Vacuum Truck Manual
Vacuum Truck Manual
Vacuum Truck Manual
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OPERATION AND MAINTENANGE MANUAL
I FOR
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sxrD M',NTED vAcuu' sysrEM
'LEANING
tr MoDEL -TPs-vAcrRUGK-GxD'9ooP
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a- . rvT.LTD.KAKINADA (A.P.)
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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
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\ SAFETY PRECAUTTONS
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\ 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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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
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t- 02. CYCLONIC SEPARATION CHAMBER
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t: Thevacