearbox'

til I

At the fi-ont, he driving flange is bolted to


L. the crankshaft damper pulley The Ghatge

L Paril PTO Unir dri'reshaft s couped wth the


front end dri'"'rg flange shaft through a tyre

L
l-
coupling. The tyre coupling s used to avoiC
any ioad/stra r being imParled to the
crankshaft puli:y The drive to the !\'lnch
t-- gearbox is takenfrom the PTO through 3

LI Nos. C secticn V' belts

LJ Alignment of Power Take off

ts-j Whenever the engine or PTO is removed


H for any repairs. the front and driving flange

Lt shaft and the PTO shaft should be properly


aligned before fitting the tyre couPling ln
l-- order to ensLre that the two shafts are
properly alignei a sleeve couLd be fabricated
l...t
E, and used.

H. For delailed installation and alignment

L procedure. refer ['4arine Power Take Off in

L.
Chapter 3.

L. Adiustment PTO Clutch

rL
\
lf the clutch does not pull, overheated or
operating lever jumps out, the clutch must

r
be adjusted.

For detailed clutch setting and adlustment


procedures, refer l'4arine Power Take Off in
OI.I6 GENERAL

t
G
(,
s
o
-
1

I
tr
L{
z
9 [{
F
[il
J
J
t-
o
Z
u
u
UI
z
-----.-'.--
tr
l<
lE
lo
G,
D=
u
u
u
u
I{
t
u
I{
?
I'I
ru
u
LI
LI
:f
Er GENERAL O I.I7

llt
r1
Engine Foundations
The engine is mounted on L section channels
I
and the latter can be bolted on to the.
of the boat To that the
ILI runners ensure

[II gearbox transmission and its bearings are not


I

subject to severe strain. it is imPortant that


the propeller shaft flange and the gearbox
url flange must be square v"ith each other. (The
rear output flange of the gearbox is fitted
u] I wlth an adaptor v',hich is to be machined to

url suit the propeller shaft) Before tiShtening the


t\,, o flanges, a 0.508 mnr (0.02') feeler gauge
ls inserted to ensure that the 8ap between
tEI the two flanges is unilorrn around their ollter

url periphery. lt is lmportant that the gap or


alignment should be checked and rechecked

trl I
when the bcat is lowered rnto thq water as
dlso afier Lf'e boal s r- !\dte' \o''l'el'me d\
u1 there is a tendency for ihe hull to d stort in
water and cause misalignment. ll this is not
utl
|

checked, there is every likelihood of damage


to the gearbox bearings and sPiSot bearings
u] l
in the input shaft due to misalignment of
these two flanges. The san.re care must be
]u taken to al Sn flanges (if used) in the drve
line located ne3r the P ummer block (or any
IJT pedal bearing;.)

Ll. Cooling System


Li Fis-7
Lli A <epd,ate ie"' c^cl-"^9e' rs -s'd
cooling the engine crrculating coolant.
' '

fri Sea water is flltered in the strainer (G) and


it enters the Sea \ /ater Pump (C) thru Sea
Ui Co(k (H). Sea Water Purnp mounted on
Ll: the skld of the engine is driven from the
end damper pulley by a V belt. The water
from the sea is pumped thru the Sea Waler
1-( Pump (C) and thru heat exchanger (E)
I,t: where it cools the engine coolant and then

r{
r{
passes thru the exhaust manifold (F1 cooling
it belore being drscharged into the Sea. As
the sea water has a corroding effect on the
unils through which it flows' ProPer Schematic Oiatram
FiE.2
of Marine Entine Coolint S),stem

maintenance ls necessary. All the copper


rJ: tubes of the oil cooler, and the heat exchanger
A Oil Filter
B. Oil Cooler

rL are flushed and cleaned by a brush as per


the recommendations by the manulacturer.
C. Sea Water Pump
D. Fr€sh Water Pump

f.f-. It is essential to use a sea cock and a strainer


and this should be closed when the engine is
E. Heat ExchanSer

f.. ofl and open it only before starting the engine'


The \,vater level in the heat exchanger should
F. Exhaust Manifold
G. Slrainer

l.I: be checked regularly. For topping up only soft


H. Sea Cock

I.[ water is used.


ln case the sea water pump is removed for
reconditioning, while refitting care should be
rJT. taken to see that the Pulley fitted on the sea

Lil water pump is properly aliSned with driving


flanop nrrllev ln case. the ensine fan belt is
OI.I8 GENERAL
Electrical System I
Lubricating System
Water cooled oil cooler is provided on Always keep the battery terminals cle:- :
I
marine engines in order to cool the
lubricating oil and to maintain the oil
temperature. For cooling the engine oil fresh
all dust and foreign matter. Atte:::-
should be paid to smear the terminals ,''.:-
a thln layer of petroleum lelly or vaseine ::
II
water from heat exchanger is used. insulate the terminals from moisture, be': -=
tightening. All electrical connections :-:
terminals of electrical unit must a a
f
Fuel System/Piping Connections
It is mandatory to fit a water separator and a
Ll lit capacity pre-fiter between the luel tank
proiected lrom coming into contact ,' :-
the sea \ /ater.
-l
J
and the feed pump of FlP, to ensure longer
life of the feed pump. Open the drain cock Precautions before com missioning J
of the water separator week-v to ensure that
the fuel is free lrom the lraces ot water.
the engine U
Periodical cleaning of the diesel tank to
Ma.-te.ra-.e rnalual a (o'npan)irg i'a
U
remove impurities is also necessary. Care
engne to be studied carefully.
I{
should be taken to see that the ievel of the
fuel tank ls not less than 60 mn.r below the
Eng ne oil to be checked.
level
recommended engine oil to be used.
|J On

level of the feed pump. The lnjector leak off Oi U


evel in the air filter to be checked
' -' U
pipe and the filter leak off p Pe must be taken
sepantely to the fuel tank Fuel piping and
L'. n- to be ed ), 2
.ranl co rL'

r' U
m nutes wrth care to oil c rculat on n
ensure
the suction side (irom tank t.
the leed pump)
Ih e.q 1c 1)(te.. Cra-.i^8 Io co- t
should be provided with proPer brackets to
prevent damage due to .rbration of the
till oilseeps out of
the rocker assembiU
engine. lt should be ensured that all the fuel
wh'ch can be
rocter cover.
checked by removing the
U
pipe fittings on the filter cover. feed pumP etc.
are with 3/S banjo with ltmm hollow bolt Fuel system to be U
bled completely to
and rvith Aluminium washer:. rernove trapped air.
U
Air lnduction System
The gearbox lever shouldbe kept
U
neutral position before staning the engine.
in

All the marine engines are t'ltted with heavy


duty oil bath type air filter to ensure that
U
Alrvays engage or disengage the Sear lever
the air intake is absolutelr free from any when engine is at idling speed. U
impurities. lt is advisable to ventilate the Check the alignment U
of propeller shaft after
engine cabin so that hot alr is not sucked
through the intake system. Under good
launching the in
craft pref:rably
U loaded

conditions, air intake temp. will be about


condition.
[J
5'C above the ambient temp.
U
Exhaust System
The back pressure of the engine exhaust
U
manifold should not be more than 101.6 cm U
of water column for naturally asPirated U
engine and 50.8 cms for TC engines. The
silencer is to be suitably located and sharp
bends are to be avoided. Care must be
u
tJ
taken to see that the rain water does not
enter the exhaust system. LJ
LJ
l--r
GENERAL OI.I9

INSTRUMENT PANEL AND CONTROLS

u
tT
FOR GENSET AND MARINE ENGINES

ln the case of Genset engines' fail safe

tI system is provided
against low oil
for Protecting the engine
Pressure and high water
L] temperature

lLt Gauges
01.5.0
ILI
ILI Oil Pressure Gauge
t shows engine oil pressure Under normal FE. 1

ILI engine operating conditions the needle


I, WATER TEI'4P GAUGE

Itr registers in the centre section of the gauge'


2. AT1METER 50 AHPS
3. OIL PRESSURE GAUGE
llr CAUTION: Should the indicator mo'/e into low oil
4 STARTER PUSH SWITCH
5. TOGGLE SWITCH
rLI
u Pressure sedion of the gauge'
stoP 6. PILOT LAMP COMPLETE
immediately and switch off the engine'
7. RPM CUM HOURS COUNTER
After approximately ten nrnutes (to allow
rLI the ol sette in the sump) check the oil
level and top up as required' lf the oil
rLI level ls tbund to be rvithin maximum/
LJ, min munr mari<s on the dip siicks' do no1

1ll run the engine as the cause of the low oil

rlt Pressure s other than lov


-oi[level'

LI Contact our authorised


inVestigation.
dealer lor

lJJ.
u: Temperature Gauge

fi Normal operat ng temPerature is reached


,,vhen the neede registers in tie 75" 85' of

fi: the gauge. lf the needle enteis into the over

IJ: heatlng range during normal cperatlon, a lault

r.
ri
may be indicated ln the case of overheating
an indicated fault should be lnvestiSated

immediately. StoP the engine and allow the

L
f-
engine to cool for several minltes'

lor wate. leaks. f the temperature

r.
Look
does not droP StoP the engine' Check drive
belt condition and coolant leveL, if fault ls not

f,r. four:d. do not slar1lhe engine Contact your

I{, authorised dealer lor rectification'

f... Dur-ing normal cperation, the aoolrng system

L ccntains very hot water under pressure


u
{
{
{
-l
{
{
J
{
u
u,
-l
u
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1.l
{ {
u
LT

a E

+ E
ol
u
Et d?
((}
u
I
ul
u
tr,
u
u
u
!r., u
Fd {
Eo
3E JJ
6F u
3
u
E
>u,
NF
u
N? ]J
ao

u
u
!
-?
Ammeter
It indicates the rate at which the battery is
being charged while in oPeration.

When the engine is started, it is normal for


the pointer to go towards the negative side
and when the engine starts running at the
rated rpm the Pointer should normally shift
to the positive side and show charging rate.
Battery charging indicator lamp on the dash
board, ,r,ill also go off when the engine
speed crosses the idling sPeed

RPM and Hour Meter:


ln order to assess the engine performance and
for proper maintenance, the RPI'4 and Hour
meter have been iltted on the engine. The
drive is taken from the oil pump drive shaft.

Battery
Data
System Voitage - 24 Volts
Wiring Eafth return system,
Normal point to point
wiring. Cables Protected
by PVC tubing 2-pole
modulator Wiring -
Optional.

Battery Voltage - l2 volts

No. of
Batteries used - 2 nos.

Capacity Depends on application.


(130 Ah - 20 hr. rating is
the minimum requlrement.)

Recommended Specific Gravity


Battery readings at 77"C
(Fully changed)
Exid e t.2 t0 t 0.010
AMCO | .230 I 0.01 0
Dace Setter t .7)0

Electrolyte Specilic Gravity correction


for change in temperature:
:c. the increment of every l0'C above
17'C. add 0.007 with the nominal value
:l- the increment of every l0'C below
17'C. subtract 0.007 from the nominal
fn
,:
OI .22 GENERAL GENSET ENGINES
FAIL SAFE SYSTEM FOR
RECOHMENDED YVIRING DIAGRAM

Ta.rf. StlTCl oIL Pi- sYlTol

Ir*, (,,rn, enrittlng 'riode:I for


rndicatrn=
FOR AL
01.6 ENGINE FAILSAFE SYSTEM trr" n,, iharge fait Lr$" lube oil Pressur'
kept rr
680 SERIES GENSET ENGINE a Higf, cootunt temPer-ature are
ir, t?.* facia and a 3uzzer is kePt
an electrical insid€
The engine fail safe :'stem is
,r,,"4 ,o safe guar: the Genset
Engine
the EFU,
coolant
from low oil pres';"e and high This syflem oPerates v'rth
24V DC'
temperature. Engine vill be
automaticaLly

shutdown when the :il pressure


decreases
Stoo Solenoid (24V):
the Coolant no''n" F'D rhe ,flex'b':
below 0.75 + 0I rSC or :':"0;;;;J-'"n
96 t l'C conneded at
temPerature increases leycnd cable of solenoid has been
*op r",,"r^ with link plate' lt will
pull
iin t;,";',"'" .I
This system consists 3j the following items'
:l; "
^,.".ir'i:
o o.",.r'"
-^allnl c'os'es l'1'I
Engine Failsafe Unit tpTno

Stop solenoid
Pressure Switch
- 21 "
Pressure Switch:
P."r,u." ,uriaf is mounted on
the rnain
II
I

TemPerature Switca
Wiring Harness
gallery with suitable adaPtor

TemPerature Switch:
I
-l
fitted at water

I
PU
Engine Failsafe Unit: Temperature switch is
inside the
Engine Failsafe Lr' i ls kePt outlet housing'

,II
I
ffoiil ihe
inri.un,"nt panel' i ::is ihe i;rpul
oil pressure a'c 'oclant temPerature Wiring Harness:
Conn"at, all the above
.r comPonents
Engine when oil
s'ritches, and shutdI " the
rr P exceedS the o*n", t"p, inside the insr'rument Panel I
GENERAL O I.Z3

rlv
II General/OPerating lnstruction:
Switch on the l'4ain toggle
switch

II:
rt"
Staft the Engine within
25 seconds

lf the Engine is not started within


the by

II ,rs t,r"- of 25 seconds' solenord


w:rl p'rll

flul and hold the


rlp Slop lever for 25 'e.onds
lamp glows
due to which low oil pressure
and buzzer alarms
the FIP stop
Wait till the solenoid releases
u. l,
ul
ul
lever. Now switch off
switch on the same and
Main toggle and again
make an attempt

to start the Engine within 25


seconds'

lL l, lf the oil pressure (or) coolant


temP crosses

lrI rhe set tim'r' whrre Lhe engine


'q r unninS

ul
immediately and
Engine will be shutdown
colr"sponding lamp glows
and buzzer starts

lrl
l;l
alarming till the main toggle
is switched off

After switching on toggle switch


the "charge'
as soon as
lamps glows' lt stops glowing
l*l engin" i, staded & alternator
starts charging

l;l the battery.

For normal stopping of the


engine' switch off
H, the main to88le switch'
ri1
I
I
The entire power circuit of
FSU-O is

l;. protected by a 30-amp fuse


link that can be

L. rewired easilY on the fleld'

r;
L,
0.
"Fuse Fail" lamp glows when

OPerating Voltage is 24
ftrse

Volt DC'
wire is cu1'

r,
f-
Fault condition will be
latched and provides
audio (by built-in buzzer)
lamPs) indication'
visual (by glowing

L. lnitial low oil pressure during


star-ting has

f- been bYPassed for 25 seconds'

f-
f-
f--
E.
f-
I-
II.7 BEFORE STARTING THE ENGINE Frost Precautions
lf anti-freeze solution is not in use and --

Ensure that
engine has to be left in the open r'
--1

(a) The radiator is full of coolant. temperatures close to freezing point. :


(b) There is sufflcient fuel in the tank' cooling system must be completely drair:
by opening the two drain points which '-:
(c) Engine oil level is correct (dipstick)
situated as follows:

ToPPing uP the Engine SumP Drain Plug {ltted at the rear right
side of the cylinder b1ock.
The engine oil level should be mainta ned

between diPstick's high and lovr marks' 2 Dr a - tap fiLted or tre rad a or '

While checking the oii level' shut down the Dran tap/plug should be tested at freque-:
engine. Wait for ferrr minutes Withdraw inter-!als by inserting a length of wire ic
the d Pstitk lrom its holder, clean and refrt' ensure tl'rat they are clear' Th s should oe

Withdraw again and note the level Top up done as soon as theY are oPened' so
as required wlth the .lean correct grade of an obstruction freed by tlre wire may be
engine oil flu:hed out by the 'rater,

After drain ng, Place a notice on the eng ne


To Start the Engine to the effect that rhe cooling system ,!
(a) Move main switcn to ON Postion emPt), and the drain taPs are oPen

(b) Press starter buton firmlY' NOTE: Need not drain the cooling systen'r in the
case of engine witn anti-freeze mrxture ir'
(c) Check the engine oil Pr e;sure on
the r coo ing systerrs.
starling al idlin3 as well f,5 at rnax
rpm. Engine anti-corrosion oil
Use Shell Ensis oil' SAE. l0 ior engtnes
WARNING: Do not crank t-he engine more than
l0 seconds' Pause for minimum l5
stored for longer Periods
]II
secoros before try ^8 agail
P tions-Sub'zero
recau t.-p"..tur.]fl
CAUTION: After starting up. allow the engine to
warm uP for a ie"v minutes and a low
operation
Cold start aid is not jltted in the
ul
the lubricating oii to circulate The ideal
running temPeraiure at load is around
can be made available as oPtional ;:::;'lu
80'C 85'C ln case of turbo The iollowing instruction has to be tottowedl{
charged engines ldle run the engine for if the engine is subjected to ooerate inf{
2 minules Pror tc accelerating' sub-zero temPeratures.
{
o"''oi iru E "''J!
To StoP the Engine :ji:,:,:",:;::'l,."
Before stopping the engine ensure that the
). Belo.v 0'C and uPto l5"L co'd ,,ut t'O{
load on the engine is released (in case of
l "Thermostart" has to be fitteO aepenOlnefl
industrial) and the engine is run in no load

I RPM for two minutes and then only the


'OFF'lever should be pulled Genset wil be ::J1'""H:::::T.
-7"C to -15'C Ihermostart ,o o" nn"o
T
stopped by the shut off solenoid provided in
the fail safe system, by switching of the manifold. '"fI
the intake ur
'OFF' main switch
3. Battery should be kept in fullr charCedfll
CAUTION: ln case of turbo charged engines run condilion (Ratine to suit the temPerature) 6 a
GENERAL OI .25

from Maintain the batteries properly.


Select the oil grade recommended
lubrication chart to suit the ambient Periodically clean the hull during dry-dock

Il temperature,

Use the correci grade of fuel as


recommended for the prevailing ambient
so that hull surface is free from sea weeds,
algae and shell growth. lt is recommended
to paint outer surface of hull with special
I temperature.
marine Paints.

I tJse Anti-freeze solution for cooling system Itis recommended to have ballast tanks'

I For sub-zero temperatue operation use I : I so that stability and seaworthiness of the
vessel can be maintained at all weather

It
ratio.
conditions bv ballasting and deballasting'
Injectors must be maintained in good

condition.
Always rernember that increase in other
board weights, and increase in length of
II Engine timing should be maintained as
recommended. Never advance/retard the
Jlshnet alrays results in increased fuel
consumPtion and impose excess load on

I injection timing.
engine, clutch and gear box

I Do's and Don'ts Propellers can be safeguarded by providing

II General

Study the engne service manual carelully and


zinc anodes.

ln case oi vibralion felt in


shafting, check
propel
the conditions of
er and
propeLler

It follow the operalrng ProcedLires.

Engine lile tc a great extent dePend uPon


clean fuel c,. Always use clean diese '
and stern i!be.

Check the propeller once in a month for


stone hlti.3 cavitation and crack in the

II Before filling lhe diesel to tank filter it with


fine cloth.
'
b lades.

Ch-.[ I .- 1- s 5g3 66(L rs n oDen

tI t Keep the su.iion pipe at least l from the


bottom so tiai water can settle down and
can be drained PeriodicallY.
positlon beiJre stafting the engine.

Check the condition of zinc anode in oil


cooler and heat exchanger and replace if
Never use kerosene. This will cause
necessary.
of
FIP components and

II
permanent ',.ear
injectors and ultimately result in major
expenditure of engine over haul.

t
II
use always ccrrect Srade of engine
coolanl as P I AL re( o-rmenda I rons'
oil

Use always genuine engine oil, oil filter and


and

ft.rel Jllters and rePlace them as

recommended.

Never use spurious filter elements especially


gau8e lyPe I Ler elements.

Marine Engines
Clean sea cork fllter atleast once a week'

of bilge pump and see that


Check condrion
bilge water is alwaYs PumPed out
$' O I.25 GENERAL
MAINTENANCE SCHEDULE
Scope and procedures of regular maintenance ^^d.1ri^h< as
eq inspectrc-
The operations described r'e'" ""'
"R"g'|" l'laintenance" involve such service oPerations
which should be carried out at specified
intervals T-:
lubrication, adjustment, and replacement have a clo3'
of these regular clp"*t't"s need not be emphasised further for they
importance
'"'l't" life ol your engrne'
bearing on the Performance and service

TheperiodsunderwhichtheVariousitemsareli{edareintendedtoapplytoengineengagedonnorn^:
oPeratingcondiiions.MorefreqUentattentionwillbenecessarytoenSineworkingunderadver::
th"t"fot"' b"
conditions. The regular *uint"n"inl" p"'ioo'' 'hould 'll'

l. Check level and toP uP


a) Oil in engine

b) Coolant re,el rn l'eat e'rhanger


(for marine aPPlication)
C-fun, in radialor (for industrial aPPiication)

Oil in gear box (for marine application)


Electrolyte in battery

_--u
Oil in FIP

jelly
Battery terminals & apply petroleum -'i
First 50 Hours also. I
b) Fan belt ard tighten if necessary

Hose con"ections in cooling systems

[r" .lu",p of charge air cooler / turbocharger

Connecticns at seawater PumP


(for marine aPPlication)

I Fuel PiPrn3 connections

g) Exhaust PiPing connections

h) Engine mounlings

Engine to drive unit couPling

Electrical :onnections at instrument Panel

and cowl
nuaiutoi.,g. t uy & gap between fan
(ior Industrial/Genset application)

I Turbochargermounting

lnjection 2umP mountin8

Cylinder head nuts iff:"1i3,?::;


Hours
ll3'I
-l-l
GENERAL 0I.27

IL
TE Run the engine, check and record

Elj a) Oil Pressure

Elj
Elj
Elj d) l'4aximum RPM
!

Etj e) l'4aximum operatingtemPerature


I

ElI 4.
u;
Check leakage from
fu"t piPing & injector hlgh pressure lines

Er lj Exhaust manifold, flange & connectrons


EII b)
c) Engine oil filter and other areas

HI d) Coolant hoses

ul
E.L
e)
5.
Gear box (for marine application)
Check ProPer engagement
(for marine aPPlication)
-

trli
I

a) Gear box

r. I b) Power Take Off

1;l 5. Check ProPer routing to avoid any kink

l;t
l;l
formation

b) to
H.t 7. Capillary tube temperature Sauge

L. Check condition of
lf the height of the zinc

EI
I
z', Ztnc anode (for marine oil cooLer aPPlication) anode is about I mm'
replace the anode'
r-.l
L.
Ir.
:;
:
AliSnment of engine to driven

lA/ater pump, recondition if necessary


unit
At every 1200 Hours

E- 8. Lubricate

f;
r,
Ir;
:
:
Throttle linkaSes

.Vater pump bearing

J utch engaging sleeve (for marine applicalion)

]i
OI .28 GENER.AL

Fuelfilter bowl, drain till clear fuel apPears and


then bleed the synem

Strainer in fuel tank


At every 1200 Hours

Engine sump and oil pumP strainer


At every 1200 Hours ;

a) Engine oil and oil fllter


(Except Senset aPPlication)

b) engine oil and oil lllter


At every 250 Hours -
(Genset aPPlication onlY)

Oil in air filter


Fr l/ replace orl
as per supplier's :
recommendation.

and seal ring (Both elemenls)


At every 1875 Hours
-
Cool ng system hoses and rubber pads for
At every 1875 Hours -
radiator mounting and stay rods
As requlred.

rcft: Check and TCDIACC AI


Air lter elen,ent - oi bath type (cean and
e'rery 1750 HoLrTs

I l. Check & reset


{
lnjection PUmP trmrng

Adju* valve clearance


-.I
F rst 200 Hours
lnjector oPen!ng Pressure
At every 3750
Recalibrate Fuel lnlection PunrP
{
:I
-T
:I
:I
:t
I
FILLING CAPACITY
I
Maximum (l)
Engine Lubrication Syrt"- ltn.f"aing jltt2 Minimum (1)

-- ALc?680rcE4lt

Engine Cooling System il

ALGP680TC.E4l I (lnclusive ot Badrator caPacrtY) I

i- nrYurcoeo/ I (lnc usive of Heat exchanger)

f - n-ff'fUOaOlZ (lnclus"'e of
Heavy DutY Air F ilter recommended
Marine Gear Box by suPPlier

COOLANT
OI.IO RECOHMENDED
System properly
cooling and ihe coolant temPe:atu: must be maintained
-^^r"^t lpmnerature
The engine requires
When the engine runs too
hot' it will result in engine danrage
L] when the engine runs too cold' its combustion
The proper selection and use
:1::::il:,t:'flli"",
of toolu'-t1 3re vet) rmF
.offo,,o, of the cooling svstem

L:I nI rhe cooling svstem with a new coorant


l;1 ili .1:t:ffI :"r:1t,:i:,,"
oil
rurnished bero,.v Frush and

k-1 Antifreeze and Anticorrosion ;.e,.t.tti"" Change


---i
FIiAlr'rminium intervals
H' i
Name & Address
of th" manufacture r Radiator in Hours

H,
I; Gulf Oil CorPoration Limited'
LLrbricants Division

l* C-n're. 49150, l'


rDL r )tr- D' ad'
rt ,
Aodheri (E), Mumfiei - 400
093 11!D A

l; iunrt..-CCt (lndia) Private Ltd"

u
r
57, lYaruthi lndustr al Area
Sector I S Curgaon I 22

SS lndustrial CorPoration
0l5 FlaD'arra'

L. G- 0, UdYog Nagar'' Delhi


- I 10 04 I
I

Ltd'
harat Petroleum CorPoration
L. ECE House,28A Kasturba
Gandhi Marg'

L. - I l0 001 '
New Delhi

t t"t-," o re. D"-d1u"' dDPr 'a'o^ -'e


I : I ra 'o'
L.
L.
"-
will only increase scale formatron
CAUTION: Use of anY hard /r'ater hardness level of water'
waier is used.
To prepare the coolant' it is recommendeO "it "."'' l,"l': ln the engine Also Please note that

coolant does not alter the

L.
rr. -t-Coolant
Engine
Use water and anticorrosion
Using only water may cause
oil the engine coolant'
as
corro;ion of the coolrng sl/stem
& ergine Parts and clogging of lhe
radialor'

L Water {.-a from deoosrt and corrosive chemicals'


O I.3O GENERAL

RECOI.IMENDED LUBRICANTS

saE 20W.40

OiIEP
oil80 80w

oirEP 9C
oil 90

Reier ch.Pler 3 ' Sea Waler PumP

Reler.-apre,I I ratne Poher Tale Off

i
OTE: Do no, ai>< lubrican!s of different
brands/grades'
i

Kgm tb. ft Nm
or.r2, TIGHTENING TORQUES

lr.-r 86 1

rylinder head stud


? 0.8 - 22. i r50 150 1a3.9 - 2t 67
Cylrnder'heaJ nuts
1l .7 47.01
Rocker bracket mounting studs
B,] 8 60 637 8t.4 I6.3
1
41 .7 17 .01
4.)
! 30

)94 304
l0 ; I 217 )24

Connecting rod caP bolt


8.3 60
Cam shaft gear set screw
10.4 75
3le. Sear assemblY
nut
77 .1 - 305
Crar r pulleY setscrew

Dan'Per PuLl:,' qc
9.7 - 10.l 95.t2 -
ln! loB t02
.\

lIT
Ei
xl
rI
1I
E
E
II GhaPter' 02
fi
fi
ft AL68O SERIES ENGINE
r.l
fi
u
H
HJ,
H
1l:
It:
tri
r.
ll:
rl;
IL:
Iri
lt:
L.
r.
rr.
r
L,*
LI AL68O SERIES ENGINE O2.O r

LI CONTENTS

LI CHAPTER . 02

LJ AL68O SERIES ENGINE

LI Section Subiect Page No.

L] 02.0 General 02.05

L] 02.0
2.0.
0 Engine Type and Sl. No. .................
Description...........
02.05
02.05

L]
0 I

0: J.2 Technical Data 02.07


02 l.l Engine Preliminary
LJ
Checl<s 02.17
0l
L]
0.4 Special Tools ....... 02.20
General Notes on Overhauling 02.2t

r.l -- 't ] 07.) t

Ll :- r
.:U
lnspection and Fitment..
Boll and Rol!er
. .........

beorin9......................
02.7)
2.2

Lr
0 t

-- : I Tapered-Roller beorirrgs 02.2 1

U,
Ott 5^ ,t. 42.21
.
Cear

L,
02.22
_- . l Covers ord P.,r' -, Bi 02 23

L, Coskets o .d Jo.t
5hims
<
02.23

Lr
42.24

u
Bushes.. 02.24

rL,
42.25

07.77

ru 02.27
02.28
02.28

rr Guldelines ior 'l


urbocharger Use ... ... . ........
42.28
a)
a7 29
29

u
Service Recor-,r-rendatons........... ..... 02 l0
Turbocharger iistn laton and Starling Proctdure. .. .. 02.10
Do's and don t s lor satislactori functionrng o[ tur-L]ocharger.
l{, Turbo Charger Trcube Shooting.
02
02 32
3 l

f.- Lubrication System


a- Description...........
02.3 3

L
0 2.31

r
Oii Pump 02.34
Description ..... .. 02.34
To Dsmantle... 02..34

lj ln spection
To A:semble
-.-i Pr c:sLrre ir:liel'Vai,.,c
02 34
02.t5

ts 02.16
02.02 AL68O SERIES ENGINE

Section Subiect 02.3 9

0 2.3 Cooling SYstem "'-"-"-' 02.39


0 2.3.0 D esc riPtion ..........' 07.40
0 2.3. I Water PumP... .. ' 07.40
02.1.1 .0
To Remove 07.40
I o Drsmant e ......... ... ..""' "'
07.4 4
02.1.1 . I

a7.3.t.7 0)! |

0 2.3. 1 .3 To Assemble a7.4 3

02.3.1.4
To Refit ...... .... ....... . ..... " 02.44
02.3.2 Radiator (For Genset) 02.45
0 2.3.3 Heat Exchanger (For Marine Engine) 02.45
o2.3.4
07.46
02..4 Fuel lniection 02.46
07.4.0 Desc riPtion 02.48
02.4.1 Fuel Filters 02.48
02.4.2 To Prime the SYstem 07.49
lnjection PumP Timing for 580 Engines

H
07.4.3
02.5 0
To Test Engine Compression """""""
{
02.5 I

Lr
o7.6
0

0
2.5.0
2.6. I
Cylinder Head""""""""" 02.51
02.52
02.57
u
u
02.6.2
07.6.3
01.6.4
To D

lnspection
To
ismantle..

Assenrble.. .
'

'
02.53
02.54 u
u
07.7
a7.7.0
Piston ,{nd Conrlecting Rod
DescriPtion...."" ' '
.'"" " """ "
02.5I
02.58
02.58
u
u
U
I

07.7.l To Remove... .....' 02.59

IJ
I
! 07.7.7 To D ismantle .... 02.59
lns pection

U
I 02.7.3 02.51
To Assemble. .....

u
i
07.7.4 02.67
I
02.7 .5

0
2.8
2.8.0 Desct iPrion. '
02.63
02.53
02.53
u
u
To Remove Flywheel " '
0 2.8. I 02..63
,IJ
0 2.8.2 ln spcct,o 1

To Refit Flywheel " """ . '


02.64
u
01. E.3

02 31
- - : ,: -
I ir,'r "'. '. 1r'' '' - ' "" ' "
'" bralrorr L)airL:eI
"
Q2.64
0 2.6.1
02.65
IU
^r o < lnsDection 02.65 'l'
AL580 SERIES ENGINE 02.03

Section Subiect .

Engine Assembly 02.67


07,9
To Remove 02.67
02.9.0
To Dismantle 02.67
02.9.1
lnspection...... 02.68
02.9.2
To Assemble... 02.7 I
02.9.3
Engine Testing 02.81
02.9.4
F na Test 02.8 r

07.9.4.a
To Refit ... 02.81
07.9.5

Electrical Accessories...... 02.82


Alternator / Starter Motor SL. No....... 02.82
Technical Data ................................. 02.82
Preliminary Checks for Alternator and Starter Motor............. 02.83
To Overhaul Alternator (GAC5R) ........ 02.86
To Remo re Alternato' 02.86

Description 07.86

Operation a2.87

Service Precautions 02.88

II Rout ne l'laintenance
Checl. r^g the Cl-a-girg 5/s1em......
Servicing....
02 88
02.8 8
02.8 9

II Inspectior
Electrical Test ng
To
. ....... 02.9 0
a)91
02 97

!
Assemb1e,..,,,,,....

Bench Testing 0) 92

! To Refit
Trouble Shootins - Al::rnator
To overhaul Sta rter l'1oto'......
.......
07.9 3
02.9 4

02.95

I 4295
0296

t
0796
Servic ng.. '02.9 8

lo D smanrle ... ... a2 98


/rspection ond Re:,oir... a2.9 9

Io Assemb/e........... 42. t03

Clutch Settirtg Procedure ........... . . 02. t03


Iest;r8 02. i a4

I Solenoid Switch..................:; 02. t05

I: Lu brication 02.t 07
I: Trouble Shooting 02. t08
O2.O GENERAL

02.0.0 Engine Type and Sl. No. AS HOK LEYLAND LTD


Engine serial number is punched on the
mrlled boss near LH side front of crankcase
near air compressor. Name plate is rivetted
@ cMof )o<xxl
to rear top side of ln et manifold. ENGINE MAX. CONT

Fig-| rYPE lx>oooooo( I BHpf-- )oc( I


02.0.1 DescriPtio n No. L?ocoooo(l RPMf )occal
Ti'e Ashok Leyland 6:C heavy duty engine is NAME PLATE SAMPLE
turbo charged vertic- . in line, six cylinder,
d r-ect injection, diesel :ngine (For ALIYU680/7
naturally aspirated e-gine is L,sed). This Fig.

engne conslsts of single rigid crank case and


tv,o independent cylincer heads covering three
c) inders each. Cylir:er liners :tted n the
crank case are centri'-gally cast. pre flnished
type. The forged arJ nitrided :rankshaft is
caried on seven pr:ssuTe lubrcated main
bearings and sealed '..ith oil seas on erther
eids. The cam sha- located rt the rlght
hand side of the cran< case is oi singe piece
\\ th integfal carns ar ] pressed I oil pump
d.,,e gear. Camshaft s suppoft:d by seven
pressure lubricated bel.ings fitted in the crank
case. Bearings are ccked n posit on by
lccking screws. Cam opera:es the valve
'naft
rc:ker through valve tappet an: push rod.
S.:mped and heat treated I' section
cc:nectng rods, are .rsed to :'ansmt the
pcrver developed ins :e the cyliiSers to the
cr:nkshaft. Pre f - lshed be:ring shells
p'ovided on the b g end a'e pressure
lu:ricated The alum -ium alloy f,istons with
r-gs are connected a, the smal end of the
c:rnecting rod by fu floating ;udgeon pins
r e.a ned by crclips.

T-e cylinder heads ar: of two p eces casting


e::h coverng three c.linders. Blth the inlet
:- -: exhaust valves :re steli te faced and
.: e hard chromiur^r . plated s1:ms. Valve
:..rs in the cylinder -ead are c'replaceable Fig. 2 Mo(ine E.gine
:-: The rocker lev::-s are bu:"ed and are
:-:.lnted on the hollc.", rocker :.aft, one lor
::: r cyl nder heac Rocke- shaft is
:..:-.ofted by brac. :ts secu-:d in the
- -der head. njec-:rs are ':ted rn the
: :der head by holc rg nuts ar: the nozzle
lirectly injecting ..e diesel :nrough the
,: hcles on the co-.bustion c-:mbers.

-. and exhau:: rranlold :P ari lie


inle',
: -a c irliei^.]sse^-o17 are i::ed of Llrc
'- - rnd s,,le of the : rgrne.

Eia-19,7.
02.06 AL68O SERIES ENGINE
,* ,,n',,ng Sears are single helical' hardened'
sr.r;; ;; rhe drive f?t tl: -itJil
an
!nd-ui. ."o.p."t.or is transmitted through
,0i".- g".. Idler gear is mounted on the
cranklase with a spindle that rotates
on a

floatine busn, Lhrust being Laken by Lh-ust


*asheru on eill'er srde of the idler gear'

Enp,ne rL-,b'.caLior is of we1 sumP


syslem
,rBriau on o"'s c'rculated b/ a ge"- driven
oil DUrD and Lhe maximum oil p-essL-'re ts

conlro'red Dy Ll'e ddjunable orl Pressure


|."ti"i urtu" mounted on the crank, case'

Oit batf, air cleaners are Provided


in
Ii"i" t,ti"- lo Pur'iy the a' enlerng
the arr
lhe L
..';;;"1- lhe ourified ai':s 1l'en boosted
L
ii""r+- exhau't gas ruroorharger
""l"
i* in" :'';ioers
turbocharged engines
rr the
be'o-e
case or
Ilr
A fuel feed PumP mounted on the
,;
".,;'
;;.0 draws the fL'er from the
fuel
lank
ruet rrler t on
l
,"0-'s.lplp,.t r: e'el to tre
pumP through dral fuel lllters' L
[noin: coo'nq i b) -nea-s or ^are' PLmP' L
r^ri r'l0 tt aio'. to"nted on 1n" r'661 side

o],'.,. "'g'n". ' Irermoslal tn the ''ool'rg


L
]ur1".., -i'",u1, ths 'nrorl trg 'emperature
ot
T
.,i"
"n
"'p,.e
n"!,
rr tne case or nla'lre ecgr-les'
-''ana"*"' is u)ed rn olace o[ I
radiator.
L
Flvwheel is mounted on the rear side
the stx
./untrnrt. TDC marks for allmade
of the
l
on
onO FIP injection marks are
l
"irtont
i;;-;;.;' periphery of the flYwheel The
4,wh'er c"n be fitled on on'v o-'
oo<rtror
I
rnuin,uin,n" timing marks position
it. A reversible stafter ring gear is
t o'es o
.fr" ,o ,t oLt ol P lch rounrir g nrade on
bolted
mounted
Il
io tn" ny*f,""t. A starter motor.
on the iywheel housing cranks the
bolted
eng!ne
to the !
!
iH.""grr ,i-," starter ring gear
flywhee

I
t
I
I
T
t
II
E
AL68O SERIES ENGINE 02.07
i

02.0.2 Te€hnical Data


ALG P68OTC.E4l I

177 .069tt27.A94 mm (5 0027Y5.0037')

t 45.8981146.7A2 nm (5 7 44" t5156")

I 1093 cc (680 cu in )
Cubic caPactY of all cylinders
l5l PS net cont @ 193 PS max @ 172 PS max @

I 500 RPIY suitable 2C00 RPl.1 2000 RPI'1

icr l25KVA rating


,,vith l0% overload 156 PS cont @
2000 RPIY

84Okg
Engine weight (Dry weight)

Irl l.'1a7 rmum :oeed of the Engine I 570 rpm

lr] ldllng sPeec of the engine


I 5.8: I

rrJ . e at ' ranllr I 2L -23.8 kglcm'


ul Corpress
speed 180
Dr

:o 200
e(cu
RPI'1
(30C - 340 Psi)

ltl t -,-3-6,),1

u
lLj
Turbocharger SPecifi cation
C rankcase
Cllinders & Cran.:ase n one piece cas:ng
tL:
1l: for
ll:
:-essure tesi crankcase leakage
to 2.5 kg/cm'r3O - 35 psi in cold bath)

u a) of ..ater at a Pressure of 2.1

b) at ., ['aYs at a Pressure of 5 6 !g/cm' i ) psi. in cold bath)

Ir: -= 8ht of c"ankshaft bore center to

ll: 44a741i4A.82l mm (17 352"/17 355 )

lt: '-: r. Permrssibie unevenness of


- -ler blo:k toP sudace 0,076 mm ,0.003") lengthwise

1r: I -jer bc'e size (without liner) 133096 /l3l.lt5 mm (5.240"/52408 )

IL: ::-:--, bor: dia. of main bearing 93.04t93.065 nm (3.663" /3.664")

rt: : . -- ;: c e : .,a1ty/taper of Parent bore 0.05 mm (0.002')

li- Pre llnished llner. oress fit shoulder located


1r:
t:
r,
Centrifugally ca:- high grade Cast lron

)l a6, 11.A9., mrn (5.0017 /5 001 I

u,
>_
02.08 AL58O SERIES ENGINE -

ALGp6s0rc.E4lllALMUTc5so/l lALx!!99!

Standard size I 33.104/ I 33.I24 mm (5.7403"15741 t')

Service size for crankcase bore


") oversize l) I 13.358/ I 33.378 mm (5.2503Y5 25II')
0.254 mm (0.01 (S

Service size for crankcase bore


t33.617t133.637 mm (5 2503"/5 261 I")
0.508 mm (0.02") oversize (S2)

lnterference fit between Engine block


& Liner 0.01 2/-0.028 mm (0 0005/-0.00 I I ")

Height of the cylinder liner above


0.0I 3/0. I04 mm (0.0005"/0 0040")
the Block surface

l'lax. Permissible taPer or ovality of


0.051 mm (0.002")
a Finished bore

Type of crankshaft Forged, Balance weight incorporated


ET
Alloy Steel, U" condition Nitrided
TI
Max. permissible dynamic imbalance
of Crankshaft
72 cmg (l Oz. 1n) t3
No. of l'4ain bearings E
End thrust taken on
Thrust washers at Centre ]ournal tt
l'4ax. Perm ssible run out
crankshaft main journals when
of t:
supported on lst & 7th iournals O.152 mm (0.006") Total indicator Reading E
Max. run out between anY adiacent
0.075 mm (0.003") Total indicator Reading
u
fr
bearings k
Scleroscope hardness not tess than 75 (Rockwell C 58 min
Hardness of crankshaft
88.9 Ill88.895 mm (3 5005 /3'4998")
)
f,
ir
Standard dia. of crankshafl journal
mm (2.9998"/3.0005 ")
6.195t7 6.713
l.
Standard dia. of crankPin 7

(For service sizes see the table of crankshaft dimension) E


Permissible taPer or ovalitY u
a) of Crankshaft maln bearings 0.008 mm (0.0003") T
b) of Crank Pins
0.008 mm (0,0003') u
Arial play of crankshaft installed 0.05 I /0.254 mm (0.002"/0 01 0")
]I
Max. permissible Axial play after use 0.3555 mm (0.014")
tr
Thickness of crankshaft thrust washer jl
7.11 | l).341 (C.Oq I i0.0e2")
].:
2.438/7.463 Q.A96" /a.a9t')
L
AL68O SERIES ,ENGlNE

Technical Data
ALGP58OTC.E4l I

tr TABLE OF CRANKSHAFT DIMENSIONS : 680 ENGINES WITH 3.500" DIA JOURNAL CRANKSHAFT

tr
TI
II
u Standard l-
| ) 9998
-
?.200 i 55.880 68.4s3 i t.700

u l)
58.707 t.7 t0 I 43.434
1I rn (s

II 3.4898 | 88.64 r

EI ).7A)

u ).140 68.580 43. t B0

u 1s.451 ', 7203 55.956 3.4705 I BB.t5 2.000 50.800 ).74) 68.63 r ).145 61!07
)L
I
tTlg i.41111
IrI
r

r 2.200 3.46q8 l3 ).744 ).695 68.453 r.7oO 43.lBO

u
75.433 55.880 BB.I

[I .ith (s4) 2.9605 15.t97 ).103 55.956

u
rtl
rice 7.200 55.880

)ii.,i' t.tot ss.es6 3 4sos 43.434

u
87.643

74.rs ).1a0 ss.geo I :.q.1qe sz.eu, 43.180

ltl Note l: When re-grinding crankpln and journals the sides must not be Eround unless they have been damaged
LI lf the location faces of the center of the center main b'earing have been damaged' the width should be
increased to 68.834/68.835 mm (2]10;12.717" ) otherv/]se the dimension should remaln unchanged.
UI
ll.l Xote 2: The crankshafl be re-nitrided at seryce sizes 52 and 54

UI llote 3: Standard crankshaft is nitrided. Thls heat treatment giveshard skin on the bearing surlaces which increases
Il:l the hardness and fatigue strength and reduces the wear and hence longer life for the shaft. Normal depth

LI of penetration of nitrided layer is-about 0,35610.457 mm (0.014"/0.01 8"). so at 0.508 mm (0.020") under
size, major portion of nitrided layer is removed, At this stage, the crankshaft is to be re-nitrided to get a
Lr hard surface again as on the standard shaft. Similar is to be given again at 1.016 mm (0.040") under size.

Ll
lri 3-nding Wheel Specification for Crankshaft Grinding

u
Irl
A59L5V I 0 (Marketed by
A54N5VN (l'4arketed by
l''1/s.

l''1/s.
Carborandum Univer.sal Ltd. Chennai)

Grindwel Norton Ltd. IYumbai)

I] :e: :F.-i-::: g'-rnc ng ,r.,heel surlace speed 6000 to 6500 ft/minute

!l !" u grira the fillets by using a grinding wheel having a corner radius less than that of crankshaft.
02.lo Al-680 SERIES ENGINE

I ALMUTC6SO/ I
ALGP68OTC.E4l

R-"g."d..r"k pins & main joumals 0.075 mm (0 003")


when ovalitY erceeds
0042")
6--....'__-,"rn"t.kut.l"r.uncebetweenmain 0.05 I/0.107 mm (0 002"/0
bearing & main journal
*f,"n d iametrical c le arance 0.229 mm (0'009")
R!.-n*u
tl* (0 00I 5"/0 0025)
O.O:e/00-53

Connecting Rod Stamped - I Section

Attoy St"et, heat treated


'/3 435")
?,.8r? Ifl845 nm (3 I 428
1

greend Par"",t u'j9 *tq"'tglq .650 ( I 875'l I 875")


cl .(i251a7
S.Jk"d P"t "t bore without bush ^m
Pel -irriUf t,P"t or ovality rn Parenl 0.0 1 3 mm (0 0005")
"
bore of con Rod lead bronze/LoPPer
" "
Prefinished,
(oated
Big end bearing tYPe U"u|"ing sudace ino'um
1-asan
r;zlg (3 0023 '/3 0035")
^rn
a^.",,R..d b'g bore with
bearing
(0 00 1 B"i 0 0037)
iametrical clearance between o.O46rc.A94 mm
crankPin & big end
beanng

g*r,a,gt ao be renewed if the


ll
Diametrical clearance e tceeos
GG .f b,g end bearing shell 0 I OZ038l mm (0'004"/0'01
5")
il"apuy .t con rod installed
E;Gto. ol Con' Rod bolt when O.I5210.203 mm (0 005"/0
008 )
tiohtened to correct torque
ffi end bearing bush Phosphor Bronze
(Iype of materiaD
ffit%l lot -m (l'8795'/1 8780")
fnt6*" of small end bush in
O. l l4 /0.05 I mm (0 0045 /0 002")

Coi. Rod r.utt end inner diameter 44.74t t44.l49 mm (l'76145"/176 175")
Fr flouting-R"tuin"djl t'ttliPt
4i nii;-47 | o nm ( 1 7600"/ l 7502")
Gfu"on Pin outside dia'
al"u*nce of pin in small (0 001 20"/0'00 175)
a,,uaJ-..-t...l 0.030/0,044 'rnm
")
R"n!i tf," t,"tt end bush when 0.064 mm (0.0025
clearance Exceeds i{.ozussttt nm (7 19o" t))9)\
Wilth?--nn"tting rod big end
Ion.noa big end to small 4985"/ 10 5015")
766.66)D66738 mm ( 10

central distance
")
0.025 mm (0.001
Max. bend Permissible 0.050 mm (0.002")
l'1ax. twist Permissible

Normal Pistons Aluminium alloY


AL68O SERIES ENGINE O2.I t

Technical Data
ALGP68OTC.E4l I

2 compression ring and I oil ring

Plasma filled keYstone


barrel honed running face
Cast iron taPered
n:nning face
parallel sides -
Chrome plated

3.430/3.460 mm

4.0)A14.A40 mm

irton ring nominal width


3.3 I 3/3.333 mm
).97017.990 mm
3.970/3.990 mm
3rd ring
. ston ring closed gaP
0.35 / 0.60 mm
{ ring
0.35 / 0.50 mm
0.35 / 0.65 mm

i :::n ring side clearance


0.a97 t0147 mm
0.070 / 0. l0 mm

0.030 / 0.070 mm

::-er.r all rings when closed gaP


,-.:::cs 2.540 mm (O l 00")
clearance
0.38 I mm (0.0I 5")

L]
L]
'0.006/0.006 mm (-0 0002"/0 0002")
0.169/0.2 I
(0.0067'70 0085')
mm

L]
r-1
rl, 508,00 mm (20 0")

LI
II
Viscous type [orsonal v;brator DamPer

r1 Single piece with integral cams

rt Rockwell C60 to C62

I-l
I: Leaded gun metal

I.i
02.I2 AL68O SERIES ENGINE
Technical Data
ALG P68OTC.E4l I

lYaximt,m Permissible runout of


joumal position where camshaft
0.025 mm (0.00 I ")
II
All journals excePl rear journal
6-0.850/60 nm (2 3957" 12 3969 ')
880
qt eA}t+e .g t + mm (l 846" ll '847") u
rl
lnside dia. of bush
e rorrlol.ole rnm (7 4o2o" 17'4030")
All bushes excePt rear bush
{
lnitial diametrical clearance
+t .Oct tct OOO mm ( I .852"/ I 853")

O.r rlO.rAO mm (00052"/00073")


:
u
u
All bushes excePt rear bush

Renew bearings when Diametrical


O.l27lo.l78 mm (0 005"i0 007")

0.254 mm /(0.01 0')


I
{
clearance exceeds
lnterference of bush in Engine block
O.O:elO.OAS mm (0.001 5"/0 0035")
u
End play of camshaft
0.102/0.203 mm (0 004"/0 008")
S!'t') u
be adiusted
u
(0.01 0") (.ro UY
Maximum Permissible end PlaY
0 076 mm (0 003")

Renew the camshaft when the


difference in the dimensions of base
u
circle dia. and cam nose dimension's
9.093 mm (0.358" or less)
IU
Hardened, ground single helical gears IU
lu
Permissible backlash between each
0.05 I /0. mm
(0.002Y0.004")
I 02
lu
pair of gears
lnitial diametrical clearance between
0.025/0.083 mm lu
idler gear & bush
(0 001 /0.003 25 ")
0.025/0.083 mm
]U
lnhial diametrical clearance between
bush and idler sPindle
(0.001 0.0032s ") lu
Fnd float between thrust washer and
0l14/0.0241 mm
(0.004s'/0.0095")
IU
0.305 mm
Renew thnrst washers when end (0.0 r 2')
clearance exceeds
0.0 I 9/0.057 mm
lnterference fit of timing gears on
(0.00075'/0.00224',)
crankshaft
0.000/0.019 mm
lnterference of Driving gear on (0.0017s')
camshaft

O"aa.f,aU" 2 per engine each covering 3 cylinders


Cylinder Fead tYPe
both inlet & exhaust ports on LH Side
Cast lron

,=rt*" t"rt cYlinder head for water


2.8 kg/cm'? (40 Psi. in cold bath)
leak at a Pressure of
1a1 tF,gt 1) )91 mm (5.598"/5.602)
AL58O SERIES ENGINE 02.I3

ALGP68OTC.E4IllALMUTC680/llALMU680/7
head after refacing
l4 I .7 mm (5.58")

head for valve guide l7 .46? I 17 A80 mm (0.6875"/0.6882")


6]ore in cylinder
| 7.500/ | 7.5 I 3 mm (0 5890"/0 6895")
-Valve guide outer dia'

lfterfe."n." fit of valve guide in


0.020/0.05 1 mm (0 00079"/0.002")
cylinder head
0,254 mm (0.0 I O")
Replace guide when clearance

Overhead, PopPet Valves


Stellite faced, hard chrome Plated stems

mm (0.43425" I 0.43475')
mm (0,43275" / 0.43375")

Stem clearance in guide


0.064/0.095 mm (0.0025"/0,00375)
0.I02/0.I 33 mm (0.004"i0 00525)
Casl lron valmet
Valve seat material
Valve seat angle - Inlet/Exhaust 30'
30"
Valve face angle- lnlet/Exhaust
lnterference of valve seat in 0.12710.152 mm
(0 005"/0.006")
cyl nder head (lnlet)
0.I l1l0.140 mm
"lerference cf
valve seat in
(0.004sY0.0055-)
:.,, nder head (Exhaust)
I 2.70 mm (0.50")

::^.entricity of guide to seat 0.0l 3 mm (0.0005")

'''1r-num Tunout of valve stem -Lo

lJ .r.. face 0.0I 3 mm (0.0005 ) (Total indicator reading)

IJ ''' 1.
-urn permlsslble eccentricity
:::.,:en valne seat and valve stem 0.051 mm (0.002")

L] -:- i^ of valr'e

frl t5 t .765
50.3 68
mm (5.975")
mm (5,920")

L]
I

:. --- 3itr:k to be removed

Ll *: .'. .z :z:e 0.254 mm (0.01 0")

L]
frf
- .-.-:= :'
-:.-: :.-. -:
alve head to cYlinder
;urface (above the

0.38 mm (0.0145')

LJ 0.76 mm (0.0299')

f;l ).57412.7t0 mm (0.08l "/0.087")


E] ))t017.357 mm (0.01 7"/0.09 3")

E;
02.I4 AL68O SERIES ENGINE (
Technical Data
ALGP68OTC.E4I|lALMUTC680/llALMU680/7
Yalve Spring
No, of valve springs 2 per valve, concentric
Free length of spring
lnner 54.I02 mm (2.I 3")
Outer 63,50 mm (2,50")
Solid lengh of spring not to exceed
lnner )4.6 mm (0.97")
Outer 30.50 mm (1.20")
Direction of Helix
lnner Left

Outer Right

Renew spring
lnner When compresses to a height of 3l.247 mm (1.23")
under a ioad of 16 kg
Outer When compresses to a height of 38. I mm (l .5")
under a load of 34.5 kg
Tension of inner spring Compresses 10 a height of 3l .74) mm
of 20.5 kg
under a load
Tension of outer spring Compresses to a height of 3l .)42 mm
under a oad of 40 kg
Rocker Shaft and Bushes
RocLer shaft outer dia. 2). 93/7)206 nn (0.87374" 10.874)5")

Outer dia. of rocker bush 74.7 65174.970 mm (0.9750"/0.983 I ")

lnner dia. of rocker bush 27.7 t9 t)2.738 mm (0.8748"/0.8755")


Diametrical clearance between Rocker
Shaft & bushing 0.01 l/0.044 mm (0,0005"/0.001 8")
Renew the rocker shaft bushes when
diametrical clearance exceeds 0.075 mm (0.003")
Tappet plunger clearance in
engine block A.04410.095 mm (0.00I75"/0.00375") I
l'laximum permissible diametrical
clearance 0.127 mm (0.005")
Push rods overall length 434.1 181435.102 mm (17.09 13"/17.1300")

Maximum permissible run-out 0.075 mm (0.003") (Total clock reading)


Tappet clearance (cold Engine)
lnlet 0.508 mm (0.020")
Exhaust 0.508 mm {0.020")

Yalve Timing
lnlet valve opens 10" before TDC
lnlet valve closes 50" after BDC
Exhaust valve opens 46' before BDC
Exhaust valve closes 14' after TDC T
AL68O SERIES ENGINE 02.I5

ALG P68OTC.E4l I

r.* 205 - 215 Kg/sq.cm 7O5 - 715 Kg/sq.cm


r,* Idlust when Pressure droPs bY

u -lubrication SYstem
Wet sump, Gear tYPe
E T:ype of oit prTq
ltlb."ut,- PumP

u Type of gears
Bore dia of gears
t7 .386/t7 .399 mm (0 6845"/0 6850")

Itr 6iur"t.i.ul clearance of gear on


0.030/0.055 mm (0 001 2"/.0022")
u of PumP gear on
u
lU
lnterference
driving shaft
[.di"l Cl"urun." between oil PumP
0.008/0.033 mm (0.00033"/ 001 3")

6 mm (0 00 | 57"/0.003")
O.O41|O.O7
oil pump housing and gear teeth
]u 5rttid" diu. of upper driving shaft bush
23.831/23.833 mm (0 93825"/0 93850")
0.013/0,3I mm (0 0005"/0 00125")
lLl t".i"r"n." fit of
lnitial Diametrical clearance
bLSh in engine hlock
of upper
ttr driving shaft in bush
0.056/0.087 mm (0.0022"/0,00345")
17.4O7 l t7.419mm (0.6853"/0.6858")
of uPPer driving shaft
H.l Dia.

u
[r
Bore of sPlral gear
lnterference fit
upper drive shaft
of drive gear on
17 .381 1 7 .399 mm

0.007/0.030 mm
(0,6845"/0 5850")

(0 0003/0 00I 3")

Backlash between drive gear and


mm (0.004"/0,008")
E.I camshaft gear
0. 102/0.203

lu BackLash between oil PumP gears


0.559/0.650 mm (0.022"/0.026")

ut Capacity of the oil PUmP at


maxlrnum engine sPeed
gallons per minute

0.Il4/0.19I mm (0.0045"/0 0075")


u.l :nC float of gears

lit CL pressure
.: !5'C
at 1600 rPm of engine
3.5 kgicm' (50 Psi)
Not below 0.35 kg/cm' (5
LL 3 :ressure at idling at 85'C
4.2 kg/cm'?(60 Psi)
Psi)

LI . ? :.lmp rellef valve oPening Pressure

E I 'ier by pass valve oPening


1.05 kg/cm? (15 Psi)

ll: --:= :n$h of oil


-::' ,:.lve spring
PumP Pressure
5 3.34 mm (2.10")
tt ll 5)
lal. :e :' ,:.ve spring tension | 0.9 t g *hen compressed to a height of 49 61

ru I l%. Effective no. of coils l0

L. :^::
"z a
:-
..a-
lh
^.2
of oil filter by Pass

ft.l i' ::.:


j
.al.e spring tension Z-Aa\S *h"n co'npressed to a height of 3705 lm'n (l'458/")

fJ, "r: : :::s

f.I _C{.: rg System

s Water circulated by centrifugal pump


Wax type, Double thermostat
ffi (
02.I6 AL68O SERTES ENGINE

:l
Iti 1---h-i..1 f)at,
.,,1
ALMUTa6so/- ALMU680/7 _l
fi
j
lLcP6orcr4/l T
Cooling synem caPachy (Radiator
40 litres I
;
and ensine)
--------T lrtres
Cooling synem caPacitY (Heat
rY.hanper and engine)
Water PumP caPacity
-l l3 I
F
Roller bearing tYPe
lnterference of ball end and roller
hearinq on drivine shaft

lnterference fit of bearings in houstng

lntederence of fan PulleY hub on


O 006/0 025 mm (0 00024/0nnnn
00098)
^-, t
drivinp shaft
No. of vanes on imPeller
lnterference fit of driving shaft and 032 mm (o o/o'oo l 26") r-
imDeller seating I o ooo/0

Type of fan r,l'4arine)

Type of fan (Genset)


19.5" dia - 5 bladed -
Pusher tYPe .{
No. of fan blades
6 iI
Fuel Systems
9 mm lift, inline 8 mm lift, inline
lnjection PumP A type PumP
A tyPe PUmP
FIP SPecification
Mechanical, RSV '_'_-f<
Governor
VL(J I\OZZLCI
M,,rri H6le Nozzle II
r<
lnjector
Multi Hole Nozzle

I
Feed PumP
Fuel fiher
l.ll, frame mounted'
dual fllter with coil tYPe
Piston tyPe, mounted on
0.5f, frame mounteo'
dual llter with coil type PaPer element
wlth water seParator and pre-flter
L
II
PaPer elernent
I

t-
I

lEt...ri."lt I UCAS \JALJ r\-Z-1.JWT


I alrprnalor soecification
G5L5A-14'i 11"rK
l'lotor sPecifi cation GSL5A-24-72R
Starter
Marin'e Heat Exchanger
Shell and Tube TYPe
Tvoe
Sea Water PumP
)L I U\JJ
SDecLflcation
Centrifugal self Priming tYPe
Tvpe
I Marine PTO
CIIO PTO
lsnecrfication
45
I Pto Rating-max Hc
I Mrrine Oil Cooler
)nell arlu ruuc I /l-
I rroe -S,ei I fly*h""1 housing with SAE l4 flywheel
| " SAE I
flYwheel housing
I Engine Rear End
with SAE 14 flYwheel Suitrbt" to gear box make such as Ghatge
Patil
ln
AL68O SERIES ENGINE 02.I7

Engine PreliminarY Checks


02.0'3 engine' a complete fault diagnosis has to be m4de The
Before dismounting an aggregate from the
outcome of this diagnosis will tead to overhau
iig decision. The following cause and effect diagrams can
be ,sed as guidelines for basic fault diagnosis'

M ECHANICAL LOSS OF
NOISE / POWER.
FAILURES,

ENGINE
OVERHAULING

AFTER LONG ENG IN E


STOHAG E COO LA NT
WITHOUT AND ENGINE
PROPER OIL MIXING
STOBAGE COMPLAINT
PRECAUTIONS /
RE-PRESEBVATION

Fig - 4 Engine Ovethouling

rJ INSUFFICIEHT GAP

L]
IMPROPER VALVE LEAK ON
BETWEEN SUMP &
SEATING TOO LOW

rl
STFAINER

SUCTION EXCESS EXCESS

rJ STBAINEB BACKLASH OAT


MAIN BEARING CHOCKED
EXCESS
OEFECTIVE OIL
LEAKS'ON _
]-1 CLEARANCE
sucrrolrsroi--
.\ PUMP

L]
r-l WATER CONTENT
BODY
CLEARANCE

kJ DUE TO
Tto
POON GRADE
ENGINE OIL

EJ
rl ENGINE
DEFECTIVE OIL
PRESSURE GAUGE

E] MIXING
OVERH EATING

El
ri
02.I8 AL68O SERIES ENGINE

,O'RINGS
POOR GRADE
RING WOFN

OVER HEATING GASKETS


BLOW BY THEB CHOCKED
LINER WORN
FILL POINT LUBBICATION PIPES
COVER OPEN

L
L
VALVE STEM WOBN
L
T
RING WORN
VALVE STEM TO
PISTON RING SIDE CLEABANCE
CLEARANCE ER POLISHED

PISTON GBOOVE
VALVE GUIDE WOBN {
WOBN
{
JI
VALVE STEM 'O' BING
WOBN

u
rll
otl Consumption
lll
u
.i{
MISFIRING
FUEL FILTERS
CHOKEO
u
u
u
DEFECTIVE FIP
TOO HIGH
ADULTERATEO WRONG CALIBFATION
FUEL

AIR LOCK
IT{ SYSTEM
FAULTY INJECTORS

ACCELERATOR LINKAGE
MAL ATI'USTEO
CAM SHAFT
WEAR
u
ry
u
VALVE TI IHG
WBONG

NJECTOB
WASHEB MISSING
WORNOUT PIS.
TON RINGS AND
LINERS
u
u
SILENCER
CHOKED
INJECTOR
CLAMPS LOOSE

INCORRECT
IOM(EIIGHIE G
IMPROPEF VALVE
SEATING

INSUFFICIENT
_
u
rrr
t{
VALVE
SC'YL HEAO CLEARATICE
BOLTS

u
lrl
AL68O SERIES ENG]NE 02.r 9

FUEL PIPES
VALVE GUIDE TO BLOCK€O
VLAVE STEM \
CLEABANCE
TAPPET TO BOAE INCORRECT
EXCESSIVE sETrll{o of
EXCESSwE ITIJECTION PUi'P
MECHANICAL
NOISE /
cFAllI€H ft Kltoc(rto DUE To FAILU BES
acEsSt!/E PL Y Of Olil Oh DUE TO
roiE t^llt Jotrnraaut ot
CFA'IKPIIS Oi ErcE33'VE E,.O
PISTON SLAP

CMI{KSHAFT
IXBALANCE

PlsTOl. m Pt]t Ct.EAfl-


FLYWHEEL BUSHES FREE IN axcE ExcEssrvE
cAPSCnEWS HOUSNGS O}{
LOOSE COiIIIECTING ROD

PISTON AND CON


ROD ASSEMALY

Fig - I Mechonical Noise / Foirures

TOO LOW NON


otL GENUINE
IN SUMP otL
SLUDGE USAGE OF
FORMA NON.GENUINE
FILTEBS

DIRTY OIL

DUST ENTRY
cLUrcH- DUE TO
ABSENCE OF
SLIPPAGE ELEMENT
SEALS CHOKED
PISTON RING GAP /
SIDE CLEABANCE
LOW
EXCESS
SILENCER EXCESS VALVE
CHOKED CAM LOBEWEAR CLEARANCE
l

lmproPer oll lmProPeI Oll


Lr
lncorl€cl Malntenance
Deroil4rf;;:1fi[Tlihg
trr
tnsufllclent
tncorrect Tighle.nlfg T
ol caP DolI
LI
Low oll Pressur€
trI
lnsulliclent
coolant Lt
Clogqed Fadlalor
Tubes Lr
Solled Coolant.--_-t
LI
Ther mostat
lnoperallve
Over Loadlng
.-----+
u
fi
ru
trI
u
02.O'4 SPecial Tools
D esc ri Ptio n
sMT Old No' SMT New No'
Sl. No.
01 03003
Drift Valve Seat lnlet
6801

Drift Va['e Seat Exhaust


0 r 03004
) 6805

0103005 Drift Valve Guide


3 6806

0 t 03006
Compressor Valve SPring
4 68t8

0 r 03008
Extractor lYain Bearing CaP
5 6836

0 ! 03009
Etractor Crankshaft Gear
6 6848

0t030II Compressor Piston Ring


7 6884

tr
rE
]r
AL68O SERIES ENGINE 02.2I
Roller Assemblies:
General Notes on Overhauling
Cones on stationary shafts must be a
Cleaning "creep" fit on the shaft,'the idea being
.O
0.0005" loose The seatings for the inner
All assemblies dismantled for overhaul
should
race must always be smeared with grease
before the bearings are fitted Bearings
and cleaned before
be thoroughly de-greased
or is carried
liy inrp".iion for wear damage should be adiusted by screwing uP the
oui. Small but dangerous cracks may
pass
adjoining nut lalrly tiSht revolving the rollers'
undetected unless cleaning is carried
out then sLcken back the nut to give the
When rebuilding assemblies after overhauling
corred end-Play' Always make a check

ihroughoul the after the assembly has been locked up'


observe scrupulous cleanliness
lp"rution' dirt or swarf left between
fittng Cones on revolving shafts should be a
faces causes oil eaks Dress-{lt but in some cases where bearlng
'rd1ur,*"n, is made by moving one of the
All oil ways piPes etc ' should be thoroughly cones. it is not practicable to be more than
flushed clear of sludge and old oil a light Push'fit lf the cones are loose
enough to turn on the rotating shaft'
;.1 tnsPection and Fitment overhiating and rapid wear of the seating
will occur'
02.0.s.1'0 Ball and Roller bearing
for excessive play between the baLls CAUTIoN: Do not sPin the bearings dry'
Examine
or rollers and the races'
02.0.5.1 .2 Oil Seals
Examine for broken cages' cracked and
and inner/outer races'
Pitted balls or rollers' Use of Part- worn oil seals:

Examine for any signs of blueing


due to qaf
As a gene'al ru'e' ar oil sea' w\'c\
been listurbed while dismantling a unit
overheatinS

L] Use a Press v'hete'er possrble'or


bearings, which are an interference
lrsenlrg
flt in ,f,ortd not be refltted' lf it can be left its
housing and on lhe shaf it may be used
LI housings. lf no press is available'
with I btoct of wood laid across the
hammer n
"g"in
i,ouiOea it was functioning
efficiently

L] fe"ring Alw"ys make ceftain that the


earlier.

CAUTION: Never allow a seal to


L] bearin! enters the housing squarely
through a de-greasing
Do
Plant
Pass

L] 02.0.5.1.1 TaPered'Roller bearings


The bearing assembly consists of t\^/o Parls'
the outer race or cup and the
(t ri ch io r oethYl en e) '
clean with Petrol or
Use light lubricating oil'
not
kerosene'

LJ
rollers

secured in a cage on the cone or


inner race'

E
f=l Outer races:
fit in their
Examination of seals before fitting:

ln determininB whether a seal is suitabLe for


The cups must be an interference
I-i housings, lf not the housings should be
fufther use:

r-l replaced.

Knurling, application of solder' or the


use of
Discard the seals whlch are hard' charred'
.ut, o. *ith the wiping edges folded back

E] tin"rr, Jtn"i than Press-in-steel' must not be


Discard if the seal is loose in the shell

E] resorted to
The cuPs must not be tilted when
being
Discard anY seal with a broken
or

L]
I1
pushed in.
Tha /,,n< musl be pressed righl
' prefetaor'
home
damaged sPring.

Discard seals in which the shell


or metal

r-j "".'".;-;;" aouLmenl shoulder


.oapon"n,, are distorted or damaged
,""0"r' a o*tt or b; a bo'l and to
n'-rt

ar."nge.ent lt should not be Possible


LJ
]
the I-rnallr. on .h"[. o lee 'es '\'h'
enter a 0.002" thickness Sauge between ,lor"J trrr,, ientr/ to necessit'1te 1 r'dLcl:o:
cup and lhe abutr'enT sno'lder' in di"rn",". of l/32" to clean up'
flt a ne"''
I-i
02.22 AL68O SERIES ENGINE
lo lrt a seal:
Oil seals should be fitted with the spring
loaded wiping edge of the sealing member
towards the bearing in which the lubricant is

to be retained.
Fig - I I & 12

Fit the seal into the housing with a tool or


ram, aPproximately 0'01 5" less in diameter
than ti-re outer diameter of the seal' by
exerting a firm and uniform pressure squarely
on it s'"4:!''s:os:
i{lTlypi,"aion seat

[I
of oit

Avoid entry of the seal ;n1o 11]s s6s55 in a


tilted position and under no circumstances fit
with a drift and hammer, as the imegular
impact will loosen the rolled edge and
release the pressure of the inner member on
rI
ill
the sealinS element and thereby cause
III
seepage around the sealing liP'

II
Problems of premature oil leakage have been
encountered on rear axles and gearboxes as
result of inadequate lubrication of the
during the initial runninS period' When
a
seals u
II
reassJmbling axles etc, the seals should be
liberally smeared w(h a lithium based grease/ iJ
molYkote Q ,Z-.p.ot
(e"r.r or or ,1 DaLbP ^D'rE - t1p

iJ
02.0.5.1 .3 Gears

Gear teeth should be examined for signs of


cracks or pitting' A burnished finlsh
u
IJ
indicating wear is not in any way detrimental'
Discard any gear which is chipped right
i{
through rhe ca e-hatoeni'g i{
Examine the bores of gears ''r'hich rotate on
shafts for wear or scoring' Check for'
excessive diametrical cLearance in excess ot
u
1{
that permitted lor that particular gear'
I{
Examine the teeth of all gear - tYPe
engagement dogs for tapered wear' This
.u,l L" on" of the causes of gears slipping
u
u
out of

It is not
engagement'

sufficient to replace worn or


damaged Sears without flrst ascertaining the
u
u
.urr". G""tt do not fail or wear badly at
]J
low mileages on their own account Badly
adjusted or worn bearings, lack of or
unsuitabie lubricant and imProper fitment are
usually 1-h: aause: on clote invesligalions
u
u
It is to change the driving and
advisable
driven gears as a set in case gear teeth
rha
U
Tr
!
AL68O SERIES ENGINE 02,23 I

Iil
Etr
4 Covers and Housings

Wherever tapped holes are provided for


jacking screws, use them.

rry When fitting spigotted housing or cover'


check that the spiSot is not burred or
TI damaged in any way, Check that there
is a
good"chamfer on the main comPonent lor
UI entering the sPigot.

ltl Aluva\s enter a spigoLted componenL ^ enl\


Da.nage *rll be caused iI t is
p']lered ^ a
trl tilted position.
UI Always see that the ftting faces are wiPed
UI per{ectlY clean,

lll 02.0.5.1.5 Gaskets and Joints

UI Fit always new gaskets and joints

lu throughout, when rebuilding

Where an oil-tight joint is required' Paint the


Ihi\ tllustration sholvs the .onsln]clion af a ne\v gaske''

l,i.I joint and fitting iace wlth jointing compound'


LI Storing and Handling of Thick
L! Sandwich Gaskets
Here the gdsket is bent brcoking lhe osbestos ,l/er
LI Fig - 13

LI Thick gaskets are precision-made and should

LI be frandLed wlth care to avoid distot-t ng


binding. Try to store Saskets flat-no1 on
or

L] edge Ind keeP them in cadons until


ready
Ihis sdskel has been straighlened and aDpears la be n

u
L]
foi ,se. A distofted or bent gasket mal
look OK but it can cause costly comebacks
and reworks through prernature faiLure
,noc'con,lition But nole the bre'lk in lhe dsbestos
'lier

Check for WarPage and Distortion


Lr Carefully check head lor vrarpage and pittlng

L, and block for dlstorlion, dents or Pitting'


Use a straiSht edge and feeler gauge to
. usa. the goskel saox burns thrat)gh 'rl lhis weok
-ompression and caoldnt la5s
'eslll'
se'i:n

U. check warpage and distortion Pits wiL show


uD around the water Passages and
L. cornbustion chambers Surface irregu arities
r0ust be remedied ensure ProPer gasket and
f-. engine Performance

L.
f--
Cleaning KeY to Success
No operation in gasketing is more lmPortant
ihan thorough cleaning of the cylinder
head

fJ. blcck. bolts and bolt holes Carbon deposits


:1c,'a be emoved erther by sr raoFg or
L.
r.J,
;c:<ing 1n metal Pads cleaner' Cylinder
-:: s, valves and water ]acket in head
;":- C be wire brushed Bolt threads in the
: r:< a.e frequently overlooked Dirt Particles
f..j 'r'- pockets in the gasket, allowing leakage
Clean Sealing Surfaces
Er"-ui".i" t"rring surface of the cover
and
Chamfer Bolt Holes
i"rl, uno,r,". of those easy-to-overlooL ";;";il[
.r[rrttY Ru* or oil dePosits
oil can
.rI". ttan can mean the difference between *'f io..-.h."n"|s ihrough whrch wire
i^I' ,r.l* life and early gasket failure i.r*], al"* out bolt holes and brush

i"ti".i-L"r, holes carefully esPecially it ihe U"ftt t" 1f."a dirt will not get on sealing

:#;.;t-hr;" been refaced lf the threads ;;.;t" ;;;; installing the arecovers l'lake
-"-ro ,"-,n" surface' chamfer Lhewrlls'rrface
not
tr."',ira oii r,"t"n f,oleseastlY clean and
-:-.::,,^ 'ubou"
,hp hole so the threaos clear so that oil can drain
;. ;;il when oolLs are
"tf"t" Check Gasket Fit
urn,"".l th;s slight irregularity is enougl
to a or uL
thrs s;mDle operation can save )ou
."rse gasket fa ilu re
il;;;;;:t d"ro'" vo' slart io rePra(e rl-e
"arlY fii and aliSn'renl o{ the
."r"rl .f'.l", o the
Fit
Check For ProPer Gasket for Lhe ,;;;i ;.; are usirg Engine or have n'aY
i.ri1i..t" the correcl gasker 8as(el
to
'ob
see Inal 'L
8"";'.;fu durinS" Produclion A
;";;-J;'^t and then checL ;; i";; g'panoeJ or shrunk rew

l;; ?;-;"". alwaYs dePend on make and


ar e mod red
f".ond, ,p"no in checking the fit can save
;:;r ;.;:t" ,o," "ngin"tthere vou a lot of tirne during inslallatloc
'n,rlrn" o."or.,'"" runs ind
may be
Holdins Gaskets in Posi tion
ii,ni" in"r"n."t in slud or warer Dort
sparrnglv to ou[er eoges of
Assuming the fit to

u
be cor ecl
listall Saskets at tl-e
".".'ti"*. "-r"rin"J
.i5li i"-trrrr.e
:;;; ;r, , .vt'ia"t head gasLet -shou'd
U.*-,"-,.t o; the 1ob allowing
tirre Ior lhe

u
ry we'l whether rnialleo [a'
e up
i"n.iion ,nf,erite Lo se1 Do no1 over torque
"iu, F]o*"u"t' some gaskets
J. inr".t"i
mal be
;r"p or Front to assure correct Tishten Bolts Uniformly
i^u"ri"a
oo".ution ol the engine ln these
iifo* tn" :^structions on the ga'l'et'
("'e'
',
'.r'. Lo Lnow and lorlo'\' lne
specifications fot lhe
-rnli".i'r"r't ,alve
,nrtaitr,io. ol and push rod cover''
.

It
It
Don't Guess',. Use a Torque Wrench
;;;.;" :gnLenirg of ct,rinrler head s r
.;;;'." ,;"* et ea''Y gasL et fa 'rande
L]l","" causes b'lock dislonor
ir-in"t" ,t an)/ Particular sequence that
,n"lia L" rotrowed to insure p-oDer -'al'ng
or the gaskeL' Bolt< sno"td be
"";;rl;* """i, :.ly so tha L comoress'on of
i,ri,""""
the wa7 arouno -t^'s
u
]t
;;";';"ti; '., e en a'l
;;";;";il"":0"" allowing coolant leakage and
].t
.

ora for . en .un


'u" aon" by snugging up fasteners'
oo*". 'oit."r is almost ;rrPoss s to il 1,nr.i"" rasLe'rers in s1ag"s C orrorete
ffi';.;' erpetrenced rnechan;ruse a cood
;",, i;;.r; bY 'eel arone manJfdclL er'1
dge
"n
,nri On sheet
-i.'*" ^;Ll' findl lorquehold f,t
having center
fi
down
;",ri-;""* .1us-
tJ."r" *]"'.n ard follow [Le to oue' .'t r.,"ir. a,'^ b" taLen so lhdl h'el
l".i,r).,t: [o- the anount o[ Io s-lu Lp :.
ias;c t,ghr.ni''g p-ocedure s
in staqe
]".i.1 no, delormed wlen
')rithout a torque
wrench'
tSnr'1r B

tr
ft
lr6\ten rasLener'
i*"""rt then
Complete last stage with final
torque 02.0.5,I .6 Shims

Follow " Tightening Sequence


g"".n" rnu,.irrut*r""i has an approved
When strlPPing' note
oOS
_errO
trOi^r OI Snt.,5
'3rslu lY
the number and

lo \ub-eqJCnt L\e'
them
/ed and keep jt
,"'i""t" or t;ghlen'ng head bo'- ' ' h s
wo4 ed oLL Lo ' ' 'te
Discard any torn or crumPled
shims and 1r
,"o,"l'a ' a'efu'ly
rt'"- U"s p:s''ote seal ard
e'in nare c\: e'
*,f,*ltu," new ooes of the
W po al, -l,.ns Llean bcfore
same thicl<ness'
re-arr']lb'r JI
ot-air,o,-t"n and warpage ln general
;".:;"." j:t'ldns ai the cenlel dnd ulorL
the
out ,,ni ,.""r- lrghtll wrth oil
Wlrcrc an orl lrght jorrt is rcqurred at a
JI
,.- ,n"- "
*i,1-, ,h"
YoJ 5hou'd become
p|.op"'
{aril'a
sequence lor the Par-t 'ular
,hrmrncd lace. t.q3r the shrns lrght *
p,n'ng co.Po,nd before final assen bl'
th
JI
engines You work on'
-[
Check for Dents and Cracks
02.0.5.1 .7 Bushes
Never re'insert extracted bushes' Use only II
ptr* down on level surlace ryilh
aou"r. face new bushes'
II
lr
Look for
nurni,gt ,"a"'n"ath the cover' Always ream ou"t new
bushes after prcssing in'
a""*" or. unevenness and straighien
any

;'.i.outrrit,: rnal You fi' cj on lhe rl'r Ncw bushes shoLlld be inserted b) " press
whercveT possible. Failing thar use a blocl
n""?"t ". "g boli holes' [he lShL -qeet
j"[]-.o ...""'" usuall/ easy to slra''1ten
hzmmer a,ld blo' l, of
of wood or a hide hammer'
Make certain that the bush does not enter
lrr
| -rr
I.8 Keyways, Hoses and Fasteners
When fitting a key, check that it bottoms
into the keywa/.
Check that the top of the key is not
bedding in the bottom of the keyvvay of the
component fltted to the shaft.
Fig - 14

Fitting of Flanges on Taper Shafts


It is very important that flanges shouid be
fltted coffectly on tapered shaft, with
particular regard to propeller shaft flanges.
The essential features are they must be
clean, and tight.

ln the case of driving flanges fitted on KEYTO AED


BOTTOM AND SIDES
gearbox, propeller shaft and rear axle, they
should be fltted as described above except
that a 2lb. Hammer should be used to strike
the head of spanner whilst it is held in tension
on the nut, instead of these units as in the
case of a worn axle, and the use o{ a I )b.
Hammer will damage the bearing housing.

CAUTION: We do not advise the


reclamation of driving flanges
by any means whatever, lf you
TO BEO A PERFECT BEO
have any cause to doubt the AND TIGHTENTED UP HEAD
bore of a driving flange after it ON TAPER

has been removed from its


shaft, we strongly recommend Fig. 14 F t..ing the l.ey aod nut on ta a tapered shaft
,itting a new one. There is no
other way of getting a
satisfactory fit.
ln the case of smaller flanges fitted on taper
shaft and used on various unrts of the
entne we recommend that the) should be
lapped with Carborundum Compound, Grade
F. They should be cleaned thoroughly with
whte spirit and brush, and thel should be
pu led up dead tight on their taper- but we
do not recommend immersing them in
bo lng water.

n :ll cases where a split pin is ftted to the


.et.,ning nut, the nut must on no account be
sraciened back, even slightly to enable the
:t'i pin to be inserted, if difliculty is
er:erienced alternate nuts should be selected.

Screw Threads
: .,.rys protect, threads gettinS damaged in
.:
':Jsed pos,tions.
-:-a: drameter threads on shaft, etc., should
:: rvrapped with a rag or rope for
:-::3.tion agalnst damage or did. A small
:-::.: of dirt will bind or jam the nut,
=,::::,iy where simmonds nuts are used.
::i- a split- pin holes and threads before
:;sembly on any unit.
02.26 AL68O SERIES ENGINE
Nuts
When tightening uP a slotted or castellated
nut, nevi slacken it back to insert the sPlit
oin or locking wire lf dificutty is experienced'
lt".r,'u" *"-th".t o. nuts should be selected'
Simn.ronds nuts can be removed and replaced
ll ,rn, tir,"t as desired. This type of nuttl-eis
."n"*"d on,y when il is obvious tha[
flbre insert is no longer locking the nuls'

ll
Unified Threads
in" ,",n"a thread is in accordance with
s.ititi ,i.nO"tat l'168-1951' and 1580-49 II
;;;;; und"t the authority of the (mechanical
Ene,neer'rg l.,]dustry standards omrlrtlee'
colloon"n',t are identical with American
II
II
"r.O'"iOr
Bolts
for all practical purposes' so thdt
nuts and bottt can be freely interchanged'

in the uPPer
f
rI
is
A
L
circular recess stamPed
surface of the bolt head'
N uts
A-.ontinuou, line of circles is indented
on
L
one of the flats of the
axis of the nut.
hexagon' parallel to
tr
Pipes, NiPPles and Unions tr
Examine all pipes carefully for crack
chaffng
L
or fatiSue, especially at bends of clips'

ln addition to being examined as above


oioa ,nouo be e'amined lor cracked u^or
;uts alr u-der t\e cones a^d seal'-gs o-
Irl
the n;DDles.
Never strain or pull a pipe when connectrng tr
,t uj lnO out why it will not meet the
comPonent
other
tr
Studs Brake Rods, etc' tr
ih".ornpon"n, is reduced to the core for
shoft length at its extremity'
a
E
Split Pins
II
Fit new split Pins throughout when
rebuilding tr
any unlt Fig. 15 lnsenin1 the sP/ri Pin
E
Always refit split pins where split pins
originallyused Do not
*^!ners: there is always
the use of a split Pin'
a
were
substitute sprrng
good reason for rE
All split plns should be fltted as shown
in flgure unless otherwise stated tr
&
Fig - 15 15
tr
Rubber Hose Connections
Examine all hose connections
for:
TONGUE BENT
rr
Hardening due to heat'
Softeniog due to oil'
General Perishing
r
rr
02.1
AIR INTAKE SYSTEM
02.1.0
air cleaner a'ir cleaner
is
TL^ eindlF hie oil- bath tYPe
J",'",""0"'i"
in; I ^:t::;"0'J,']."' g"'
,L:
"?1,
i:l?"J^,:. il";JiT:3',:1",llu
the "*r'uuu
cvlinders rn
f"'Jt"'.#;J;J;re entering
case ofTC engines
s lor genset
II A;r :ntake systern comPo,nerl are shornn
applicaLion
;r"'the.^,;;; "ni'"'urin"
II in followrng illustratron'
Fig ' l' 7 & 3
EI t:'n:L'J,:*
n", been
ll Y"'.,"111*.lld

ft
EI
,.J."""

rhanPes
":ii ::
i: ;;::11^':::,iilIi- : ff :
indu.iion s/ stem uit
t1"unl^l^,1,

iJ"lil"", t"*t,ng mav be reouied


Mor e
for nomal servlce requ! "."nrs.
in se' e'o
i

o JI" i" - n. i'c" "'11


f. for soecific
"
Li
requirements
"i1
l\o-"'"1X";::1,1"j":;
lwo )ears
f.
I
;: il; ; .t"'n". tot lon8er than
I Fig-4
f. I DescriPtion of shel' F'lte'
a. I
X,t=.]"rI"'
]o'a;*i
'Hood
'"t"-,oly
A Ra n
'omPrises
;s given at the toP

f. il"r:;;;, rhe al" cleane' 'rom ar' ^


foretgn Paftrcles enttl'
I ater/

f.
I

fi'te element is a sh'et :tee't":'l:"


pauge
The
wire"wool
f. or,"a"o * t" *"''ll c
I

bo\i\' ,s n oLrnreo
fi:
i:^lt".i:l,;; ihe bo,",
r.
I
at" c'eone' b1 "neans Y .'l;; . 9,"6 ror
I
contd''rr J 5 ''r I es 01 .o']- '11,.","0 ,nsroe 'he
engrne). Oi! level marl
rs rn(

a. I
bowl
Air Cleaner
rL. Servicing the
i.rlo* ,r.l1 Points given below
in sequence

rL for sor-vrclng tl"e a'- cleanet


clips and,re'ro/e th"
a'l

rf. tTi: ,n" i-biree


,"""ra" cleane''
;;"t 'to-nntt'"o with Lhe ':rr bott s a'rd
E. ln" air ( leanernount'ng
""r"rl 'L I om tne mounllng
.cmo.e
fL i" ", ,na otsconnec'edLo a'r rnral'e p p'n8s
d\o'|o enlr\ or
IL .tJ;I" ;.,; iY u 'rotn
l;:;;;r"1 .;t ''sioe rhe ai- rnLdre s/'t"n
rr- ";;.:;"';";
c'|iPs holdrnB the 'rr
remo /e the sam''
Do\^/r a1d

Il.- p"utf-tf," Uotto' fllter elernent


from the arr

rL
Ir.
cleaner'
ii""*" bowl, lltter element in Detrol/kerosene'
Fi, in" .O cleaner element in
'""*r"
position
(3 5 litres) uPto

rL
f*
,,i oil in the bowl
the level mark'
.u ,i" -** seal on the bowl
mounting face'
and lock all the
@
I. =,tn" i"*' with the shell
-rolding cliPs'
in the V
02.28 AL68O SERIES ENGINE
02.l.l Turbocharger As a result, turbochargers
significantly to the Protection of
02.1.1.0 General
Kl3 series turbocharger is used in Genset
environment and the
Engines and K27 Series turbocharger is used
utilization of energY resources.
for marine engines. 02.1.1.1 Design and oPeration
In exhaust gas turbocharging, Part of exhaust A turbocharger comprises of a compre
gas energy, which would normallY be and a turbine, The turbine and compressc-
unutilised is used to drive a turbine, The wheels are mounted on a common sha'-
turbine shaft is connected to a compressor, This sub-assembly is known as the rotc-
which draws in combustion air, compresses The rotor is supported by journals house:
it, and then supplies it to the engine The
increased air supply enables more fuel to be i^:'"":::X'J:"ili"",u*,n" drives thel
burnt so that the engine develops higher
power. Increased air availability imProves
combustion of fuel, thus leading to lower fuel
::13[T::. :^;:i."r]:lffiT'i#?;1"'
The turoocnarger rurolne
*
!
(r 's';,, o'- ;'-;l
consumption and less emrssion
The advantages of modem turbocharged ::;?ff :::",'{.?": .::::"i.,ffi [
engine, compared to naturally aspirated engines ":1,"""1

"':;:ff i:::i',''::";:il%[
of identical power outPut are as follows: :::1;; "1,^:'
- Lower fuel consumPtion "*f
- :T i :::5 ;"::% il" ff'L',IT;"i:"'*.L
-
-
Lower emission
Better torque characteristics
Lower weight and
package
a smaller engine
The compressor consists of the comPressor
wheel and comPressor housins By rotation
of the compressor wheel, the air is drawn
Il
- Lower engine noise axaliy, and deLivered radialiy at a higher
- Reduced power loss at high altitude' press,Jre lo the ,ntaLe .",]anr-old lncrease ir
u
Ir
it
II
u
I
u
:jH" a,,".uy il
.
No.
I
2
3 ri:::",*:15 u
ii"#:i":"'- u
4
5

l::
6
7
8 li:::: U
9
l0
ll
3,i'r",:l::: U
t2
t3
t4
fl:l?i.:'
u.,.
u
t5
t6
[lili'r"". U
t7
l}:li'rT{;,.. U
l8
l9
70
2t
3:'1,:"
i,1:'"' u
72
23 5esment lLomoressor sidel
'fl
u
24 CJmpressor Housing

26 nent (Turbine
r:
5,,d Side)
27 Bolt Hex
7B
j-!
E-
29 Blind River
Core assembly
u
otL
DRAIN
PIPE
OIL FEED
PIPE

FOR GENSET
Fig. 6 Lubncotian CKut - Turbo <hot7er

pressure also results in increase in Oil supply to the turbocharger immedi


temperature,To reduce the compressed air after the start of the engine and mini
temperature, some of the turbocharged orl pressure during it's operation, en
engines use an after cooler. proper 'rnctroning of Lhe journa,s.
- For reasons of impro..,ed drivability, a smaller - Oil contaminated with dirt or foreign
turbine size is chosen such that sufficient material will wear
boost pressure is available at low speeds n
the journals and journal
seating area of the shaft.
such cases, part of the exhaust gas is by
passed once the requ,red boost pressure is - Dift in the oil blocks the oil holes in the
reached. This is achieved by opening a valve journals and central housing leading to oil
operated by a spring-loaded diaphragm. starvation to the turbocharger.
!l-t.l.2Needs for a Turbocharger - Dust, sand or any foreign parlrcle entering
Turbocharger components are made from special into the turbocharger compressor housing
materials, processes and are precision butlt to will damage the aluminum compressor wheel
,.,crk under extreme operating conditions. to turbocharger failure.
blades, thus leading

ever turbocharger needs ADEQUATE


'lc\,, 02. I .l .3 Guidelines for Turbocharger Use
I-EAN ENGINE OIL & CLEAN AIR for it's The maintenance recommendations for
:-crer performance and extended life. engine shall be authoritative for the
Why a Turbocharger needs them operation of turbocharger. Special attention
should be paid to:
--: clearances between the rotor and the
:---:l are extremely small and the parts are Operating Guidelines:
-::- red to very close tolerances. The engine should not be put under full
---:::harger rotor-assembly rotates at
load immediately after start. We recommend
'-,:-=-ely high speeds. the engine to be run at idling speed for a
shorl time (60 seconds), Accelerating the
r:..:narger uses fully floating joumals and will engine immediately after start can force the
.::::: ?i less ihan hall the speed ofthe rotor. turbocharger to operate at very high speeds
--= :--:ccharger components are balanced with inadequate lubrication.
:: .:-. i-. balancing limits. Run the engine without load at high idle for
few minutes before the engine is shutofl
-,-: -: ^.-sing travels at very high speeds. Turbocharger operating temperatures and
spee(s should be reduced before the
02.30 AL68O SERIES ENGINE
Sincethe turbocharger is precision
Maintenance Guidelines:
it should be handled with Sreat care At
. Turbocharger and boost pressure control case it should not be dropped ln case
valve do not require any special maintenance wastegated turbocharger, don't use the
However check the boost pressure pipe for actuator control rod for lifting the
its proPer fitment, damage, etc' turbocharger. The wastegated turbochargers
. Specified engine oil and the oil fllter should comes with Preset actuators, this setting
be used anJ should be changed regularly in should not be altered.
accordance with the recommendations' Remove all the Protective plugs from the
- Regular maintenance of air intake system ie air turbocharSer.
filter elements cleaning / rePlacement ln Check and clean the eng ne exhaust
accordance with the recommendations Clogged connections to the turbocharger for foreign
air cteaner wlll restrict the airflow at the material i.e. core sand Particles, loose nuts'
turbocharger inlet. This mal lead to high e$aun bolts, washers etc, cracks and distodion at
smoke and wlll also resuh in seepage of oil from connecting ioints.
turbocharger into the air intake system
The exhaust system should be checked for
- Checks have to be made on oil feed PiPes' blockage (damaged Pipes, faulty exhaust
return piPes, air intake and exhaust piPing brake, choked silencer / catal)'tic converter
for leakages & restriction The connections &
joints should be checked to ensure that they
are stll tlght and no damage has occurred'
etc.,) leakages and their ProPer aliSnment &
su pport.
q
- Check the engine breather system and oil
seParator. Blocked breather will restrict the
free flow of oil from turbocharger' This wll
Check and clean the
compressor outlet to
connectlng pipes and hoses
cracks, aging and damage.
turbocharger
engine ntake manifold
lor distortion'
Check
u
u
-
result in seepage of oil from the turbocharger
into the air intake as well as exhaust system'
Fill the oil inlet hole of the turbocharger with
clean englne oil, when the engine ls started
intercooler/after cooler for leaks & blockage
Checl the hose c Ps lo their o"ooer
functronrng, repiace
where nece:sary.
with recommended clips u
rl
after long storage. After the o I change,
prin'e {dead cr arl t tl'e eng ne berore
starting and before starting the engine in
connections to the
Oll feed and drainpipe
luroor\ar8'r sho-ld be e'drri''led {o'
carbon deposits, dir1, cracks, distorlion, etc.,
u
u
during cold amb ent conditions.

Service Recommendations
pipes should be thoroughll cieaned before
fitment. lf found damaged it should be
tt
u
02.1 . I .4
replaced. During replacement care should
The turbocharger is designed such that it wll be taken for proPer routing and ltment to
usually last as long as the engine' t does
not require any special maintenance'
avoid excessive stress on the connections
Check air cleaner, filter element and lt's }I
The turbocharger has to be serviced uslng
kit and other parts at suitable
connecting piPes and hoses to the
ft
I
overhaul turbocharger for blockage, d stoftion, cracks,
intervals. Before any damage that can occur danrage, agng etc, and should be cleaned
by rubbing of either the compressor or / replaced. Check the hose clips for their
turbine wheel with the housings. This interval proper functioning, rePlace w th
depends on proper maintenance of the recommended cliPs where necessary. -rI
engine as well as the nature of duty and the
Air filter element should be c eaned at JI
severity to whch the engine is subjected'
Servicing turbocharger is a task for trained
regular intervals & should be replaced
recommended.
as
tr
sPecialists and should only be done in TEL
authorised seryice center' Use only the recommended gaskets for
LLmenL of lhe tu.boc4argcr to Lhe et gtre.
Jr
02.l.l,5Turbocharger lnstallation and
Do not appiy gasket sealant (Sheilac, -lt
Starting Procedure
Use only the correct Part No turbocharger'
Anabond, Grease etc,) at the oil inlet' oil
outlet and comPressor inlet connections. Do JI
i.e. l urbocharger suitable for 11rg 6rgire not use thread sealant in the oil supply line. lt
Check the turbocharger visually for correct
part No., orientation, external damages,
excessive rusting / aging. Don't use the
Ensure coTrect fitment of the turbocharger
lo the englne (rotate the turbine shaft and
check lor it's free rotation). Ti ted ftment
u
JI
turbocharger, which was kept unused r,vill cause turbocharger failure .(do not
(storage) for prolonged period Necessary
rlearing aro ,nspe(tion of the luroo harger 's
attempi to change the
orientation on Your orvn)
turbocharger
I
-I I
Before starting the engine, fill-up the oil feed - Periodic cleaning of crankcase
hole of the tu'rbocharg;r with clean engine oil breather is necessary to allow free
to ensure lubrication during engine start-uP
flow of oil from turbocharger outlet.
Examine the ensine oil and the oil {llter - Regularly check the oil feed and
condition. Replac! the engine oil and the oil return pipes for
leaks, air intake
system pipes and hoses for leakage,
filter if necessary (idnere to the
recommendation for correct grade and blockage and exhaust PiPing
change period). Oil filter should be filled with
connections for leakages, blockage
clean englne oil to minimize cranking time' - Check the fuel inieciion system for
Purge air its proper functioning.
the open supply lines'
from
Disionnected at the oil drain connection - Close all the turbo(l-'arger openings
between turbocharger and crankcase Crank with protective plugs when it is not
the engine wirhoi starting until oil flow is in use.
observeb in the turbocharger oil drain line A
steady oil flow indicates ,-hat air Pockets are
- Contact TEL authorised service
center for turbocharger complaints /
out of the lube oil svsterrr A funnel can be
used to retrrrn oil '.') the crankcase service
Reconnect the oil drain c.-..r,eclion. Don'ts
Staft the engine and id. for two minutes - Don't run the engine with low oil
before putting the engine '.'' load. PreSsure.
Check the enpine crl Dr /-'- )re Do not run - Don't Put the engine under full load
the engine. if "ol p.2 i',,:',,1 : found less than immediatelY after stadinS.

man ufactu re r.
Don't switch off the engine under full
load.
With the engine in .-r. ' , condition, check
air, gas "on
line :'," J:-ions for leakage
- Don t run the engine with leakY,
-for and restricted oil leed & d'"in
and their praper : -' .--.'-'ing Oil feed & PiPes.

return line connectict: '--- leakages Check - Don't run the engine with blocked,
air leakages downstrez'- --: the comPressor punctured, aged, deformed hose /
outlet, gis leakage a: ..,-z--11 manifold and pipe connections from the air cleaner
at turbine joints, to the turbocharSer and turbocharger
Do not accelerat e ir,-- immediately Lo the inlet manifold.
='7lne
after start. ldle the e.z-.. e for atleast two - Don't run the engine with leaky
minutes after ,r^r:c .l ---'d before the connections, blocked, and deformed
engine is stopped. connections to the turbocharger

E Premature turbocharg=' --ilures can be turbine inlet and from turbine outlet.

! avoided by installing i -- '- -- zctl'l first time' Don't tamper the fuel injection

L
It
|l.l-5
everl time.

Do's and don,t,s fa,- satisfactory


functioning of turb x.-?ar=er
system.

Don't use the actuator control rod


for lifting the turbocharger' Don't
tamper the actuator settinS.
Do's Dont d ismantle the turbocharger

If ' Use of specifled ,-'-----'-


oil fitter and
recommendation.
p*l--,t -
)f engine oil &
:hange as Per
contact TEL authorised senvice center'

I' ' '-- =----- oftoair


Regular cleaning -' -
element actc--: - a
fllter
the

I, '
recommendations.

Check far oil pre:=-::--- =t engine idling

f, :ondition Minimur -
as Per the rcc---
:1ing.
fressure to be
dation during
---'-

I : e the
.--a'ting
::
engine fc
the
the engine
engine,
- -

for = -
seconds after

-.:conds before
',1'

I oz.rz
'r::Tiiaiu^
al-oao sERlEs ENGINE
ct,^r"el Trouble
-
Shoocing
co HP LAI NT
(
I
o

q)
c)
o
o

o
l.

q)
L
o
-cI
b0

o
Ir
rI
REMEDIAL ACTIONS E
POSSIBLE CAUSES E o o
o
'o- 00
L
q)
E
lr
DO
q, q) L o
6t d L c)
o t
d x c)
o.
o E il d
o o
q)

'to o c) l) o
! o
6t
Llt co
x
ul o F o o o
Clogged air fllter element Check and rePlace.

Restrictions in air intake dJCt lo Remove restriction or replace damaged


oaftS as requrred
compressor inlet
Restrictions in air outlet ducts from Remove restrictlon or replace damaged
comoressor oullet lo intake mani[ord
Restrictions in intake manilold
Dads as requrred
Check and remove restriction I{
Arrest the leak by replacing hoses, cliPs, TJ
u
Air leak in duct between air cleaner
and comPressor pipes, cooler or tghten the clams as regurred

Air leak in ducts between comPressor Arrest the leak by


and intake manifold
Air leak between lntake manilold and Check and rePlace
replacing hoses clips,
ooes. cooler or tighten the camPs as required
gaskets or
t shten fasteners as required
u
u
cvlinder head
EoreiSn object ,'',
"^6,"51
lr""oine\ / intake d,lct
- an [old
Lo colrpressor
Remove the object
e igrn o[ rl-e oorP I
Remove restrction
& check lor the cause/
enlJ & r o"e' L I
or replace damaged parts
u
u
u
Restricted exhaust system

Gas Ieak between exhaust manlfold Check and rePlace Saskets or


and cylinder head.

Ra<tri.tion in turbochareer oil draln line


damaged pafts as required or tiShten
the fasteners as required
Remove restriction or replace defective Parts u
u
a-.r.:t.t.'d cnoine cTank case breather
Thick oil sludse or coke in
turbocharger central housing
Check and remove restriction
Change oiL and oil filter, service
turbo as required
or replace
u
u
Fautty fuel injection pump and injectors Check and rePlace /
Check for correct setting
adiust.

u
u
lmproPer valve timing
and adjust as required

Worn-out valves, piston rings, liners,


intemal engine problems (lncreased
Check and rePair as required

u
blow by)
Boost Dressure control valve stuck in Refer turbocharger manufacturer or his
u
open position AuLror,sed Serv,ce Centers
hose assembly Refer turbocharger manulacturer or
u
u
nrs
Boost pressure pipe /
damaged / punctured and valve stucl' Authorised Service Centers
in closed Position
p"i". l"O-f]-g"r service center' analyse and u
Turbocharger damaged
correct the cauie of failure (turbo {ailure
normaly due to lack of oil' low oil Pressure'
is

ir,l pno'ne oil (ondltion, foreiqn pafticle entry


u
II
!

LUBRICATION SYSTEM
Description
I Engine lubrication is by the wet sumP'
!: system. The oil circulation being done by a
gear type oil pump driven by a separate
gear fitted on the rear end of the cam
shaft.

Oil is drawn by the oil pump from engine


sump, through the suction strainer and
pressure fed through a full flow paper type
oil filter element into the main lubrication
system. An adjudable oil pressure relief
valve is fitted in the main lubrication system
to control the maximum oil pressure
Washers are used for adjustment of the
spring tension which determines the relief

I, valve opening pressure.

r'
I
Filtered oil under pressure is fed to the
crankshaft main bearings, big end bearings'
idler gear and camshaft bearings through oi
ways drilled in the crankcase The cylinder

tr walls and gudgeon pin bushes are lubricated


by splash.

]I The front and rear rocker shaft assemblies

u
1r
get the lubrication from the 2nd and 5th
camshaft bearings via vertical oil ways drilled
in the engine block, cylinder heads and
rocker shaft suPPort brackets, Lubricating oil

l{ is fed to the rocker shaft bushes and valve


guides.

II Oil which
valve, spills back
escaPesout through the relief
into the engine sump and
II T\ere by the maxi'num oi Pressu"e is

u
l{
malntained.

Air compressor, FIP and Governor gets


ubricated from the main oil gallery through
feed pipes connected with banlo bolts

t{
lr
After lubricating the air comPressor, oil
:eturns back to the sumP.
P:De connection to the oil Pressure

r{ :'ansducer is taken from the oil way feeding


:-e centeT main bearing through an adoPter
:-l feed pipe on the RH side of the
l.{. : -. ^ kcase.

u. l-:.^k case breathing is effected by providing

E
E
. :'.ather pipe at the toP of the front
:.r: ei s de cover.
: :.:ass valve fitted on the {llter head of

r.
---: : fller assembly ensure oil suPPly to the
:-=': in the event of the fllter element
.-:.: - = r'cgged. This is to avoid starvation

u, :' - :r the engine bearings. When the


- :.:: .)-'.'e is opened, unfiltered oil is
E
Tf
-:::: io the bearings and therefore
'.' , '. er.gine bearings. lt is absolutely
':.::::-. :l ensure that the filter element is
' : :'.- 'j- :he recommended nterval.
02.7.1 Oil PumP

02.2.1 '0 DescriPtion

The oil PUmP is of gear type ard housed.,in


Lhe RH srde towards the rear end
ol L\e
Ufo.k The drive Sear of the. oli
"nglr" ,rt"t Lhe drive fio'n tl'" < amshafl
"r"t,
spi.ai gear th'o'Jgh Long're couPl ng'

the
The oil pump driven gear is pressed on
other end of the driven shaft with a
woodruff key to position the oll hole in the
Jriu.n ,huft ihrough w'hich lubricaton reaches
the oil pumP bush ftned in the crankcase'
From the bush oil reaches the spiral gear
fltted on the camshaft and the thrust face'

02.2.1'l To Dismantle

l. Drarn engine oil Remove the sumP'

Disconnect the suction pipe aLong with


the
2. suction pipe'
strainer, and the intermediate

-l Renlove the delivery PiPe'

Fig-2&3
. Unscrew the mounting nuts of the oil pump
and remove them'

Unscrew the set screws holding the


thrust
,.
housing. Remove the thrust housinS

j.' Screw in a bolt on the center threaded hole


.t the oil Pump driving gear \\'th shaft and

/.
Iift it out

Unscrew thesetscrews on the oil PUmP


suction branch Remove suction branch
and
II
dismantle the Sears
I
02.2.1 .2 I nsPection
I
Clean all the parts thoroughly
them on the worktable'
and keep
II
. Check
Fig'4
the oil pump gear contact surface in
for anY
II
oil PumP housing and cover
I
END

abnormal wear' Slight wear on ihe cover


can

be rectifled by resurfacing the cover over

I
a

smooth einery paper placed ln a Po'fect


surface. lf the wear found is excess' replace
the oil PumP housing cover'

.^A .^rH fn. env


II
lnsert the oil pump gears in the housing and
check the r:adial clearance as shown.
Fig-5
Check the backlash between the oil pump
gears as shown
Fig-6
Check the oil pump gears end float as
shown. All these values should be as
specified in the Data.
Fig-l
Examine the suction pipe strainer. lf found
disintegrated/damaged replace with new one.
Ensure the oil ways in driving spindle driving Fis. 5

gear with shaft and oil pump gear are clean.


Check the bush in the crankcase for any
excessive wear and replace if necessary.

t 9 Check the thrust housing contact surlace


with oil pump driving gear for any wear.

f 02.2,I
Pepla<e rl wear ,s ercessive.

.l To Assemble
f,. Keep the oil pump idler gear along with
E idler spindle in the oil pump body and press
the idler spindle as shown.
@@
E Fig-8
E - the key on the driving spindle. Fit the

tE
Press
o pump gear aligning its key way with the Fis. 6
(ey on the drivng spindle as shown.
Fig-9
, S. de down the driving spindle with gear in
E :^e oil pump housing.

I' - lreck and ensure the backlash, radia


::arance, end float with the gears in

f, rr;tion are as ipecified in the data.


: '. the end cover wrt gasket and tighten the

f. ::::rrervs wth spring washer.

f, : -::k for smooth rotation of oil pump gears.

f. ,-::< the oil pump for


:-:'=':5 1 in a testing ring before
- :-: engine.
performance,
mounting

I" Fig. 7

f.
I.
f.
rf
ff.
02.36 AL68O SERIES ENGINE
02,7.1 .4 Oil Pressure Relief Valve
Oil pressure relief valve is fitted at rear left
hand side of the engine block as shown in
fig. lt consists of spring loaded valve and is
adjustable by Welch washers between the
spring and threaded plug,
Fig - l0
Removal and I nspection
L Unscrew the oil pressuTe relief valve
mounting setscrews and remove them.
2. Unscrew the threaded plug and remove the
spring, valve plunger and clean all the Parts.
Fig - ll Fig. l0
3. Ensure that the seating on the conical

4.
portion of the valve is uniform all around,
Examine the valve plunger and valve seating
I
surface for wear and pitting. Replace if

5.
found pitted or damaged.
Lap the valve plunger on its seat with lapping
CRANKCASE
HOUSING t
compound till a correct seat rs obtained.
WASHER
PLUG I
5. The oil pressure reading should be 3.9 4.)
kg/cmr at 1500 RPt"l when the oil
SHIM
SPRING
I
temperature is 85"C and not less than 3.5
kg/cm'?. ln the case of Genset engine the
VALVE
I
oil pressure reading should be 3 3.4 kgl
cm'? at 1500 rpm when the oil temPerature
is around 85'C. The pressure can be
I
adjusted if required by special shims FiE. ll I
between the spring and the threaded plug.
I
02.2.2 Engine Oil F ilter
Engine oil filter is mounted on the rear left
I
hand side of the engine block. The filter is
full flow type with replaceable paper element.
I
The ends of the filter elements are provided l
with rubber seals. I/
Oi from the sump, pressure fed to the fllter l
housing by the oii pump. The oil gets I
filtered and delivered to the lubrication :
system. Please refer figure which shows the i
direction of flow inside the fllter.
Fig - 12 I
Bypass valve of the oil filter is housed in the
filter cover by a retainer and the spring :
opening pressure is set at 1.05 kg.cm'. lf T
T0n I
the flter is clogged or the paper element is ./6\,
,J :
no1 of correct micro value, the differential 1J
pressure in the filter housing increases to !
more than 1.05 kg/cm'2. Due to that I
differential pressure on either side of the
bypass valve, the valve plunger overcomes
the spring tension and bypasses the {ilter
element allowing unfiltered oil directly to the
lubrication system. Oil without filtratirn \n/lll
ad\er.c) aiaect the engine l.'e. t.e.. rrore
wear/seizure to engine bearings/crankshaft etc
So al',vays use filters supplied by Ashok
-!F- -**

Filter element is kept over, ithe spring inside


the cylindrical shaped housing to Prevent
vibration and perfect sealing rubber washer
fitted it the top of the flter prevents
unfiltered oil entry to lubrication system.
When engine oil is replaced the engine oil
filter and 'O' ring must also be rePlaced.

02.7.3 Engine Oil Cooler


Shell and core type oil cooler ls mounted on
the rear Ieft hand side of the engine block.
Oil from filter enters oil cooler, gets cooled
and then enters rnain oil gallery through
transfer block. Water from radiator outlet is
used for cooling the lubrication oil circulating
in oil cooler in case of genset aPPlication. Fig. 13 Oil Cooler - 6enset
For marine application marine oil cooler is
used. Schematic layouts of marine oil cooler
and genset orl cooler are shown.
Fig - 13 & 14

To remove
Disconnect connecting hose and pipes.
unscrew mounting bolts. Dismount oil cooler
assembly. Remove the oil cooler element
and clean the same.
lnspection
Check the oil cooler element for leakages
and replace if required.
To Refit
Reassemble the oil cooler with new gaskets/
O rlng. Refit the oil cooler with the engine Fig. 14 Oil Coolet - liorihe
in the reverse order.
02.2.4 Engine Oil Changing Procedure
Before draining the engine oil the engine
should be warm and on a level ground.
I Keep a suitable container below the sump drain
olug and drain the engine oil. ln case of marine
e.gines a separate drain pump is provided.
Fig - 15
i:move the engine oi filter housing by
:rsening the nut holdlng it on fllter cover.
:=elace the {ilter element and 'O'ring with
-:. r genuine one.
'..D the {llter in the housing and fill up
:::rt 0.75 litre recommended fresh engine
: r the filter housing. Fig. 15 Morine Sump & Drcin Pump Arrcngement

-.:' keeping the new 'O' ring in position


-:-"i the oil filter housing and tighten the
--- ,..lh washer.
-:-::. the sump drain plug with washer
:-: :: up recommended fresh engine oil
'---:-.- thecylinder head cover oil {iller.
. : : :-: engine and run :t for few minules.
--::. :^e oil level after 30 minutes. Oil
.: : :-: - C be up to full level mark.
:- : -- : lei,el rn the sump should be
-: -:: -:: between the maximum and
-,- -::k Oil level above the full mark
.1- :tr :igh engine oil consumPtion
02.38 AL68O SERIES ENGINE '

ru>uct/) Jr.Lt>uldt/)
EOOYUIE EC)c)YU-rC

(DE<oYurF IDd<()YLIJF
EC)(JYIU.! EO(JYLIJd
>-oorur >-oo_Jut

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Lcxozl-
ILIl<T]
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I
o>-J-ZOl,llcts o>-r-zouJE
I
I
I
I

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I
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I
j
j
AL68O SERIES.ENGTNE 02.39

A spring loaded, self adjusting seal unit'


cooLING SYSTEM
07.3 fitted in the impeller casing, comPletely
isolates the impeller chamber
from the
bearing assembly which is packed
with
02.3.O DescriPtion mounted at
The impeller tyPe water PumP grease dur,ng assembly A
grease cup is
is driven by
the front end of the crankcase provided for periodical lubrication'
two belts connected to the
crankshaft
from boltom
Water drawn bY the PUmP A ihermostat kept in the front end
of the
through the engine to
tank of the radiator is circulated water outlet pipe enables the
head up
oil cooler' crankcase and cylinder attain the operating temPerature
of 75" to
thermostat back
through the water manifold' g5.C in the shortest Possible time'
the
tank of the radiator' From allow the
to the top
the radiator Thermostat valve does not
top tank water flows through cooling water to circulate
through the
and is cooled by
tubes to the bottom tank radlator till the cooling water
temPerature
mounted) in
engine driven farr (water PumP attalns 75"C. At 75'C
thermostat valve
the case of Senset engine' oPening and fully opens at
85'C and
starts
the
allorv the water to circulate through
ln the case of marine engine
a seParate heal
fdO dtOr.
{re<h \\"'Cr 1
e/'rd'8er rS u eO Lo LOOI lhe
'resh waler
ro -
^tr.. ol drain taP ls itted on the
,ao "'o'' radiator
A
thermostat housrng enters heat exchanger' only' To
r"'e' boitom. This drains the radiator
geLs oo'eo ano LLen passes'l"ror'qh corrPletely drain the coo!ing
system two
water
lil .ool", and then enters engine mcre drain plugs are fltted'
one at rear lefi
roo' tre ^rgi'l^
pun D Mar ^e o''s6lsr hand side of crankcase and
the other at
water pump sea
lubricating oil. Through Sea mrddle right hand side of
crankcase
exchanger and
water enters marlne heat
cooling fr-esh water it is
sent back to
after
sea through e h:ust manifold

WATER OUT
I ET PIPE

CYLINDER
HEAD
FRONT

sea water
-

\^r'ATER Schernaric Diagram of l'larine Entine Cooling Syster'


PUMP A- Oil Filter
B. Oil Cooler
C. Sea Water PumP
D. Fresh Water PumP

E. Hear Exchanger
F. Exhausr Manifold
G. Strainer
02,3.1.0 To Remove
' Disconnect jthe radiator/heat exchanger
hoses
i.
bY unscrewing the iubliee cliPs
2. Disconnect cooler/marine oil cooler
oil
' pipingVl',oses by unscrewing the lubilee cliPs'
3 Drain the coolant from the radlator'
a' loosen tl'e radiator mounting bolts located at
in" boltom of radiator and stay b-ackets I
either side of the radiator' Remove these
frottt ,nO dismount the radiator with cowl
from the seat in the case of genset engines'
II
5. ln the case of marine engine remove water
DUmD, sea waler pump dr'ving pulle' s and
befts. lYarine engine is not orovided wtth
cooling fan assemblY'
II
6. Remove fan assy and water PumP belts'
I
7. Remove the thermostat assembly and water
PumP inlet hose I
8. Unscrew the water PumP mounting bolts on
the engine I
9. Remove the water pump assembly after
removing the connected hoses and clips' I
clean it externally
I
02,3,I
L
.l To Dismantle
Remove
the intake
the impeller casing
caslng
assembly from II
2. Unscrew the lock nut and extract the
with sPecial tool
hub
I
Fig'2
Unlock the tab washer and remove the nut I
3.
at impeller end of the shaft' Extract the
I
imPeller with sPecial tool
Fig-3 I
4. Remove the lnsert and 'O' ring from the
imPeller lf necessary' I
5. Remove the
casing'
cuter oil seal from the impeiler
I
6. Remove the circliP with a circlip plier and f,
7.
press out the lvater pump shaft with bearings'
Remove the v,'ater PUmP seal and inner oil I
seal.
I
3.
?.
10.
Unscrew the Srease cuP
SeParate the hub and pulley, if any one of
then damaged, by loosening the setscrews
Press out the bearings from the water Pump
II
shaft.

02.3.1 '2 lnsPection


I
I
all the Pafts and clean them
Degrbase
thoroughlY.
I
Check the ball and roller bearings
damages.
for wear /
l
With micromeier check the water pumP shatt
bearing seats, mpeller and hub seat for any
D^^l--^ ;f +ha \^/arr l<
l
AL68O SERIES ENGINE 02.47
Replace impeller il found damaged. 8). Note the temperature in the g-[f
Reface or replace the impeller insert along When it attains 75"C the valve will stirt
with 'O' ring depending upon the wear. opening. The valve will get fully opened
at 85'C.
l'aeas-,e the bearing oulelace 5e,ili^g
poftron dia in impeller casing. lmpeller casing 9. Erar ire tle impeller casing waler seal seat
hd5 Lo be repa.ed I lhe \eea- ., e.(e.5i\e. lor any damage or wear. Rener,v or replace

Ir
I,.
lnspect the key way in the hub for any
elongation, hub and pulley for any damage,
renew or replace.
10.
depending upon the wear/damage. lt ls
advisable to replace all the rubber parts
(seals, hoses and
Check the grease path
'O' ring) during overhau.
ln the
I.- Remove and check the thermostats housed n
impe er
casing is clean.
ih- -osl"L housirg ior prope, l.rcto- rg a

IT fol ows
8. . lmmerse
pan of water
the thermostat va
in a suspended way and
staft heating it. Also place a sender
ve n a
I

12.
l. Check the rubber hoses and hose clrps and
replace f necessar).
Check and ensure the front cover hose
seating area is in good condition. lf lound

IE unlt in the water which in turn


connected to a temperature gauge
through a capillary tube.
p tted rep ace it with a new one along with
new gasket.
02.3.1.3 To Assemble

I. l. Keep all the c leane d/ln spected parts on


work tab e.
a

I.
f.
r.
l
f.
f.
f.
f.
f.
\
f.
f
r-" €IF

L.
1-
L.
DESCRIPTION
WATER PUI'1P II"lPELLER
NSERT
O RING
rLL. NO. DESCRTPTTON
20
1t
27
WOODRUFF KEY NO 90
HUB PULLEY
PULLEY
FAN
QTY.

I ITlPELLER CAs'NG
PUIlP INTAKE CASING
23
74
CUP ]/8' BSF
GREASE
CONNECTION HOSE

L.
lorNr 25 HOSE CLIP I
DRIVING SHAFT 26 JOINT PUI1P INTAKE CASING TO C/CASE I

3ALL BEARING 77 5/15' BsF SETSCREW 1.3/8" LONG

f.
1
E.OLLER BEARIN6 18 NUT 5/I6" BSF I

] STANCE PIECE OUTER 29 SETSCREW I

r--
)iSTANCE PIECE INNER 30 WASHER 5i I6"DIA 3
:iR.cL1P 52-2 DlN472 3t BOLT 5/16' BSF 2
]. SEAL FRONT 52 OOI3? IDITVI 32 WASHER 5/I6'DIA 2
l: 5EAL, I t Pn75.t25.75tB 33 BOLI 5/16' BSF I

-O'K NUT I/2'BSF 34 5/15' 80LT X 2 r/4" IONG I


\ ..,:SI:R TAB 35 nBr)tr !/ta' A(F
OL6UO SERIES ENGINE
*.0'
Ir"r, rr," insed along with 'O' ring in the
Press.
i.-p"tt", "u"nty preferably :" ".n11: in the
S"l-ttut th" insert seated oerfecllT
e is eren' lf the
oroove and Lhe surfar
!rlu." it not even it rra/ lead
to water

leakage.

Over a machined metal


surface keeP a small
r.I
J*,,, .r the
]r*,.'
-nrno
gr :ndrrg comoou'o

,n" 'nsert iare ho'crng the


and
rmPeller

and rolarrng t over grlndlng


u
u
u
^, obr";n lne
l""o"r"o b- ubott l0 t'r'e' Lo
sur{ace.

Pres\ Lhe ba'l oearrng In


pfra"
:;;,
,n"
, D tve
\^oter DL'ro shafl
rr'ler ano outer ois1a1(e PreLes
'n tl^e ro'rer
bearing aq
It
It
shown.
I.I
Press
Fig-5
the flat, woodruff ke)s on
punP shalr LsY wavs evenl
the water
u
JI
Smear multi PurPose
l" *"
grease on the bearrngs
gaP between the distance
pieces
JI
,^O
fullY.
]I
Place the inner oil seal in tl-'e impeller caslng
the oil seal to its seat usrng
a
JI
and Press

JI
lr
drift.
-' a( along
No\ D cs rn Lhe ^lter - t-rmP
cdirg wrLh a
,ri J".lt"*t ,n Lhe 'moe'er
Jrlft and ltlne circliP
in the circlip groove
.Il
Fig-6
lnren tho mperlel.a\r E
and Dr's5 Ll^e Jr
;,;" ;";-,^u,
'n Do-i1:on
o' dr ''at
,"" - rls \ed|ng '' PPr
surra' e
e t' An'
Jr
""0
;r;r;; "' '"'" gn ,aL" a' ;^ 'he sed' JT
;;;;;; o.'- '" or the oe'|re'
;n as'ns ma)
II
lead to water leakage'
II
Press the imPeller
ii.i. "i,*"tin"
-.t*. io
"tighten
on the W'P'
assembly
*, *" Place the tab
the nut Lock the tab
toil" to*uta' imPeller slot and
l{
II
;3;;";
it" otfl"r. towards the lock

App, -uDer Easket 'l


nut side'
Frla' on 'mpeller ca:ing
A'- d'v 'or feu
II
II
orr'k"t ,"ai-tg pottion'
";;;"t
;;'.;.,
Pta]e tn" gasker on rt and

Oan"" t".,^t
of grea'e
"on
grve a
o er the gas(e1 1o'
the 'rL"l" casrrq ard eas'
lr
II
remo'zal in future'

the imPeller casint over the


intake II
Place
casrng and tishten the tn'"'
t"t_]llll^
,^" .,- II
PulleY assemblv
on tl:
,l-'.. '"d
",^ili-"uo"n.r-"to ttti^s^ -1" tt'1^t;;.*;1,;
"nat.
r'"v on the Natel
[t"tIr["r,["'*i*
t"'-^"],--*' riohten ir'e
the simmonds nut'
DUrIP rr'"'''
screw ,n fully
Fill the Srerse in e'"'li-tYl 1lon"
.-.1 .eoeal 'l once agaln so ds
t ,r"r," *,
7,i i"" Path in Lhe 'rnPeller ca''nP'
"o
o23'l '4::,T"tt'"t" o5e and rLb'ree 'er th; i'p o the
,. t^"riil",,*
^ , ;;"; con-ecrior- and on
lne ;ub'ree ' lD
i)""' t; " , Do noT Ligl-tec
at this stage
Lhe \^dler DLImD
*,rn a ""* oast cl ''nounr t"t:l:
ll."-in ," lhe ergrne crant(dse'
i:'""':;";, .,*'"g. "l'::-:i0",::
,':th Lhe tront ' ovet
T"1t:::
nroDerl) '
tqhrenng rs
pL'np d'serirbrv b/
i;:"",;.'
n olnt't'g oo't:
rns oe I r!
r oan Ll'e te\led thelrostal
J* sufl'(:enr A dbo.d
EI ",1^""?"1;
202 liquid gasket
"'.",";
EI ,"un,"i",i" ""0 over the
hose with a iubilee

L. I
cliP.

lnstall the the:mostat


.""
housrng
clrP 'n Ih' \o ^:
L. 6. 4 r.,"" 'ubrree ,
aot"*.,'ng to ^dlel PUmD 'nle'
D''L o r" Lh
E ;", ;;; :^" '31gr pur'P,

f. o'.",'n",o' out^u'dS
\ 1n Lhe
f 1n . r, . '"" P'-P,,O'",I1.?
" t,
, ho .,o D-
f. ,o1R6 r L,n
,,, j:
o:;l "''
r.shie^ 1,.<

E alr r na'o
Fig-7
r-ounr'ng l'olts tull
/

f. Fit the fan t""*b17


in the 'ase ol gerr5el

f.
a.
engine
ln
^lie
' ol l^r'd''n' r18rl ' L'rP g"
t, e a
P rrD a' d 'a
ry"re' '
oL' '5'
lc

ar d I t"^ d ''e bell-'


f. -;"" "- ;d.Lor v'rh .o;:":l:"
;:1,""1
I. Ensure
Its Dosrtlon
equat
the"ran baoe rnd
cowl
s :;t;"
c

::'.J:l::
L. rhal 2 ) ol 're olade rt-e
'n'

.rli'".i .'.'o,t'"g' I I *rLt-"d,'r'or


mo 'lrng

I* ;;; :;" ,,..' b,'a'Lets


g, gee.ei e gin"'
tyolunt f'""r exchanger
bolis :n

in
the ca p

case of martne
[.
L. enPines'
i',tan" -'o'""'neat exLhanBe' hoses
ai'th

I- lltr"" ''o' t^o lighter the


'a."r"l a'ot"'n plugs and lrlt up the
ruL''ee ..rrDs ''rll'
coolant

f. in the cooling sYstem'

L.
E
;;,;" "n-gin" 'nd
in the cooling sY*em'
check for anY lcakage

h.l{,n hour check radiator water


level
II
II
I
I
I
t
t
I
I
Fry.8 I
rLL. NO. DESCRIPTIoN QTY' ILL. NO. DESCRIPTION QTY' I
i oeo ENG RADIAToR wlrH FANGUARD I n
t7
RADTAToR BRACKET-LH
SETSCREW 6891
I

4 I
I
6
2 JUBILEE CLIP
SPRING WASHER 7/ I 6'DIA 4
I8
3 HOSE ST
I

NUT 4
19 7116" BSF PLA]N
4 AL
I
I
PIPE

5 HOSE
I 10 NUT Ml5X | 2

8U5H
l
4
6 AL,PIPE
I 12 RUBBER
72 SPECIALWASHER 6
7 HOsE
I

DISTANCE PIECE 7
23
8
9
IO
JUBILEE CLIP
HOSE 5T
P]PE - WATER PUMP TO OIL COOLER
4
I

I
24
75
27
BOLT M l6xl
RADIATOR STAY
8MI1 PLAIN WASHER
1
)
4
l
II
I
HOSE
4 28 8MI4 PLAIN WASHER I
t2 luElLEE CLIP
78 WASHER SI1M DIA 4 -r
t3 HOSE
I

RUBBER BUFFER FOR RAD. STAY


at
I4 AL, PIPE
I 29 2
-t
30 DISTANCE PIECE . FOR RAD. STAY 2
t5 HOSE
I

NUT 1"18 ai
3t
4
I6 RADIATOR BRACKET.RH I
.l
rt
02.3.7 Radiator (For Genset)
Ra:iator mounted in front of \^ ater pumP a
cocls the cootant dqring circulation Radlator
:t
ha: top, bottom header tanks connected
a
wi-:r tubes and heat transfer cores lt also ta
ha: provision for filling, draining. over-flow.
ar: pressure relrel The Principal iuncion ol a
tl : radiator is to transfer heat energy to the
cc:ling air at a rate whlch w lL malntain
cr:,ne .oolant ooerating temperature.
AL68O SERIES ENGINE 02.45

tr
E
E
E
trj
E
E
E
E.
ts
rE1 ,- NO. DESCRIPTION
HEAT EXCHANGER
lorNT
FLANGE
Fig. I Marine Heat Exchonger
QTY
L

7
7
rrr.
2I
23
24
24A
)q
tlO. OrSCntPtlOt'l
OlL COOLER U,H'E
HOSE lli{
SEA WATER PUMP
BELT - SWP
DIA

L.: SETSCREW LI IBLIEE CLIP I

i. 'swp HosE - 15" L.NG


WASHER l4 I

iz vl ot P PE swP To HE
]UBILEE CLIP 8

L.:
f- rl
HOSE
PIPE ENGINE WATER PUI'IP
HOSE
PIPE ENGII]E WATER PUI4P
CLIP
TO
TO
H

H,E
E
I

l
I

)_
l,l
ii
1A
iz
38
STUD 5/16^
t,t. l.li
MOUNT NG BRKT
wl'sgrn
NUT
BSF
{ DIA l4 swc
5/lb" DIA roLoK
I

I
8
I

L.. WATER OUTLET ELBOW 39 STUD I/2 BSF

HOSE rl/4" DIA 6.5" LONG 40 WASHER KOLOK


PIPE OIL COOLER TO ENGINE 4I NUT I/ BSF

Lr,, HOSE l.l/4" DIA 25" LONG

HJEr.changtr (For Marine Engine)


Fig-9
l-h".od,tX
.r;; ;;;.;t"
,i"' .*lrr",. ihis
system -ay atso be clogged
grease or other lmourities
should be removed by
\ir\ f or
by
in

A SeDarale HeaLe cnange' 's o-o'rdeo for n*'ag ,' e s srem sF erdl llrre r o'- l
;."ta n tt'" 63" 6l v ra *.te. l on-oi"'ng d Srea e c sso'\ ''
,
^ot'
"i'It ," , nu,' [r om the-nos ar 'sit I
o
Let the engine run when fl';:hing
t the
"Io'n"o ' 'ooter: ard
;i";: ""; ",' ' 'ns"' gots a't e o'l S) s1'ra
J"".n"a- -*i"" na'"i o"nP rl'r .l r rci corta
aaa., t"u'v\dlel s L eo rr heaL
e 'l' q't Note; Make sure that solution does
--n"Ll' '
rr

to cool fresh water' dn/ dcld or e'en tl e "-


in'tf," .1"'ning fluid as it l-' llke 1o a'lect
To Flush Cooling SYstem om'
mrg5t be the cooline sYstem unfavourablY
C[un', e ol the too]''tg s]stem
;"a;t.* DecdJsF or ourer cord'l'ons ol
Ha.,^p cra.ned o t tle so''er t ' '' he
t 6 '\
il"".; :, i-prrit es 11 ,\e coola 'L e'l
., ,"i .".a, ,. 1 -es 'r'r: t l'e e-Yr
o'r ' e'g' e c's I e
L,,rla rorable outdoo' 'ond:l runn ng.
;;,-;;;i;" or d,. , rn e.is[he etc cdr s e"t''
The use of hard water fosters
the
,.ir," ao"r;.lg ' to"t't
raorato firs be rerr-roved
- r5'n -\ ;.r;r;; of fur whlch maY
ar', l" ,r"r"""o o 'r as\ing r' h o sr
a
fur
olution' " rinnlio "r an acid free solvent The to
'Hg ;;-;"t ''g
;rn'.";
creaner (supP"ed o' l4/t a"n]ouing agent must not be
aggresslve
nuaiuto,
:;p;;; i;t and zinc materlals usec
in
"i
Hindustan Petroleum corPn )
the cooling systems'
A 5% caustic soda solution [o- thrs
(sodium
se'cral lrmes
La-",lo"i- -r, or\o b''ne'r eo Also flush the cooling system
;:;;-;- rn odd ron r r'l'dro r' after aPPlication of a fur solveni

I;'rlo-"" Dla.led lrom rheWhen in(rde 'r'11\


d-' q
a
Should lime has deposited
"i,a,,i". ,,01'
too l- eavily tn
,,.--n i", ot a:T or "r aler' 'o jn"
'i.'i;^ :l,il":;, "0"
",;: veo lh;r sheel
,orry disPerston ir the comb

ill rNJrcrroN sYSTEH .hamber (Position of sPraY)


--ro,
02.4
nozzle spray'
DescriPtion Correct shaPe of hole-type
02.4.0
i* l,,i'*"0 pump driven by the iniect'on
the rrel rrom Lhe ruel t1t 16s 6i- rn the
Good miring oi tne {'lel ^
"::""H;:;ucks & water seDardlo- and " chamber so thar Lhe {uel
Hit;;;;-;;*rter
"
a o'.ral rller :;;";;';;
;,'" aL tl'e cor'e'r t '.'e
(sP-aY
:"ii'";; 1";" ruel rhroush rhe
;';;;r'l; Lhe 'nlecrion Puno ";;0,;,';
disintegration)
erer ts,
e
, Lhe iniect;on PLr'D va\'es
"'."-".,1 trel througn rl'e deti''e'v
"ir.i'in" n of inie - on 'tith a
",n,".,,on Precisely defined 6ur21len :r
,.i'r"i"o"* "" "t o[ 'o'ec' o^ ^h'ch
LU r-

,"n" pun'p 'oto Lne hrehI6pP'essu-e


i.,lec"on nozrle- TU t'
i,".' ,i"',; tn" depends on the engtne sPeed'
hole "'o/7te' oPen aL aandP'l-ssu'c I' lecls t'e a etaln L'r''le'
,1., .., , )2O KBtcr.t
-,",. fne luel PreParallon requ'es
tqe cornbr'stion cnanber 'n
'tlJ, "^
,^","n a-;'j.. ,.rren a onbust'ble
" a
''t';';;
]nit:are orlr r

,.'f., -i, uon'''"o tott The fuel reed nas oecc to-'med' The
'"t" tton 'o
lll-"" a", ,"tt . *a)s r'ore fi'er tha^ needed' ,l*,Jo n o". rhe begrr',rgrs or r let as Le
::. ";'"; rn" io..nut'o" of
h Dbre\ o'd
e tn'ect'on
i."]'tl ."* Lne tuet gr'tery oI ttrt"
mn at a ( erlaln Dressu-e 'Lrpl'ls
i;";..";." or 'gnnio" kno'rr
::":.i;"';";, p"'Ja' 't s a cnaraLIeTrsLrL
:";;;r.;^ r a dreser ensrr e ln d
of II
^,
i;,
"'";"'"t

in.,'-us**',
ro the ruel tanl th'o'rgh
of the dual
li,. il vatve fltted on toPa return lrne'
-tl,"'and through the leak off
d1

;":;,';
the in]ected
,",0r,""." chamber engines' <luring^the
fueL must be small
:' ;;; ;";;"r'od raDoJl ooo' secondr
'ale or o'essu- Jse 'n
-he
II
ti'. *.*'
t."i ";';;
'i"; 'u
collected into
inlectors also return to
tir.,*n t"purut" retLrrn relation to
4,a.,,"" Orot"tt is controlled
in
the fuel
line' Tl.re
1"" ;;,'.;-,'";
":,;;:" l- o:'5e'
he oo:e,Ir\e-rs
cn8''re''
,,-., obrain CO.\tdnt P'essure
lit.. ,"
rocnbL'>1'or

.,t :gn:l'o1 'e' 'h' a'not


1' oI
I
II
position speed and load
of ",."
'-i.. ; .' -t-'o"ti be c st-rbur'o o 'e rhe
,t]l',rr.,i"-,"t"t
'"ngin" governor "" 'r'e' l.o"r n s(' n a ^d' thaL the
by a variable specd
,fr"
,ountei ur lhe rear of the inject
t^" ,", o:it l" or n"
*. :;.t""
on punrp
;^'s' 1 q ' e'rr 'P "nd
n377tp5 oeperdS r'..rn''
on r'^'
n-1",a.

;;;;;
"'
a"a0"","" p'e'su'e temuint
rn other
I""rl , ", '.e, sr o.r'c De
as constant as
*:-'
'i''--.'5n^::
ne'lcd
.D*
II
I
.f".nfil"., of the fuel' Even minor
impurtt es
po:srbly cause
,uai ", nn" dust' etc ' can ' D '\c
n., o' , rd-lL ang'e ls a^ D' b'r'- '"'lrn
"" oA :rhou' a L' oLr' r'as'
t ," I
;:" ;: " *ea, o' the rnre t:on " '
o
i,,
::;Jr;,,;;" pressure ln dLr-ect ini:ction
,n,.'ilo' ,lo'-'' ge re ; ''7
the
bc l
mJ 'r-'l
l
:
;r. ;'"" e :-ccnls " '^:" )
.o-]rtrl-, O"' degree ol 're'l''
dnf
or o nB to ''l5irucl' '
-'"""'"
chd'r^cd ac' "oe
'"ed 'nro " ' '' ';nl
1,.""",1"
^ii 0r".""'""t should be taken to avoid
dJSt enler,ng t5e fuel
-ank'
IIe fue, -nL'St De r,]jr'Leo
, .-0".*" (na-be' -"d'
rto tl'e
r ell
l
ar
:
ln the comb'ustion charnber rises to
rs
deflned conditionsr l-1
- - and the temPerature
.orrr",,"d - ln an accuratel/ metered load
quantity lr
)i'OIg" sOo"C so that the {uel
is
ignltes
most
ao""n"'ate with the engine t\
*"t""n-- lnl"tt"O CombLrstion highest'
is
O""rt"O'" and engine efficiencT minimum
At the correct tlme' l!
*na" *" exhaust contains a For an accurately
determined period' l:
lf
,aorn, of unburnt fuel' r\ n ecteo rhe
cornblrstlon ls
Co'rdrl'on a'd
ln a perfectl; atonrTcd lr
;:;;0,"; und too -"h luer sL'led lo 'he
,1:, 5t,'.n Putt""
'smokes'; tnis can re"urr I combustion systern'
l:
";;.; Camaqe
overheating with consequentiat (o-bL'sl-5;11 on
l, o,r,o" iu"..l'" erc' !arortrablo is shown in Fig ' l'
J l,r' r's Ft,el systerr layout
aO'u n"t onr/ rl '1e "
1l
aaa'o"-p"tf"ttfy
Drepared: each combustron
r-m laroul for Martrc and Ce ct
U""n t:: ,

0,".",11"0''*t o'**":. l::ot:11::,1 ,ho*n 'n Fig ' 2 & 3'


-{t - -a --I

AL58O SERTES ENGINE 02'rt7

:
r
I
f
f
f
E
E
E
r-
f.
E.
E.
E.
E
E.
f.
E
L1
L.
L. FEED \
E. PUMP FROM
FUEL

L. TANK
'
I.
Censet
Fig. 2 fuet PiPinC Lo|out

L.
I-
I-
I-
L.
r-.
\ SINGLE FUET
02.48 AL68O SERIES ENGINE
2. On the Pressure side l.l lltre dual fii:e- s
02.4.1 Fuel Filters
fitted on the eng,ne. This narn '"=
Eflective fuel filtration is absolutely essential consists of 2 bowls each containing a f:=

for trouble free oPeration of the fuel insert. The primary filter s of c oth t):.
injection equiPment, Fuel fllters have been and the secondary final fi1ter is a pap^=
designed to retain even the
impunties and protect
sma lest of the
the extremely sensitive
filter insed.

These filter elements should not be ceane:


II
of the injection pump
II
precision parls and

nozzle from damage. they shou d on Y be reP aced a:

re.onnendec .rr Pryals.

Fuel Filter lnserts

Paper rs cularly suitable because the


par-t
3. ln case of marine engines aparl from
regu ar fuel fllters, an additional single fuel
II
impo11ant proPefties which determ ne filter
quality, such as Pore size and Pore
filter and water seParator is provided.
I
distribution, can be maintained ellective y 07.4.2 To Prime the System
I
durng manufacture. Yoreover, a paper filter
has a large su-lace a"ea gir ng
Keep a1l filter covers and piPe rrn,ons etc.
tight. Fuel leaks mean air ocks in the fuel I
I
a

corresponding y longer service life However system and consequently erratic running.
for first stage filtration cloth filter inserts
also used.
are Alr ma/ be introduced into the ststem if
the lters, injectors or any of the pipes I
have been removed if the luel tank is
a lou.ed to run dry, or il fllter is choked
I
Coil Type PaPer Filter lnsert
For corl type i ter inserts folded filter paper I
is wound round a tube and ne ghbouring Open the air vent scTew, on lhe fl ter.
I
layers are glued and one end of filter insert
is cosed by end Plate. 2. Operate the hand Primer on th: feed I
pump untll the fuel flows free of alr
I
The fue flows along the V-form co axlally
from the bottom to the toP and the d 11
l
bubbles from the fllter.

Close the aiT vent screv/ rr.'hen the fuel ls


l
..t
particles whlch are held b,ack accumulate in
the fi ter po.kets. free from air bubbles. :
:
Cloth Type Prefilter I n sert 4. Open the air venl scre,,v on lhe .lect on

For first stage f, tration cloth lyPe fiiter pump and repeat oPeration 2. :
insefts are used. :
The above operations are sufllcient to c ear
:
ln cloth type filter inserts the fue flows the air from the systern under rormal
radially from outside to inside. The cloth is conditions. lf however the n]ectofs, the :
coiled round a perforated tube and the ends engine fails to staft or rnisflres on:tafting
!
sealed at the toP and bottom bY end luf,her prirning is necessary, as folov s

I
coveTs.
5. lf the engine does not stari. slacken each t
Fuel F ilters on Ashok Leyland injector pipe union nut at the injettor and
Engines crank the engine ,.vith the stader r.1or-
'-rShten
uniil fuel flovvs without bubbl('! then 1

On the suction side apart from the strainer the un on.


il+-- i. fi++a,-] ihe
*gs ---
I
i

AL68O SERIES ENGINE 02,49

lfengine starts but misflres, this operation


can oe carrted oul wlth the en8ine ru"n ^g
thereby conserving the battery'

Timing lor 680


02.4.3 lniection PumP
tl Engines

:l
rl
flfl
An lnjectior' timlng mark is provided before
TDC on engine flywheel which refers to
cylinder' ingly a matchlng
Correspond
inlecilon l ming mark (Chisel mark) ls
lrst

pror:ded on FIP flywheel' Both the marks


mtrst coincide while first cylinder is at the
flEI end of comPression stroke'

For setting the injection timing follow the

a. procedure g 'en below'

f.
m,
I

1. Align the iniection mark (10't l'

f. I

I
BTDC for Genset, 26" BTDC for
l'4arine) of the flywheel with the tinring

L. mark€. fitted on the flYwheel hous ng


by roiating the engine in clockrvlse
UABi OI{ ENGINE FLYIVHEEI

L.
I INJ

f. d rect -'n (vlewing from front end)


I

frst cyllnder ls at the end of


f. Ensure
co mpIession stroke' Otherrvise
rotate
Fic

L. the e.gine by 360" and ch-'ck for the

E.
same

L. Fig-4
Align the chisel mark of the FIP
L. flyvrheel with the marker' which is

L.
E.
ftted cn the FIP

Fig-5
E. 3. I'lount the FIP keeping the mounting

L. bolts lcose Fig

L.
I-.
4. Tighten the
couPl ng Plate
2 bolts securing
and FIP flYwheel'
the {lange

I-. 5. TiShten the FIP mounting bolts at the

I-. bottor suPPon brackels'

L.
r--
CAUTION: DisassemblY' servicing or
overhauling of FIP should be
carried out onlY through Ashok

t- Leyland / MICO authorised service


outlets' For latest calibration
COMPRESSION
02.5 TO TEST ENGINE
Use Adaptor with gauge for checking Engine
Compressio" lJse Adaptor w'r h gauge in
place of nozzle).

Fig-I

Warm up engine to norma oPeration


temperature (approx 80'C). Disconnect fueL
delivery pipes and remove all sir injectors'

Set the Adaptor Compression with standard


gauge compression on First cylinder'
II
Fig-7 I
I
Check the valve clearance.
I
Crank the englne aPProx 8 to l0 revolutions
by actuating the stader motor' The battery
must be in properly charged condition as to
tI
achieve a cranking speed of atleast 180- 200
I
rpm. Keep engine stop cable
condition.
in puled in
I
I
I
Repeat this procedure for all 6 cylinders'

Compression pressure @ 180 - 200 rpm


should be 2l - 23.8 kg/cmz (300 - 340 psi) I
Pressure difference between each cylinders
2
I
should be belo,,v kglcm'?
f,
lfcompression pressure is foLrnC belolv l
mr.rm-1 'e, or-rmendalron ergine 'quir es
I
reconditioninS

ln the ast case it rnrill be necessary to check


f
valve tightness' condition of Plston clearance -I
of the respect ve cYlinder'
f
\iy'et ComPression Pressure Check I
f
I
is
l{ rhe pa-L'cular c) linder comPl essro.,] P"ssu'e
below the limits as per above dry check
procedure, to locate fault with valve tiShtness
pi,lon r,carl re -epeal lfe onlress:on
or
I
l
(

p-assLrb cr "^ ahe' oourirg leru d oos o'


e^grne or' niecror hole '[ or'r conpte'sion
lhr-
persists the fault is with valve seats I
AL58O SERIES ENGINE 02.5I
?r

TI ll-r
EI
EI :1-zl g'
loDoool'l
EI flE
e@
'-l ! r-L! rll

EI ,1, n
f,l 29A

f "[6,'
3r
,
I

EI
2A ?9
," 6l
rr'i
t'i I l*8"
EI l*\o ip- .72

EI \l=12
$-a
L2l

x,l 'u-B
11-g

L.l
E.
E I Lx\taded iew CYI''d"! !:"d
"f
22 DOWEL FOR ROCKER BRKT

L.
2
Is-v or cvr HEAD & vALVES - collPLETE 23 BUSH
2
I S/A OF CYLINDER HEAD I 14 CIRCLIP
VALVE SEAT KIT - INLET WELCH WASHER FOR SHAFT

L.
c l 2
E VALVE SEAT KIT. EXHAUST I 17 SPRING LONG t1
C.E COMPOSITE VALVE SEAT KIT l
'28 LOCKNUT 2
D INLET VALVE KIT I 19 BALL END l2
G VALVE KI-T - EXHAUST 11 t9A SiA OF ROCKER LEVER( WITH BUSH ) 6
VALVE GUIDE I l0 ROCKER BRACKET t2
SETSCREW FOR CYL HEAD COVERS ! ll WASHER FOR SPRlNG 2
CY,HEAO COVER 1 l2 SPRING LONG ')
R.)'(ER

Ei
ROCKER COVER GASKET 3l SHAFT
OIL FILLER CAP
I

34 ,ruo - t.r BSt I 4 6' POCr lR BRACNET 6


I 6
CY HEAD COVER WITH OIL FILLING 2 35 6
NUT I/2"

L.l
LIFTING EYE 1 35 BSF PLAIN
6
CYLINDER HEAD GASKET t0 31 NOZZLE SLEEVE
6
SPECIAL NUT 3/8' NUT I/2' BSF . SIIlI'IONDS SPECIAL

L.
t1 l8 6
VALVE COLLAR LOWER l2 l9 CLAI1P FOR !NJECTOR 8
3 VALVE SPRING INNER t1 40 NIIT 3/8'BSF. PLAIN 6

L-
VALVE SPRING OUTER WASHER I/2'DIA KOLOK
a
VALVE SPRING COLLAR ' UPPER
t2
iiJi] l,)j,i,'ii t qocF t q BR/ ro t Nozzr E -AvD 6
t2 42
VALVE STEM SEAL -.]WFI FOR CYLINDER HEAD COVER5

L.
3 74 8
) VALVE CONE t7 45 i,t e i] ,iL o x " I oNG Lrr- I INC Pr a'I E

.: VALVE CAP
BRACKET
6
JOINT FOR ROCKER ln
L,, oil waYs drilled the
two veftical
2.6 CYLINDER HEAD a."nt arr", cyllnder heads and middle
rocker

E.
O

support brackets, and along the rocker


o 2.6. O D escriPtion
to tr,e rockeT levers The rocker

L. Cylinder head is of two piece constructron


covering th[ee cylinders each' These
are
snait
shafts are locked by the bracket mountrng

L.
r--
interchangeab e Replaceable

are fitted in the cylinder head The


stems are chromium coated and
valve

inlet
seat

inserts, ','-alves and valve train mechanisms


valve
valves
Loit, in tr.f, a way that oil holes align with
ifie middle rocker suPPon bracket The
uutu" *"4, and valve guides are lubricated
by the oil splash from the rocker Levers
are idenlifled by their large head diameter' and mist.
:-
I-- Rocker levers are bushed and - are
assembled, on two hollow rocker
shafts -
Water outlet pipe, exhausl manifolds and
inl"i .u" rora are mounted on the left hand

L.
L
on"
"u.f,
corresponding to the cylinder
head. These are rnounted on each cylinder
head seParately by means of three supPor-t
side of the cylinder heads lnjectors
fitted ln the cylinder head by holdlng
nuts

f,ro,flr-q hool'" one al the {''nt and Lhe


are

E b.ackets.

.-rbrication of the rocker l-evet: (


oLl'c, at i ' 's3- or€ tr'1ed 01 t; e
H"uJ ,o lift the fuLl engine
cTli'der
assemblY
the coolant from the engine and
the drain plugs.
radiator by oPening
Disconnect the battery terminal to avoid

*w$ffi,_
accidental starting.
Remove the air intake pipe, inlet manifold,
exhaust manifold, water manifold, thermostat
assembly and turbocharger. Exploded view
of inlet manifold, water manifold and exhaust
man fold for Benset a.rd mar,ne eng nes are
showninFig-2&3
Remove the valve door covers and
disconnect the fuel pipes lrlted on iniectors.
Loosen the rocker shaft mounting bracket Fig. 2 lnlet & Exhoust lionifold - Genset
bolts and lift out the rocker shaft assemblies,
then withdraw the push rods.
Release the in]ectors lrom the seat and keeP
it on a suitable stand to avoid any damage
to the nozzle tips.
Unscrew and remove all the cylinder head
nuts and then lift the cylinder head lrom its
II
seat.
Fig-4
Then lift it fuly outsrde b7 holding on erther
It
end and pul ng it upv',ards. Keep the
cylinder head on a wooden surface to avoid
I
any damage to the machrred surface
I
I
Fig. 3 lnlet & Exhoust l'4anifold - ll'orine
02.6.2 To Dismantle
Valves are to be numbered one to twelvc
before removing lrom head so ihat the
valve can be refitted with the matched valve
I
seats if found seruiceable.
Fig - 5 t
l. Cean the cy nder head externally ard place
I
2
It on a wooden table.
With the helP of ilre valve sPring I
compressor, remove the :p it cone. o[ t'.^;o
I
II
halves at a trrne.
Fig - 5

Then remove the vave sprtng cc: ars and


springs. Repeat the Procedure for each pa r
of valves and remove a L alves.
I
I
I
II
I
I
l
AL580 SERIES ENGINE 02.53

Remove the valve seats if found excessively


worn or damaged
Press out the valve guides in a press using
EI a suitable drift.

El, Degrease all the dismantled Parts thoroughly

rl
rl
and clean the oil ways and water ways uslng
a wire brush of suitable size.
Do not use abrasive to remove carbon
deposit on cylinder head surface instead

fl
flfl
se^tly scrape ;1 6g1 esing a scraPe'. Also
ilean Lne carbon deposits rrom varve Surde
bottom, injector nozzle tip surroundings using
a scriber.

02.6.3 I nsPection
El Pressure tesl the cylinder head for any crack
at a recommended pressure (Refer TechnicaL
E, Data) as follorvs:

E. L l. Seal all the water waYs on


bottom side of the
the
cylinder head using
E. a sPecial fixture.
adoPter on the water outlet
E, |.2. Fit an

r.
\.
Port of the cylinder head and connect
an air PTessuTe PiPe line having a
control valve and air pressure gauge
in the air line.

L. i.3. Dip the whole cylinder head assembly

r,
L. j.'1.
lnside the water and open the arr line
and ma nta n the air Pressure to 2 8
kglcm)
lf there ls anl crack invisible to naked
eye, air bubbles will emerge out
L, through water from the cracked area

L. P.:place cylinder head lf found cracked


l-eck the unevenness of the bare cyllnder
r-. -::d. using a stra ght edge. lf lound more
.-::l C.003" it can be relaced in a surtace
L, .- -le' maintaining the minimum th ckness of

L -.-= ,, lnder head as specified in the data

l-::.: valve gude bore for wear and anY


L" -:-.::. ReP ace lf the wear is (excessive)
L. - -: :rai 0 254 mm (0.0 I 0")
-: lrelsrn: the nerv valve guiie ensurc
L" '-. . .le r letting interlerence flt with the
. - -.- head Wlth a special drift press the
f-- .: :llCe and nraintain the va e gulde

r-
r-
: : ., :'r zDove the cyllnder 'read as
:-.'.: ^ Caia
Fig-7
I :: .'.-::-:r- the ,'alves are entering in the
L"
r-
\
.
: : l- :: smoolh Y and the 'learance
' - --- : :, de io s',errl s as sP:cifed'
,.e ia:e for Ptting a.C wear.
:f:..e the valve usinE a valvc
L. rei.ovaL at the seat should ii
I-**-*.0,* seating fa(e of the valve seat l[
ju'ug" is not
:#';"r; "na .aPPreciable
lf tlre wear
inin tr," uatue can be lapped
exre:s''e' lhen
,n" r"1* seats is found
""
I""'r." .tn" valve seats lt is ao rsable to
replace ihe valve seats as a set

the seat tightness of


During assembly check
valve on valve seat

Fig-8

Check the vatve springs for


free length' solid
tension as specified in the data'
f""g,i ""0
cao {o' ar'
t Cneck sp-'ng collar dnd valve
\^/eaT and replace
i[ wear 's e're5s 'e

L Check the sPlii cone e-t the valve stemif


[.",i"" for any damage and replace
necessal}.

2.
' Check hollow rocker shaft
rocker lerer bush
[.0". lever tiP contactir g with-if va]\
fo, ,n.; *"ut and reP lace
e
necessarY'
stem II
rocker

t
lever'
E]',rur"'tf'" clearance between
Ortf,l'-""0 rocl<er shaft is as specifed in

D ata
I
3. the cylinder head studs are tight
Ensure all
and the nuts are smoothly entering in the I
rh-ea6e j ends.
threads using a
rf
die se1'
^1':essd.l Lrr- Cl6ln
I
01,6.4 To Assemble
T

l. Ensure that the cylinder head and a i I


;;;p;..nis are clean' Always fit new
valve
I
seats

Keep tire clean cTlinder head


on a work
l
2.
table l
.1. Cool the valve seatsto O'C (approximately) a
' iy i,pp,g it in liquid oxygen Themixture
valve
I
slats'can"ul'o be cooled in ice-salt
irr^ 6 hours' if liquid oxygen is not
"0"* a
available.

With the helP of the sPecial tool


fit the :
valve seat inlet and exhaust e'renly a
,]

Fig - 9 & l0

Press the valve guides


"Pr"ss
in the cylinder head
;;";;rr;; trsns a qPC ar lool
'n a rhe talte
--^l.,ntu,n gu :e p'oje t "'
Int.
above the cYlinder head surface'
aL68O SERIESTENGINE 02.55

il., a thin
- carefully by applyinglaP with
Ls''"",r," uulue
coat of carborandum Paste' 'ir* grade at

II
II
-?,rrn *"a" and
l^^i tir*"1'-rn"
then smooth
mating surface of the valve
,"a "rfi" seat should be true' concenLrrc
f."" f.o. any pitting or score mai'ks
"ni
EI Fig' ll
II
EI
wash the head and
^L^' l'^nino finallv to remove arl L'aces
;i;"' ,;':i;;" pu.uifin

flrl "t
lro,"g p"t* t^d loose carbon P:rticles'
Check the valve seat tiShtness'

flEI head
valve lnveft
Elch the number on the
i',e cytinaet head for further assembly'

collar' valve
each valve, insert the spring

f.
On tnner
i", ,"ul followed by valve springs
outer and uPPer sPring collar'
EI
I

f. Fig

with the help of Lhe pair


- 17

valve spr'ng
L. l"-rr"".-, tool p'ess the
)I.1.1".'---ri, the valve cones in
of valve
position

L. of the
ii"*i, .",""t" the tension are seated
;;;; ;il-;;"re varve cones
valve

E. proPerlY.

E. Follow the same procedure


to assemble the

L. remaining valves in Pairs'

L. Fig - 13

L. Clean the gasket faces of


Place the
the cylinder
new
head
cYlinder head

L. ;";;;;.:;
,ui"ir- ,"i "g ca:e ln' l'-
c:
LoP rn3lt prn'hed

L. i- 1t-," gu .",- to .'rr d!


nead'

r.
r.
Al,,vays u
i".r.i
e T^"' c' '-dcr head gas'e1s
mL,.t L' 01 and no lo I ng
comPound should be used

L. Lift and slide dorvn the cylinder


ouer-Lhe gasrel' EnsL're no
!",,
head gently
foreign. pan"l"
rr.p#o be''veen c)rinder head Darl'r
g

surface and gasf et'

nuts to hand
Screw in the c;linder head
10 The
t",em firrt dno lhen ProgressivelyThis
rs 1o
.5".'n.a- ,.'qu" in sequente'
::';;;"t ;;"1 *a1:nB or tne cTrinoet nead

gasLet a-d avoid gaslet leakage'

Fig - 14
as
filur" ,n" rocker shaft sub assembly
follows:

oil ways and holes are


'" Ensure the
16.1.
;i";". Fit the circliP at one end of
ir,. f,ottot, rocker shaft and slide
down the rvasher over it'

'"- Keep and


16.2. the rocker shaft upright on a-
t;;l: irake the center oil hole of
tf," tf,"ft to point towards assembler'
Sri"u, oil over the shaft and
"ngin"
rocker bushes pressed on the levers'

Fig' 15

the flrst rocker le rer with


I
" - Slide down
6.3.
Lrtf, taking care the rocker lever ball
o,n e.d i'-:o the oPPosite s'ie ol
lhe
rocker shaf- locLing slots'
I
16.4. lnsert the ir-st rocker bracket
it with rctker
and lock
shaft through Allen
I
SCTEW,

Fig ' 16
tI
15.5. Assemble :-e successl"'e
rock:r
washers a:l the sPrings in sequence
levers'
t
shown n exPloded view' While
as
lltting the rocker lever anc rocker t
brack'et foll:w the procedure explained
3 and 16 4 t
in ParagraPrs
I
16

Fig' 17

16.6. Fit the we:h washer on either


side of
I
the rocker shaft with convex surface
faong outs le Tap gently witn a
drift
I
on ,fr" ao.'"" sut{ace and se'ure
the I
washer Pro:erlY'
I
15.7. Follow the same Procedure
assemble the 2nd rocker shaft-
to
l
Check and ensure Znd and 5th
rocker
Fig. 17 l
''l
bracket oil 'vaYs are clean' t't
Ensure the 2nd a:d 5th bracket 'O ring for :
Iii-f,of" ufign witl- the oil way in the cylinder
head.
I
I
lnsed the Push roJs' :
on
Lift and place the rocker shaft assembly I
heac r P:srt'on in such a w"r
the cylrndet
-ir.r"
inrt 'o.t"' 'a'L 'oc[ing slot coincides
The rocker shaft assembly
*nf-l if-r" t,ua
*itl slide do'vn to its correct Pcsition'
rl^
II
rl"
rl'
(rashers in injector.s
Frt coPPer wtrtt
rniector bc'e bY screwtng
deeP socl 't head

TI, aonnect tf: over-i1ow PrPe and


and tiShten the

EI t-o th" inj"-to's


' l8 Fig
t\
EI F," the ;a>ret on wale' rnan:floto
t:",,"1":.t;;;o
:; :::';"t; T:}"
j::
EI lll::^ T-',";,;"*,,i 6'o,6'" co,r p 'ng
EI ;"J; "; each c l'ncer
EI ,', ,n" . n'u'' manllolu]'[.i::";';":]
l':t:]:^
f.t Trphr.en tr I e /ha lSt
to"the cY iisr head'

EI ,,',, l"^ ast€'|oo ',.:


rh,1 co, )r 8r-Lse.
r l l:e i:: ll""j"
;"':

f. l ^^ ^-, , -,Iin.." ^ead


fou, co
^
T ghPn rnou " 'r
. -.1,:lio ^1""
tr 31,,i
edLn
'o
c r' '":,tl-1^',1'lt,JT''.,o,", ,,,' ,t,^

f. l'--o'"'"o rr care
;lil^I;' "o"''"' r"..:iri^,f.,:,J.ij:'
,.'" ;;u";:
"'

E. bolts"".
and nuts maY la
enter the cYlinders'
":;
E. '"4:'" and

f. *n::' .*";i:'.T,":f
-
E. For taPP:t clear-ance
Fig 19
follow the procedure

L. " '-*tt"t"belor,':
mentione: the
the crankshaft and bringTDC'
E. -
fir-11 cYlinder Posrtion
to

f. ccilPress on stroke
Creck the Pointer through
flywheel

f - r e' 62rr on
; ';;g -'tdow aligl irsr c/lrnder rs

f. ,,' rri'n="t and ens'tre


in comPression

f. - A j,ust r"e firs1 C)llnder val/es


:;';;"t" 'o osoa mr. too2o';
lappel
for

f. bcth inlet and exhaust


for the
f.
f.
- Fc low tne same Procedure

",""t
1". cylinders
i ' ')n""i 't
For this PurPose
'having TDC marks of the
(f S) (2'5)' (3'4)'

f.
O'n"t'" '"e
'"-p"'tt with gasket ard
Fit the :/linder head cover

f.
E.
,'g^t"n ',fa boh w'th
trisLall '''bocna'ger'
lJ;i a"o
"
i
washers'
Connect lhe Lurbo
exhausi ourlet ,nd "rr
'in"'
orl

E .
inlet cor:rections'
Ensure :1e radLator
and crankcase^drarn
plugs
B'
o-'
Br87

t
ILL, NO. DESCRIPTION QTY,

I PISTON I

A PISTON RING

I
I
SET

8 ENGINE SET I

6
D S/A OF CONNECTING ROD
2
]
GUDGEON PIN 6

t7 I
I
CIRCLIP
4 SMALL END BUSH 6

6 CON, ROD BIG END BEARING SET I

7
8
sPLlr PIN l/8" I i',l LONG
NUI 5/8' BSF SLOTTED
t)
l1 I
9
Fig.
BOLT 5/8' BSF
I Exploded View af Pisron ond ConnectinE Rod
t2
I
02.7 PISTON AND CONNECTING ROD Remove the pump assemb y and the I
strainer.
I
02.7.0 DescriPtion Rotate the crankshaft untll one pair of big
The Connecting rods are alloY stee ends are at B.D.C. Remove sPlt Pins,
I
stampings
big
of ercePtionally
ends have :teel-she
rgid
I tyPe
design' The
lead bronze
retainlng nuts and bearing caps. \"4/ th the
help of a rvooden Plank Push the
I
bearings with ihe bearrnB sut{ace indium connecting rod big end aong w1h Plston, I
coated Connecling rod sma l ends are
upv;ards. Piston and connccting rod
provided with bu:hes' assemby can be removed or refitted only
I
'!
The pistons are of special aluminium a loy throuBh the top s de of the cyl nder bores' /
fitted wlth three rings. The o 1 conlrol ring Follow the procedure detailed in sl. no, 5
',]

s 4t'ed aoo.c - gudgeon o r a'is to remove rcst of the Pistons with


O l-. g1r'anl b^ t, pe of p ston c'o"rr 'o-rrs connecting rod.
:
1
the combustion tl'amber in the case of genset Reft the connecting rod caP wth the
'l
7.
engine and sph:roidal cavity in the p ston
respectve connecting rod along wth the :
crown forms the lombustion chamber n the
bearing she L a
case of marlne englne The hollow gudgeon
pins are located in the Pistons by circlips' not be inter
Connectlng rod caps should
{
I
changed under any circumstances For
i
02..7.1 To Remove dentif(ation, matching numbers are punched
I
I Rernove the c)l-aer he:,i asserir"iie:' Refei- on corr,.'cling ' -'d i-'g c;'d and cn the .ap
Cv inder head seliron Place tlrc pi5ton and connecting rod 1

Dra n the oll frc:- the s'.lmP assembli on a :uitable stand in the torrect
r-.,
To Dismantle
rl-- rod and the
II
Piston
Clean the connecting
externallY

II
E
Remove
::,;:;"
the piston 'ngs 'ro-n each
pi't01
;"'o ti " ot'o" ring eroa"de"
Fig'2
Er rl'pc '.'

f.
locat'ng Lr
Remove L'e g-dgeor p'n .,aal
:;i":';i"',:;;3 - ''odno or'^r I'
orr tr '

f, ;1r,:" ;; "; "; ^e'|er -?^rLPabre'


!'ioi"r" ": t pl:tor 'oL'rd
P'rsl'

E Press out the small end bush


in a press

El lnsPection
E,o' Thoroughly clean all
the dismantled pafts
L. r-'
rhe Pr\tons [o'- ar y e teor
L. E^an-rne
,"ar*" a't hcd"ro s Lrrnq
drd s :

L. rnarks.
1r 'lr'r 2'oo i
r- -, t i,ecl ard ' 'ro tne D:5t
n,o,h u, " ds 9e 'lr'd ln
DJta'

L. Check ihe piston ring lateraL cleat:nce '


their resPectl\e cYiinder
bore
\.
L. Fig - 3

L. eccl L'e t
ror '' b t'l ea/d^'e ' L'

L. re Pectl\i e c; nder bo e

L. Fig'4

L.
L.
C"ecl< the co'ir<:ctlfg
.'-' Oo:"..' ,l' ,or'
,] ,lrr"
"
rccJ brg end and sn':
"' ,
-t''1 e' I bo
, ^.o d 't ' - 'colr

L.
L.
"iie connecl n; oo'
Fig ' 5

L. C'reck the fit of the


gudgeon Pin in tl^e
clearance is excesst
e

L.
I--
:--.all end bush' lf the
':llace the bush'

I-..
L-
L.
I--
I
02.60 AL68O SERIES ENGINE
ln a connecting rod fixture check the
parallelism and twist of the connecting rod
i, ,hortd not exceed the limits Cold
sraightening is Permitted if minor bend/twist
is noticed. lf excessive' replace the
connecting rods as a set
connecting rods after balancing are
ln factory
grouped
=,,+
in three categories with numbers either I or
2 or 3 punched on the connecting, rod b g Difference between dimension at
end outer surface. They should never be 'A' not to exceed 0025 mm (000l")'
intermixed inadvertently, which will affect the
balancing ultimately the engine life'

Fig
'B' not to exceed 0050 mm (0002")
in this or oPPosite Plane.
fig. 6
II
Check the connecting rod boLt elongation
F.r\t fil Ihe 'or^oc lng'oo oo'I anc
("\\ r.1
II
the nut bY hand With a micrometer
measure the length of the bolt Tighten
the I
connecting rod nuts to the recomnrended
I
torque value and measure the bolt ength
II
t

agaln. Difference between the length would


I
indicate the elongation o[ connectnB rod
bolts. lf found beycnd the limit specified'
replace the connectlng rod bolts'
I
Fig-7 I
Examine the bLg end bearing shellsfor sgns
Ftg. 7

I
of excesslve lvear oT pitting' Replace if
I
necessary.

l
I'leasure the crankshaft journal diameter and
select the matching bearing shells. l
On the cleaned connecting rod fit the l
selected bearing shell and tlghlen
connectlng rod bolts to the recommended
Yeasut e Ll- e D o'
the
l
Ior que \ alLe
connecting rod big end bore ''vlth beartng
shells installed in positlon Ensur-e the .t
bearing ctearance between connecting rod ai
bearing and cranl<shaft lournal is as speciied'
a
Loosen fully one connecting rod bolt
opposile lo boartrg tot'n anc -e' cu e lh' al
connecting rod bearing pre-tenson with the
help of a feeler gauge. lf the pre-lefsror)
a
(bearing crush) s not maintained the bearing
shells maY rotate ln serYrce :
:
:
a
02'6I
AL68O SERIES ENGINE

te
f. Ensure that all the original
parts being used

E. their resoecti\e lo'atio-r'


are refitted '1

f. Confirm that the Piston


taken for assembly
sPec fcal o's
E. ,s ,nsp'cled ard as oe-

f. rleat Lne D. on r.] boilrng


\A'ler o'
'n t'

f. ou"n ,ut lng care the temPerature


does not

f.
f.
exceed I 50"C (302'F)'

Frt one crrc rp in one of


the plston groove

E. Hold the connecting rod


firmlv in a vice and

r.
r-
,;"".- ";r,." oil in the small
,na ptu." the hrit piston in
,n" i"""""'"t
end bush' L ft
position or"r
rod taking 'are the valve
'5 oPoo' le :o
L. ooclp', on '5e D:sron c o\4n ' or' ' ':
I; :;""" L I B I oo bed rng '|^'' circ p
L. eurf, ,f," guag"on p n and
fit the 2od

L. Fig

l- Always heat the Piston


gudgeon c
to rlide
\\'thout damaEc lo
ln

\ '
L.
-a."ii,ion.o,nln"d quclgecn prrr bc '''

I-- : i the Pis'.: r r-


ngs ln rhe P itc' Lr!lr'': a

L.
f--
liSton ring e'(Dander as
describec

Fig 9
l'"e url"'-

f_. ' Fll ',ie spring Ioaded oL


r-'g in ihe

L. th -a ilSloo rng Sroove'

E. The :i ring ls barrel hone:l and


ihe
Borr the
2nd rre is 'taPer faced
I-tng

E.
I.
nas lof' ma,-k
ar,"r,,ol7 Top mark shouid
ie
over its surface' Durlng
{ace

iov'/ards the pisr'cn cror'tr

L.
up,,,a'ls
F t t, : pl; n top ring ia the '"r:t

I. Pistc'r groo\'re'

L.
I.
-- -: the f tment of all
=-,--.
the ihree r-ilgs
ti.," :ing end gaps do not
fall in the
end gaPs of the
, . -,-. , " n*i, The
I. . -.-, -as should be staggered 120"

F
.5 To Refit
07.7

L Ensure all the Parts are clean before


assembly Smear the cylinder liner bore'
piston and bearings with molykote or c ean

engine oil.

2. Remove The connecting rod caP r'ithout


disturblng the bearlng shells in resPect cf
lst
and 5th cylinder' Rotate the cran( shaft
and bring the lst and 6th crankP n to
bottom dead center (BD'C') Postion
l. Use elther a Piston ring compressor- or. a
tapered sleeve ior assemb1," of Plstoo n the
resPective cYlinder

Fig - l0
Push lst and 6th plstons with coniecting
rod from the toP of the crankcase while
rn\enrnp lne pisLon :n tl^e c;lrnde oor l"["
ca e th"o va 'e pocl'ets n 'he piston '-e
i"
oosrtron. t should lace the opoosrLe - ce
the enpire cam'ra't cs' g35r rgrerer':e and
o'
I
ao'_".,"lrr"ar, ram5raft slce hl: De^l
punched on the Piston crown'

Fit the caP \aiLh bearlng shells ic the


II
resDecti\e connecting rod' Take ca"e the
bearng notches of connectng rod arJ cap I
arc oo the sanre side.
I
Screr,v in the n',ris and tighten 1o the crquc
specifed. F L the sp t pln and locl it bt
I
fo drng tlrc two lnd:.
I
I
Fig

(ln no accounl must nuts be slackered olf


to bring the spit pin holes into line lf the
o,n roli oo -ot l,1a up 'PDld' e or 'r hco I
ln" n-r. la,e '.e1'). -6' PiP5 h i I

I
I
nrp the nut.

Fit rn the same manner- 2nd and 5t[')istor


D) roldlrng "oo <eeP:n8 'he 'e:ecLi '
crankshaft pin at B D.C. Posit on I
Repeat the procedure to assemble lrC and
I
4th piston assemb Y.
I
Check and ensure the smooth
rotation without b nding of bearing
crankshaft
she ls'
I
Chec\ Lre colneclrng '6f, end ;a7
I
resDeu
"ri
.p tou ra, usrng d reeler Sau8e lhe
ploT -:ould be wln^ tLe spec''le ' lr'n:t

Check the Piston Projection with resPect to


II
the crankcase, cylinder head parting surface
al lop Dedd C'^t e rr.D.C.r positio' and
shou'o oe witn 1 lhe lmrls sPe( [ed' I
I r Lhe otl put-o ,rssernolr at c LhP c' ''er I
You|t 'he su^ p -'rd ,g' I e it by 1e1len .lr
l
1*
D
AL68O SERIES ENGINE 02.63
l,rz
flE
I'i
f,1
fl SFA WATER PUMP PULLEY
v?
^ -25

E. -16C
oso ttllntile eNctNe

E
E.
f,
f.
E r1
r. io21
Fig. I Exlloded View of Crcnkshoft

L.- L. NO. DESCRIPTIO N


1LL,
77
NO, D ESC

DOWEL
RIPTION

l---
6
I CRANK SHAFT 24 D HEADED BOLT 6
NUT s/B' BSF

L
1 S/A OT FLYWHEEL 25 l
SET SCREW 3/8" BSF
26 LOCKING PLATE I

l0 LOCKING PLATE 77 KEY FOR PULLEY

l-.
I
ll STARTER RING 28 KEY FOR TIMING GEAR
-rI14ING GEAR
;; CRANK sHAFr
t"it tr...t ro FoR ABovE I

fr
6
iJ.*'l,o *ot"*
I
S/A OF OlL THROWER :;
.Jiit lt"* r'lARrNE ENGTNE)
1
t8 S/A OF DAI4PER ;; I
o-o*r. ito* r'lARlNE ENGINE)
L.
1
l9 CRANK SHAFT PULLEY ;;
I*1.* ir"* .lARrNE ENGTNE)
6
l0 BO LT i;
l* tl WASHER 7/ I 6' DIA PLAIN

2.8. I To Remove FlYwheel


L.
0
2.8 CRANKSHAFT AND FLYWHEEL ( and oth
Remove marine gear box' -:ch
0
l.

L. 0 2.8.0 DescriPtion
The crankshaft is supported
in seven Lead- connected equiprrents in the
:ase of marin

r-. maLn engines.


trronze, steel shells' indium 'oated ihe
;;' ; o ' ttd . a'e dr rr''o 'n '\' ) Bend back the iab washe holdrr"
L, ., -t,iln ro o'o'..oec 1-$1 " 'e1 '6 tr flnvheeL locking nu 's'

L. engine bearings'

'nr oil seal at front


An end of the crankshaft \ Screw in lhree 1ac<'ag bolts
''he fl)wh:' :gnter
-'he il :aCed

L.
1-
.err, tn- ^.1
l,-,a. i,
J8l Ol ( 'r' " r LLe ''"'
orno ['rt ea' a e 1' '6 6n' s;'
,"*"r. and uPPer halves ''"'
h

of flYwheel
holes provided ln
evenly and remove rhe flY"tl-'-:
"hem

g:ar rlng 1c. 'g bolts afler


Unscre\''/ stafter-

L. P6"'i 4
""
Io.ri, nr .)P
^ rarq. d;tma'e' r-,^- 1g .- ,ab. Dr,. ou. L t''r
1'1
t ' oor'
,J n, ." ' a'tL e' 'nd 'a o
L- f,of"r ,n tf," flange and in the
flywheeL are

;lii"o "tf-:e, att'l il'trciore '""illThis


asscrnble o7.8.2 lnspection

L.
r-.
l.i, ,n on" particular position
,;
"'.nr""rs"
'., ith the
cranl<shaft
s to
the timing mark on the flywheel
t.

).
Clean all the cornPonenls

Check for any wear/overhea


th: -'ughly

marks on the

flywheel. lf excessively ove


heated/worn'

I-- The stader gear ring is spigoted


-,o tl''," ly"rt.,-""t lt can be
and bolted
re"'ersed when replace the flPvheel'

l._ :-ne side of the gear teeth wear


ou1'
Examine the flyv heel gear ng for rvcar'
g' r'in11 f the
I-
l-
vl5cc.rs tlpe bration damPer
_l tne prlley at

r the aase martne


','
the end of the
is bolted
crankshaft'

engine sea 'valel PunlP


ReveTse or repla'e the
contact area of the stafter
out or damaged
: nion i: "r'orir
02.64 AL68O SERIES ENGINE
02.8.3 To Refit FlYwheel
I Fit t"e gear ring on the flPvheel,

2. Secu'e it by bolts v,/ith tab washer and tab


theB'well.

Fig'2

I Renrve the three jack ng bolts and fit the


Ilyu-:el on the crankshaft lt car be fitted
n c-: Fcsitiorr on 7 a: e;<plained : reldl

-1 nse. lh|ee ock Dlate5 a"d secure i' e Il)-uvhee Fig. 2


by l:hteoing the nuls io the spec':ed lcrcue
and ,.ck I \"iith the lo.< triale.

Fig-3
II
I
02.8.4 To Remove Crankshaft
I
I
Pla.: the enq nc on a:'-rtable sta.l

l-i.c,--.- . s lhe .l f de[ 'cads. pusl- 1--jd5 .]nJ II


II
lap[.:.,s.

l. nrc : the eng nr'. Pan-ro'e the slrrr'rD o I

ourl-: fl,rr'rheel, conn'jai ng rod and p:lon


lsrc^:lies Fis. 3

I
'I P.c;r'- e soitcrrl liil c i,";heei h:-.:rrg.
I
5. Pu rut the crankshait pulley anc L bration
dan-::r from front er,c of crank:halt wth I
'he .,tp o' -Decial loo.
I
Fig'4
l
6. Ren':.e t rn ng case

I
I-t
7 Unsc:w al the main bearing cap bots and
remc e a I the main bearing caps witf bearing. \
{
-l
I Lift c..,t the trankshaft.
-{
-t
02.8.4.0 Yibration DamPer
The lamper iltleo on 680 engne is of \
viscc-s type. lt consists of an inefta mass
and s sealed with v scous flu C The \
damger helps in minim zing the torslonal {
-!
vibratrons of the crankshaft.
\
lf any trace of viscous fluid leakage
is noticed, rePlace the damPer. -
tal
NEVER ROLL DOWN OR HAMMER \
THE DAMPER since it contains I
AL58O SERIES ENGINE 02.65

o7.8.5 lnsPection
r'le'o I on
Clean li.e c arl h-rl lhoroLgn
t.
ln-.rp"a or ''b'e with suldble
uDDofl

MeasLr'e ea(l lolrnal ar d LTdnNDn od.r-l


2. 'a fino ( Lrl 1le o or'L\'
,n.".""1. "i"" "t ^':o
marks' or scralch

I,l ;"y
.;;;;,. overheating
1n casethere : n: appr-=riaL-'le lear'i Canri-!e

ll O. '-' lor- 't


-d r': ol '
'u-F j I

f.
LnC .: F ._ '

' r-o- )'"


I.t
fI
I l'n"
;.
,"
tJ-f'." t..u,." ii':i; a5
",'
gi,",en . Palle ro'
j2'09
'o' ' ''
-'ll'a'te' 'r iii'-- il' -'
''l

flEI Che.k llre cr':nk:rafl 1-1 egl l-'q-3re.' "t'''1


Jflri: '1,;ndlng. Th- rur :'rl slror
ihe rl-'. sPcr: -:cl'
rl i': 'r"

r-l
a.i ,, a:
Fig

I a5: - _rr'li ":r li_

r.
lrciLr ,lrr
(.. 1

--i ir Li -lil-
L. ,-+:oii ,,] larilir::--of
.r."'r l57 (0'Ll : lc 0 il !l
l5t'1.1

f.
a.
'r
Chc.-l iie r: -ln:;5 o'
o-.i,-rd,,,a. lt :hcu
'j;l;;.t..P" ttt"
--l' ir-:'r'rr' I'
j noi le c!: ll'lr- '/) ir
li r::r dnc:;
-li:-''
:r': rirrrl Fic

-lrcve nr: r-r:n te r lr 'ie'a


Lf il

a. i;.
.,. , ,n. e'- Le r -' ' r

I- n',,0, 'n" cl I\''lr 'r (' LnI \J 'e'


crse .' e L l'cresc on aJ o' .'
e 'l o ' d.' .'

f. o"lot ,n^ P'-i-o ''tr


l,)"1'
ou c
,"-itt l'"g of the crankshaft" s
5'ond

1- necessal)

L.
L.
:'r 2.8.6 Crankshaft Grinding
Wh le the cran<sh:ft is reground
nitridng extren-re care should b"
wilhout
tu::!^t:
r-e-

L.
E.
cnsule that aa e>:essi''e alTloLlnt
by
ol
noi ,".outd fro:n the {llets d et ' d
nllo -r, ^r't' ,, 't' \^s rol
case ls
usrng a

'o

L. I. n" o,c [' :' ad -''

L.
L.
no,", rn"
li :r
cr'ankshaft shc.rld
i(
crankshaft breakage'
' 'r'
n91,!e,,refl?:"L,T"::
S" 't

L.
I-
: o.rttro! /-r I Td 113 o 'olI F' 'J lS 'r
BL,,,"B rr g.l-l0.I rnc\e\r
.,r""otto"ol*ln the correct fillet
corner radlus
s'o 'ld bc
radius
of the
on the
gr nding
---rt-f. lf the
I.-- ,..": , lers r.han the atlove value'
ren'r'lvcC
exccss
at
'e
the tTRTOEO Cr.Si RENl' , al

II ,^.ar., of nltrded case gets WHEIL WITH -io rrcoFFECi BADlLlS


USE GNINOING
ther-clbrc bc iakcn :'.
owtNG
' .- ".-1,,. Care sl-ould
-'he cas: ?]
OF 6RI:IDLIG WIIEEL

,.. . , , qgng r:r at fillet radius'


l^--., i,]or', lhe digging in at -!,n
fillet' Lt s
02.66 AL68O SERIES ENGINE

lf excessive wear is noticed on the


crankshaft thrust washer facing surface' the
same should be ground to a wldth of
ee.eSale8.eAS mm- (7.710"t7712") in the
prrndinp n acrtne Wh e assembling rn the
!nn.n"l ,." rne orersize thrust \ a'1e' to
ooiain Lhe speci'eo oar^kshaft end plav'
1. Lappng of the crankshaft is necessary to
."mouJ nltriding bloom and altain a surface
inish. The correct surface finlsh shou d be
0 micro inches and if attained by grinding
then laPPlng is not required'

02.8.7 To Refit Crankshaft


f"lain bearing caps bearing and bolts nr!st
Lre refitted in their original posit on For
iCentiflcation purpose the caPs are stamped
\'.'ith index marks A. B, C' D E F & G
starling fronr the lront of the crank case
\Vhen correcty assembled a1l marks on caps I
l.
and crank cn5e must coincide'
Fit the top halves of the main bearing and
crankshafl thrust washer n position' Ensure
II
2.
the bearing :hells bed down correctl/'
Smear c:r the nra n bearings and on the
oi
c ankshaft lclrna s.
tI
I

4.
L ft and c:refu / p ace lhe cranl<shafi
P
c sitio n

ace the :'cttonr l-a "es cf the bear ing


l
II
I
P
:- e ls in lt',' :.rp.r lr:l l't cran <:h'l11 r
''r'r
t:rust ,1.,;l!-,1 n ihe acntci mair' be t'ng
c:-p. Snrear J on the :na n cearing :he l:'
I
5 F: the mil r Lrcaring c?ps in origrnal posrtion
t:king care of the :cer Ia B C etc
-eac/ i gllietr ihe
t
I
,. n,., a, a 'i aineii .
b:aring cap etsc[e vs ,' ]th tc< Plal:e to llre I
!aecllcd ta
ti-e ock
:lral
P
u5 rll
a,:::
-- 1orq-e
"'rerr'lr'
rP
I
Fig I
C.1ec( and :.!ute tha sn'clth loi'llion of I
tfa cranl<5h:r'l .'ilthout ln/ birdrng'
V.'ith the h: p of a dial gauge or a fecler l
q:uge chccl. ile crani<shafl :nd floai an' t
lfoua U",'. lnrn Lhe lrl'ri sLre:ified' I
Fie l
F -- the timrr,. case.
l
: Fr: lhe crarishafl pullel' "'rbration damper
ard secure 'l by tightening the boll to thc
I
specified tor-uc and tab it l
r0. f''runt the L-.ltom hall of fl;''"' heel ho-rs rlrl I/
i1 -.5Cmbie l-:r aorr.ea:Lr-i1 r'cd anl pl:il" j
N ...,heel, r,r -.ump :lrd :umP. I
AL68O SERIES ENGINE 02'67
a. Lift out the injectors and keep it in a safe
place.

13. Unscrew the cylinder head nuts and remove


Ell"' I:.:;::,';" cabres rrom bauery terminars the cylinder heads. Remove the cylinder
f.l,
-
Drain the cooling system
Rcrro.e the adlato-/r edt q'6'3r 3e- ard
sea
head gasket.
Remove the caP nut on engine oil fllter
and
tsl,I r"ater pLrmp aler drS(on-eCli^t
;^"'- :,
1Le -vdler
''rd fan
14.
remove the filter bowl with oll
flter
'16'. 6eg^-i1s botLs element.

trl:
f]
?:l::",J::'.::"",
15. Remove
b!ock.
the filter head from the cylinder

!;f Remove the oil pressure relief


valve'
t6.
iff:t:li;.i:? ;;5't"11!L'#+iT
'*"rflow Remove the fan assemblY'
line fror dual lrlter
11 .

|-] 1 l"o in" i'" 18. Loosenthe alternator adiusting link and
rnoLnted on the engine'
remove the water PumP belts
and

f. i , ,, r.= I ,r" o l pre s 're Saugc o:De


connection
alternator'
sause Remove the water PUmp assembly from
!j 1r ?1:.il::-i:,EmPerature
19.
..unt-.ur" after loosening the iubilee
clip at
E f ,,.."""., me rhro'''" 'e/er l!: Lc-ri
impeller casing.

Release the wire lock and remove the


!41 '" 5::::j:ffi':T,"n.", pip" r.m exnaust
20. pul'e\
,ior",tn 0".p"r, lrom lhe crank5hafl wn le
f.l ;,;;;i;
Disconnect the propeller at Sear
Dox e'rd n
O"o lo, nr.]-,"l, lhe \';sco\rs
removing.
da-nPe

L.1 case of marine engines' 21. Unscre\^


- Ll'e rr anl shaft Pulre) moLntit
g

L.l , WrLr a tib L-a1e' nord the e'8 e


wrr, a s,pDon oar nool
;i:'";!i::d on the
ed on:-e
cvrinder
a scr-ol'
lAo.'P
head iront
I"li, ur,"t releasing tab washer
Remove the crankshaft PulleY
lock

L.i )7. Remove the self starter assemblY'

f.i
--..-
,
and rear ends.
Ren^ove the gear bor and kee[
case of marine engine'
it do"rn in 23. Remove flywheel from the crankshaft
the help of three jack screws
Unscrew lne lly\^l eer noJS ng
with

noun' nd
1 '''"
r- ': e a.Jterrat3l 24.
-: ln t1e case genset engine remo the lock wrres'
" 1-i'1" oi-'; o"'':'- 1'"g 'n" "nlrnou.after releasing
bolts
th" upp"t und lower half of the
e'8'e lrom rhe molr'Trngs' flyvheel housing carefullY'
E Turn the engine side ways and
remove the
o" 25.

f ' ::,:':T:"T': o4.^rna,,v 1 -'! \ :i'


-
)6.
su'r-r p

Remove the oil pumP strainer' delivery


ptpe

L. Tl "'" ''" -l: ;:;l;;";;; and tLen the o'PulP assembll'


Rotate the crankshaft and bring
down a
f- P-' r'' 'n' r'r'' rr' ., rr''" -'r 27.
ol,r'ot .onn".ting rod big ends lo the
E fI1:,:i".li::,,";il':'+;f',".: Tili":,l
head
["i,". o""o rentl- posrtion' Remove rhe
sp,it o'ns. nu's ano caPs oI the
re5pe(L've

E
}. connecting rods.
Push out the connecting rod with piston
Ht:il::i$:::::ffi'il" 28.
,"ru'Jt,to .'ng a wooden planl'' tatirg
care the bear,18 sne"s oi lne connectlng
F -..:;.". rle :-,reclor prpes or" fr'el
.oa, ur" noa damaged' Re{lt the caP
to

L
fr
'";,;1., J,-, the -esD-Ctiv^ connFCllng rod "nd -cterr
, :,;";i:""',.',"--i; ;; ;i ", ha.d' Do not the
'nterchange
fr. ol'lt'tlo"" t"oid e-rry ol
dr'sr' connecl rrg rod cao'

f.
r- ::::::,1;".?::""'"1"[Jj',, ,^ " ,","
)9.

10.
Remove another
rods in the same manner'
two pairs of

Reroove the timing gear housing'


connecttng

ts Yi,l, "Jl'ix,ffI;:"il'i,i',T-:;":#:l: 31.


i).
Pull out the crankshaft oil thrower Plate'
Remove the sPl[ Pin' castle
nut from tl'e
,ni"r. n"", oot and witndrdw tne 'dler 8^a
+ :;_:::.,;;..,:::"T:;:'and p.:h od.
.nrndie. burh dno Inrusl 'tasFe::
or.tu ottto SERIES ENGINE
the oil PUmP thrust
- ..unt case 'emove
the oil pumP q:i"-"- C."::
i.-rti"g Lift oui a bolt in the
,'i.o- o, s:rewing in
^i*
.enter threaded hJle'
co e'
?emo\e rr^ o.ea:rer ard tappet side
,.";;;" o'RH sroe and ren or the
"r,
iwelve taPPets
the ca-'shaft gear mounling bolis
I
I
...Jnscrew
and remove the 'lmshaft Sear
Lrnscre'r"' the
After remol ng tie locking wire
*rnri ihrur't '.,h"' mounting bolts 'rnd
:ull out the carn: :ft carefuilY
I
Jnscrer,v aiL lhe
..rln bea lrrg caP bo'ts :l:'d I
l,ft out th" caPs lh sPecl3 tool I
Fig ' I
I
)7. -ift out the ctan':-aft
from ts seat'
lt
_r8 lemo', e the bc-l rg shelis

iare "n"
of A.B.C
it
bo
from the cr'lnk
..."- i,l brck rr: man bearrng caP5 latr-rg
catron r-r-:' K:
- D : F.G, ldentlfts to a"': rl
Lne
lr
II
."'O' O
cire'rl oi -.: rtir'rg c:Ps'
-nisplaf

1emo .'e LH lnc ii : de co


ers both fi 'r't It
ll
I
and rear.
-rc .'l:ri:
l.cmo,e tlr.t
f,no.( Ir(" l
.]cur':l_g bra:li: '

llll
07.g.7 lnsP e ction
l'
lecrea:e .-,1 lr: il trr:ln'' ed colrrpon'
irllrrt,, En.. : the ,',11E,. ''vaY: and '' i

.vays are ctar'

Clean thc i,lrc: linet bores !/th a c:!i'


,;a', .r' 'ardr' o'e' r':
.l o 1P o',a
ar, n. '
',
,"..,; '
al' rI 4
of the cylircer
o.rra"t-*'"rt,t '': the englh
\'Year L:-'--l
,n". bor". ilorn- ' I the maxlmurl
\(en
I or'
.t.]..1.in, r p r .onr,1 Lor'
:
Poa
l.D rl ' /'P :'
or-tor 'rr- ''
rh"n O)51 0 rene\\ the loer''
"
Fig'7
Pr-essure test the:ngine block as follows:
Seal all --'e water lvay oPen
rgs
7.1 . at lront
excePt o': oPen ng erther
side or a crain Plug'
alr pressur e llne having,
a
).). Connect ar
control \ 'l /e and air- llne' to lne

oPening er:1

/I : 'rho'e '"anl rase 't hc


''n.1c se t'
\\a r ,!.r' oPC- lne ' O1l'ol 'd"e
r *-i.-. ,ir oressure to the
]
I
Ir AL68O SERIES ENGINE 02.69

Tll !f there any crack in the crank case arr

EI bubbles emerge out.

Lilt out the crank case and keep


it on the
E, l yrork table

EI Trrrn the c.ank case stoF wa)s clean


th?

trt r-ai' beari-8'dps anl


-"", ^* oo,-,io-^ of lhe 7 Trtn oeat ng at :
,,";t",;t". lt all Lre
trt ,nl ,igf,,"n the bolts to the speciied torque

EI Alter
'
.^nro . 'g Lhe 'rlrnoe- I ner' '
,'no-' Uo " " of f"
Sec tL e
I 'e and L' "

f. , . ,.i", ,=1 O O
r -\e . noJrc ha ' L' :
't
,",-1i.,".,e aL as sle','led 'he L.d^r
-'r---

EI
I

;: i.""; b",o-o 'n'"r ri I'Pr'i!" rI

rl
r.
crankcase.

C' :.1 tn( -.,e.er"--


ifr" ...",. .at" i
: o'' '"' o' 'r f
founJ une'en lhan li:
'

,,,,. , ,O'. ,tC I .t al I ' 'C' r Cd


L. .,','"'*'
n",,i" "t"
1''-o 'nlr lL" 1'r ""'
lhe cranL ca3e is n-rnlrrterned :ft-'
l

L. nr
"i
-rilrlnins.

L. Fig'3
L. Ch:cl< for- a'ry cr;Lil< or blo
l: tT:
' tr:
L
L.
ar.-
. < Ca Sa.

Ci:ck the c,linder lncr i'rojl:itror-'


':
;t ^,1;, I""t tefot: ard '.rfl'' f''r-"nr
abo\ c
lt e
'

L.
r-'l r: rlril
il.-,t ,urt .. and 1 ll"lrr il lrre
!r' !-L!a rilrl i-e lie n'l

L. Fig'4
L.
f- rLrC r\: .'"nC "'r
i']o.,1"'l o o'r
,.1'.- recorllm:nded lm l
'r
'' ''
t",'r
:'

L.
L
\....,re
;;,. ,
r...r,
o c
r ...1,-

. .dD o^ dr ' "/


L. i, , ]"n .frce'1 -rs'
'
I P: 'o'ot' ' " -o"n - 'l'
"t'':
'^
L. ,,
"
Uo,,t ,,
li rl^ oo
,f.l" speciled torque l lne bore' the
'U"r.ing
"D

L. Parent bore in a;s


Line bo'e
i.i

r-
1..,a ,are 10 'raler'a' re1 o'Pd
n. ,", ng
.n ,,"r- f'" art? t O" t the 'te" lound
abnormal rePlace the crank
case'

L.
I-.
Fig-s
bore r
C ecu rhe (amshat bea rrg pa-erl bearrng

L.
L.
bb.-
- case and the camshah
ine .ran(
curnthaft oear;r'g should \a e

rL
inlerfereoce fit as sPecified

Fi the main bearings' selected according to


"ar'l
, .'.,," of the ' nal outral or .t"e
a- ^, ,,-. After c'eor' g LhPm 'v:th a reln
the cap bolts to the
oitot.to sERlEs ENGINE
of
7 ,- -,n Fnsure the oil clearance
LouTnd15 v',g li not
are a: specrfred.
th" aa,n bearings defect is and rectiry or
.n".t *t.,"l." th'
replace the affected Pafi
explained in Crankshaft
Check crankshaft as
and FlYwheel Secltcn
of the camshaft lobes
Ln
ChecL the hardr'ess be between C60
RocLrvell sc ale a'C
shoulo
to C62.

Measu"e the. ,."- lg.o:.:'."ts']J]: ,fl: 'l'


nose dta. lf the dilterence
ll"'" lp". t"o rj:'ace the a'ns\nft'
,

Il
Fig.

Fig'5
fhg6( the run out-oI '1"::1il"x
iorrrnals b7 suPP,frtrng
ether end of the
rr orr
iournals'
j:"::
Ir
rr
Measure rre
and tne resPecti :
bearing oil clearance
amshaft b-".'i':rct
:::::t:"
:3..i""'l:: -
snouro uc ;r".p'".r"a u
u
V;\Lrar') exarn ne t-.e idle'- gear
ard cianl. ,hat r n 19 c:-a: crd "iTt:;:r9::
.o.,.i'.', Ji',.,." ,, rr
wear breakage'
found defective'
Pttrng ano
rr
cranr ha.r r;-r- B se-t
wlth 1ne^
t?li^].rnt
,. I
rnterierence flt
.j"';;;.;;'. e'|.€ ep'|d" 1no
r
gctr cr r

I
,l found ,n Sood :ondLtron'
I
E,an-,1e
cover for
tne li-''18 n"' u.. o
anY damage or ril", "i$,.J"
"5
I
necessary'
I
front stde wale' rnlel rove'
I
[o'
lnsDecl Lhe
o,",ug" and'eptace iI
recessac'

I
uni

Cove' the
c'P 3nd rnjeclors opecrngs b'
Llrn',-,'oLr, t ca:rs till ther 2'q fir1eo bacf
in the engrne after overnaut
for. .?/
II
check the tappet prunger ;j:::
e,g2(3ge and ",.1"::: ,r"-b.O. ot ,n"
lhen - I
II
measu-re,
serv;ceable \ ,,l" rdrF
raPP'I prucger '-'O ", . ,^ol,o
case tapPet bore ano ":"- ";;.
-t1",rne
be as sPecifred

aneL! DUSL|oo ?'los lor ar'


,nO Ue"O Pep,".e
it nece 'a}
e (e':'e ,&ad'

I
VisuallY check sumP
ends for anY damage or I
crack.

Check PUmP :uction'


oil
lrller for anY de-n.rege
deLivery PiPes and
or cracks and rePlace
lllI
if necessaq.
:^'^'rti..n of Piston' connectlng rod' lI
I. AL68O SERIES ENGINE 02.7I

f Visuallv check the water


outlet PiPe, inlet

f. manrfold, e'haus1 manifold


for any damage'

f, lnsoecl the fuel pipes from I l'P' 10


inleclor
'a]tli*at""to"t'lllv at flared er^d neck a^d
f, ."";;.;; ""J"ttutv Replace atl
ti-e fle\ible

f fuel prPes during overhaul

f, l,' lest ll-e rnjector c'erflow


p:pe'
Lea<

f. Clear all the oil ways


.r*tt"*
n c'an( case' cyrieder
and ca'rrsnart thorough'v

f. "-"1"
Cne!t rrdnL.hafl pulle, lo' anl damage and

f ex-essl\e ^edr
ard roF a ' 'l necessa_v

Ei, Check all stuo threads ano


th-eaded 5ol^s !n

r.
L.
in.'.ru.r
necessary.

To Assemble
case and 'er l'f) o- eDla'e
AS

L.
t_, Replace all unserviceaJle Parts' Rene"\'
seals and Saskets'
cl

ro o'r --drre1 d" j


L., Ens. e .\c 'a.tr ' asc-r'
'' Po::'' steon
r-.' '^,,n -ia",", L.n.
:',;",-";, '-e 're
r'na1
-c o'o''
r""c l-s o
E. t
'-l ",10" ui"l app
-a.]U,
ll , ',"
€ ') '

L.
r_.
pernaLoc 50'

C,. r ..\' ' .1' 'a ' 93 €'nr b


ccth
re anci
before
l"i"i".',""t bcre u'r-- a newthe fne dust
ts, ;i.J; ,;" clear olf frorn lirer lor an)-
r.;i.i;, Checl< the :ylinder

I._ [i"." n"," or. ttatlt be'ore and a]ier fltment


,ri.i ""J "r""tital tc: larnp with
I00 watts

f; Lru l-.

L.
E
. . ./ ^,( c " "cl'
'n c ,' '^ "ne
bor
"r
d
e dnd
P'ac'

E. ..-... !(t, € f- 6 ProS L to t\


lte . -rne c linder liner

L. -'. ."-- g*,,, Alterr -'g


,...- ," f",t"tl u,' Ireez
-'he llne':' to m nu:

L.
L.
.lf n u f."",at or l' the ice s3lt mixture
'-
-.;";
ti* hou" a"d varming the crank
:::: ln steam or- hot '"alei

L-
E
:-::< the water- wa s rn ten
.-,-ll"
.
c,"1n',n"tt
j.-' .lor",
Fr' the
the block and

''vater inspection
brass plugs
holes' with

I--
50'
:. - : lomPound Percraloc

F
:'--.:'-.'.o ,\,ater jac<el Plaies cn LH side
. I '. r',iih ga:ket after applying
=^s,""
.. -, ..ip.,nd Permaloc 50 onTighten
eithet-
.' '-: gasket se3ting surface
Cool the oil pumP shaft bush to minus 4'C
in a freezer and then flt it in the crank case.

Fic

Take care the oil hole and the slant edge


I
faces torvards the camshaft gear. Thls
proper fitment ensures the lubncation to ihe
can.shaft oil pur,-r D gear. II
Fig
I
Befcre fitnrent
nrinr: 4'C
rool lhe :arr;hafi 5ear Ni.s tc
'.[ c c.]nrsh.i: ierr rg: i: tl: ,
Fit
I
:rank case :quare '; us ng r rlr '.. \'\ r la
i'ttirg 2i:d and 5tlr cenrshatr be:r'i;' .:n;.]r:
'.he bearings o i hole co ncide:; '.^' :h ih:
crankcase ci vr'ays ead ng to rcriier 5h:.11:
II
i,Vh e liling t[-: Iir'!t .,]nr!'rrll r'r,lr -! ie.
thal lhi: 'Br-oc!e o. tlr: c!,lr oite I
per rirer-, rlels eai<c(l in tit dov,: a:1e,: .
I
lhe : r'anl ca:,c.

I
.\/l' ' .l , '. i.r irti: i lr l. rq i :,lc l.
!ha: :r !r. 1r I iii :,ii it.:l j1i' 1' '11 -';l
a,e.t, rja ii r',i::
rq.l
li ,t ri,': 5irtat l- ..lr -!,, II
arc llol alal-,ragaa. 5c;lur n llr!- al rr:-:i:
bear'.g ic:r iq :arc\.1':r ,.r1,. ,.,:tslrer' erl rck
I
th.- -/nd Jr_r .1Lh 5ii i.r j 6rrr .-, |:l,ai:
bear rgs Rerro . e the ou-' .r the nnr-- brr-e
I
cf ihe cilrr:h,rit bear,.-': :nd iri!,., a :he
locl,:rr:u tcTc,..,: i _it n.i itrc'.:c,,rrr; oL, - 'i ;rr
I
lic D oi i.c aarf,ir.,i. bcrr n!].. ' ,,.',ra
p.cleitrng replace r.,.,rtir aorreaL src ll :he I
loc <,rq scTcvla,iih ,,r,a sl'cr
I
Tap n the rdler
posi:trn t
tro I in the cranl .-a-c :.rc
!!Ln8 a 5Pef ri tcal. f
Fig-9 l
\, 1, a br
50, :n the
.pt
< ca rr'
o' '
nll L-:.k p alc
l
Seati]g surlaae
cTan
ard placr ,n" nnr1.1 ever il
i l]r
:r
Air dry and apply shellac ;uper over ihe
ga5k.t surfaLc. vount the t ming bacl: plale
:t
after alrgn ng the 2 ciou,ei holes ,,. th 2
oo. P -. r I ,,.
" -l
p,1si:lbrass l.anrmer an'l ieai t p:.[e.ii,,.
J
Ti!lh:.n tlre t\r./o set<fr-o.//. b. a srr-ey, dr .'er
on ::c Ii :ide bottorr, 'iir.hler- ti-: i.,,c
J
J
L.

irolt: n':lr lr a: .l el- Uc: .- ; tha ll,l- : le


',vl-e cck lirerr.
Fig t0
-t
-t
ll i |:r. ,: ',;rt . .L/'j ir 1;rr;i]11it 11,, :. ;

l
.. tf seliif g aor ri)olrnd pe if .rio: !iiri..
r-r- r, rn,.n, drrvr-r .r.k rh.' s .o ii i.,ra
1

l
Ir AL58O SERIES ENGINE 02.73
IIJ Apply cean engne oil on all the seven
Ir camshaft bearings, camshaft journals. lobes

f and oil pump drive gear teeth. nserl the


ramshaft in the crank case gently b) roiat ng

f and fting at rear end inside the crank case.


Check for smooth rotation. Fit the canshaft
thrusi ,,vasher i"rirh lew shin-s and t rh:en the
E iour- bc ts. Four slols ln th: camsi:li,
.\ ts' l-1O .lC
Ia'6 l1e ara- :'
--hrust

E Che.< the :an':haft end P :v anc t :rotrld


E :e lhin specilcations. Ac,trst thc e-,a plal
r'.
iorre:tly b,r adC ng or- de e: ng ihe :' "s ci
E 0.0C rh eS: 1a, \'r '.p , :-
ihru-.: ,,vasher boLt wilh sing e
'o,.r

E Fig - ll
'.vire

tr Keep the lelt n clean eng'e o 1 -or .bout


E. an l'cur. nseft I n the uPPcr .ir.'.heei
f- hous rs groc",e snugly.
:-- , o. ,^d oLt -' r't
She r off rr a knife
:1 ':1o

l- ''e t r-l :-"'r. - or ,r


rfter ,eat ng lhe lelt perlect '
,.rh ;

1; Fig - t2
1- 'T; P ,:o' ' o' Li'.
r- tirc ,,[,hee lcus ng :eat,. -]nd .:.,:: iirc
il),,', i:: ei hcu; ng ga:l<et o'c, i A. r and
l; app. ; '.hin coat of grease -.\er I-: !?!i(cl
lcr :re pe.fecl seating ,l ihe f . . hec
l. housi^g and easy renroval ii iuture CentT
lhe flTwheel housing uPper over
l.
place Lhe
gaskei and tighten the eight bolts rvith plaln
washer to hand tight.

IJ with a clean cloth, the crank


r]
t1 Reclean case
main Searlng parent bore, nrain bearing cap,
main bearings and ensure all are dry. Place

r] the main bearing half shells on the crank case


in the.. respective seat. The bearing shells on
2nd, lrd, 5th and 6th journals have identical
LJ
fl width and therefore these bearing shells are
interci angeable. lst journal has more v,'idth

Il and nct interchangeable. 4th and 7th are of

t
same.vidth.

Heat :ne crankshaft timing gear in a heater


to l5l'C. Fit the key on the crankshaft.
Fit th: timing Bear at elevated tennPerature
using a drift and aiigning the key way ro the
key ari seat ]t perfectly.

Check the crankshaft oil ways for cleanl ness.


Smear molikote or clean engine oil on the
on the crankshaft
main :earing shells and
main curnals. Lift and gentiy P ace the
cranks'aft on the bearings.

lnseft:re crankshaft thrust washer uPper on


fi a artao t t *t *1 =' o' * t
-.7:1",,1"-..",.nxH'.,.i';""T"':Ili:
"xt*=''*-t'y|1.:: r .:"'*on
',1*',.",

APPrv morikote ::
:l:i,:"- ?'i,he caps
q!!
-xin bearlnP Inrrer >u' :
e, A, C, O,
ir," .,unt :': :11:i';',1".11".,,n o"".nc
i;,1 lll ;,#.!:-:"j:''^";,R':.::"':"'::
or i'
^^''l G is at rear sloe n'"1
'fi'^ Jr-:";l^" j,: j,L,'r"#"i,.1i?.
*'Jl*;;","J -on
-l'[
:?#, 'h" ''""'
1369 tnq cranrshaft '
iJ]il"""tn"''o

Note:,ti"
ffil."t"'::il'l:X^:::.::" U:'*i
'H;:.;::'li,;{'1.*:t'
Punched
above the f :+' " ; *
machined sudace'
(ap bolts to nand
qrrc\^ rn the marn Dearing
i*i-*,*';;""""r fi sr lhen.-'.| *1:::
w?enrh tighren :l-:i".::::. ,ora1ic. ol
l:;::;,J-:';' iJ.: ;i::i^,;""\rol n!',''oll
found l'8ht..rrr.st,
oind,ng. tt' ' .O
-:: '": ::. . .-o
n

fl ^r-cer P,shL ,.,..


", l"
nd
'.i
:;'.:. il""-"'"1ror i o' : .t,l;:; .I::
f r^" .,aer '.fr' checl
,
"nlo "
ttt" caPs
.

Lakes Place and


rect tt'
.
" rer
l.a ,r" ,
.o.ng
II
.-iL,.( o, L '.:'r
Fig ' 14

-.. I
tl' II . lee ""i, o"
" laou]o
il--tjl I
g

i; " :.,T;'qt. :*,


. ,,
",n
I
r'\ IIh'' P' ",1:;#:;J
aYral nu
'tl L Na'n'r' I
f pru,'ng o
"'''nae''
:-'emb-''i.::'i'"J;",:'"ffi::' i::
l
,t
lI. Fo,
"i'",.,.^iJ"li:,-l'' I
beartng, 11""i ff:
lr
ll".ili^'
orston, rings and
clean eng'ne ot
Tl;n
'
t
I
molrf ote or
I
Lnsu'e the connec:'"'
l'.lr:io;:P.:; lilf; I
lll','jl*":"'..^;"1 3.;i;;;:;',
Demove one co . : ):l I
Do.,L'on
::"';;:". lr^. .":" I
'.",? ,1"", .rJJ15
I AL68O SERIES ENGINE 02'75
I
I il'* .*. r. o,,
"," 1 i,1',.',l i" ?,,,1 11

I ronnectinB
uia
rod as alreadY e<Ptat "!'',ti
-."#.ting Rod section'

I .herL rhe colne.l'ng rq6 ends^ecined9n


play- the

I )6.
:;:il'f
Cnerk Lhe
,;;',i',r,oJ,a
,
u" as

,on,1;o^tt''l
,l:tn*::;o"""ol:
T j'',"0"1,""a fher i

Ti :1".:'T;':::,o,Ji:'
t"uJU"t I to 6

fir, tf'e Pr'ions


' 15
Fig

En.ure rl e o' \a -nd


o'l ho'c in rte 3-
', .o o, : ,n r" "i1 .,iio]J t,."
f1 l
" -l

@
o,l ou"r th" s-afl
g'at."'o p,r." ,h"
'ighl ,1""-
.,e
E1 lrdrl case rea,wlth i. ":
gasKet ]:; rignr-r dr

EI thrust houslng
two bolts

l-I Fig - 16

l-l (.noar g'ease ?" tn:- 9l:'


o,e,uli.',s:i',^1".',"1i
Lr washe, . rhcr t,o" - ,n,u.,

L
r-
a5e r- :s po Lon. ,r -l '' o, ,n" ,^,^ur.ng
rnner on
washer'
the Sreasel

Fic
,,'.
lace

tl
^urr,",

T
l. uol ' l^ ^ -.
L
o
,.l ^n ".0.- J;""'-l
",." o

1"1""'"i' l:".^ Y.l ;lXi";:';:


on tne ote sea , 'or'.dra .'']1",,. a, Ln"-
L. ?x':"fi3, ::', :"" i"'J",:'Io," r;gnre"
''e
L. ':rl:.t;::,.' o"'i''' ' 'o'q'" rl tn' sPl'r
dnd

L pin.

L
f.
Fig

checr rr.e oo:'. \noLrro


, uc
IB

t: o'.'...o t';:.t',t,Jo
and end Pla Wh - ^::,
f, in data

E. Fig - 19

L
r_
I-.
I*
I".
f.
I-
I
ENGINE
oili-ot,'o 'ERIE<

' . ,-3";"-"i.'J""?o''l ," '''" ;- 1"" '.1


o Lhe 1]r'rq o"'t , ,., I o"
-,tll'
,l- hal gedr n oJ'-
r'e

spt:ified tcrque'
Fig - 20
c-..rn :haft gerr
C - t th. dlcr 3n r 'n-i soecrll:d or else
i
h: -- lzish 'r d :hot'lc = '' ' .r..1 .b"ain the
,- aa" tr: dei-cil I ': --

cc ect baii'' a:h'

Fig'7l&77 I
I
,''rD"\"'Ij"r:'"
-' ''; I
, 1,".1 rrd after
.- 1.,.n ,, . elrl and::''-' I
ll'tl llrrrllrB
'rT I
i
,,,1

L ,:'1 ; i''i
,1 ,,-!l
.' jl"'-'"
.L i'iLr'

lf, r' -' '-


I l !li't'rr i- '
, l,' ... rr,.l -. .
' rt "
-_^_' an.
Nover hanrrn,, ,,r)"r,., n;,,,
darrrper
*.'.t,f..
):,)ce ir is filledbe^ t.o,,. t"rr,.,l.
o.-pn' shorrl.c! .l::i."';";, placc ir '
rncl if ;tnY leal<age tror'''
t.: i i.|]l :l
''r'_'-
!ll ll
.'r : ll,'' '
.':..,'.' irrr' lr'l orr iii'
ri Ii.' llr ll rll i L,]'-(:
r!.'PC i lrri

'.'' : r 'rr''!
il'l: ];-,.li:'.er''1""1,,1"',ffi
"r"''er,,'trot
,ii.'i,r'li5,i'"ii"'
"
bults uP",.
i:::
,.;-,i",.;;'"";"*i
r :.-rntir. . 5pg ,f,'1
'id" ,.:"1"".t;::
qo'''1? dt .^rl.
lo:\ _
"o"' ". ,o "
r"^,^,L lhi - -:
que

Fig ' 73

' , 1"11"

:i;:
;-:.,;;::, ",,.
-""r. il
1.[ii:
.;t"ii,:j.
,*,:::;:.,
AL68O SERIES ENGINE 02.77

Il"] r-.
llr( rLC v ","" on
": - the connecting pipe' Fit
*ou'LLu
l- rno oDe o rn-
1l ' <rd1 ' o ]" ^:
,]
", t"-""tt "nbr' ^
E ;':;t:;,;;";"'', .. .o;,1-o lo; ."1

E :":ii :,::l', 3" lj J:'^';: n:


E i,,"';,

1''-)'
E*o,", tlrl ^ zr". -
E
E ::i,::;" il';."il*1.t.";-::;'i l: sumP

.,1i,^. ,,e th.'e 1u'' t\ J' LD" (L)

E
lJ. :-'
r_ :: r::'_":",";;; o;;,,,. r::r

tr ''
' ,L
'
" a';'';Y:.:".1::l' "
i"
l-. ,"1-l;l:"i','':': . ou''',.
'

la "- '

l-. "- " M,;; s'-P & Droin P!'iP Arrongemenr


\..^.",
- .za.
r,
L.

E
Fis

t^l:",:':'
E,^ - ii

fL. "

;,- -;n
r,
L.
f, :: '', l.'. ,'"--
n' c "o' r' I lftp
' he 'ni '9' do t - o'
., ,n- ,t" P"' "" 'u'L'
,-.' ,: . ".') ," t or ? nuts 'i' .1o-h"
bY 'nand
.-:.;:- ril .vtlno"' heai
to the
-,.l"'." t,-L,"" ,f,! cylrnder head nuls
-. ,L lo OL-,. 11 DroDe' LqLc^ €
Ir I n
r/ 01 55)
,.r-, ur'inl"" ""r' in ltgure roage
.:'-;-:+,i n. J' t' e c)"nder "ead

::: < et

Fig 77

-'.' :-''-, or,1"":"'. l:.11ii:^:'*"0'


sERtEs ENGINE
orli-I.tuo
* I *:,':*
" *r" ;l:ii,t
I ;:t
'"Pt"t'
'::':,."*'J
+'*: *, x,y #" :""' :
, o"
"0"r, ",0,0^'r'::"*J."1"";i ::];" .;r. *irh
::1"i:"0 ;;';; the setscre\tos
qreare
?n ,n" uu'u" caPs
on tne varve wiLh
46
applied on it'
on the
o,'' ,n" r ocler sharl assembly
"
::11;")'\":; ;1".
41
-1.:r'-;A
t'...uor oast<ot EnsL're
-.,ot tne "' :::E:i
o'r '1a/
T::i:l ::;;;i ,s oo,rruc,'ng '1f'c
from cYlinderhead'

;":,;,^",'" ::1 :^ :^t"J"i'I.:;'


,.,,i,nf
Ti::
,!_- ,orl,er arm tree on ,,,"
mout n"ts frst
,,rf",ten tf'," rocker braclet
li"il"o tttt l"o 1o the
sper'fied iot lue'
are lired in
I^-lrlr the intectors' lr'ectornuts .t the
I
nu':,il:": ;;;;'"bv r^o'|ding I
injector over-flow PtPe' a
on its periPhery'
Flywheel has timing marks l
Fig'28 I
1

MoLrnr rn{. ny*1""lll


i

oe lltteo on onlY
ol" :::i:::-.}J;:
''li'i,,i".,
:11
rhe ""1.s_,s'uno " "..f
o, ,,,an. Irghren L"o the
to
i'ui" 'n" :'::'f'"d. 'oj,1"frin" n,*n""'
run oul
inasher' Check the
face Plate'
Fig ' 79
on the flywheel
Fit the timing Pointer
housing'
Fig ' 30
An lniect'on l mios
ma
: f:,:;'r":?;: :i?Ji
It:111
IDC on eneine
linde''
,ll;; i
orrlbChisel ,ut,hing
Corresp^o:
c) n'a'kr is
'",;ection timinB^t',t '' ;;i; rhe rnarks
.,.ovrded on FIP flYwheet i' aL the
mu:t (or.rc;de whrle lr sL c)li'der
strore
end of comPression
timing follow the
For setting the iniection
given below'
Procedure 1 l"
I Al'en the rnl'ct' " marl" tlO
?i"'
',;;'
t' Gefl et' 2o' \ 'rh
BlDc
-l::
th? r''nrns
;; ihe -re
"h'elflr //neer .lor-s ng'
n,]utt rtt"d on
"' lhe engrne In coLk^r-e
'otot;ng
"I'""tio. ii"*'"t from front end)'
end of
first cylincer is at the
Ensure
io-p.e1. olsr.l .
th: cngrne DY Jt r
.:]","#..",::'i;:
sarne. of the FIP
AL58O SERIES ENGINE 02.79

the FIP keePing the mounting


II
II
3.
4
Mounl rne
Mount
bolts loose'
Trphten the 2 bolls securing 1ne
flanSe

.o"rPt,ng Plate and FIP flYwheel'

II
fl.
5. Tighten FIP mounting bolts
the
bottom suPPort brackets'
FIP to iniectors
at the

Connect the fuel pipes from


to the
EI' ,-^"n lr-","'" th" n'L' on e:Ll^er end
,orq,"' Fn the wo tnjecior otoeI
flEI il".inEa r
"
ii".rt *nn" *obe' bu:he< 6en'[in'ng
pipes together each side'

fl' Fit fuel overflow PiPes'

fl'
El
F,t rhe
*itl oil ro abour
,"a'irr"J-,n"
i""oi"* two o' r
0
ngs
/\
tr
oil fihe-
oil filter housing wrtr newliL'es afre'
Posit'on'
,l.r.roi.,h. four nuls with double coil spr'^g
Et ;:il;.;.;
,rr"-Ufy pf"rt"
of the fi'te-
construcLronat oetail'
reler lubrication syslem
El sedion.

L.l I;t the oil pressure relief valve on rhe


en8ine
.rr"l.r*:r,,n Lhe SasLel lrghten the
four

L.l
\lE,I
bolts with sPring washer'
cylinder head with
Fit the water manifold on
the mounting bolts with
*.ri"i ,"J-,'gnt"nwasner'
double coil sPring

L.l
LI
head
Fit the exhaust manifold on cylinder
'n"rt"'
*,,n fd'e lo^drds
s relall'L ''c
'n
.;;""":-;";" soP and t'8h'en rhe borts'
L,t .:;";; ;;;;" ensr.res L;'rert rne 'nanirod

L. cooling PiPes
on
the inlet manifold with Sasketbolt'
L,
1

lYount
, i"0",'n"- -de and L o-ten Lhc '"
L. I
each wrll, douo'' o'l 61 ''
a 'shcr '

L
L.
Frt the flexible hose on the

,t-"-i,,
-.'1 '15' Yount
rmoelle. cas'n8'
qng'^'
the
waler PUmP
waler pu'no
trot t 'nd 't ll-

L.
w'l1
"r.f..a u"a LrRnlen ll"P roun'118 bolls
1Fo' a'-erbl7 oI
wale
i"r:no *rrn"i.

E. ;:;; cooltrg sYst'n 'iBhlen the


"i;,
of imPeller castng'

L.
hose cliP

Lpen the Le,ted Lherroslal 'n If,e


f-- ,*,-"tir, housing' ['t I e ']ose wrth hose
..,,0 on *ut"t pump 'nler' lYounl
he watel

E.
I

o,,lt"L f,ot" or lhe waler ma.li{old'

E. Fit the alternator bracket on


the four collar

E.
I
tirit,-*nitH were Projecting
RH ,id" .ou"t' KeeP two distance
,nO i'nnt"^ rhe rwo bolts *rth
,
from the front

spring
pteces
washer
T:^hr6^ {nrrr n.-ls or^ the
02.80 AL68O SERIES ENGINE
ALTERNATOB
lYcunt the alternator on the alternator
62.
slrnmonds nuts'
bracket \^Jlth two bolts and
- 3l
Fig
I : LLe allen'dlo r a."rb', sl dr-g s'ot'ed
f.."1
"-
l-r^" ,f."- ,,,",na,"o
"f touslng
,i" t:mrng g'ar
r "de
'r'tn - bolt'
Io'lo- roli
I
r," r:::e rr'ou.'' '1e
;;-; i:"r'; 'nc d ' ' Lh'
^in
s d' 4 so
9'' 'o 'd:o
Io^
I
;.; rnd l''rr':'or
," I ) c, lT' cd rPAr P'r
'cl
o' ^\ ie
I
;-;,
PL.1o ou'r( o-d
r'-cr r -' O-l'c ' PULLEY

I
,\.r -st 'r
.;;;
.'. .r^ t
' 6 i(\rnJLor 'L
' n o-\ I
\ "o \'r 'r e el
I
:;., i." tAi 'a' ,
mounting sln'monds nurs
11a 1r '' ' l''.lJlo
The vJaler PUmP I
o"ri t"it,on ls corre't fi Lhere
louo ', ','s', r''-.'t lo ro
rs
r'11 I
on the lons.e i s
'le ol the beli
'1i OLrn'i ' ]rnr
t
t
O"r
lqOr,r n- l.'
,';" "i' ror1'
"'
sp. ng washe' .

-Ii:r 'r::cmbl,' ancl I gl'':n J


i'lount lhc :: { sl'r
llle thr(lc rr!:: ""rth " a;1"'t I
Fig ' 32
l
66 l.lounltlloli: erer :tr,l -onl-rO iTl<age! j
P a.e lhe r '- ci :eparrtor
with the gasket .!
6l hrealher o\er
on ,t," nl s Cc cover lrt the I
It and tl:lhLen tlre three nrounting setscrews'
and clamP :
Flt rhe o I pressure gauge pipes
the PlPe firmlY 1

69. Fit the water drain Plugs'


Fit the oil seal housing on the flywheel and
14.
tlghten the setscrews'
Rotate the crankshaft and bring the first
,,l,rder P.Sro Io rDL CO'nDre Son
.1,^r. Cn"a, rh- por,e through flrwLeel
."Jl"n ^.oot t g" l.r d) ra-' on thc
n ^ ""] ,.,1 ensl'e '1 11 il l^1 5 '''1
,1.r,.-to" Adjusr '.l" [rst '''nder 'al
es
(oo-o
;;":;';;,"" Le to o5o8Eorlo'^ lhe sd'!e for boLh

ni", onO e au,L.


ro lhe oine [''e Fo'
",..",i:" I a/'n8'r'nde's'
IDC rnarls
,'r*P"'" fl;unee' '
"o, 1r'""p',."t i. pui,r," r'o) ')'5) \3'4)
r. tt ga:tet o et, the
P'a, e 1n- roCLer ro,f
.,f'-". f^"rO d'd llgl te1 lt'P mour'L'' 8 bo'ts
with double coil sPring washer'
l'1ount air intake PiPinS' turbocharger
& air
mark'
.i"-", ""0 fill the oil uPto the level pumP
water.
l"lount the heal exchanger sea tn
&-oil cooler and connecl the hoses/pipes
case of marine engine
Re-tighten thecylinder head nuts in the
Engine Testing .orr"?, '"q'"ntt to the sPecified totorque
the
and adjust the taPPet clearance
Iz.r.r Aher major overhauling the
ecgine' carefulry
are bed'
:,;:in ;" .nci* so that the rings racilitv
correct value
II. :; if th"." it anY exiernal
;;;;r. ',"
check the ergine using a Final Test
IT ;i"O* the r^Ynninl-,^l
ir^.." -""t follow tesli'q
02.9.4.0
Start the engine and te5t the
following

rr
rli
for
below the ergtne
Oi"."arr" given points:-
ac'FS-or cs oi lhe R P'1"1' of
tnstalr Lhe engine wilh all r() I L . Adlust the idling and maximum
test bed. ConnecL Lhe Tadrnlor rll up Lhe . the engine'
ho'es' I
i'"'i )"",'"* trstem with At various speed and load check
the fuel
"" ,"0 ?ngire oit to the ''\el' 'f the
i"3'ir", l.
:/rem rs Lo ce 'onrncrpd 'o consumPtlon'
E. l"^],1"'
".u.t ol \ dteruPDl/ lack uP
-"" '".,"r""' iou'c" (furl, ooen cord rtor\ ( lhe orl pressure ''36ing \ould be, Iq

E ,^^ ,i"r-ouu,
,"1".r"r,,, ]nJ to-o'"'" the
rg -cu' c
l',-,-^,,-. ,t l600
;";;?,i"t" l'
PPI'1 ,rnen lhe otl
as'c un'l 'ot 'ess than l5
E ''l;,;"
L oor
tLe P Pe 'o the ;.'",, "-i case or cer 'et engrne the
;:,; ;, ; ;^; r'P Conne L ''"'o'"g tno'ro be J - I a k8/
fsnlq6r oil bath tYPe .1i ;'
E. o,i ilrrr." *uut"
air cleaner'
"s"J;;
im'"-'"0"
i'
aL r50O 'Pm \ re1 rhe or' temPerature
as:c' fhe P essure ,ran^ be

E. Give the fuel


- connection
to the engine and
ru"m Conre'L rre
r.o'Lre ao;usted .ir '."-a'llo
between the sPrlng ar
,?'" ,;:""j.'"0 ;il;''

E. "".i"'"in"-
i.",1' .ro'" suitably' I ub c'rle lr '
ro(! er
engine for

L.
a ba'te ) about
r".i *,* tn" engine oir' Co^nect For the flnal test, run the rhe
to the self starter' , n"rr Durrng t\e le-l'1g' obscrve

L.
F ess've
..,.,,t lne e'l'aust "none' <

Lf the cooling systern issuPPly


to
'onnected the i.i ",
l" .-"r." is r auscd - rdrl/ Lr\ or5ton
t*rc" oi water then

L.
L.
"a".*f
,-u"n,f, ,ru'"t oullet 1en-rPe -a
IrlnLrin"a berreer 80' to 85'r-'
,
u'e snould be
".lrr,"n

":;:,
.' "1g 5rr'' 'r g wL':| 1 An;Le
:r
Inl o.f".t't ar,
oT

, ru."u', ' rrrecLor' Be't;r'


,"-;." oJnor. .lolrced
ouri'g lhe test
o-nDr'l'd re-no e the

L.
L.
Running in procedure for Genset Enginesas
nrn ,fll "ng'n" for abouL three
hou's
ou", r," i"t.-g
.nn,n" [ro'' t' e
"l-?o."".r,*
installing.
lne tocne('rors gr\en
bed ater
^hrle

L. 02.9.5 To Refit
L.
L.
Refer section 02'9 0 and Perform
operations in reverse order
to re{lt'
the

L.
E Running in procedure for Marine Enginesas

E. ".rn ,f,I "ng'n"


for about three hours

L.
E.
f
I.- _
R.
1540 36-8

F cne'l' 'o' o''' abno'mal


'.-'.g" the testing ,//:ller

E 'eoLs' Atte'r I e' I


the
. , .il fuF' or
- - - ,-
" i*t remove the nlecto"s

L' ' .
.:-.-
'r^, 0",,"'" u"o then fi' them
rdlustment if required'
bd'k
,ri-IGo tt*to't"ot*= o Es
ss Rl
o r,-t.t *t cA L Ac c E
;;.--.,
No'
Alternator I Starter Motor SL'
02.1 0'0
label
make has identification
Alternator Lucas
of the unlt'
tYPe and SL' No'
'"io"t'"t

Starter motor-
Fig-l

lucas make has


a identiication
and SL No of
the unit'
II
,b"'-rnd't"t'"' type
Fig'7
Ir
I
I
Data
02.10'l Technical

Alternator

Make
: Lucas TVS
I]r
-{
GAc5R'24-504 I
Model

30 AmPs ( 24
I
CaPacitY
Volrs) 720 Watt I
I
Starter motor
Lucas TVS
lIl-'
l'4ake l-
for
l-
l.
Model
G5L5A-24-72R
Genset Engine t-
l.
G5L5A 24-72lYR t-
lr
for l"larine Engine
l.
Voltage
24V
l.
I

Lock torque
4.6 kgm lr
I

2l kgm t
Running Torque I
for Alternator
Il OZ. t o.z Preliminary Checks BATTERY CHECK
and Starter Motor
tr Starter Hotor
E test eguiPment CHARGED
E Recommended
,'' , t Moving coil voltmeter
Scale 0

E 2OV,4OV

tr 7. HYdrometer
are tyPical only
Test figures quoted
ts no'"' l.
I During testing' the
engine should be
ts startinB (without
cranled wtthout oPerating engtne
E admitting iuel) bY
stoP control
E Test I (BatterY check)
CONNECTIONS

E.
f- Hydromerer I""d
I 230. lf it is below
t ll 'l:';;u' .::".:JJt, .
tI '

f. test.

L" Fig'3

L. Test 2 (Battery connections)

L. /.suarl., che.t .onn"c''ofl-


rnc and the Presenc"
.t,
t::tt.ff::,;:
t
:"1".:,t'", p'int to" tightness
ng,-"o':":l
\. :"":l::l
L" ""1"*"r.,
and check
BATTERY VOLTAGE
ON LOAO

L. Fig'4

ts Test 3 (Battery voltage


on load)

L. lf tad P - does,nol-OO"'**rtt*ld
to'"J"o,-11

L.
L.
::l:.:'""'
,',tt-eter
o.n,'"-g.*
"i
"."i " .
bet\^r'een battery
n"'"''i;
ShoL,rd readr nor j::,
-. ::;".""i
:i:
L, lao v l[ the readrng !s I
',,"" '"' cha'8e an'] lo^
Ierest

E.
I
.'.ith
"tl"n
good battery'

Fig-s

L.
L.
Test 4 (Voltage at
te rminals)
solenoid oPerating

I.- ottmeler 'd' th dno


sole"ord
:trnnect ,
i -,",r cr anL engine
,
:;:rating ::'..^,,.,"" '.1"
value shourd be wrlhrn
"nO
: "erence "' """*91 .^., r lf the .oltdge CBANK
:*. - _1 \,/ of 'oltage-rn 's' r v'. cnecL ,tare'
f :-::s by mofe Llrdr'connectlons'
"- o.-.f
nc""/ il

E .-hall and
cables
STABTER
-::ass3ry' SWITCH
L-'
f

l.il 02.84 AL68O SERIES ENGINE


Test 5 (Voltage at srarter on load)

Connect voltmeter between earth and VOLTAGE AT STARTER ON LOAD


staarer terminal. Reading should be within
0.5 V of voltage in Test 3.

Fig-7
Test 6 (Voltage drop insulated line)

Connect voltmeter between battery positve


i terminal and starter terminal The reading
should be 0.25 V rrhie crankrng the eng nc
f the reading is above 0.25 V check I
starter cable, connections, including chassis
to engine bonding strap, etc. Rectify ii t
necessary.
VOLTAG E OROP INSULATED LINE
II
Note; lf the above checks are OK and st I the d
starter does oot crank the engrne, check "l
the starler. rl

Fig a

CRANK
Alternator ENGINE

S :
Recommended test eguipment
:
D.C. lvlo,/ing coil vo tmeter Scale 0-24 V
40v

2. D.C. Mov ng coil ammeter Sca e 5-0- 00A


DRIVE BELTTENSION
3. Hydrometer.
:
:
Test I (Battery check)
:
Hydrometer Reading
FINGER PRESSUP

Same as given in Test Under Stater.

Test 2 (Drive Belt Tension)

d be 6 mm (l/. ")
The fan belt teosion shou :
;nder moderate finger pressure. ll it s
oose, rectiry.

Fig ALTERNATOR CONNECTIONS :


Test 3 (Alternator connections) :
a
Check for r o-re\ | connections and
cleanliness. Reclify if necessary.
:
Fig - l0 1

1
AL68O SERIES ENGINE 02'85

st 4 (Cable ConrinuitY) CABLE CONTINUITY


Switch on the
Remove all connections
voltmeler beL\\ ee-
II ll"i".*,l.i connect
ll?i''l'J'l"o e-a'h read in Lurn 're
rl

II :;::il;"";; ,."uaing on Positive 'ead


- ll NNECT
TI Fig
REMOVE ALL
VOLTMETEB
BETWEEN -VE
TI Test 5 (Alternator Control) CONNECTIONS AND EACH LEAD
IN TURN

TI ConnecL ammeLe-
beL**",1 ttaf e
D': : r:#
n and n-o,- oulput
baLter / ard switLh
te m'|1a'|-^Jd'
on "'-
,o- o-e

tI min.1e. o,"
,"ltll:^'\Jl
'cd" "
1",-,-,
.,, .
,p=-o
-,-cr ,

ft
EI
Am.neler shoulo
amrneter Ind'(
aonn"a,,"g lrnl. of
ate

reolace. Even then' ll


o-
' , - ]' ,, oere ,. e.
alLer'aLor'
lnere rs
_o ou:fur.
,Ou, ,.
ALTERNATOH CONTROL

rl
-et''rc.
,iu",i'"*"tt ano a'1err alo' ano
defective unit' @
l:l Fig ' 17

LI Test 6 (Circuit Charging


Voltage Drop) OISCHARGE
BATTERY AND

l:I ggn'q( 1 to U L Lcrr nar 'o-ne'


I
SWITCH ON ALL
LOADS EXCEPT
WIPEFS FOn l MlN'

LI :;,-;.; d' os\


and alternator and
dl'osL'|a.'cd-r
then ean "?
t
,l''1-.

L.l """
,;' ,r;;; I ordl ' o'rase o-oP sr uurd

I-I not exceed 05 V'

l-I Fig ' 13


crRculrcHABGlNG'ot'tf;*t".?1"t"1,r.,.",r,,
rcnoss tlsulareo

EI
LAMP TEBT TNAL
Control) CONNECT-TO WABNING
Test 7 (Alternator

l_l Con^ecl ammelcr oerween


;;#.' -'.'3'" o,,'P-r
soreno;o

'"'";jl "[*:l^t:l
d^d

l-- I
voltmeter across battery'
.rrr'.r" :p."0 r1. I o-'-reLFr
r'd' 'L
','oo""oo't''L^tt'' \ ortmeLA' -no rrd t rd
l_- I ',1
n -' za o v. r[ InP dbo ' e
-ead'^t dr
L. ."i .n"tg ^g \\ sLe"-r 15 sa"
'ra( [on'

L.i
I

alternator and
lf reading is incorrect check
l- regulator seParatelY
and rePlace the

L. defective units'

Fig ' 14
ALTERNATOR CONTROL

r--
r-
L. -
L.
r
::IiJSlil',,.T,JiH+uH
iri iare.,or a"Pno,.'
",ii#lttti*fil*"'"
ACBOSS BATTERY
d''
til
iii
1l
iilt-t ot.to sERlEs ENGINE
i-*., ao .'ERHAUL ALTERNAT.R
I

i
l

02.10.3.0 To Remove Alternator


i

Disconnect battery terminals


'.
Disconnect

wiring connections Remove


the fan belt'
Unscrew the hinge bolt
of altemator'

02.10.3.1 DescriPtion
machine of the
The alternator is a 3 phase
armature tyPe'
revolving freld and stationary
Its output fr-om the' stator windings
rs

rectified by means of built


in silicon diodes
Lhe srip '''g
,n heat stn(s mounted wlthin
end shield. OutPUt control
is effected by
The machine is
varying the rotor excitation
,"tt ti.iting in terms of outPut current'

Cooling is provided bya radial fan mounted


shaft The
on the- drive end of the rotor
retur.l ve'5ion'
standard mac\rne is insulated
The regulator is housed in the alternator
itself.

Terminal Arrangement
The alternator has three terminals
i'e'

positive terminal, negative


terminal and

'\
warning lamP terminal /L"

Rectifier
The rectifier Pack comPrises
of nine silicon
diodes, six main outPUt
diodes and three
field diodes mounted on suitable heat sinks

Rotor
Forged clarv or pressed claw rotors are
Pair of four fingered
claws
ur"i. A
the field shaft from the 8
pole
envelope
imbricated rotor' The ends
of the windings
are brought out and connected
to two slip
rings at the end of the
rotor assembly The
.oir is suppo'ted by ball bearings housed
on the two end brackets

Stator
of a pack of
ft rtutol. assembly comprises
" phase winding in
laminations housing a three
the slots. lhe slalor is held in position by
Ring End (SRE)
the drive end (DE) and Slip
shields
tt"ttt
iiliilrro* ENGTNE o2'8'

POSrIIVETERMINAL

'illrnwrsren .-
AssY (- vE)
SPFING

*"T',JiJ",Xsxih

NLIT

t\i
t sl*G assr'(+ vE)

\:
HEAI
FIXING STI]D SIN(
HEAT

ll
AssEI.tBLY

F)g. l5
""'i",;i:,'ll'31

rr
[\

[\
ln-built Regulatornsr,lor,seo c-.,ce N.\r no
fhrS tS a " , ''- _ .^- ;Ce alre.'On
movrng D::1s ' "o']:''.,9-."".:: re.rsIors are
:$J:;"::,::
"nd
t
*;Jo ng, Pn""
,aPidtT rising
;;;J'
A lt"t"u:'t'.ts^,
vohage ts g'' ".0,"d.
'
Tr,.a lraa ,tott
o'?t'- -r
..1. .5s ono r.en Self Excitation , .,,-.".,r.g Current
[\ frred on . Pr 'nted i^.it_"- ne r d^
l-\ encapsur ..
:ll" ,, ^i.uro,- p..e "n'
" ""
a po,lror or eener"1e1-,irL;.,,r"* ira, o,
( Ac ) rs rectified

l-\ as rhe 'ode' 't t"'


., . u.r11gry flo.r'ng
I"u".-," tu""ntt " "- *t} ,"n"
*n*, t" -o.n'. -lne''
lo ,"^l'tl^.,L". .l'ed rn rhe
rhe three field d'odes 'nt" 1],,, rror the
pu.l oY'p".t.l-T"",
E\ through Lre tt"o'
les. tha-
l"."f"l;:,:ii", no,o,- , "r,
.,
,",,'i".
At +,,ae ) 6i66es
ierd iArr
nsld
:^d:::
'-PPre
rhe inrLrar
"r"n,ou*i ,""" .61er
ro.ror neld
nelc

L-\ srar,ona,

iillil- "lli;" voltage-w


clrliont L(rwrL 6 ,,.- n^,,",,
.. .r':^p rro,Il
causrng 3n

f. I ::.::':"".""i".:"
";
" the macn:l::r
nce o[ the
l^.I."u,,,o" or ,n"

f. to :ontrol
o,o'| ano *'":it,:'",
'",,-r;
'
^nlv I'erc \rrrent .f""0. u"o
::-: r;t ;':
I
arr.rnaLor
/.5 Li i! ";;'
r- rhe reg-:dlor 'l
n.r::o
^: :"J, il"I:::
alternaror'
il:'J:l:: .;;,
ioLor Lero .urr"nt
;:;
.n.,|-ol"-t
,---^ .^, , pa,es, thr
::::':;#:: ::;
E. in between 5FE
shield anct
untrl the alternator
become5
,1,,
ru';
",.r"0.
L. of three studs'

L. 02.l0.3.2 OPeration
Charge lndication
opnerarec oL,rpL,l 'o'tage
;' ;""'-*'',*"", ;,';;'"3.';;
L- Ev(itation . i,,h r.)r eq.r.alenr
lnirial
?:[.il:,
f-- when r"e lflt'"L.'",]i"*,'"'"ngin",, is
rs e<tinguisheo-
]ir"''", ia" ^,r,
nrnB lafl"p

I- conlrol swt(' '


, ."-rtr , ur r enl flows {rom ;;;,", "" "e",'li
i::i":"::"'i;: ;"'n" u-'
"1J,1

f-
l._
';:":::"; ;";"" l:" l:'i,,',li;
rhp rolcr f'elo wtnding
::,i:; r;i ; "t"'nu'"d
r'L ''
and rhe roLor
;.:
's
,;:'
"T:j",'::"
:::;:J;li,'i::
""'n",
J:'1'"; :'J*"s -
o'n'
p*

> magnetised
nartiallY Fie t5
02:88 AGSO'SERIES'ENGINE
Caution: A will rapidly wear and becau:e
slack
OutPut Control ---€
slip may not drive the alternator at
The main battery charging curent is rectified
required speed. Too tight a beh "" 1

from A.C to D C by the six main outPut


impose severe side thrust on
---e
diodes in the rectifler pack which function as
bearings and seriously shorten their life
a full-wave bridge rectifier circuit'
BatterY
The alternator output is controlled by the in
Check with a hydrometer the sPec':
built 440 regulator. The regulator functions
gravity of ihe electrol)te in each of :-:
as an electronic control switch of the rotor
'OFF' battery cells to ensure that the battery is -
field winding circuit switching the circuit
good condition. Check for the tiShtness :'
and 'ON' at a very high frequencY to
its terminals. The specifrc gravity of the
maintain the alternator output voltage (and
electrol)te should be uniform in all the ce:rs
so the current) at a Predetermined and safe
lf the battery is found to the discharged' i'i
working limit
should be independently recharged or
substituted before proceeding to fufther
02.10.3.3 Service Precautions
checks.
Ensure all co.lnection are secure and clean
Brush Gear
Ensure that no connection in the charging
Check brush as per recommendations
circuit, including battery' is broken while the Renew L\e br.lsh a'rd spring assenblies if
engine is running. the overall length of the brushes are worn
Observe correct Poladty when refltting the to or less than 7,9 mm (0 312') lf
battery or ,','hen using a slave battery to brushes are satisfactory but require cleaning
start the engrne use a Petrol moistened cloth

Do not flash the alternator outPut leads to Check the brush with spring assemblies
check its working. fltted in the brush moulding

Disconnect rll alternator terminals while The brushes should move freely in their
carrying out anY welding holders, if sluggish rectifY

Ensure that the alternator is not mounted Rotor SliP Rings


close to the exhaust manifold without any The slip ring surfaces should be clean and
Protection. smooth, lf the sliP rings are burnt or
unclean and require refinishing the surfaces
02.10.3.4 Routine Maintenance may be cleaned with a piece of very flne
emery PaPer.
General
Keep the al'iernato[ reasonably clean and Bearings
ensure that '.entilation slots or air sPaces are Check bearings as Per recommendations
clean and ulobstructed Check mounting and renew if worn
bolts for tiSh-,ness
!
02.10.3.5 Checking the Charging System
Belt
Ensure that the driving belts on the BatterY
alternator is in good condition and is neither
:
Check the cable ionnecfions and ensure it
i
too slack not too tight, lf necessary the fan is tight. Check the battery and ensure it is
belt tension should be adjusted to obtain in good condition
approximatel) '/2" - /," deltection of the belt Driving Belt
when presseC at midway of the longest
Check whether the driving belt is slipping'
point between PUlleYs. lf found slack and adjust the same to
a line should be
II." o.ot""o'ng {urther
ilni,, *n0"0 acr-oss both *1. *nl:: on '::
cable
circurt for cable faults *'io. ,o facilitate easy alignment
Check the external
and rectiry if faulty'
reassemblY'
and spring'
*'
Remove the three [hrough bolts
Alternator '
:^-. wiihdr aw the drive end
shreld
suitable movins "-"
::;;'; " ;",";:il:t:; :':l::"r"";.r. rolor' Discard the through
and neg -''^t
between Positive
voltage should
be -1o11'1g" has been used to
the alternator' Battery ;;''; heat
:*;;" ,r"-throusn bolts loca] -sl^ou::
rron ot
registered a heated soldering
,.'",,"0 with
ammeter if it is
not
^'-
-
loosen rl"em if
necessary'
Connect an external I -]'l' n'''" to
"J;" Use a
fitted with one snould be overheated
the gently taD the
d'rve
and slowlv increase nll" ",.."0" t"' "r and
Staft the engine from the sLaior
;". ,; ":i; -'^)-:T
light Soes ouL
":""':;"
i:':i:: H ;;;; assembl; awaY
and sliP rings end
shield'
'^Jrn;ng The chargtng
t."aatd' tnt charging current' damage the slip
ring when
aPProximately
to
Cautions Do not
\'au!rvr!'
current may increase end shield and rotor
and then will
of alteTnator k""ping tr'" drive
maximum outPut assemblY on the bench'
observe the voltmeter
1"" oili"t oc,*" sliP rings end 'h'eld
connected in the
circuit , ay the stator and
on the bench'
to a value between .sr"mUtY carefullY
should rise
The voltage lea'ls from the
volt system lr voltase the three stator
;;-';"uo.nt in 24
r-.lnsolder
linrit the regulator ::,, .,"t,er-inal lags (Do not remove
;t;"nr<l'" than the above sinks) and seoarare
is faulty and needs
rePlacement' ;" ;;t r-tom ttttt a hide
housing using
ll? ,."".';;"'ing
.nallet.
02,10.3,6 Servicing
'O' ring from slip rtng
Remove and discard
To Dismantle housing using a
rhat o
and octaLh rho
Dalfle ng
]"0 ?""- 0""'
"r:
lL".* ;; ;t.-"e nuLc e^d 'rield' thP o' r'cs
no' d'*o'"
., , a*' n"rn sliP ' rngs ::;
Remove the nuts
sPrns";:t::: Sroove.
'r1u."
I re e t"''l,r,onn"a,
il"? ,r," DE shield od"" *':,:o:::0":
,vasher on ,," (oo
.
bo' ' diameter cvlinder
terminal' of bru-h
.-lo ys,ne 79 rr,^ "::. "';',;;
'lt-n":
motoT or.
leads of the t egulator
ar
].'oi'',"'"' the rotor rs en
l]:i::"lfiri:
regulator' ;urtable) so that
'A' of ii"""i,,'"0"' ana e1l
diode lead from terminal the -:::1t,"::::Il
Di"r.onn"tt
the retainins screws :upported' SuPPo'1 'olll- .,, .n,",0
;rr; ;;,. remove rotor {rom DE shierd
.nrrnp atrd Pla'n ^asne'\
a'd withd'a+ t\e .:Til o"i"tn"
b'u'hes' ivith a Press'
Iu,i oo^ comPlete 'rith
tern-rinal retaining "':t :::1:
Remove Jleld
-.;; r". insulalo r'om.rteril,1,.:t",|#
anc
ntrts. crinkle washe's'
' terminal Posts
posts
and freld terminal
Withdraw brushes washers'
box Discard sealing
#;;t'
Remove purey 1,:
r:::,il-:J::.1:
rllev fan wooo
i-rro ototo sERtEs ENGINE - its groove. Apply Silica set
l5l or Fe'
aPPears Y':'
02.10.3.7 tnsPection compound on gaP that
leads enter sPacer' WiPe
off exc
Bearing Renewal
compound.
Drive end fi{ure c' e
Remove the three screws
and washers Locate the rotor in a suitable
is suPPortec r
,".rn* *" clamP PIate on the DE shield oress, so tf'at the weight
rotor ie:-
out the bearing with a suitable io rotor <taws Pass lhe -'-E
";;;h lead slot in the shaft and
drift. "of the
through
the '' D
rt bor" new slip ring and locate
to the housrng by press'ng " terminal pc-:-j
Fit new bearing
ring on to shaft with the
that bearing remain perfec+'ly .,
the shaft lez:
in.
"nrr.ing poli ion"a at 90' relative to
square in the housing
slot.
and secure
:-'
Place clamp plate in position Place sL'table Press tool wilh
a
washeTs'
with aPPropriate screws and cutaway Portion in line
with field lead suc-
the slip r':g
that the sPlgot re8isters in
Slip ring end down un:'
the bore. Gently press the slip ring
-0."r,
of the winding leads from
C* anJ tool sPigot abuts the rotor
shafi'
"no' ii
sliP rin8, terminal Posts' of rotc'
withdraw the sip Steadv the field leads coming out
'rna
Use a suitable extractor
of the slip rti'g .tot trim of the ends to lea\e

ring ass"mbly' Removal aoo.o<rmatel/ %" inch Projecti6"


beyond
and a
will render it unserviceable
,i. .o,o. ,nut . Wrap the leads
asrlemUty arounc

new one must be fitted' ring' cut to


the
the terminal Posts of the sliP
Remove the bearing circlip Discard length and solder in Position
circlip. Adlust the jaws of
the beartng lathe' locating the
locate between Mount rotor in a suitable
extractor so that the iaws outer race of SRE bearing
with a support'
anJ
r"." and the bearing sPacer ensure that thel
";;"; l rehllv shim slrp rrngs Lo
withdraw bearing wilt' in
.on."n,"t with SRE bearing
the spacer and renew if found "r'" mm (0 002) Remove minimum
Examine O.O5
damaged' , metal to achieve this degree of
"-"r* reduce slip ring
from roior and concentricity and do not
Detaching the rotor leads I 36 in) To
mechanical aiu*","r. below 28 85 mm (
],0'--.,",-undassembly imposes leads and finish it is essential
,,."*", maY weaken the oO,u,n u good surface
or tungsten
p.oar." tn" Possibility of failure lt ls
under that a hiShly finished dlamond
for
."rUiO" iiPP"a tool be used
this
at a later date
" conditions
op".ating
that leads be operation.
,tr""t,, recommended
renewed as below
glass libre sleeving
Trim the leads and the
length or copper of
und ,,rn,,, twist a new
and solder
,,, t*O to the existing wire of fibre
,.rono Apply liberal coating
,le-"u" ou"' the joint so'that
it ilides over
final coat of
th" ""i'ting tt""u" Apply a
shellac. Trim excess Iength of lead

the bearing spacer over the rotor shaft


Refit
groove
so that the moulded lt li'::i:::t;
l-r.to tt*ttt ENGINE

Testing
i.3.SElectrical
I
t
H::J '", l:i' ,: T':i ;:ilil
:u,,,1'-"1r,
',] .:::T:x'-::"i i'J::'::"li: [?' ;ll
I- ,n" -a. body. 1l^"1'',to ]1.o.
T"e
w,nd,ng ,s

I ir',n- ,"., righ1. '.he


,"n"*",.

l
rrE
defect,ue and
rotor assemDly "o""0,
' 16 Fig of Rotor Winding

I cnecr. r.,e
rotor ! n: nch. tt:t;-":l,";"t
erisLan(e cirnultaneol,''y
'
, ,t '
lnsuJoron Test

]I on"l -"7 l.
,
,

DaLteD oPerated
'n"",00"L*""-
,,',."a.,"l-
E balreD :"0 rn::^*.:?,"1," o"
"
ll 'i" l''J,i';,,;"' :;'"'j:li::'." I:lTi'i Mcdsuring
'
Rotor Wjnding
P".;r16n6s wrth BotterY
E sho\-rd
lrt,ng rt.," amr-reter the ro-'Lor a..er.ol.. ond Ammeter

tl OOOl-o^ not
't
renew

Fig - 17 & 18
Ll t;"::.:
tl ltn'"ti ..",'"''t'
)""^*,'"t
t :t:''
"::0,:1;
3nY 1""o,or:::l-:;
a to V\ ,e t
'i::ff:.i";[:i,il'
t-l a lz rolt

tl teaa. w'th
i"op ,n
[rsL Pafl
,,''u't
o'
?"":^:]:" t,qh' lr ,he
':: :T' :"";;"D ,ran",
'^: ":^-, ,-^ ,n" o't ", ,,h',o'
fig. tt * ta

Ll e6n o lh''"'' l::"- "::il ;.r. \;<ue'


Insulotion Tes!
t-] '::,0.n
";il'" ;;;
j: 'o, '1""' / rn4 nB c' oLrld
'"o'
I o' S|otor Windjng

Ll ^",
"" "' l ll.'n^i''iJ,.'::"
i
l-l ::1 :: "f t"j""::",'::'H';
l- ."n",u- ^,,.,,-
.1. '::::-
]t, ot llf
l-. (onnc'1,og
i '_ '
" .r.L,r
oel^ecn "'

li ::: :": 1''[:t-^ ::,:','." "::"":' Sto.or Winding


Continuity Test

L. ";:;"

r ':*J:,,

Diodes
lest eacr'
.

Fig -
:i""
"',.';:'"";19 & 20

, i,.a n,ne d,ooe- separ ate'/


ds

a"d
dg. te * zo

ba11eD
- l) voll
:' -:r\ !' ,-
follo,ars: LO|r - . .,1 one o, the
rzV, r5W oll?'1",'^"'J","I'uppr,"a,o,n"
drooes one l:]" and ihe other
Lo tt"'
";
i::3:"iIT";";'::"^l:.:.Tn"-.,.".,,on
irn,,,n""'*"'':
.l:':,:^."j:::.1'J:
o'
lrght durtnts r
T"h" lumP should
only'
the test connection
'"""-
,; ,"; ."" ",:o: :':,:l',:::'j:1;:'"
srnK d5rL'
the drode and heat
Regulator
of the regulator can only
Individual testing
be carried out with sPecial test equipment.
Hence the regulator must be checked by
substitution in the alternator.
02.10.3.9 To Assemble
Reassembly of the alternator is simply a
reversal of the dismantling steps:

Assemble the rotor and drive end shield.

Assemble the slip ring end shield and stator.

While soldering stator leads to corresponding


tags on the heat sink carry out the operation
as quickly as possible using a thermal shunt
to avoid damage to diodes.

Assemble rotor and drrve end shield


assembl/ to stator and slip ring end shield
assembly ensuring that the scribed lines are rn
alignment. lnsert the three through bolts with
"loctite" appled to the threads and tighten
them evenly and progressively while gently
tapping the slp ring end shield with a hicje
mallet to draw the end shields squarely rn
position. Finally tighten the through bolts 10
a maximum torque of 45 lb.in. (0.52 kgm).

02.10.3.10 Bench Testing


Equipment Required
Test rig capable of varying the alternator
speed from zero to 6000 rpm.

24V Battery to the rating of alternator.


Variable load of at least 50 amps capacitv.
I l0 volt flash tester or meSa ohm meter.

Two single po e single throw switch.


Bulbs 24V - 2.8Wll)V - 3.2W for Warning
lamp.

First grade moving coil vollmeter 0- 40V


ran8e.

First grade moving coil ammeter l0 - 60


Amps range.
Procedure
Clamp the alternator on the test rig with
the cowl removed. Connect the test circuil.
Connect the fleld amn'reter 'A2' in between
the 'F' terminal of the regulator (Green lead)
and 'F' terminal of the alternator brush box.
A variable in series may be connected
across the battery. The cables used in the
AL680

- th]l."" is satidactory' then


quick f'
"" i

J'' The warning lamP


:J: il';;",or
.arse rnc speed
d,1",. -- :' ::: j-^eSiStOr
T"I
Until
Close the swrtLrr ,01"t the
variable,.load
.--"r",
1';;;;';-*"rthe7515Y' li-". "T::::
should light' "nO
"'
,;;." ;""., oo"'-"n:l
---11<r l:'i:"i',;;"*
(l)' \ts'] '
ll],,.'l'*"".^ rated
.:llt'l;"'illi
is within the rimits
indicated in ParagraPh i['''.r;''':;":;t
I ^r +ht alternator slowly
lncrease the
tp""u "l^^',,,-" specrfred
extinguish to
alternator outPut
rdr rs
- and obserye
the warnrng ' 'P the a"'"'*'-
lff the -emove
n' the
-' u '- regulalor'
*ho
1,,! o
{ote3 ;; :; ;.." ", llT. l"#;-:*,n""" "i,.'ll -ar^nnect
reconnect
varlaolc 'vo"
resistor aM iuT",^,
laa.l Run
r lead. RUr
,.r,
rom and lest aS .,
proceed as "u.,.Uf " 'oua - lnn.
aL
*', Jv"--
the alLernator
he alLerlrdLu' -^.,,tr ,re
.] - resulL dre not
ll-:"i':ffi: tIa'tanost,r.and
(D (s) and (h)
indicaled in Para
\ lf" rhe
\uJ ..^ resurator
noi

:: .'.i:. ;"t"'^traPh the "^",,1:ror and


anc

':l.o :ffi':,il i;;:;"^*"


d)
lncrease the
alternator,
:::;t;: ':?: recheck
,n" *u.n'nr :T^ .:|il[ R,n

:u "F::il
ammerer should
tno* ";-.",,"n,r urrenr .-".",
ir," uu",nu,.o' ,il" ::':'".;r*ingvorrrneter lt_f;:jmT ;:;:
The
^tJi, provided l,tl l^"t .r,^
between "': rerminals and
rssernblies "''ll'l-
assemblies ,^,,. ln oi
rn case ol
T::;"":*:"; .i' .''"11."''n"',,,I,"'
reading " -defe.tiu"
s corresponding
rru-'-<inks.
dlooY "-,r
rhp lead assy.
voltmeter , ^t':" r>
a.a in t"-':"-,'";r.inol
the regulator
*;tn batteq Polaflly und
specrl,ed. r p,l"ce"oing the negatrve t-"'-/_.'.ited,
to be rePlaced belc between tJll',." naLing
ri""0, - t"o wrrl 8er oPen
*"
fudher tests'
i"",
neat srnk roun.
"---*:.,- Replace i1ir {ouno

e)
Inc ease the ahernator
:::":"J,:.":':^t ''l[ :;::::::::: T:;"." :::: "::":"'::1
and adiusr
f":';::,1""r.'- ror rared .i. ,"
anY
the
case
out PUt
1ll-1^1',i',"0,,.,",
even o" ,n"
develoP
t\ :jil:''l;""'",:': tlr'r"r,,
:1"i'
^l*"'J'":'.l:
lead assY'

t\ lrmirs specrfied i '


ahernator rmmediatelY
t( Rep,ace rolor
I To Refit
t\ and recheck
" - '*' 'llv shod
crrcuited I otol an lead
02.10.3'l
Mount the aiternator
on the bracket'

[\ caution: belt tension'


i;;;"'", rhe reeurator Adjust the fan
: , '^. tn
t' the
' aPProPriale
[\ then Proceed the
caDres
(c) are negative Connect
I lf test (b) and
terrninals'

I as belowl
-r-r,r."
tn"''t::* t"j,
il"l
t i1
(ircL,,r,n8 rhe
o t*-l';;";
^ :':""j' 1,""","L
read observer

I the altelnator
warning
wlth a lun
iamP to light'

E Nore: rr warning
l1T'.:"::::,:;-T 1:iX"::::
f. then Proce'" --

E chart'

Run the alternator,


tT".::"l
;*"'":
f. in.."35g the
sPeed
'1.,,

E extinguished'

f.
f.
*'.", ;'':;",-::"';*,.::: ,: ;:l ;:::?:[:
'-
PrOce<u
rectifY.
r
_ r...-
1
02.94 AL68O SERIES ENGINE g
I
o? to-1.12 - Alternator
Trouble Shooting
DefectlCause,RemedY
Warning Lamp does not liSht Short 'F' and negative ter"minal of
when lgnition switch is on. altemator by a jump lead.
(a) lf the bulb now lights the Replace the regulator.
cause is faulty regulator.
lf the bulb does not light,
ground 'A' terminal of the
alternator.
(b) lf the bulb now lights the
causes are;
(i) lammed brushes or brush
lead adrift. Free brushes. Replace, if necessary

(ii) D t1y siip rlng. Cleanthe slip ring.


(i i) Rotor open circuit. Check that the ends of the rol:-
winding are soldered ProPe"
to s ip ring terminals. Resoldc-
the windrngs. lf open, or rePlal:
the rotor.

(c) lf the bulb does not llSht


even after grounding WL
terminal the causes are:-
(i) Fused warning lamp bulb. Check lor short circuit, if any, ln the
wiring harness. Then replace buib.
(ii) Blown fuse. Replace fuse.
(iii) 5hor1 circuited warning lamp
holder. Rep ace Holder.

(dt f sti ML does not aPpear Replace regulator.


when ign tion switch is on, the
cause is faulty Regulator.

i. Warning lamp Glorvs dim (i) High resistance in warning lamp Check and correct.
(ii) Regulator defectrve. Replace Regulator.
(irii Rotor defeclive. Rep ace Rotor.

Warning lamp '


on'. Ammeter (,) Loose belt. Tighten the belt to the limits as
shows no charge ,,t hile engine is indicated in routine maintenance.
running.
(i) Aux. Drode lead 'A' open. Check diode connection and trace
shorr. Rectify, if possible or rePlace
rectifier assy.

(iii) Shorted rotor Replace rotor.


(iv) Stator open / shorted Replace stator assy.
: Warnrng lamp 'on or dim but (i) Faulty brldge Replace defective heat sink assy.
a.n-neter sho,vs , 1a"gg tlo"n,
outPui)
5 Warning iamp goes off (i) Faulty rectifier bridge Repiace defective heat sink assy.
Ammeter shows low ouLPUt.
(il) Stator winding short. Rectily or replace stator assy.

6. Warning lamP (Ammeter) (D High resistance in the negative Check connections ensure use of
flickers considerably. llne. recommended lvire,

(iD 51ip rng dirty. Clean the slip ring and recheck.
I
STARTER MOTOR
f,ERHAtJL
oned for use on
I0.4.0 DescriPti_on [he
AYial starters
t'' ,^.
:'-:^-.o hecau:e of the

ilT i Jn. :l ff {*i:r ;rjl': ":,;: ;:

ilst:j" i:r:::ir;
il,:E tl
IT:#:*+#";::li**u*::
,'* -o'- uli", Ji
*Ti:is XS*.X;'l'"1.",
derived'
stafter STARTER PT'S]I

I:**+ti5-,6:{i;ti
oDeraled 1wo
siage
lln' , to (ontrol
"r"o
'[r;:: ":";:l:::
;-,xjitt''r[:'':
externallY'

;; ".,;",1"
n
- -o".'"' I l',1 l".,Tlj
:*,:'l .I,"]iJ,."'
Lhe
LhroLrst'
,-'l::i,' l"."li
"'::"
:T .'" ':"'J t'"i;-' ";;i,'["",,'ll"[:
:;i"l:",t.;;J._" ^:^:I?[ -:..#::
dr,.ing eno
ior",a,
fir"d
,no Ln" ^ "a.g,
,i" -.gn-r;. l.ll" "?.' ."* ^;Ln
rnp

IX""1:'";:";*;;;
,*i
: ]:'
of its a';al " re" Lr :'T.i;'i"-"".:::
-l,".ro,o "*,,-n
"n6 ' ,)n",rt",.u,, . ro.losc
")-,","t,"",',t*"I
cJ.rs,ng
ihe seroL u ''ir-
rh,oJgh il-- na,n
,nd ( on p'^t' '^i,.'-t i,',,,",- rnin e
.,1, ,r

;; ,.;J:";: "" "'*^"


',, -ere,sed Jil"
rno ol- t' ;;",,:"..
t"o,n" o
]1"*. d,r"neug"d Pcsrtron o'
o",,,on

',''-l, on r"re arn"aLJ' Plungel


'::?i0,.""
..
- "u.',;r, / shun[ '^ 10 ngs l:ri'
ro hold lne P;';on..,'n r"d, rhrs redure
':nPr PUsn bullo' 's 'lllir"ur"o ,o u""
t -"..g or e'iSdgerner
. ',,.,n16"l. will rernatn tt'
' n"' as It'e pinionnrine
,' ;;;; ' regur"' ensine
Fig - 23' 74 &
75

ffi'-'*i{*
ltF
lq
1i'
I

1'l
ffii;::r'[Pllq:[I i;i"H'r:";i[
:r
,
d'iq :::-.",,:-llit*
l".ro. br-rt below the shearrng
[J1"]# i"'J the una is 1,hus -an, err-ectrve
teeth of ihe Pln'on
H-l;;; against rhe exces'ive load'
;1;';;"^;"J due to
are
Where required orl 'ealing Precautions
comprising
raken',n'"io an otl seal in the drrvrng
'""0 'a rubber sealing ring inside
""J Pinion
the

O2.lO.4.l Using the Starter


be rigidly
The following points should
observed when starting
the engtne:
are
l4ake sure that all engine controls
con-ectlY adjusted
the starter button firmly and
release
Press
fires
,i *."0i""'Y after the engine
at once' allow it
ll the engine does not fire the starter
,"'.".""i.-t"" before pressing
butlon again
down by keeptng
Do not run the battery
when the engrne
t.-f]",tu't"t button pressed the cause of
refuses to start Ascertain
failure to start'

With some engines it is


often.helPful
,to
depress 'he (rJt' h /r'1sla'r'"qlrornIQru'
the
ON no account should 'tt"n"f^':^"
Joar.ut"a *t'"n the eng:ne 's runntng'
6cr ur both
:iffi';" '"tio" d'-'g" TYqgts
rins sear teeth
;; il;:; unj to nY*r,.""t
02.10.4.2 Maintenance t,o ensr"e Lnat Lhe
Examine the slal.ter :no
mounlrng bolts are se'-'ell ta'rened 'all
tighl
(onoeclions a'e 'rFdn dnd
f:t
?i.' tlt'" should Le examined
"l",,"lti
wne'e
t',1r""-'- putt't'tur "r rhe Poicr lrre (durL
l1
.he
al lJg\'
cables erte' 1ne te'1' signs oi
arr[1i""t must be free from cn due to oil' etc
t*n'"t t^a deteriorat
recommended
Cable sizes/len$h generally
are as follows:
Siz e
Length*
Upto 5.5 metres 6li 044" (Single cable)
5.5 metres and
6l/044" (Double cable)
above
* Refers to of cable from battery
length
to starter and relurn to batery'
-1he bat1ery and
oeLwe-e-l^
toLal resislance
. ,r, P^.eed. u.uu t / ohms for
Brush Gear , - -^ clear o{ any
Check that the brush.
'"uol-'Tru"r"n.t ,nO
ob,lr,ction
<pe that the "5"'l-,:
t^"'i
lT;:"
DTusrrE) dru "."
[',n",. no,o",.,
pulling
rlli' , ?i,^- o"sh spring and gentlv
:l;;'J il;f, L-"4' 1r'?'.','l
the inside ol tne ;,J["1".1.:?
iri.k'. .l"un
;:il "-.;" cloththe .moistened ]l
brush ll ?,"r"1;,*.,?i
sLrre to rePlace rts contact
11],;L. in"t the curvature orcommutator
'..;t;;t
m:"" accuratelv with
periPhery.
ie
Thp brushes should be well oedded
"'' ":- 'L^ '^mmrrtator perrphery over
l'r".rtr, L"o o"t *"i tt-t* t :T;:lri::' r"[
'from co
not. lrft each brush
'r""'og"''n'io'n'o" with sPnng.
-^^' fine emery PaPer ol
-r .<,/,,,,'-
ol , , ,^r
ff:j";I:
paner around,the t?T,T"".t"'ln"\A.Lh abras,,/e
brush (o.
srde outwaros' to rhe
#:";;';;;"" brush sea' a'm on
!..r-i'0"' and bed to-theLoi;:l.trt:::
by oiawing th" :'"f i11::,o. Ra,se the
forr'' ards over the
commuLd
r ePeat rne
and bedding
r. ,""i Ur."'f't"'
;;,;'; lor the brus\es ":::;
'brush gear in turn Afier ?:,ji;
ha removed "orn iLs holder and
ed awa ' '
?i''i".."i" *t' and ab'asive c'ea' or
'",.errii,"tusrng comPressed a'- some
rl-c b'ru'r'es
i:::;; i,."" b;rlows E^a.rne oord' /e de
i^ ..iut"-,r.rr no Pdrtrcres ^[
in lheir conla(l qulfa'cs'
""";.JJ"o spr;ngs 'sing a
Cl.e-k pressure ol brusn, or rn lhe e'e
under
atr'-g o"a,"t" i-ooked
of the sPring
Fig ' 76
for stanct molor
lhe b'ush spring pressure
ln the fortorving lable
'. o."n Spring
Unit Volhge Pressure
)4 950 - 1220 gms
BS5
SL5 74 llo0 - 1500 gms
the
As r o{ Preventi/e mainte'ance
measure at
the engine'
;rj"; ,r--," be removed l'om fo'lowins
il:tl;:"'; v"''' to tn"t* the
Brushes
ii.'il.-*n"'
wom to
must be
aPProximately
'f"f:t;;iii
J
f mm i:it
where
li --^.'^r'","^r lensth or to a Pointpressure
e{fectrve
ll.lr. i."r""*"t irovide
:: -t^::"";^'i that brushes are Ftred in
:";;-;;i; and under no crrcumstances
ll",f';,,J;' or different sraoe
::r,";:
tosether. 1"P'':"^l::t ,?]"" ,, d",.,ru"d
ffi ^td;tttolt"it* I 10 11 14 151,6 17 t8 19
20

It
-
I{
ig is zt
33 32 3'1 30
I{
Fic. 27
tefer ro Fis - 27 !*
il;;ttt a
"""0,"s [ake o"
Commutator I tn<.re! /
'-
')qr
\L't
nut5 "nd
a
i"'"',".-,,"'. .""']:" ::,:';1.!^" :i"l;;i Ionlrr,=tot cover i1l)'
l'it br'r-l a
'- r^"'.r 'r1s'v5' t3or
:il:?,:":#'T9 :',^;"" :lLJ,i; ::i: unsc'ew
, :t::'.1 ,:;'" "'rshes 'ro''r
a
ii
l;l .l:":"fl:i',"f,:';o' I:,"" :l:,1*;. ::],'":,
":: lre€)-
screw also
l:::.,1;: .'"::"1
^f r,rusf' lead io tne brush 8ea'' :
i.,J "..n"tuu"t
,

[i',rigi *l:+j-:#
:
Note: L:,."i:;, iJ':":'";
-:.':i,.',i:ti, 62n be denL'r'ed 'vhec
::",;::';;; "a''5
""i;;
:*l"::t 6:."*.t,,.:, ",,*, il"'"'-tt is reassembled'

j"lt" e
"
Lrs nB aom.,\e nul 126' '' rh'
onmlrtdlor end
arsnge" r78)
hlifl ':,:i::l ,;ilLne dTrnalLrc
::::', ner'
,,,ng " bo" sPar
o1' ::' '': oeno\e nd,n n.l"q "llli ';il1t,:'',;1
::i,." l:J"";;" cov' end sh'e.d 1'0r ee"u ano w;Lld,o^
ommulator end
'
":: ^o]]i"t.
' '1,:,j nn a

02.10.4.3 Servicing :t:':"Jil;,'"'l ",..',*


02.l 0.4.3.0 To Dismantle uh' n 's done l.,olo Lhe armaLure :r.?',_q T''t^"lo'1"i,
or
erhaulrng ll^
' crd 1er
f*.a with soft metal
Bcfore o
"+?: :"":'il "i."
[ttfftil:,1T: ;;1" clamPs

6 e"aultng
,n; rime \DenL ^
.::".:' Remove lubricating Plug'

(l) and washer


Plunger nut sPanner' a--nve split Pin and nuts
sPanner'
lil"fii]iJ
//l artc ""'_ :ii'l;:
;"i.3;0"",!'^li:
Plunger nut (inner)
ctter iorque'
)i.rtutt tl.tutt'
Exlractor for' ciutch
sPring (37)
Remove Pinion
tcrque'
Socker for checking cr'rtch
' cr)llect :l'-rtch
race 'lot lltl :':l: ::
AL68O SERIES ENGINE $r,'
il i.

-------'-----'--;\ .h^uld D" .,.-


rhe clutch.,-lrl"eas.. that rhev I
Note: :""1..:;;;" iI
together rn t' '" *^,. orisinal tr
tn
::*:t|""'.L;.JI'.I-'.
positions
I ;1heir ^.ioinal
starter is reassembled'
I

:i: n.fffi;the
I ;,;.r* shims and rubber
sealing ring from

T bore of Pinton'
nut (32) by
I ,.0""r..r,""
,"rn,
plunger relaining
o{ tubular sPanner'
{rom bore of
;;;ar"- armature Plr''nger
armature'
r I 6, .e.uri.g Pos'tive
Reno,e rhe tt'tu" _',--r.-,^ corrs ends ond
re,minal connectot l:]: ]: ..;;"'d sw'rcn.
Le ')"
au'iliary field connectlorrs

,"0,',* *" ":1


i-i.,r," "'"t't
i-1i:i"l,lin""nd'"iJ
Yoke b/
taPPlrrB

wooden mallet'
leads'
the solenoid coil
L Disconnect
solenoii h^rng.511q'\i
il41 and

L .lnscrew
..move solenoid swrtch
lrr/'

l- l lnspection and
Repair

l- 02.10.4.3'
commutator. ,^- shor-,'o be

l- .rne Sudace o' I r\ ,' .,mmLrtaLor


. ..
, rea^ and n"" 'j:.'-:,i.'.'^il
^. it( OT Uneven
l- ";l'JI...'"" ;;;n
ff "
l-","," .'"un'ng
:T:f !r".",.
::':.il"1'
r: :'
.",i, o'."'oo-"cLlm
o Lpe','ni1
tn-

l- ],i- ,u.,o.. cond't'|or' ' "::" larhe and rh-


.oaoon"nt should
be set LIP t''t
.ommutator skimmed'
A coa.se cut
',-moue
sno.uld
. :)*xo-[. T,:::t ;
,u'fic'enL 6oPPet coo-mutaLor
p,tt,ng or d "o'1o' ,^-, ,'.'ah"-,"r-1u,,o".
,hould oe uqde :ul.^-'':r. a d-prt 1ol

::::'i,":' ,"J-i'ii'^ " , ;';i:':;


cedain p'oPr'eta? ."":"- "':
ha.ksa, blade.
but,,,,tn
,l " i"t",arion ^i'l
rn'. DurP-o'e' "rt
-;:::' -
i' ilt,:;!-'::-o;J";.,'"
t'"'"'^^'ln"'it"e
emerBenc/ ano a ltne

iil,:",1,1: iL:",:;:"1,"' "J;il: ;:


',".',iii^.,llll,'l' i:[: ;;" ;"u""inB 'hl
o:"^::"'"::t
:::;il;'arrnalure".:ll
or nun.
':T;:::l:. I::'::'';, 'li u'"
bellows'
Fig'28
,, .,,l^i.h the commuLator
iilo o..,' sERlEs ENGTNE
'r',"Winding
Armature short
?i'1"L" tested for continuity and
;.: :; ;;;;-"1 ."-'*-'X';'' u'"i;
insulatlon use d rrv
.l;
re<t the
:"^) :'', io;--i!; burb wirhthe two Probes
".""" to armature
-""o*iln is applied..
.t
I"- ,n" other to all the segments'of
of the
in turn ln the event
il"'..'.nir,"i.,t round
lrr.*r" o","g to be faulty it rn!'st

be rePlaced'
race is pressed on to
When the clutch outer
;;"' ;;,t to the rePlacement
.new or
tool sFould be inserted
<r.itable
J'mature core so that
the Press Fis. 29
;l;';; ,ff".;""
il].t'ro.^ toor andLnot
'i"
of the commutator' lt thrs may di*ort the
rs il:
i.r."""r"""a by the Press
cornmutator segments

Fig ' 7i
Field Windings
I ield windings car
be resred for shoflot
liLi,.r',.-,n? voke and poles bt
means
';.;";.1"q
;;;:; and,u.':10*
'-..oodiao IIO volt 'o rn serl ;il."i1on
r;ft;i .it"uto* rorLase Posrlrored
of the sysle"n' one probe
[J' """ - to the yot e and the
.r.,1",0 u" lppri"d of
l,i"'" "r,",ol
ihe
10 the ends of eacn
tight
"o not
]''"i- iJ'n' t' rn" lamo does
"*t'"
then ihe insulation rs
tntacr
eas '' by
can be dete-cledinstrument
Ooe^ circr-ri1s
I he
Xl" t .r-l ohm l4eLer'acro\s eaLn of-lhe
.i""1r,0 o" connected
;|"6;r ;;,;* ,""" ,j";^'J'U;
L Til ;JT
. ohms is obtalneo rrrer o
;J;r,;; i. rt'^ *ina'ng 6s'rg 1q5ted

lnlernar shon in
a,1 a]
::1"?" |[:
I
th: oT d i"'-t
bY means ru
""*n'""
detected
no such instrrmonl 's a '
arrable
L'"i* the)
,")',{ ,n" eristing vrndrngs are sL'spect'
,t t" checkeJ bY subsl'tJtron
",O should be replaced as
Unserviceable coils
follows:
withdraw poles and
Unscrew pole screws and
il:;t ;;-;s the Po.si1'|on "t,1"",,.;i;3'1t":l
facilrtate reassemD!Y'
order to
,"i1 ,,'," o'i" o::'" ':t'^lo:1"\";1":""Ji:
corresponding No l
ts on "
numbered t' +,"uJ r*"t
I .t"
oieces are end'
!ili*'* L"ul"e from the (ommutator be taken
musl
irin." r^"pruting'ofir'te poles < are
tne po'e pieces with
les'er
li", ''a" commulator end o[
rh,,Lness are lowards the
:i:',:; "io"
;; the numbe' corresPond'
,nto :"ore and
d)
:::"f'["Jm*=:f
that
rnanner- - ;*ti
*,i';";3r. is wnen perfedly
;"*" potJ'* ;t-
' inr"rt
insert Pole
c""
screws
sc'
^--"rcia\
- .- ^mmercia\ pol'
pole ?3 l?"
"i.,.'
l,^li[ i;,"-; ""*:
"'*f t I["i;
J iu."ptu..
d) ri'hren,i";.:*t:;",'{,*:di"::I ':".:t;:$, l'":;'-o r'

-,,n ,n" o:.,lig


.0.":.i i3o,t?,.,"'?,?ll
'*";;'*uandiryg e)

l? tf,""ot'"t Yoke
$rt;'"T; "',,'i*"* be to '"1
:i": i";* *1i,1;,:;:t
,.""' -' '^r1< ol the bearrng
Turn 'or.)''',^
" ";:i;i flusn wtt' ' '' -
f2qs5 sf rhe casltng
t he
tll"Y' i'"T""J:"" - ' nr LtSe d
Ptnton'
wh"n f'tri:i. ^u-j1".n"" pinion and Dnarrns
Bearings in the dr''e
clearance u""1.- o
;|.,T"il';' o os
to ^,n
ro -m mm r

*' t'ot ^,^ ,. bea.ing eno u'


ln.ei ..,.",n" comrnutalol
"[: Brush Gear
nj '":l:"" ":^f lt'l',1.:[ .^ :,,., rlarron. us,nB o
gear.' '"*bes a"o
Che(k the brr,sh
ramo
<nle ru

:l'"1.::B:: T". l'^.:;"1,1::,5:I::


*' iii"t ;,*;::,ilirl '-ffii:#'u'i'l*+#;::r;
si ;ltm :.
:"*,:#il.i" ;'
r:
Ou""* un, o{tsrntauttY
'-hecks
i[ the larnp
l'gf's

CE bruch
'.11.'o'l
"i,* 'il"';;','e
,.he rnsulation

Clutch a rnultrolc d
lh,*'*,."$i:t*'-
:
-^-
.
tiii'il,-i-**" ^,,rh

udo""o'
l,li ""8,* ure.\narrortanl ;8.-''il:-
i''o"l" om drrna
{r .oe,,frc tun' t'o-
'[,,j1,1"*"*'*0"'i ', "'"

''
periornrrnE

ilf,;:i :';'"J':';:'l ;:l;'|"}:: such as :


-t"'t-:lt'ti::":: -,.r ^rnteCl
oPeratrons' n) ,,'' as a erree
-l'n'i'l*-',,-"tu, {rom danE?
in'" ot"tt'ng
'",'"1 '..''." hrBh sPecds'

'r i"i:;:::;-r-i*,rr{sli e s-lr1


p','"on and
drr4dLul

'
^ Pro'^ I
'' ug''t" ovetload

ffiu'"..'l,'****$'"**r*t*
*;;'t resenoir'
"#'lt
oiil-rteoo sERrEs ENGINE
l-arts wirr be very high ln such an e':-:
The ourer race
(I 3)
]', on ro rhe
*nitl nOU>rrrB ''' i;';,i:^ wourd sliP a1 a P'eset l::::= :-:
-:-:
is. o"y":--^ disconnect the Pinion
the wt"ole clutch ,zr which -..ir"or,, tc'c-:
',i:,,:'T:^,;:..'n" 'nn" race (7) t'H:
which
As the transmittable
'nJ'i",i.*-i"" ";;;r; on axial P'esur"-
ln'"11: l'^lil"X,l: il:":;*n'* in turn depends on the torc-: i
^t^"Y:":.::. '

and is capable ot, 1r':, .lo,"u." arranged ",I"t


and.
(or'i" i;":';.* by 1r"e v;due. "l P-'::^':;-- when 1r^e rn-r-
,nne.
:lteTnallvelY
"t":
lrl d l]:l:'
>(o'''' o,,". plu,",
L1'],'tn"'I li"'i;t is acn;eued con"m' erd t'
llil ffi .t JTI :"ii:",;:'":
l]-^- )'^,".n
,."0,
t' moves [owards
ortn* Lhe oressure Plates ar:
^=;.::;:::: l"^:^l'":;" hackine r'ng leadilg to the (whcrJtc'
;,"i:"::' ;.;;;"J'^,ll: It^"',:i;";"" li: Dressure
('
'ou.' ,ing tt']".f '::",:,: :::*it";;; oi Lr.'"
'^''r at whicn th
r: 'o."""' Prares (r2)
the
lL"rr'""t',nl +pp:ng Lorque;
'

";:': ;':.,'i';i" -" belween ;,;;";;--'"" be adusted^bY*^:::::,::


'::- cond'tion fo' .ti"' ( I 0) between
,,""1 sh'ns
lhe
],.- rndispensable 1""',J**
^" iniLial Pressure Plate and bacLing
rtng'
u..tt'c,^'ng of clulch lr< outer
l,?1.',""
:;;:;;',;; ;",i :'.:',::'11i.:iJ:l l:
the cover of 1ne The pinion will have a
cer-tain axial float,to
^'^'irled rn
on tl-e r'rsi d'5c
(steel)
ensure that ir is
not bound to the
::;;;""'*
armature bY the ,nrft
nrt and a helical
he mature on armature shaft
spring (2) mounted
rs ene'grsec f a!
When the starter
-^r 'to< and moves
tot'aro a;''all/ An)
lo"d the prnion *'rl result
behind Pinion acts 1houl
J; r"ember '\
.as
e'e'1rr-s dn/
resilient
t
il""';";r ;:";;- a
":[[;,
l*,." ;"", ra, e ,no-insLiwilllroo'",^1.,,t, pressure on the clutch Plates
dcl roc ol tne a
screw-Push badlY worn oT
aTe
lill clutch
l#:i j':"?:"':: ",;"'x:: l::'-T:: Lrur I' Plates ru:l o". renewed.
discoloured tne)
I

,,''
ne\^ r
Padq
, - ^,,, .n
should nol be PUt
I

il;.i;;",.";i'- "" ":",'::'."^no'::::".,l:; rnorv,uuo,


lndiv,oual
idL,,,,i!, P^r '1 lor leslrng
rhe strpping I
pre\.ure PlatesO"'": *!P.?]"t-r.e .nless facirrlres
,tnles5 ,^r
-- and
1L' ouler and al!o Wl ere no --'n 'o' '1^ts ey,si
cenlrc o) ribs In Lorque
LU' Yv! ."' -enewtng
^ ^. ^,, ^. a,
th" P^'or"^ b\ rne
:;t",; -^,.u^.,.as
Da(!''19 r'ng
padr of Lhe clul n , n* . .,L ho fi1red
'.'-'^,'
"--
ar t
r'(e
"rd
d;2phragm
::;;":" ";; ;;".", tn"
":.",: ?:"jl:|.
slipping torque is
li- ^"^.
,t
n" r'5s '' the a'ial o'essure
the
lvJ,ffi'"; loi",u"t
'JJ:::" ,:"" o'ates a'-ectr' 'nrrea'es
-12'.r given under assemblY
es 1'3n'-t'ed"i^
i;:;": t^" l:ii lll Pinion
st org llo
.r rnF oinon ree'h d-c DadlT +orn
be'ome oi
l'li',i. o"t''""""he Drdles
rol-que 'gqui"nc al tl'e
,r0".., ,na slart;ng berng a'matur e
l.i::": ;;; ,;"" sno'rc be're samecransed

;';" ,i " couTse o' drive :::':;;, ,n" ""n pirron has
il; *"-out"' Plates-inner race-pinion Leeih drd 's n'aoe
o[ the same
";t;. "r-O"l"t
re" being o'er 'un bl material as the old comPonenr'
.n lre e.enr of s'a Lo run
l"^ "".;. the p'nron 'till be forced dLre [o Oil
'rl"',,i"'".ti"" wh'e Lr e arrraLu'e seal
'rlted ''!rrh oil seals'
Lhe
This will
,lt ^.'". *'i tt) r"nl'in 'T'121iqn3ry' On lhose s1a".1cr\
w'lh rhe Dinion and Lhe
lnner race to ove outward< .''rou"r"r"urrrg r:ng ''s:de
tie o"i'e end shierd <hould
be
',":."";t in the
cause Lhe
a^idl Dressure
l.o 'nrtiar will "t';r-;; is dismantled
I he inner Plates l'..r)n.o Lime rhe starter
ol,*""" ,n" , 't' race loosely ove' :::":; "^"' "*n i't"" rhe sealing ring inside
i.rr'" .'""t wrlh the innercl.nch wilh a shim on
will slip thus
,i. t"t*,. i'";t and the {rom beinq run al il ,;;.; mrst be lilted5eal must be fitled
:];J ; The ne v o'r
..[**'"'* 1^" atmature end rorvards Lhe dri:lne^::1
l',n' "'"
high sPeeds' ',r-o sho'rld be sedteo inlo rts rece\5
,i'",0."i
is caused when the Pinion with a good sealing comPound
AL680 SERIES ENctNE 02. t03

0?..10.4.3.2 ToAssemble 02. t0.4.3.3 Clutch Setting Procedure

Hold the armature (8) in armature clamPlng la) Both inner and outer plates must be
device, or in a vice fitted with soft metal or smeared with Veedol Artworth heag/
wood jaw clamPs. grease prior to assembly.

Lberally smear the sPrlng and thrust washer (b) Clamp the aTmature to the bench
on armature plunger (28) with grease' uslng a ciamp bracket and fit the
lnsert the plunger nto the bore of the orque ,trench to the pnion L<ing d
armature and tighten plunger reta ning nut
special socket. The torque meter
(32) using the aPProPriate too
shoutd be flled so tLat torqLe r-
nserl pressuTe pates, back rng and shim applied in the oPPosite d rection to
washers nto c utch outer race (6) the normal stafter rotation.

aly by pressure springs with


Lightly smear in t (c) Adjust the clutch to at 150 180
slip
grease and place them in the r ho es in lb. ft. This should be done by
L. clutch inner race, over the guide pins. Each
spr ng should be inserted with its largest
removing or adding shims between the
clutch plates and the back ring. The
L. diameter first. shims are made to thicknesses 0.1

L. Lightly grease clutch Plates (38) and place


(0.004). Adding shims will increase
the slipping torque and vice versa.

L. them on the splines of the c utch inner race,


takng care to ft them alternatively bronze
(d) Sip the cutch about l0 trmes, and
L. and steel. Flt steel plate first so that it
Lal.es 1l-e pressu'e of rhe clut' ^ so'in8,
then adjust the clutch to slip at

L. Assemble clutch nner race together with


between 120 - 150 |b.ft. f slipping
torque is above 150 lb. ft. remove

L. cLutch plates and springs in the . trtch outer one 0.004" shim and recheck. lf
s ipping torque is below 20 lb. ft.

L.
Taae.
add one 0.004" shim and recheck.
pnion sPrlng (37) and s de I cn the
L. Grease
armature shaIt. Repace caste lated nut (1), tighten securely

L. Grease bore of pinion (2) and lnseft rubber


and then lnsert sPlit Pin.

L
L
sealing ring and shims.

lnsert pinion into drrving end shield (40)


order not to damage the fe t !ubr cating
in
Pour approximately 8 cc of oi nto the oil
f ler hole in the drive end sh eld. Allow
suflcient time for the lubricating pad to

L
L
pads, the pinion should be twisted n the
direction of the spirai of the pinion thread
whiLst the ubricatng pad is fted by one
absorb the oil then replace the lubrlcating
p1ug. Wipe off any surplus o i which may
have run into the inside of the driving end

L. flinger from inside the cast ng. Also a


suitable shroud should be used along with
shield.

L. the pinion so as not to damage the oil seal' Fit solenoid switch5) to commutator end
( I

shield and secure in position with fixing

L. Note: Before fttng a new shield' ensure to remove screws ( l4),

L
L.
the protectlve paper pad which is put there to
prevent ingress of foreign material when the
DE shie d assembly is stored for service sales
Reconnect the solenold winding leads to
their respective terminals.

L
L
Slide pinion and driving end shield on
armature shaft. Push the pinion forward and
the

rotate lt until its thread engages n the internal


thread in the clutch inner rdce. Hold it in this
that the dowel in the
to yole, Flsuring
Fit coq'nutator end shietd
yoke ls correctly

L
located.
position and replace shim washer and nut
I'4ake sure that the shim locates over the Replace screws (16) securing the ma n fie d
I shoulder of the shaft and tighten the nut coil ends, positive terminal connector anc
o' e*t tt' eN t N t Test Data
Bs5-24 sL5-24
oiio I u
" end shield to
LockTorque
ffi;riving
-att 4.6 kc;m
82 kgm
yoke. Torque (r: ru. tt.)
tighten
bolts (5) and I 370 AmPs
Replace fixing 780 AmPs
Cunent (Max) v
it is not binding v 10.5
qoin the armature to
see 9.0
Votage
l'no it tr"" to
rotate

()b) lo armature Running Torque


Fit washers and
nut 2l kgm
3.5 kgm
Torque
plunger and tighten' (15'2lb-it)
(10) taking rr]-1:iacl 550 AmPs
oanr.ri e D,ushes 400 AmPs
^care Current (max ) v
il,f,n ,' ,."0'"'"0 : l': ;lJ3;,'i':";-mr'st be
16.0v
18.8

l""Io!!"ii',1"" :""#'i;i; as desc.bed Voltage

5Peeo
1450- 1650 rPm
1200 rPm

earlier'
field leads Light Running
leads and auxiliary 120 AmPs
Connect brush 70 AmPs
to the brush gear' Cunent (max)
74Y
bitJ:il Votage
check 11.a1 l6e',elario-nshrP, Jt:;: 3800-4200 rPm
3500 rPm
Speed to i
::*. :::J [-,*'.::' ]:^"':.:l ll; J; be
e'te"t--Dv
t:: Tho above values rorresPond
Battery used
shoulo
io it, n,Bn"tt d''1;e,..'rnouro
ra'stru^ teriPerature ot.20"C
Wnen 'ttt" trlSBer '' on Lf'e
";t'n
,f,orfOet be fullY charged
nn u.pr"-.,spuu"t':,il'T I""" rt.,e

trrgger 4"" '' - Performance


Tests
oo:Y.::i
catch Plate
i,,'.. *tt"* ar'-"-' *i
:"1:t",,\:::1
bedded over
mrrst be
Testing '*"n"
of their contact
area'
02.10.4.3'4
Mechanism
?n' ,n"
t" "
^:l"nTn"tt"l,
ihe^po-cr,i"Jl'"n".
:f #i
ie+
Engagement (onnect D,a,on and
u''"'"- . -, ,, 14 m-.
ln' e
to a battery' cleat
De 5Et "' -
Connect the starter rrq flY'wheel must
mater' ll beLween
lne lolr torque'--the t',11"8*i"*q'lat
lock rorqv'
insed a slrip
oI r'(ulaL'g :neLL ,n"
a"r".o (ur'.^., ", o RPI.4
'iu: ii,"u: :1"';'.:.'" :l:"i'iP:
tte lgnl runn,ng
<necrfied voltage
Te . Data {o-

(onLactq clo5rr^g' values.


llt""o "t"
th'''"1"' o'^':"tJ'o' lnsulation Test
operare i,'..ltinilij -^^^a,ied Lo a I lo
"1,:1"'?i";,:; re orve in usrng test P'?3"-l in series
l:': :";,.t ':s
. rrnax'rI.UlIl) ^li,t .-,,.,".
>eYY
. ".rd
- ,Oltage.
-,,,.aOle
ll;,:; "'';"; :l::i"*1. ':Lj: ;:l: ^,t(
,n,i. u , s walt ,lamP "'^rt" in-" .r, n,n"
one nch chec[ the insulattc.r"
::;*" '':i^ il::1;;1;' between
frar"
1e,"ninar and
(). n^.ir;,/p
(254mm)'
' ""'' - (for
*t-in'l^^and frame
caution:
?:;::
that lne
-:ii.,lL f#
rs-]"';;;
stader,
;J
ml
damaged bY
(,) ri"gualu"
l"rini"a versons onlY)
durtng attY '' these tesis
lf the lamP lights
otherwise windings
t

tautty'
the insulatron is
overheating

- 'r ";no itr;l t' cr^ rhe 5e' ^nd


Remove ttt>''"' o

*age conLdLL'
I.: AL68O SERIES ENGINE O2;I

T-
f o7.l o.4.4 Solenoid Switch

f D esc ri ptio n

f These are two stage solenoid switches' each

tE swltch consists of a solenoid oPerating coil


assembly (5) on the toP of which are
mounted two fixed contacts (4) The
solenoid plunger is inserled through the
ceolre of the operating coll and carries
E movrng contact (10) whlch is held in the
'off p"osition by the coil sPring (7)' Catch
E D LLe (// is "lso alta'heo Lo le op
ol.r1(er d1o Prevenl5 ll'e o -rger 'rom
o' lle

f i, .,, J'ing i" , home u' t: Lhe t rgger


1l is

E
E.
raised.

When the solenoid oPerating coi is


energised, ihe magnetic field set up in the

L. winClnS, dra,,vs in the solenoid Plunger until


the firit stage contacts are closed' and the
L. catch plate rests on the steP n the trigger'

L. This position is held unti! the trigger is ra sed


by ihe triPPing disc on the stader

L. armature, alowing the plunger to trave fully


home and close the second stage contacts'

L. Both contacts will remain closed untll the


operrt ng coil is de energised' when the

E. mor ng contact will return to itS normally


ope,' posit on under the influence of the
L. coiled spring
FiR. 3l

L. Fig - 3l

L Dismlntling

L Remlve t\'. ckLip (18) with No 4 twickliP

L. plrer:

L
L
WithCraw .ontact sPring
contact assemblY ( l0)
( l7) and moving

L. Remove tritger sPring (5).

L.
L.
MoYing contacts
lf n-cving rontact (10) is drty it can be
cleared with sPirit of very {lne carborundum
pape: unles; it is very badly burnt or Piited

L.
L.
when t shculd be set uP in a lathe and
refaced. Aiter machining, the contact sur{ace
mu$ be :mooth, flat and on the same
plane. This is most impoftant as... if th:
E
L
,rrfr,", ur" uneven, Poor contact will re3ult
and the uhole operatlon will have to be
r--oeated after a short time. Not more than
,,flJ

L
I
0i -. maz be removed from the contact
face: and n the unlikely event of this not
being enough, a new moving contact shouJd
ul
MOVING CONTACT
FOR IYPE 267
Fixed Contacts:
sPirit
Fiye.j (ontacts (4) can be cleaned wrth
::""'#ilI";t:.rndu' P'P"' unless they
condit'lrl,,Iii,i
]r"","'. olo', burnt Pined-u,l'o,
they should o"
rn posrtion on
-l"l':::,.'l
the swrLcrr' n.o," ,nrn
_ .6
ti.tl.i 1,em the
05 mm- tno''0,,
?1," ,",n.'"n, ,o
and Pirt;^s the
::ffi: :1i?.."
- "i;:,"'",
l'"^,"*, *"" o o: *^:*:: ,"i:.n;"":
con[acts are t'pP] "d -ll-jn,"d ro rhe
state, theY must be assenrL
:fi';.';;1 "*d on..u.'*h"::';'".jil?
olaced in se.vice usrn8
u."u.n"r,"* facilities
d

nxt"'" lf no macn'nrng

1."
"".i;it'"
a new switch shorrld
De fined'
I
Fig - 33
I
AssemblY I
Lightly smear plunger
( l4) with pelroleum I
jellY.
I
Replace triSger sPring
(5)' I
and
Slide noving contact
asserbr) 'l0r {
.on,",L ,P.'ng l7) on
the PIL'1e'
{
t'i88e" 'r' LLo s'ol 'n
locate the e1d o{ Lhe (l 8)
I

il; ;; and rePlace t\^ickliP


; ";"
'onta(t gaP E l'79
-' 033
Checr tnat
il;', ot;;;removrng
rhe sap shoud
::i"1";'""i:l
Packlng
add,ng
the fixed contacts

Check the gaP 'D' is 2 05 f 0'6 1 mm'

SimPle Service Setting


settrng) ha/e been
After rhe rrechanical ne'k n'a) De
..i:l:" t"' tre flollowing
l,)i*n the
;..^ the Drunger Iorward untrl
the gaP between
nr."',"""att 'Jsl louch then be
,i. *ur"t t"" calch plate 'nould
the catch Plate
:;;r."",i.;t', I mm berore
hits the trigger'

and push p'unger


so that
T.ip the tr;8ge'
-ror.Lrcts oll [hrs
,nf r",ono iu:t Lou r' F el' the
;:"i',;; pt"ng". to-p'"t"s.ils,1r"
AL68O SERTES ENGINE O2;I

Electrical Tests
ll Check that both contacts close when 15
V"Lt' i.,; I is aPplied to the
00
solenoid
IJ winding
E the switch to a test of a few

\l Subject
.".ine, au'ution at twice. the
iJ--"nru." that the trigger oPeralion
normal voltage
is

E ,iirfrt.tory' An) faullYorasse'nblY :'


,"l.r"."g'"ft of Lhe trigger caLch Plaie
E will cause the catch to trrP

El When these tests have been


successfully
end ( o!eT
romoleLed, Lhe commutato-
EI ;;;;J ;" carelully fitted and tre nachi'e
H subjected to insulation test'

EI Solenoid Winding
ln- ,h" of the winding becomtng
LI it"r"" .l"u"nt
damaged the comPlete switch

L] should be rePlaced

Catch Plate and triSSer


L:I rnto.., it cat( h Plate and Lr gger
for wear'
"
ir'i".' tHo'ra"' 01 tl e 1rr88e' a^d Lhe
L:] iott* of the slot in the catch Plate show
,ign of ",ounaing off' the two comPonents
1-.]
must be renewed'
]JJ
l-l lnsulation Test
Ur'n* tn" Prod' cornetted to al5 lr0V
,'-"^1, ,,oPr, at o ir ser'e' "\'lh ainsulaLion
watl
r-I ir.p'tn" voltaBe' checL rhe

l-l Jt "it'itto"
,u.r,i'," b/ touching Prods on
ierminat B and frame lf the lamp liShts the

LI insulation is fauliY'

l-l 02.10.4.5 Lubricationtng rs luD-l'dLcu


r^u/
l-l The oTrve end beat
1Seno Sy'tem l50r
trom a rarge reseryolr
^ir
v.L

l-l coria,nei ;n the drtve end shreld'


which can
of starter comPonents
L]
Lubrtcation
is as follows'
U"-Oon" ut overhaul periods
I nstru ction
Location
Saturate wick and felt oad before
Servo SYstem 150 oil
DE Bearing assembly. ToP uP with 8 ccs'
Frequency - once a month.

Lightly oil.
Veedol Atwofth Srease
Pinion Sleeve & Helix Lightly oil.
Veedol Atworth grease
iYating inner race Grease both sides ol plates before
Veedol Artworth or anY Heary grease
Felt seat in triP Plate assy.
and
Strongly Srease the sPring
L. Return spring on armature assembly smear the Plunger shaft'

L.
I nner Tace fibre thrust washer
-)F shaft and Pinion bore Shell Retinax or Shell Alvania 3 grease
Smear with grease.
Lightly grease the surface
c-^.. ,^/i+h Freouency
_
02.I08 AL68O:SERtES'iENGINE
mav be due to incorre.ct flvwheer-to-: -"an'
|l;ll;,i,'i^ .o,Iii;lt!-".L"n"ffir"-"n,
-U3-6,
ZS
?e!we-e.n Pini:l ,"19,flv*r'""r
+/- O'03I ins (3 18+/- bZsmm,) between the face of the 'ly'ivheer :'-:
clearance. This clearance ,r,orrO
r

ii" face of the pinion when the pinion is at rest'


"ng"ging
lncaseoftroubleitshouldberememberedthatitmaybetreatednotonlytothestarterortheba::=.
ignition systems or fuel supply. The following are
hints for dea - i
switches, wiring ,connections , uut also to the
with trouble limited to starting Plant such as:

Recharge battery/have it checked =:


t. When starter is oPerated its shaft L Discharged defective battery
a competent garage.
fails to rotate or rotates slowly'
Loose or oxldised battery Clean the terminals Tighten all

terminals/con oded or loose connections and smear Petroleum


jelly.
connectors /defective earth
connedors.
Starter terminals or carbon Spot faulty earthing and deal with it'
brushes earlh /short circuited
Brushes wornout and
have proPer contact with
do not Renew brushes /clean commutator' if
commutator is badlY burnt due to I
commutator. DirtY or oilY or
badly burnt commutator due to
sticky brushes skim/replace comPlete
armature. I
sickly brushes
Replace switch /clean the contacts'
I
Solenoid switch defective or
5.
points badly pitted
I
Armature/Field coll defective Replace armature or field coll as the I
case may be.
I
7. Excessive voltage droP Check and rectily circuit of starter' !

l. Pinion fouled Clean it I

2. Burr formation o' P'n on or Deburr it bY filing.


ring gear
3. Defective Aux Coil Change Aux. Coil

4. lYountlng loose Tighten mounting/units

5. Worn CE/DE bush Change CE/DE bush

6. CE bearing Pin loose Check the tightness of bearing Pin


fixing screws & caulk it if necessary.
l. Sticky starting switch Disconnect stafter .able immediately
Starter continues running after at battery or starler. RePair /
release of starting switch.
replace switch.

2. Short in wiring Harness Repair fault in wiring

3. Dry-DE bush Trace cause and lubricate

4. Pinion flYrlheel gear fouled or Clean thoroughlY /deburing gear


damaged. and pinion bY filing
lnsufficientlY charged battery / Change the battery or clean
lV. Pinion engages but starter does terminals.
not crank the engine corroded terminals
7. lnsufflcient Pressure on carbon Change brush sPrings/brushes
brushes or wornout brushes

3. Shofted/earthing armature Change armature

4. Slipping Clutch assePblY Change clutch assemblY


l-
l-
L
L
L
I{
L
L
l-
l-.
L
L. GhaPter' 03
L.
L
ra MARINE AGGESSORIES
r.
L.
L.
L.
L.
L.
L.
L.
L.
L
L.
L.
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s
( MARINE ACCESSORIES
f
03.01

rL. CONTENTS

CHAPTER . 03

L
L
rL Section Sublect
MARINE ACCESSORIES
Page No.

03.03

L
L Number of Propeller BIades. ..... .. .
03.03
03.03

r1- Propeller Tip Speeds


Cavitation
Propeller Overhan9..............
03.04
03.04
03.04

I-- MultiplePropellers........................... 03 05
03 05

L. Propeller Shafts....................
Reduction Gears...................... "" """ """ " 03 06

L. Specific Type of Hull for Fishing Vessets


03 06

L.
L. Engine AliSnment to Propel er shaft ........... ..... """" 03'07

L. Seacock and Strainer 03.09

L
03.1

L
L
0 3.2 Engine Cooling System '.........'.. 03' l0

03.12
Marine Power Take Off - Model C- I I 0 (Ghatge Patil) """"""""'
L Description..........
03. t2

L
L
Technical Data....-...................
Construction & Assembly-.........
03. t2
03. t3

L lnput Spider Drir e AssembiY 03.i3


03.r1
Clutch & Operat ng l"lechanism Assemb1y... ...

IJ C/utch Assemb/y a3.1 3

L Adjusting Yoke Ass emb/y.. .. ....... .


43.13

L. S/iding S/eeve Assemb/y 43.1 3

L
L.
Clutch Shoft, fhrowout Fork & Clutch Housing AssemblY
Final Assembly (AssemblY
lnstallation
A & B) ......
43
03.14
03.t4
13

L Alignment 03.r4

L
L
Remote Linkage
01.r4
03.15
03.15

L
PTO Settlng and Adjustmeni
03- l6
Lubrication C ha rt ...................-..... ..
03.17

03.4 Sea \ /ater PumP 03.17

03.4.0 lntroduction 03.1 7

03.4.1 Technical Data 03.17

03.4.2 Operation 03.1 7

0 3.4.3 lnstallation 03.1 7

SafetY 03.1 7
03.4.1.0
Flushing 03,17
03.4,3. I

03.4.3.7
Piping connections 03.19

03.4.4 Commissioning 03.1 9

03.4.4.0
Preparation start uP 03.l9
Start-uP-Procedure: 03.19
03.4.4.t
03.4.5 Maintenance
L.,-
LI MARINE ACCESSORIES 03.03
Slip is the difference between the
LI O3.O MARINE PROPULSION
theoreticat distance and actual distance
covered in a given period of time. Thls
LI The most basic Problem of
propulsion is the transformation of engine
marine
relationship is usually expressed in a

LI power into thrust by means of some form


percentage calculated as follows:
Actualdisrance

kl propulsive device Because of its


Theoretical rstance
of d
- X l^02,
efficiency and simplicity, the ProPe ler has Theoretical distance

LI become the most widely used propulsive


PITCH RATIO expresses the relation

LI
device
between the diameter and the Pitch of the
propeller' To obtain Pitch ratio, d vide the

L]
L
A
PUMP.
screw propeller is basically an axial florv

The rotation of the ProPeller (RPM) and the


pitch by the diameter. lf a 60" wheel has
a pitch ratio of 0 7, it has a Pitch of 42"
(60" x 0.7) and is known as a 60 x 42

L
L,
angle of the propeller blade, known as
combine to form a thrust force on
propeller shaft. Thrtrst is transmitted
pitch'
the
ProPeller'

It is to be remembered that all propellers


are a compromise. However, it is generally

L. through the shaft to the thrust bearinS'


which is the principal point where the forces
good practice to utllize the largest propeller
diameter possible within Practical llmitations'

L. generated by the propeller rotation act uPon These limitations are:


of aperture in which propeller is to
L. l.
the hull Size be
installed.

L. 03.0.0 P roPellers
There are many factors to be taken into
2. Type of oPeration - towboat, crew boat'

L.
pleasure craft, etc
account in selecting a propeller' from the
practical to the very theoretical The thing 3. Shaft angle required for large prope ler'

L. to remember is that there is no known 4. Weight of propeller, shafting and gear

L. lormula which will automatically give the ideal


propeller size for a given boat One can
boxes relative to boat's srze

L. merely aPproximate' The only true test s


the "trial and error" method'
03.0.1 Number of ProPeller Blades
Three-bladed propellers are more efficient

L. over a wider range of apPlications that any


other Hence most of the
ProPeller.
L. The major terms used when
propellers arel
d scussing
calculations are based on this tyPe ot

L.
wheel.
L Diameter

L
L
2.
3.
Pitch

SliP
ln theory, the prop wlth the least number
of blades (1.e. two) is the most effic ent
Diameter and technical lmitations in most
cases, make a Sreater number of blades

L. 4. Pitch Ratio necessary. Four and sometimes five-bladed


propellers are used in cases where an

L. Diameter is twice the distance from the


centreline of the ProPeller hub to tips of the
obiectionable vibration Peak is developed
within the operating range when using a

L.
L
blade, or the diameter of the cir"cle scribed
by the tips of the blade
three blade ProPeller'

All other conditions being equal' the

L. PITCH is the angle the blade makes


relationship to the centreline of the hub and
in efficiency of a four blade propeller is
approximately 96% l.f'al of three blade

L. is normatly exPiessed as the distance, in


in one
propeller
'blades
having the same pitch ratio and
of the same ProPortion and shaPe

L. rnches, that the blade would advance


revolution, if the propeller were
working in a solid substance Thus' lhe
a screw

theoretical distance in inches covered in one


An old water front rule of thumb for
proPeller selection is:
all

\ "Tow boats - big wheel' small Pitch"


minute could be measured bY RPM X
\ "Speed boats - little wheel' big pitch"
L PITCH. However, we are not dealing with a
03.04 MARTNE ACCESSORIES
03.0.2 ProPelter TiP SPeeds

the speed' in MPH'


o.oDeller tiP sPeed is
,r*"tt"O uy the tiPs of the ProPeller
U,"d"r. The greater the tiP sPeed' the
more Power consumed in PUre turnlng
',q of
30" propeller with a tip sPeed
"ff"n
50 l"1PH will absorb about l2
horsepower
in oure turning effort This in itself
is a
horsepower loss because it
contributes
a the forward thrusi Generally
".rni"n gredter Lhan lO" in dian'eter
orooeliers "huu"
lfor,a no, , tip speed over 50 MPH
II
On propellers, under 20"'
,."tt". tip speed
;
should not exceed 120 MPH
d
!
i
D x Shaft RPM x 50 x 314 I
T= x
12 5280
\-
Where
-
l- Tip sPeed in MPH t
D Propeller diameter ln inches' t
t
03.0.3 Cavitation
When propeller RPM is increased
to a Point :
where suction ahead of the propeller
reduces a
the water Pressure below its vapour
a
pr"rrrr", u"oo" Pockets lorm lnterruplinB
the solid flow of water to the
propeller'
This condition is known as cavitaiion'
:
causes of :
One of the more common
(a propeller
cavitation is excessive tiP speed
a

turning too fast lor water to follow the


".o.to";
blud" Cavitation can usually be :
expected to occur at propeller
tiP sPeeds
results in a I

exceeding 130 mph' Cavitation


loss of thrust and damaging erosion
of the
ProPeller blades

03.0.4 ProPeller Overhang


The maximum distance from the stern

bearlngto the propeller should be limited 10


Propeller
no .i" tr'un one shaft diameter'
produce a
jif to vibrate and
shafts are aPt
t ;;ipt action these limits are exceeded
This condition is greatly accelerated
when a
propeller is out of balance due
to faulty
machining or damage'
f,
E
rL 03.0.5 MultiPle ProPellers:
The most efficient method of propelling a

rL boat is bY the use of a single screw'


However, tiere are other factors which when
taken into consideration, make the use of a
single ProPeller imPossible
nOTAIION \-fz FOTAnoN

L f a boat has to oPerate in shallow water'


the diameter of the prope 1er is limited
L
OUTAOANO TURNING
Therelore it may be necessary to install two
PROPELLERS

and sometimes three propellers to Permit to

L
Li
a proper pitch ratlc for efficient propulslon'

Propeller rotation is determined from behind


FE.

Lr
I.
the vessel, facing forward The starboard
side is on the right and the port side on
the left Rotation of the propeller is
determined by the direction of the wheel

L. when the vessel is in forward motion Thus


a clockwise rotation would describe a riSht
L. hand propeller and a counter clockw se
rotation would be left hand propel er'
L.
L. are nlore
RiSht hand propellers frequently
INEOAI]O TUANING
uied in single screw installations' But twin PBOPELLERS

L. screw vessels are equipped with two


possible combinations of rvhee!s viz" a)

L. Outboard turning ProPellers and b) nboard


turning ProPellers F6. 2

L. Figl&2
L. A rotating prope ler tends to drift sideways
L. ln the direction of rotation ln a single

L. screw vessel this can be partially offset by


the design of the stern Post an the rudder'

L
L
ln a twin screw vessel thls can be
completely elimleated
rotatlng ProPellers
by usinS counter

L
L.
03.0.6 ProPeller Shafts
The connectng iink in a boats propulsion

L oaclaqe is the p'opeller sha'. fhs Portion


o[ tn; or,ve t,u,. ,"*"t Lhe cLal lJn(l'on o'

L
L
transmitting enSine torque io the propeller
and propeller thrust to the thrust bearing'

Propeller shafts are classrfied into two

L.
L.
?TouDs, lair 'hafts and r^e shaF"
The
Iection or sectrons of the shaftTs lotally
within the hull are termed tine shaft Tail

L shafts are that Portion which is partially


or
rotall, evDosed to water outside the t-ull'

L
L
8",r,." tn. ponion oI the 'lall rs subiecled
to such erosive forces as water' sand and
bending movements due to propeller
over
ilu
I

03.0.7 Reduction Gears:

Selectionof the reduction gear ratio is one


of the most imPortant decision to be made
in any marine power installation A range of
reduction ratios is normally provided to
assure oPtimum performance under a given
set of operating conditions Factors taken
into account while selecting the reduction
gear ratio are anticiPated boat speed, usage
of bout, p.op"t pitch ratio' propeller tip
speed, engine horse Power'

03.0.8 Specific tyPe of hull for fishing


vessels

Vessels in this classification that flsh by


means of nets drawn through the water
offer a special problem For example, a
shrimp boat may travel as far as 500 miles
or more to the fishing grounds. Owners
usualy wantto cut this travel tlme as much
as possible, However, when fshing, the
boat has to tow large doors performance
requirements calls for a compromise in the
prope ler selection and reductlon ratio to
obta n the maximum usable power for both
operating conditions. These optimum"
condtions are as a rule achieved when the
speed in knots divided by the square root
of the waterline length (in feet) equals elther
0.9 or 1.0.

r. e. ./rwr 09 or Ll

Where V = speed of boat in knots and

= loaded water line length (n ft)

This assumes the hull to be a normal


displacement form with a reasonab e beam
to length ntio.
The optimum of V/rIWQ = 0.9 or' I I is
simply used as a base to establish the most
practical speed of a displacement hull.
Beyond this point the horsepower Per knot
increase becomes economically unfeasible
Thus, from data taken on a large sample of
displacement hulls, a general formula for
estimating a boat's "maximum feasible"
speed was developed where 1.34 times the
square root of the loaded waterline length
(in. ft) equals the boat's speed in knots i.e
l.34.,lLWL = V, where
V = SPeed in knots, and
Lensth (in. ft)
L
I - l\zz
MARTNE ACCESSORIES 03.07

5 Iot.o.c Alignment

l- I Proper atignment "l * "igl:: ^:. ':':',:"';;


S I
tJ. I
'*:llli*;Tl::ll:'ii"":?t:"3"'1
il':"'"in"..""'"*:: l'l^:,3"1^'i,?"ifi
*lln.:9";
li';;;;"; u2r;qg5 oads
[- I xJ:::':::;:,;) o""a "-'1"" I:: -l:[
i"d
i'1'*"";;"-'"gn'' ar-d 'r'aft
"ng'n"
I I
ProPeller shaft
L I or.or.o Engine alignment to

tr I
L I .tne ra-e our o. Ll-e o'p.g:
,il ,l?';^J

;:*::h*i:h;rr j'rqqj'ii
l- II
S |
:l;;';)"";:ll':';:;:"i'':');'
::J:: ;; n' ''""ru"'11:'.'l:10":
o'-" " "'-'"u'i
l- I
- i::,'ll::"'"."
'"o
'!he' "::
tnaL
^'be -sed tne

f- I Fig-3
l- I **n rhe ensine in Postion 'i tl" ::s.]":
!- I
L. I :::,,1:;',n"J;':
lil:':;:",, o"t ,n.
?ii":"-jl"T'1.1
"'*1.,"1:' I.::
L. Fig. 3

"
<h _

r- 1 I ,-
l[,J'il:'::;"-"': .,- .,,
D -(a- no cr, .\, '"
',

tr 1
!- I
ffiflr;::[:*;;1T:-:i;]
:li:m;,.i::,,'".:';:Tlxi"i,i:"J';.|;=
*"J.1

L. I lop',"il: 'lill' :':;.:"j"lj:,i.,';,i


l:;iii",;.' ;;'" p'""r","' par.ricurarrv
rcr

L. future realignment "J


L. I *,ilt also be necessar/ to move

II *
:*" ;;;i""il:[;,:;
:le::cr!:
"\ri;,.:"1'":;

=
}.
f I
l^"JL:::::':,.:t:l#fn'1arr,
;,;:':^r^. rhen comes
between

to hs.arsned
I\. I ii'*i' ;:'i,:: o" p""'bre. to match

E I''[;i"""';1"':,11
E I ;*:jk:.:",J:flt;:;:i::''Tr:i
;;
^the
"':'':'-:1q::i"];

N I
E I nr*]*;,i:-*i'.1:",:::,"i%":l
fi.xi:i.lT|"i,"".'"';l:,I".T:',iffii
03.08 MARlNE ACCESSORIES

be parallel.

lf the alignment varies during rotation then


fu.th". uign-"nt is necessary or the shaft
couplings should be checked for
improper
ir-.J ..-i.,-o*. Face run-out on the engine

c*Pling ' an usually De corrected bY

."po.iti"o",'',g the coupling on tts splines'


Snaft .ouPIng run'out is usually due
lo
,na(curac) of Lper fit or l"ey interference

Some boats are not stTucturally rigid and


.oa" aury their load in such a way lhal
in", *itt :loe' or 8o out of normal shape
*iii, toa-Oing and unloading' When lhis
"u",f exists, it may be necessary to
condition
niut"'u .o.p.o.ise between the toP anda
bottom couPling clearance by leaving .
Ir.rL. .f"rirn." at the bohom or This the
!"""" ,^a propeller couP'i18s
i might De 0'OO5 ro 0'007 whrle Ll-e
f
"".'un."
top would niaintain the standard 0002'

During the Process of securing


flnal f
it may be necessary to shift the
eriglne manY times When t
"tinnni"n,, becomes
f,
lolarent Lhat rhe aliBr rrerr 's reasonablT
't
close, tl-e noles Ior lhe lag studs
a'c
.lrt"a -a drilled Then with steel
{lnal ta
sccured, the ne( essan oT

nrii *ooo shtms are rnade -o


^l,onment and Lhc
:
ensine is fastened in place The allSnment
rs

inJn ."ct,e.k"d' and if satisfactory' the :


coupfinS- i, bolted together
and rechecked
again.
:
:
Although it is not necessary to
align a
n"riUr"' .oupfing as accurately as
a sol.id :
, orofi"n, ,." i loser rt is in the 'n'tial
;ilme.nt lhe mo"e vibration free ;t w'rl bP'
I h"e mosl accurale melhod ol a';Snnent 's
-arign a
io the shaft on to the engine with
fle*lbl3 coupting out of the system This can a
-u
i" Jo"" *i r',, ,p.t"t the same size as the
.o"rfin* U* not flexible in nature Flexible a
.or'0,,^gt ,r." used onlY for noise
and

vrbratio-n dampening not to correct


inadequate alignment'
I
Lr
fI To sum uP:

flEI 03.1 STACOCT AND STRAINER


I Marine Engines uses sea
^"h^L Pvland the fresh.water system
*.iJ.'t";r-'..c,'i"8"from outside the hull is
Sea cock with filter arrangement
should be Provided in the sea water
system,

fl ;;" water
;;;;-;, - a sea water PU.P throush
oil
in't waler is circulated throughanda
)".,"..'",..n""t"t
7. The filter in the sea cock must
cleaned everydaY
be

E
r il],
then is sent out'
and exhaust manifold

in o'fferent
A ooat may have to work (rear the Port'
areas
The drPlex L/Pe sFa cock bei'
aduanrageous as one
iner can
cleaned while Lhe other
rs workrng

rr
E. ;;;r
L,,,.a.
',1*1.'r,,.'r'
f
wale's
ln the areas f'''l of llaine
"'sharlow
e> ample weeds'
ll,. *,in oolluted waters l ne
.

sea
and in
ale'ae etr

free
water
from
' 4. To Dre.ient enlr) o{
;nto the sea waler
,n" ,ora ot gral;ng
sea weeds etc'
in'eI
ma;
a stralner ln
be used on

L
be
l"-l] arr*tii^" s)stem 5noulo the pump the hull
I-oi u', o,r,"r.*'te it nay. danage
r.
f.-
"i,.
;J;"","
syslem srmilarl) slePs mus[ be
"i,n","" thut th" sea water flow is not
."ri.","0 bY the sea weeds and
other
5. This grating must be free from
deposit of sea weeds

As soon as the enB ne is sta'ted'


anY

organisms 6.

L.
must
,"u *r,"' on lLe de"'er) side
ls no-marl) ltled r''l he suctlon
I
A (Al k 'i"u- be checked

L. :r:":iil
'rll*" ,n"
'.)(
-,,.t". '31qr trne rhrs ': fitted
l,ne rn Lhe 'naio'11/ ol
the
At*a,s tl'ere must be a wat'i'cdse
on

L.
7.
is not working and .\ilLer' ln
ilrlt. wn"" t;" engine
operation' the sea cock
lne derrvery ol sed of the
ii" L.", is not in 'o i;;r" ;. ". \^dter coning out
L. -rr, u" closed S'm:lar Pre'Pnl -ll'e "\ale-
l/ Defor e sLarl lnB
6",jr"-, r;a. ,n'ned''ietr ' thorough
checl mJ\|. be Taoe n ' he
sl em'

L.
s)
,ft" s) stem'
"", ".i., ooen"d'
ir"'""i,* tn; sea coc! mu\L bc
L. There are two tyPes of the
sea cocks'

L. l. Sea cock - single filter


DuPlex tYPe - two filters
L. 2.
s"a cocks ate oI
f- These fihers used 'n tne
-"t"il'. iro" nav'ng sT alt
oe'lorated noles'
ln'"" i"'a*,ij"' i' ou'd oe capable o'
ra pa t'cres In
i,i"',ng .rno and otl elrr'r-tellter sea ' or I
f--
rL.
."1*r,", wilh r'l e 5rngrearter must be
'l ' ]"^^':"'-
'ni Ihar Lhe
-,''r" and creaned dnd berore
':;:,J';;"":'v
,iri'", T his w'rl ens'-rre
free
'n"*
**"t ""g;n"
t; the system on the other
L
L.
nind"ibv us'ng ouple> LvPe one 'lrLer
:i;;;;;;;J';"
'n"-af,-i,
olher
*"y the use
nrier
of
as filier can
's
duPlex
can
wor*ins
tyPe
be
5o
rs

cleaned
be

f. ";,;;;*"t;t
without stopPing the engrne

L.
f.
The sea cock inlet is fitted
ril, lnt"t of the sea water
I;:].";;;'JIY
-;.;*;t
on to the hull'
musi have a
in *'" rorm or a sratins

r
I.- any {o-ergn malerral such as
sea
,;
*"J0, "tt enterrng the thatrllet and blocking
this Srating is
the hole. lt is necessary
any dep-osit of
brushed externally to remove
the pratinq. Further
03.I O HARTNE ACCESSORIES
/ SEA WATER COOLING SYSTEM
FRESH WATER

L- - - - -- ---+- - - - - -'l

HoT OtL COOLEO 1


rnou OIL To
FNGTNE ENGINE

ts€^tJ
.-
lt.
-)>' ' I WATER PUMP I
I
I

I lsrnatuea
----
s.! Mlttt

:,
I lsr-qcocx -lGrr{t.rli
FE. t

the
water from the sea first flows through
0 3.2 -o.a"l^ COOLING
ENGINE SYSTEM
heat exchanger. where lt cools the engtne
fn to maintain the normal running cool.nq ware" {soq vuate'l and
tler Passes
,".o.rutr." of the engine comPonents' the ii".rg" ,r-" exhaus r'n'lolo' ' ooli.lgAs't
Oito*ing .ooting equiPments
are Lrsed
o"to-! o"'ng fl,5rharged ,rlo L-6 5ea
,t'," ,"" *J". has a corroding effect on
Heat Exchanger
(fresh
the units though which it flolvs coPperproper
iijt"rt"a for" cooling engine coolantcooling maintenance is necessary' All the
;;. lt uses sea water for tubes of the oiJ cooler' and the
heat
engine coolant are to be flushed ano rteared as
i", ,"io-'n"no"t'o''t rr e wdler rlevel ed
"^anu"n". ln

Ensine oil coole r i* h"u, exchanger snoLrd oe he' I

tt ir ,r"O
fr.rh
'*u,".for
engine oil.
coolrng engl'e orl' lt u'es
(engine coolant) for cooling
requrorty. For ,opoing .lp onrv 'ot
ur"d. ln case the sea
,"-ou"O to. reconditioning
to
Naler
while
woter rq
oLmD
reftting
that the pulley
rs
If,
care should be taken see
Water cooled exhaust manifold
53a water lrom heat exchanger
passes
fltted on the sea water pump is properly
a,rpred with driiirg flarge pulre''
ln case' T
inrorgh exhaust manifold and
gets
in!
"ngin"
fan belt rs Lo be replaced lhe
brac(el is ro b" 'emoved' I
I
d;scha'ged into the sea.
f,"r,
"i.h"ng"t
schematic diagram (Fig - l)
given here water from
A l'4arine oil cooler uses fresh
a"piat, tf," fresh water/sea water
l''larine cooling system
circuits'

is provided for
heat exchanger to ccol the engine
After cooling the engine oil fresh
oil
water f
.""ri"e tO *t':" :]-:':l"t,.ft'Jn"lL]
enters engine water PUmP'
r-^-..,i+l-, 1-,6.+ 3
lil-t rr-r.NO. orscltelgl
I HEAT EXCHANGER
Fig. 2 Morine Cool'ng A"u" (s"o,

1
WoY,:
F. ruo. otscntrnou
2l
23
OIL COOLER U.H.E
HOSE l.l/4
SEA WATER PUMP
DIA

1-I 2
l
jorNT
fLANGE
SETSCREW
7
4
24
a4A
as
BELT - SWP
IUBLIEE CLIP

Er twp sosr - ts" loltc


4 4
WASHER 14 16
5
S/A OF PIPE. S\^/P TO HE

L luBlLEE CLIP 4 17
6
STUD 5/16" BSF
7
l8it *o,". ro H E
wArER PU'',P I
34
3S PIPE l.l/4 DIA l4 swc

r.
8
HOSE 36 MOUNTING BRKT
piee eNcrue wATER PlJt'tP ., Fr E
I
9
WASHER 5/I6' DIA KOLOK
t0
r
t 31
tl CLIP l8 NUT
STUD I/2

la
BSF
t2 WATER OUTLET ELBOW 39
u.\(F l l/4' DIA 6.5" LONG 40 WASHER KOLOK
t7

L ,iib,r coore* To ENGINE 4l NUT I/ BSF


t9
20 HOSE ll/4" DIA 2.5" LoNG

l-
l-
1.
l;
\,
l(
\
f..
L.
E.
rr.
L.
I-
irr.
41
46
tlO. oesCnlertOt't
ffi;pE ',
JUBLIEE
CLIP
Fig.

E"T ExcHANnER To srMrGHT


3 lAorine Cooting Circuit (Heot b<chonger

PIPE I

2
trt-.
5i
5J
55
t'tO.
' Exhou.n Monifold)

OeSCntertOt't

:,Tt?iH':";{":.,",.t:T'1,,o'.,, o.,
ADAPTOP FOB EX HANIFOLU
03.3
03.3.1 Technical Data
l'4ax torque
: )46 lb. :
II
I{
i9ax. Power
DescriPtion - light duty
86 HP !
03.3.0 dre specially al
'io sritlake-Ulls
67 HP
-tt^ P.wer and
- Normal duty
47 HP I
5"r,lX"o matint applira[ions - HeavY dutY
raLe-o{f to drive
-
ffi:;;;t"J as front Power rr'ey are-lel r 2l O0 rPm
il""'lr,".t-." fishin8 boatsr g' Mar ine PT o
Max. SPeed
al
:;;,"nJ and selr iuPPortwh(1 P'otecLs rhe Normal engaging force with
std'
98 lbs. (44 <g'
::.'1.-'". tipht casing hand lever Provided -r!
ug'uintt corrosion Flexible
':i:,;i';#"""i' :o Lhe engrne as 1270 lb. in.
,"o"i ao"pri"g ensures safety rnisal'gnments' Torque on oPerating shaft I
;il' ;t-"i" in" pro aga'ns'tn a 'V' g oo'e
( 1466 kg.crn) !

Or,oti Jrt is Provided ^ (AnSularl r5" a


pulJy fot belt drive to the
wirch Stroke of operaLing lever
i
a

I
41 SCREW HEX I

DOWEL PIN I
I aew s.our.tp HElo 43
V'PULLEY 2
2 NUT IAI'1 PROTECTOR 7
45
l I OCr WASHER
t2 TAPPER ROLLEB BRG I
4 ADAPTOR EEARING RETA]NER I
5 SCREW HEX HtAL) t7 47
SLIDING SLEEVE I
<,pRtNG wASHEB 1 48
6 .OLLAR ( SPL ) 2
7 CLAI'1PING PLATE I
HEX HEAD BOLT 2
TYRE COUPLING 2 50
8 HEX NUT 7
9 L OCK NUT 2 5l
iinrw gex . HeAo sHtll I
t0 THROWOUT FORK 2
iig.ew HEx . Flelo 53
WOODRUFF KEY
5PRING WASHER I 54
t2 55 OPEMTING SHAFT
1l SPIDER FLANGE 6
CLUTCH HOUSING
t4 icntw uEx . ueAo 6 56
SET SCREW
SPRING WASHER 51
t5 58 SPRING WASHER
t5 r
l1 ,rui ltro gecx cr,cr 59 PIN COTTER
PIN I
DRIVING PLATE 60
I8 6l ADIUSTING PIN I
l2
t9
[:?$-"".i1li' IFoR IrErl- 56] t7 62 ADiusrlNG YolE I
20
(p-ni.rc wassen [FoB lrEM 2ol 6l loiusrtruc sPttNc 6
2l 64 nrrrase spntNG
17 PIN LEVER FINGER
55 LOCK WASHER
13 COTTER PIN I

4 66 CASING
14 HAND LEVER INruT SHAFT
LEVER fINGER I 67
15 68 BRG , RETAINER PLAII
76 HUB KEY .
BALL BEARING
77 COTTER PIN I 59
CIRCLIP EXTERNAL
LINK LEVER 4 10
28 7l GREASE NIPPLE
79 I INK LEVER PIN
71 FLANGE
30 gSf i-"r sHowNr 73 FLANGE
ll :
iiirir,rc'?&:'"If
truor sHo/vryl 74 KEY SQUARE
17 -- "15 LOCK NUT
l3 PI AIE INSiRUCTION C()VEI(
GREASE NIPPLE
34 icnew sex . Hrlo 76
BOLT
SPRING WASHER .77
l_
-o
i-l
l-- o:.r.2 construction & AssemblY ,3.3.2.1,1
MARINE ACCESSORIES 03' I 3

Adiusting Yoke Assembly


The adtusr rg Yoke (61) 's fitted with
1gv..r5 Fnge' t25) by means ef
Pin Lever
| ' The oower I e Of f s n'ainl/ cons;'L of -
is inserted
t-_ "L firger r2)l Aoiusting Spring (5j)
in the'ot provided and then lhe
adlLslrng
l- (A) lnPut SPider Drive AssemblY
Pin (61 ) i-s Pressed ;6 36i locked in

position by lnserting a Pie'(-' of wire


LJ (B) clutch & oPeratlng lYechanism
through the small cross hole 1'rovided
on
AssemblY is
f-... the pln Th s adjusting yoke 'rssembly
then screwed on to the threarled Hub ot
L o:.:.2.0 lnput Spider Drive Assembly -l e F;o & Bock Plate (17) loll Il-e lngers
- press tre "o"trng p'are sulfi(:clll/
so lhat
lnput shaft (67) is iitted r'v th Bal Bearing
1- held

tr a Il-c e'dse sPrinss r54) 'rre in

i'"te 1 ' 9t 'nd tub &


f:l J::j:'?'i:i'ihi;U"il',[":^'"? Pos Iiol d-o DriuinS

lJ '
;T:":.'i:::
-'"
;'a'!:
5tlenl"':'"';""',
'. .,- rs i led :o '
?:',1:
tf 03.3.2.1.2
Back Plate ( l7).

Sliding Sleeve Assembly


l- 'dsno Tle Sfdlng Sleeve (48) is fit1cd with ink
l-- :::j,J",".,::':::-r':H^:"'.'l:;":1".;
o-
levers 128) by means of Link
11qr ard P,r cotler r59)'The
Lever Pins
lwo ,haNes
l--
Lo
Ftled to Il'L' (olldr or
:1"',^:,,".:;i:". :;'l::;:,::: lt,ec ol Colrtr 14o7 a-e
Head Bolt
the Sleeve with Shims (52)' He'
q
(50) and Nut (5 l). The 11s1!$ Hose
Pipe

tr,,i::
l-.
5:'i ".,i
"""''.11,""',","^""'o
(30) is attached to the Collrr through
lltting r3t1 The other 6n6 s{ the
r)
flexble

n;"'il:":;""i;'";T,l 1l'^,:::::1 Tf;


and Nut
hose is provided with fitling ( l
lam (2) for securing it to
the Clutch
\ ;::.:::":l';::;"'::":;'",
;; ' ; r' ;':"e'
; - r': 'f-
l r- Houslng (56).

f-- rr
"::'i
E The s ding sleeve assembly is lllted
to.the
i,,I",:il::,J|;;.'TJ'#.i,::';:";: adiusting yoke assembly throLrllh Pin ,(50)
which i:rm Pin joint between lnger
lever

L, :',:1",,:;0,": ^',1l:,' :;;',:",,:, ,


'^ "r1 r'rui i.':
(25) anC link Lever (28)

L- 03.3.2.1.3 Clutch shaft, Throwout Fork &


or.r.r., a,r,.n & oPerating Mechanism Clutch Housing AssemblY :
L--
AssemblY
L The Ci.rtch Shaft (a0) ls fltt''] with Ball
I-:.':I': Bearing (]n case of C'l O PTC
two taPer
L '::':i
asscmblres' - Roller Bearings (16)). The shrri is then
rnserlec ln the Clutch Hous nrl
(56) and
L rr p ace by
(l) cutch Assembl/' Bearing Retainer (47) is fitted
end of
L Hex. l]ead Screw (34) The orrlf-ut
(2) Adlustlng Yoke AssemblY' rhe shaft is fitted wth Key iiS) &Pulley
L. (44). The Pu ey is held io Postr'n by
Lock

L. (3) sliding 5ee;e assemblY Nut anC Lock Washer' Pulle; s held bY

ocking plate (39) and hex il'ad


Screw
& (+2) ile operating Shaft (55) s nleried
L. (4) ctutch Shaft, Housing Throw-out 1n
lole
Fork AssemblY th"'ho"rlng through the 6,655 J"illed
L. and Throw"out f"* 1S:1 is fitteJ
on to it

I. - ora.a,.o ctutch AssemDry. Trvo v'codruf keys (54) and


iet Screws
.

'. (57) ser,.rre it to the shaft.


L ;:'-,.';0,";; :;;'";1';J,.: - "";
the Screw (5) in either side oi':':
;-"". ...rloag sub-assemblies
Unit with adlusting
il) to (1)
Slacken
coupling ClamP flanges and
remo ' e
---: t
lj".no'""r"a,n" C]utch (Sub assembl es
tyre.
I
1'ir.
" -r, Sliding Sleeve /h\ Secure the adaplor (4) Lo lhe erg''e
C''-'
alrea-dy explained I ower
the \"'
iiu ,j on to 1f,e iian. gtace 1r1s L6y (74) rn pos'1ro' l-: I
crih l"o Sl,drng sieeve assemblv
-inro .l.de coL,Pti"g flange 173) on to 't'
Iiri.n njoing tre Collar assqmblv
r72' -'-: I
downwards so that the collar
trunlons tr\
\r/ No,v -r:de the Couplrng Flange !
togerl" a:
J,n tl"e forks ol lne thrc^ou[ 'orq' Co.,pting r'a' ge t73) close
as usua
cf,ect ttte alignment at the
""trt" ho'e l'rLr'-8 flanges
io"o""."o ro prace the grease
b!
in" otoo"r" side of Lhe rhro*o-t forl so ff ualuitt"nt is required adjustfrorr
"ny- sh1nl
"n
.-nr,' in" n"* proper ly lts ;n (he l-os'ng adding or removrng necessary
t"O"i,H" support plate of the PT'O
Unti'
when
*,inor, ,nr"rt"ting with moving parts p.op"tiy aligning secui-e the supporl
to the casing with the Nut ]am' et
secured "r. and replace the
plate to engine frarrre'{irmly
Assembly irr" [dKe cdre Lo ligt'ten 1l's clamprg
Hold the Clutch and Sliding Sleeve rews fulrT ond .-rn'lorm')
Shaft so that the
sufficiently lowering on the
s.
have
Hub Key (26) can be inserted ln between It is desirable that PTO unit shc'uldengjne'
'and Hub bore keyway to full common base lrame to that of
the
ir," tr,r"h by
dePlh Then taP hub ano Bart
o'316' v"lh
i'n,t *,,, avoid misalignments causedetc'
oore ol uneten shrinking; deflection of
the hull
i,Jri'. n,,.t''"t so Lhat the taper over' relrtting of
tf,e guU a Back Plate properly
fits Also it will facilitate removal and
in"- ,"i, without disturbing the original
-th:
(65) and Hub-
.iro i"t"" the lock Washer
Nr, flOl Bring the hydraulic fitting end of alignment'
housinS (55)
in"'ri""ilr" ho"se outside the(2) lf it is not to have a common
possible
and Lock irurn" ihen PTo may be mounted
,n"O ,".,t" it with Nut lam irr"
(81) on to ) \ [rr DroDe- are o[
l'
Wush"r 1:; Press Pilot bearing seDa aLe 'lrg^n-er
moL-.ting fra'ne st'oulo oe r
gid
the Pilot e;d of the Clutch Shaft
(a0)' i; ; ro
to avoid deflection of the unit due
A & B) "nougL
03.3.3 Final Assembly (Assembly to belt side-Pull loads'

'n r[ t '
AdlJst lne dd ' trng oI e 'o 03.3.4. I Remote Linkage:
:

,''nen t'c
otl,"* P P'oP" ' c'omP'o
The operating Hand Lever (24)
"" ' the three can be
L,"r,n it engaged Now adjufi srde of the oPeration shaft'
concentric 10 ntt"A Jn
I"e;"ntt of ih! ot;uing Plate the "itrtJr.
in! Si.O and engage the clulch so that lf remote is adopted for ease of
driving Plates remain I n -r-1 r '
clamPed linkage
r'' oDer'dlor rom d con'en'r'l t'lt'^ / h're
pont then
,o.,t'"n 1' o!| g t" dr:' 8r'
Io]rl'nS p-","r,io.s 'hou o De
[")-' ,. (ac " b dor'e \^rirr rn '.]ero
designin!/ielecting tinkage mechanismr
,rioa' nung" '^ t'loul d' / " ' -tr'- e c:lsl.l
No I
or o J'

-orn, 'l " c, 'tch ho'l ''ng er'ters the pilot \4) Ine to q'le e eneo on lne Clu'ch oPera[l1g
.*" that
,uf.ing bearirg
Pilot ,, ,r'-'.or'o Lor'{o rn 10 the a'ue g:ven r
t1."",",n" input shaft and the drNing Plate No l2'
the CaPacitY Chaft' on Page
ieeth mesh with the sPider flange teeth
l he l'n(aPe shoJro er \ -rr e 'Jrl lra el
ol
Tighten the Screw Hex Head (20) to secure
(56 t After s'ol, g
qte;,e r43t Value o1 lnq s"gular
th'e housing lrrmly to Casing
,i.or.i i, giu"n in the Capacity Chart
The
a,serrolT cl ^(l' lhal alr rno"rr I Da'ls"are
.ree,y Lurning
'n engaged a' a d''engaged linkage should be adjustable
I he l:1(age -noulo ra
/e
'ockrng
Posltion \Lr oPerdli'8 end to keep
ar'lngee ent"at thc
when
03.3.4 I n stallati on: in" u"ni totrt"a in disengaged position
not in oPeration This will ensure any
the
Clutch
03.3.4.0 Alignment u..iO"ntot possibility of engaging
au" ,o .."'ilng of the boat in rough sea'

Follovring methoC is to be aclopted for


tA\ ,l is Lo Preser\e lne standard
adv,saDle
piop.af the Pr'o "''l hard lever provioed for endu'ing proper
I

L-; MARTNE ACCESSORIES 03.I5

L.r 03.3.5 Maintenance:


Force Required to Engage the

L. The oPerators and staff concerned with the


Clutch

L. rnuin,"nrn." of the P T'O Unit should study


in details the instructions given in Tre
The length of the standard operating lever
provided is such that an average oPerator

L
this
has to exert a distinct and full force to
chaoter before con'mission'ng the "nrL 's engage the clutch when the adiustment is

L onlY md rtenance lhe un'L rccuites


pii.roo,. TDIJSTMLN [S ol tee cl tch z-d proper, The clutch adiustment is normally
judged by feel of this force on standard

L
L
pialoorc tuBRlcATloN of the bearinSs lf
ProPer car-e ls taken
i'.f.b unit will give a
to attend to these'
long & trouble-free
hand lever' ln case of remote control
mechanlsm , care should be taken to see
that all ioints are lubricated periodically to

L
L
service.

03.3'5.0 PTO Setting and Adiustment


avoid rusting and subsequent jamming lf
there is no fTee movement ln joints the
operator force which maY result
improper adiustment and slippage of clutch
in

k
r,
FrequencY of Adiustment:

A new P.T'O requiTes severa! adiustments


until the friction surfaces are worn in
ihe Iolu !"--q9 tl19JqlY{t"q1

f-- frequency ol adlustment depends


varlous factors such as type ol load
upon
(shcck
(a) Remove the name Plate'
urn the D T.O. shaft lrll lhe
'A clusting Prn'

L. or smooth) degree of load (full or Part)'


J"gr"" of in-ltial adjustment (properly
(b, f

1o l) can be reached'

L. adjusted or under adjusled) etc'


Pr" t I it 6ls2's Lhe
Prlt out rhe 'Adjustirg
hole on Lhe floot'rg Prate i I 9 t Turn
L. The clutch adjustment should be chec<ed
every three days during the frst
month of
clockwise the Adiusting Yoke (62) till ihe
'Adjusting Pin' enters the next hole

f-- op"lutlon. every week during second


mcnth'
(d) Check the engaging force on the OPerating

f-. "i..y
fS days during the thlrd
there after the above schedule s
month
given
and
:s a
lf it is not up to mark' repeat the
Lever'
procedure till correct adjustment rs

L. rough guide onlY achieved.

L. When to Adiust: (e) Refix the name Plate after lhe adiustment
is over.

L. lf any of the following


adjusiment of the clutch is essent
symptoms appear'
NOTE: While turning the Adjustment Yoke' hold
L.
al
the oPerating lever half way between
The hand ever requires less force to engage engaged and disengaged Positions .to
L.
L.
'a)
,b)
the Clutch (see Point 3 below)'
The hand lever does not remain in engaged
Position bL.rt lumPs back
on ts own'
facilitate easT turning of the 'Adjusting
Yoke' with hand

L
L.
,O
(d)
The P.T.O does not Pull the load
The Clulch overheats due to slippage
load'

L. The aoo mDlom- are P og-e:s:r e


e 5)

they will apPear in sequence if the prerious


L.
L.
one is o.erlooked' SymPtoms
'a' & 'b' can
be obseryed when the clutch is being
engaged and hence can be checked
in time'

L.
r-. wARNING:
Syi 'c' and 'd' will be observed rvhen
itorn,
the clutch starts sliPPing on load'

Fallure to adiust the clutch in time will


leadto slippage on load' Slippage on

L
\

t
load causes tremendous heat
generation due to frictional losses
iuh.h t'n burn and crack the fi l':tion
TA^ ,1"-ada thlls caused may
03.1 6
AccEssoRlEs
"irr*t
0 3.3.6 Lubrication Chart
GREASING POINT
LUBRTCANT
I
l) NipPles(71) Provided
on shafts
Use anv High Grade'
ii'r- o"t?
HiSh Temoerat-

Bun lubricant
e

for A11r FLcr '


-
--
I
Pilot Bearing(8 **..'"*r' n.''"t t'erating temPe atu-e I
on toP of
ffiilffiouia"d 200"F such as II
clutch Housing
(Tide water)
l) Vidol Alitho 30
on toP t-''
Nipple(8O) Provrded :
Main Bearings (69)
No 2 (lOC)
on clLlch 2) l'4odilux Grease
N-.--,pptazal Ptouia"d

Crease H (H P)
3) MultiPurPose
p".',d"d on etrer srde
N-',PPl"(76)
of the clutch Housmg

ffift,.,$.,:i.:".ill",]:l::::.}il:,;ffi,-?"r"i#,":1:i:,
niPPle etc
:"il;";':-t" iammed

ForcollarbearingensurethegreasingbyremolngtoPcover'Theexcessgreasefromcollarwillbevisibleon
clutch shaft'
RePlacement can be up to
03.3.7 Driving Plate thickness after wear

,';l;"tli;[iil"'ii\l".T:: i*
-!^ -in;mrlm i;'''-';"" 'n"
rhe srandard ,r,icrn"'s,ofrnen?iJ"lil,'f".,
3/ 16"' During
overhaul
-t^'^A can not be
out is that Adiusting Yoke
is worn
that" e Drrvrs Prate
:::::.::r,.:'::'::::,
screwed in d'l/
more' Length of rel':ase
sPring
replaced The standard Free
ce normally
release springs should
During overhault
rs 25 mm lor L-ttv ' ' "'

03.3.8 TroubleShooting
Lrnoer i^'-'allaLicr'
:-1. irr€ r|'?: mentjlllYl:--:----
faiIng Prematurel/ Fn'u'= clamp'r g
e'eniy Iigr'r'
set"'"Il]iij-- ' ll & --:-- der adju$ment
yre couP|ng

tf5 E"-A;il;#; ' -caged Position nder adjustment

ffiilt tut lng toad der adju(ment

ffiffihu"ts/s-ok"t
.n pood condiiion.
- ^^.r I'r
gads are lree drru 5""-
-
t-" adjustment ir.: . : :ll rn,..''g
mo;; t"k'CC"d "fter
----... d;-tl" th" rePlace the

tr rte.nlffittt
; cffconditionlhen '^t "nd
"-
of the bearrng
ili-'u oroP"' g,t"using
... free
t- MARINE ACCESSORIES 03'
I7

t- A3.4 SEA WATER PUMP


03.4.3 lnstallation

t- 0 3.4.0 Introd uction


AL680 Marine engines are supplied with
Heat exchanger,Oil cooler & Sea water
I
PumP installed and
connected with
lohnsor pL,mps are self priming ce11r;fuBal necessary pipings. However the following
impeller
o"ros *itt., rotute and radial points aie given for future maintenance and
'-o,in,"o o\ernrag o' the bearing oedeqlal' installatlon
Lr. 't-n"
prap rs De't d'iven and I aLes or ' e
rj ao.n engce crd,l.sha1 througl- pullevs' 03.4.3.0 SafetY

The Points mentloned below are to be


[t- 03.4.r Technical Data strictly adhered for trouble free running
oI

L Stork PUmP model : 5L1003


ir"," pr.p Also non adherence of
instructions rnay cause serious damage
this
to
LJ the PUmP that is not covered bY

TyPe : Centrifugal self manufacturers guarantee terms'


LJ priming tYPe
Make sure that the engine can not
be
LJ L
a3.4.1 Operation started when work is done to the PUmP-
and running Parts are
combination
L lonnson pLmp. cenLrrrugal tyPe w'1h mo"e
engine
,ns.ffic:Pn1l/ sh'elded'
L-- ,unning a,"urr,," ano can handle
lore'gn
2. When installing the PUmP unit' should
take

l-. oan,crJ. ,-.t-, a5 sedu\eeds' etc


upto
iru.t n"r, ' l'e 1 rnp '5 se'f Primi, g ') Pe
8Tl.1
\\ rll appropriate Protection and warnrng
measures to Prevent contact
with hot
t-- inUultt porltlue suction head and
va!ve' The
,",,-Or,a",-, a(Lion TPlies on tl-e Pri''lL;Ple
o' PUmP Parts'

l-- .in. pLn D nas to be filred 'r rlL


lf there is any risk of liquid so difying

l- ^'".i,on on t.
r,oJid on(e. \^-en it has been swiLcl-edr'n'' switch off the pumP, drain it and preferably
th'" i, pra.-aled 'rom the suclton flLrsh or flll wlth oll f Permitted'
l-- "',
Th" urpirut"d air is mixed with the liquid
contained in the imPeller' Through
the 4. lf danger arises in case of static electricitY
l-_ centrifugal lorce the liquid from
the volute the entire PUmP unit should be eafthed

la flows through the upper half of the PUmp


casing .ln the generously sized
pun.rp
ProPerlY

l-- .,..Irno l,ou,c car oe de-aerated


," ' ' oischarge lne' fne
lhe ai-
de
03.4.3.1Flushing

Before putting the PUmP into


l-- "l.ro"*
a"ror"a liq, o
Lds h'8rer speril ' gravir' thar
,drain olf any Preseryative
agent
oPerailon
and flush

f-
L"
the liquid with air contained in the
Jhis causes the liquid to return to de
volute where it is aerated and
volute

then
the the punrp thoroughly

O3,4.3.2 PiPing connections


wilh hot water'

u".rt"d ,grin ln the uPPer Part of


the

L. pump casing. The following points should be strictly

L. The air is eva.uated from the suction


line
adhered while installing the pipings
seawater PumP'
for the

L. and the iiquid level in this piping


rises' Once
x, The piping to the suction and delivery

L.
starls
all air has been evacuated 'the PUmp
connection musl frt exactly and must
not
pump' A
working as a normal centrifugal be sublected to slte:' durrng oDeration'
- ;s
L.i or"aon6rlion ', good 'r'rnr tionir I
should oe possro,e 'o- the asPlraLeo
Lhat
dr lo
The Passage of the suction Pipe must be
L. escape without backpressure
!n the discharge
amply dimensioned. This pipe should be
as

L. short as possible and run towards the

s
line.
o-fD n 5u/c d Ad l'lal Io a'l oo(l'et5
,,ise. 'f fhiq iq r o' Possrb'^ a ^' t
so the -8
The pump has a non- return valve' .
"n
,ra,,- und discharge lines can not facilitv should be provided at the
bt highest
III-.,tr-a*tr"'AccEssoRlEs

1220

062

12l0

010 0
c 210

0100
0B0 05{0
1720 -1080
1110
1?60
112 0

II
I
I
02

"^5

t
c65
0 6,. Ij
t
t0 60 r05 0 12(l .I
rlbo 11;o 1o'10 11Bo 11ro
0650 0230 0120 oslo ozLo :
r:- , R.h,esenrdtive Diol,fon ' seo \Noter
Pump

iia No. D Es!l\il]1e!


I
trLnt-lt!99!!I9! Gasket !
Hex Bolt
t00 PumP HousinS
Bearint Housing !
lmPeller
120 PumP Shalt
t30 suction Cover Bearing Cover I
t40 lntermediale Cover Ring
210 lnternal CircliP
Ring
270 lnternal CircliP
210 Key
140 Gasket
Oil Seal
Gasket
250
Name Plate
Plti I
300 Seal Ball Bearing
310 Mechanical
Ball BearinS
s00 Hex Bolt Plug
520 AIIen Bolt Housing adaPtor
540 Self TaPPint Rivet
5s0 lmoeller KeY
PulleY
5 60
Spring Washer Bolt with Nut
PluS
620 u foo, valve when
640 Window Cover It is advisable to i*,rll one or static lift ts
[7n ., a. ",t t' : t'-lt" ::,:'fl :i : ;"
l', a suction line is long
"
rsrge than lne st'clion totlit
"t
.u.,,,n high.
::*j" "';'^ ""t""'"1- '"0"*' should O.
be
whirls' It is not advisable to have a common
et and
Xioll"o.' "'""1 a;r Poc[
o' for
";;. oT L,,o
l'"a,,"" oo" or rrore purros 'and
'n:ghl more suctron rrnes 'ro'n
,r' ,n"r" '" a risk thal this .Pressure
because or a" l",J,lir.,,
;" ";:;;1 ,- ;o' ;n51ance different sources'
!i,*r'"" '"rer Dresswe ff$:lfft: Selecl the sLclion l;ne
didmeler as {r''nctror
a"rrur."t sl luld be taken
DY noL be smaller
rr mr '<t 1l-ldq
tirliotr".,l"'
safety valve in
the PrPrng
in" Jonn"ttion ll should no1
rr;m;ng PUmPs
suoa"n tr't :"''-' ll i."1",::.,l?*rillriil u"' L"o tu", t''"a for serr
: ?Li;,; not'equired-untes: *:tt"irffi
1o hiqh prel,.rre i'rPulse lYa' .--^ /^ni
i-*ttut AccEssoRl Es 03' I9

ensure the
During the self oriming Phase,
and wrthoul
tl Ol.a.l Commissioning:- air can escaPe unhindered rn the discharge
causing anY back pressure
tl tl"l tl:^-ot'l:
i\I
ensure
Before commissioning PiP"

l:ilItl [:1':";.':, :*recommendec-


i.:{"i";"iotr x Check if connections and seals
are not
a I lillltt,'';""] ;r'o'r,'r in" leaking'
: lH:r^' i;l;' c'''ng
"':"-?:11'l^ililiS and
r I l[HH:il tointi su"n u"r"* *::5 r::
ili"o*'Jl''" ;q:";;" io Pu' t:i3 l:: 't'" t"
,r- EnsuTethat the system Pressure,
temPerature are maintained
with rn

fI L";.:r'""",;:..il pumP
li""ffi ,'-l"
oP"""n "i1--11;:.
e erhaul'ng'
ah o '
recommendations'
"t or--if
t - ' c t-, r
n Lr-r Su _I ro''l
excessive
is
CAUTION: lf no fluidnoisePumPed
is aPParent'
il.
t, I
FJI'/ oPen the stoP '"1'e
pp" Ciot" rne del'\eD JoP 'at'" the PUmP must
immediatelY' Contact
be stoPPed
the

I 1 Frl the PUmo and Lhe'


sur I o " ?^"^"::J:: O'-O Manufacturer :t
for
o'-g' tne Prm:'rs iuttrorisea Service Dealers
[ 1. il,,[',i";:
,l* ,.u' tn" r;o';a
iu]o"o 't-'
ta'1s 'o o/e'io/v' hel P'
t: n the p-mD s*afl a e ^'
Lrrle : Dr r and

L-1. I 03.4.5 Maintenance


f
l-ur
r:qurd r[ necessan '
.nd udd rno'" free running of the
For smooth and trouble
ol '6taron^ar'd ensure Lrons 8i\en be'L ^
\: I . checr rhe d, e( t'o' casng
orrnD, l'la,ntenance ''slru'
in the PU,P hotrld be lollo*eo 'tct'r'
L:1. i1ut::i:,:,,.di'u'"d
lhv an arrow)' J,d
boti' the sL"raco or tl'e
purrp
1-l KeeD
"
!.- I or.o.o.o tteParation start
uP ,i" -,' .l"" "+ a crcan '' oo"s:blc'
L1 Take the following Precautlons '* Ball bearing are sealed
and Packed
no lubrication
wrth
ts
orease {or life and
L- Before commissioning
the prmp '-"rn::,^" il: necessaT/'
L- I' ::::::;:.:; "." 'l ' '''
cu''P 'r'
h^

horwater 'r' oPen the searhg *ili"""."1;":i'I:,1


mo
L i seal at least everY
f necessary'
LI il:".il^;'T;'i:'J,1""^:'iI"';"';;:;
[ol.;i *"; d'|ow rhe qea'| to run d"\ x
oil (SAE l 5W/a0)

Draln off and rePlace


oil once a year or
l5W/40)
(sAE

!L I-
L \ every 2OO0 runnrng
hours'

i"ffi n""l -lr, pu-np '-sL


\ ::1'*,11"ff:il".J'"T'o'1"I0' . ,r a ^ ol long 5r 'nJ tu' Lh(
ed b' har d
;;;;"; ;" l'"n-o o' it' snrl'
least every week'
L I litl tne pumP '!rn '^rd1e " '":'lT:":" :: freezing' the pump
,i lf there is any danger of flushed
;;ri be drained and PreferablY down
shut
l- I ro* ,tnf-,-oif uft"' ha'"'ing been

Ll.
l-
Never run the PumP

start-uP-Procedure:
dry'

I 03 '4'4' l
the pump rs gi'en
l- I 936'ng protedu'e or
I below in seo'-renr e
L
tr
L
l.
1
:i:::]r"i::."'"ril"';:i,x;',1[x'Jil[
dn oDclrLrct'oo5'
li" r'"" r'on-.
GhaPter ' 04
I
L
L DEALER NETWORK
l
II
I.
f.
f.
L
L
L
I ,toa=^ NET\A/oBK o4'ol

CONTENTS

CHAPTER .,04

DEALER NETWORK

Addresses
Ashok Leyland Office

Network
lndustri:tl Engine Dealer

Marine Engine Dealer Network


:

Iln5[uevuaND LlHtrED
\ & MARKET'NG DIVIS'ON I
j SALES
d oFF'cE a80 - Anna Salar, Nandanam
Chennar
I f,trJiJi"''E- :.oRP:o:AI;
*'i'i' Salai' Chennat
ovu " Telepone : 24341515 (19 Lines)
fr, r"lp'ram : ASHLEY
".
Telepone : 2534)lal
(20 Ltnes)
04l - 23178-.041.-
^, o*'-"'"' t 74146210 i 24340lso
,"i""^,
I
: .)s3424e3 i", ,ir.,rt,
i:[1'l.,,TS:" ex
r REGIONAL OFFICES SOUTH
W EST
CENTRAL :
CHENNAI:
EAST MUMBAI
NAGPUR : Ashok Leyland Limited
NORTH Ko,koto: Ashok Leyland Limited
NEW DEIHI I Ashok Le/land Lrmrted
Ashok LeYland Limited Road Electric Mansion
A<hok LeYI'nd Lrmrted Poon:m Phza Palm MarS' lst floor, (rear side)
Floor "Motiiut House
First Appa saheb i4arath€
672 Anna Salai'
8/8, Tei EuildinS CiYil Lines
\- l''lar8' IAuckland Place
NasDLrr - 440 001
Prabhadevi
Na nd anam.
Bhadhur Shazafar Calcurta - 700 017 Mumbai - 400 025'
- ll0 002 r"i zszossrrsiz' :slzset Chennai - 600 035'
l. New Delhi
217 301 8 1
Tel. 22400915 22475041
Fax:2530744
Phone:24305093
rel: 243't1536/'{651
t Tel :21710180 24305460. 24300534
22400578 Fax: 2{3't521 I
233541-oli08/51 t^x : Fax:24375186
')331-795st7104t19 | I 7140a591
rl 11O.
l-, I
e
^.: 73777746173357
I

r-I
_l
\-,1
-l NORTHERN RECION
IAIPUR .'
LUCKNOW:
Ashok Leyland Limited
CHANDIGARH: Ashol LeYland Limited 9 Rani Lakshmi Bai l'1ar8
Ashok LeYland Limited lFloor, Umarao Comml'
ComPlex
- 226 001
sco No. loo - lol, subcitv160 HosLel
Lucknow
li- -Lenuc
022 - OpP. Government -- l el: )75410
;;'r*' chandisarh - 102 ouj
t- Tel:603037,604295
M T Road' lriPur
Tel , 36la6r' Fax: 360578
F^x,116286

t: EASTERN REGION
PATNA:
GU\4AHATI:
Ashok Leyland Limired
L- CUT|ACK
Ashok Leyland
:
Limited
Ashok LeYland Limiled
Lavkush Tower
Bhangagath

L. Bharatia Towers
Badambadi
Elat No. 507'
Exhibition Road
G-S. Road
Guwahati
Tel
-
: 529874
781 005

L.- Cuttack - 751 009


Patna - 800 001'
: 52961 I

L
Fax
Tel: 310184/315314 671 I 59
Fax:329004 Fax : 565710

L
1- INDORE;

lj Ashok LeYIand Limited


Srlver Mall llnd Floor

l-.- 8. RNr
ihone :
Mart,'l^oli"^..,lt"L'',rrrr.u
2526i78 2522277
Fax :

l..- Gtre*H ^rc'ox PUNE:


l-- :
AHMEDASAD Ashok LeYland Limited

l. Ashok Leyland Limited


401
rVrh
- 406. SAMPADA'
Floor' ll
Rashmr Socret/
Arthashilp lV floor

rih',".'1,:li,lil' ;;'
L. [T,"lIj:,:: ^l"j:,abad 380 ooe

f.- Tel : 6565249 64421


T]ex : g56l97l' Fax
: 6a22683
SECUNDERABAD :

L.
r---
IourHrnx *rctox
BANGALORE:
Ashok LeYland Limited
MAOURAI:
Ashok LeYl'nd Limi(ed
ll floor AR PLAZE
16 & 17 North V€li
Str€et'
Ashok L€Yland Limrced
205. ll Floor, Lal' I
\-4-94 @ 97, M G
-
- Landmark
Road

L
500 003
Nandaleke 2 ( I
Floor) Secunderabad
loi I3. Connautht
Road
*tl*,:;Pil,r'" Madurei - 625 001
11a199817141699
rel: O4O'a75-41335142336
II
-ia
04.04 DEALER NETWORK
i
GENSET ENGINE DEALERS
STAT U S DEALER NAME AND ADDRESS :
.t
lo-s.r.. a s.*i." p Ltd, shoP No5' KsM complex
-h".m,ku.thy 523 726 r el \08s92) 72374
Main Road'

Balanatar' Hvderabad - s00 037 Rensa


:
ffiE,
Reddy Dist. 7el : 04O'23'175675-76'
Ltd.,5-4-l87ll&7 :
SECUN DERABAD "Tel: (040) 7s4432s.
;r--;"lLt, NtJ&4 Lalbahadur Stadium Hvderabad 500 001
Sh"P :
6sO5772, fzx. 31309)7
Auto Tekniks, 4-3-143ll ArrrDUr. AdracentaoRing Roid R R Drsr,ic('
8d29. 16698. Frx: 6s09J80
Hyderabad 500 001 ' Tel: (oao;
ao I

Professional Services, 54-9-7' Between


2 & 3 Cross Road' 100 Feet
viiayawada ' s2o o9r' jI' ti'!11 Tel : 0866-5531206/2544925'
Srinivasa Engineering Services' 38-22-90/
I lndustrial
VISAKHAPATNAM (0891 ) 5s3209'
Engg.Co., VisakhaParnam 530 007' Tei:

f.. n"-. C S Road, Ulubari Guwahati 781 001'


Debee Tekno Service, Bilas ComPlex'
Tel: (O16l) a53425
78 I 028'
;"bJT"k,t" s*"i.tJriPu'a Road' Beltola Guwahati
186 t25 1et: (0374)333776' 3404s3'
Branch S P Motors, New Court Road, Hi,ituri' Tinsirkia
Fax: 333241

ffi MarketinS & Services' L Road' Bekar Eandh Dhanbad 826 001'
Superex
Tel: (0126) 20s717
Road. Ranchi 834 00t.'ret: (05s1-208108.
@

R; Ht-,".L P*I.d'125 lndusrrial Area' Phse ll ChandiSarh

i"r, tolz2l 657653 & 651928' Fax: 640774


CHATTISGARH , Bilaspur ' 495 OOl Tel : 07757-56134'
Eite Excavators, H-4, Pariiat Colony' Nehru

premnath Auto P Ltd.,42-i3 Scin tse ' New Delhi llO ool' Tel: (0ll)
:iisa:0. res. 3329430, Fax: 3350922
:zss
NDIlC WorkshoP' Nev/ Delhi I l0
Premnath Auto P Ltd ' Mand ir MarE, O PP:
o0l. Tel: (0ll) 3350937
IGNOU Road. OPP. Freedom FiShter
Premier Power EquiPment' l7lll M:in i-55219IO, Fax : 0ll-5569621
Neb Sarai, New Delhi - ll0 058 Tel ; O I

pajifond, t4arSao Goa 403


ffisaudade.
ioi.- i"i' icjs:rf 712115. 7ta561 F^x' 73ntB : .

, Chinchinim Salcete Goa 403 715. Tel:


V K EnterPrises, No 557 Dandevado
(0834) 760533,760532. F2x: 760534

GU'lARAT
Nri.h.ah Engitt"..ing Co" 403/l Balaji Estate, Narol
lsanPur

182 443 Tel: (079) 5731581 & 5731885 . Fax: 573 l68l

ffi oPp: Kutch uday Press Plot No249


GANDHIDHA14
Candhidham 370 20l Tel: (02835) 22885
384 Oo2, Gular3t. Tel:02762-
Branch M/s. Raikamal Automobiles'
s1326. Fax: 57831.
o20l/12 Road No' 2' GIDC Estate' Panoli -
M/s. Excellent Power Generators'
,ist., Gularat ret : 02646'72111 rax 727)s -
;;i ,,;*;;;;; '
complcx..N^eir Jaynarh Petrol Pump.

L".i"i'i.J
"mmerciat *riu"t 360 002' rel: {0281) 388784' Fax: 38150s ' - -
Dherbar th' Rajkot - 360 OO3. Tel: -(0281)'
" -
M M lndustrial services,
Bran(h
VADODARA Nd I Shoo No. G t4. KarelilbauSh,
11
I

t-
)lG
tr tEnser ENGINE DEALERS

rk
rIE
LOCATION
HARYANA
STATUS ;-EALERNAME AND ADDREsS

rI
\

tF
lpr
PA N IPAT

KARNATAKA

tl'
tk -ii;;;;
Station Bazar, GulbarSa S85

rI; r02. rer: (08472) '' "' ""'- a;; il;i;;;-ort Road. Bunder. Hansarore

rI; I;*1,:,',;il'.,'.h'f;;'o"'o
rE c oc HIN
c-inr.. s.t.a & services
Tel: (0484) 2395911'
^Pvt'
tt'>''
Limited'
t z' ZISSSt:
Chittoor
r"*' 2393511
--td"
Road

t-...-..'--""*laza' Karamana'
Trivandrum
El: IIIIociated lndustrial a.",""*-

rll THIRUVANANTHA' OO2. Tel : O47l'344073 KadaPPakada PO Kollam


-

Ill-[
PU RAM

:;i ;&:'; '0474'7qtt7 :. ;.:::: ; KoThiLode 673


Zill. T..hnit"l Se"ittt' @Po
1Oles1 3s5877
-- -;-ai.
r"t, (0a95)
tu. Tel:
oOlT 3s5877
- ------ ---- ------ Palakkad 678 707'
cin zac
services'
Z;;;;-T..hni."l
L-l Tel: (0491)

rl
PALGHAT 5568'D

\. I

--aEn.o'p,i."',sC!1-!!9Y! <..r
=--+43
50t rel : 07622-55731'

t- INDORE
R--..-..-

L- lncon Automobiles Main Road. Singrauli

l.-
l- MAHARASHTRA

t- o"p.i-r"a,".41,*.1',r'.111-935491
D B Automobiles. 1325/J6 )nrYajr uu/q":'%:' - -r'-- - - '-usrrral Area. Behlnd tP

la tt

t..
ri
la 6ih-" B".brL rL(0616119803

la
l... uSANeSHWen Branch

Shree lagannath Motors'


@Road.
Raurkela 76e

l*. o0l. Tel: (0661) 504e5Y'

\ PONDICHERRY
vi.lilIt . ag"n'i"'' Ill street'
ffiherry5o5olo'
PONDICHERRY Ter: (oa r3) 377!1-
\
l*
l*
PUN'AB
LUDHIANA
04.06 DEALER NET\^/ORK
GENSET ENGINE DEALERS
STATUS DEALER NAME AND ADDRESS

RAJASTHAN r 9or' ra'


(o]fz) zze:o ::::;
Branch Area
con"]IiIF2O ll Beechwal lndustrial B
':-:-
lndustriat Proiect & Po*"t
Phase
Bra n ch
BIKANER iii-ooe. ra, lotstl zsttoz' Fax: 520666

Branch

IPUR

KOTA Branch

UDAIPUR Branch {
I
TAMILNADU street, chennai 600 001. Tell
@hetr/
CHENNAI Head office
(044) 5228853
(Moore
t
Ihrkrro"rri works' 5l Syedna Mohamed, Burhanudd;n Street
CHENNAI Showroom Engineering
Srreet), Ch€nnai 6oO Ool Tel: t044) 5246541, Fa.: 5777A98 t
ChakraPani EnSineerint Works, 278ll & 279ll T'ruvottiyur I
CHENNAI o2l. Tel: (044) 595221 2' Fax:596t767
COIMBATORE
ffilUvarstreet,RamakrishnaNa8ar,coimbatore
icl o16. r"r, (0422) 441843 F^'' aaSlsl , : :-:: :::. t
Te1:O4344-76443
SS Oi.r"t systems P Ltd', SIPCOT ffiping Cornprur,frosur-635126
workshop Road l'ladurai 625 001. Tel:
s--.il'1."r'r"kari cenPower aBency' 45/2'19
FaY 747647 I
loesil t<tuo. 747i4r 742530 (P-O), Natercoil
9A5/l,ARCamPRoad, Periyavilai, Kottar
NAG ERC O IL Tet 04652-261740. I
""t '- '- talem 636 o04 rel: (0427) 449886
MS Engineers' 154/2 Me)'yanur Roz '; o';;;;;"rn
- - - '
TrichirrPalli 620 o0l Tel: (0431)
Vinayaka ASencie5' ll5 Second ..o.t onn*"r'
TIRUCHCHIRAPALLI Branch 4At 777
4a1772. 482477' Fax'
S,*"" D* Cenre Tirunelveli 627 009'
Maruti Dieset Power, l/lB Salai OPP' Science

Tel: (0462) 574957, rax: 576t36


TIRUPPUR
iIEIA grnSrlor" High Road' l'4ullipalavam' vellore
Chakrapani Engineering \ /orks'
617 OO8 Tel: 10416) 291290

UTTAR PRADESH Disr, Anpara 23t 225. Tet: (054a6)


@a
P;;."-"bil"tJ,k-t"Jl"ld-ani 263 l39 Tel: (05946) 27262
Head omce , Near Etectric sub
ffioti 281223
,i",ion, f.npu. 208 o22 Tel: (0512) --- - .
servic;J-86 I Mlc G,jaint, KanPUr 208 022 Tel: (0512)
Anand Diesel & Electrical
3Dlll. 357347
273 OOl. Tel : 05551-337037'
GORAK KHPUR
Nirmal Motors, D_91 T
&Jt'dt- s:dama Buildint' oPP' ELrndelkhand Universitv'
o'h;;;;
i*i,'ir'".r, - 284 0ol' rel : oslT 32088s {PP)
@,,
Shubham Cinema, Lucknow 126 uu i.l:",i,i
Lucknow 226
iiTl,, E::,
-";,';.11,

012'
A S Engineeting Astociates' S-39 TransPortnaSar' Kanpur Road,
LUCKNOW
Tel: (0522) 433488
I T , Kanpur Road, Lucknow 226 012'
Illngir,."rinS Associates, F-J
Meerut 250 002'
Syndicate Motors ,t"dt.), N"rt P"lt." Station TransPortnata''
Tel: (0121) 5l 1934

& service' Vi' Rd' Barddhaman:1]103ft1o3{45q


Mitose Diesel Sales
l'lecheda Road. contai 721 401'
ffiNear
Tel: (03220) 56425
22 Chittaranian Avenue' Kolkata 700 077.
tlt,"t. D'*t.l S"l* & Service'7756131
i"r, tO:ll 72.56137, 7363757 ' Fax:
%oad, Beliaghata' Kolkata 7oo olo
Mitose Diesel Salei & ServicF'
f,
K MARINE ENGINE DEALERS
DEALER NAME AND ADDRESS
E.
/aa l0l
PP:#
.

E, BLAIR
PoRT Branch Andaman Automobile ASencY' MB
Tel: (03192) 33788' Fax: 331 I8
'le As".a""n Bazar. Pod

ti k- .-" Andaman Automobile A8-ency' th.rt\rb.1sti,


Tel: (03192) 50236 rzx tr5'
Garacharama,
& Nicobar lslands.

II iJdir"n Ent".Ptites' Post Box


l0l. iel: (ol192) 211808
No Ir8. MB 72, Suppty Line. irr
Andamans - 744

R I'o^''*'* , -_.1""1
1] Irxosna PnaoesH
& General Atencies, P B \o. 36. \ j Ll'lr'ir
!tI
'et
Kak nada

Brinch Sri Kamalapriya Auro


\ lr.nrrrueor 531 oot. i"t, 10884r 365007 f1a7':. ltqtot. Fa. 163188
lilr h'r^a^-r*"-,,-' Sri Kamalapriya Auto
sl0 oo4. T;l:
&
(0891
General
'
ABen(ies, ,r' ,, to"'" '
50840rr
561882 ' r (. 52681 9

\I u I

H"^" BIr- Ent.rpri..t, 9 Kanniyakumirr r' Teen Batti, Diman 396


,tu le:0)616-14282'

\\l llovall
Branch
34724v

tL Ee4 P Ltd., l/l Al Ameen, Pa.: i l'1ar8i. tri,,1 /''r ) Cujira'

l;t1
I - lcutanar
Branch .layshri Harine Service5
Santacruz. Goa 403 005. Tel: (0832) {{503c Fax: 13891 5

Guiarat Fisherie5 Central CooPer'rl lve Asrociation fta. , '"""1 ,, 558 3054
.,.rl.s & Service

lr- lrHYeoraeo Bran.h


Buridins. Ashr am Roro Ahmedabad rrr0 009. Tel: l0-l) 6581f'r '
tr,!ldrng Yard Bh idiYa

L- f-*n Branch Guiarat Fisheries Central Coopernt lvo a.*."o-, l-aa.. ,'" "
Plot. VeraYal. Tel. 31331

Li k*"*"-" Sundaram Motors, Vasudev E n.l,r /,. Maidrm 4tl .ross. :l r r'"Ilor (' 575 001 . Tel:

L- lt*oro*'
Branch
(0824) 423078, 4a0a72' tax' 441 I 8(,

t- tr'-"1 l04A 'lrrirrjrd.r pO. Kan.:r 670 r, r() 197 821531


82l5ll

L.re TVS&Sons
Branch
Ltd., NH-17, 0(''
<ANNUR I el (0497) 768078.
TVS&Sons Thinp Krr:..r 67000 ,rl /
Ltd., Thallessery Ri,,1,1.
Ltd., Narional Hi8hw.'/. Krtoor. Ko.,i 682 rl/
t,\ \04841 536717
Sares ornce TVS&sons
l;, 1"""' Fax: 538450
T V S & Sons Ltd., l41653 N^S^T, lt,rldinB, Civit L,.es, padi!.r,r"r/'
[o(h, 682 024' T€:
(0484) 137579. 337s8o F:x: 33800'
\ l.octrt
T V S & Sons Ltd., X/869A, Kotlrt,,,rrrn lunction. a uva-par.r\,,,,,
f-. Alangad 581 5ll. Tel: (0484) 570:

l; I'oc'rt ,.;rrt I cl: (0476)


T V S & Sons Ltd, Neendakara PL,lronthura P o. (ollam (. )l
F*', 681420. 681339 580861 Fax: 68141'.)
TV S & sons Ltd., K K Road CrrL1161.,tp p O, .lcrrayanr /,,i
/. {rL)2 Tel: (0481)
1.. lGrr^'-' Sales office
566150, 550502 583713' Far: 563"ttt pO. Kotrryam 686

E l-,'^'* f V S * Sont Ltd.' St. Lazarus^C('r',l,lox, Nerhaji *..0,ao,,",,"'""


Oo2. Tel: (0481) 560887 560189
1, 1: (0481) 564929

li k'.lry T V S & Sons Ltd., l.4ariyapally, l''1 , Rord. Kotta.".n 686 r)(//
T v s & Sons Ltd,5133461A l'|,av""' Road. Kozhik:3e 673{rr14
t, t: 1a495) 777875

la,l-"'""'I 711624. tax 72A511

T V S & Sons Ltd., Vellyil, Maieed_(,.,,,tctl Co.pound


L.m#tu
\.f; T V S & Sons Ltd'' Blo(k No' Xl/r' R ,,7 Ydnrer
Brar.h '1945' 384{ r"
671 651. Tel: {049J'll l'96
hrissur 680 651'
T v s & sons Ltd., NH - 47, Byc 1,.,'. Rrad. O urir.a, f4an r,t/
I

!.rH*
Bran(h
Tel: (0487) 371495 3706tt' F^x: )/t))9
04O. Tel: (0471)
i , t - sons Ltd., Neeramankata r",.r""n.l o, -i*"a.',"

Effi
Bra nch
4st67l. 491672, 490559, Fdx: 49llt:
, .naba, Mumbai 400
layshri Marine Services P Lid ' l" r,,
;1rl,t.r Jouse, :..soon D,','
ilo!. r"r 1ozz1 ll85ll9. ?186135, 7,8or9

$=l* ftindir, Ratnagiri


Jayshri Marine Servi(es ?
Ltd ' N"'' Sl,i,d,, SradrJ- Opp: M'r
Bra n. h "
415 612. Tel (02152)
I- 2065u'
o4;O8 DEALER NETWORK
-' MARINE ENGINE DEALERS
LOCATION STATUS DEALER NAME AND ADDRESS
PONDICHERRY
YANAI'4 Branch Sri Kamalapriya Auto & General Agenctes, Shop No.l&2 , S.i e"arii"lrli ni." I'l,.tt
Complex. Behind Police station, Yanam 533 646. Tel: (08868) 32lat3
V,EST BENGAL
BARDDHAMAN Branch Mitos€ Diesel Ssales & Service, Vivekananda Collete Road, Barddhaman 713 lO3. Tel:
(0347) 6s724
CONTAI Branch Mitose Diesel Ssales & Service, Bye-pass Road, Near Mecheda Road, Conrai 72t aol
Tel: (03220) 56425
KOLKATA Branch I'litose Diesel Ssales & Service, 22 Chittaranian Avenue, Kolkata 700 072. Tel: (033
2256132, 2363757, Fax: 2256132
KOLKATA Workshop Mitose Diesel Ssales & Service, 2 Khudatang Road, Beliaghara, Kotkata 7OO OlO. Tel:
(033) 3s05057
stLr6uRt Branch Mitose Diesel Ssales & Service, Prarap Market, 2nd ti,tile Sevoke Road, Silituri 734
401. Te[ (0353) 436245, Fax 436245

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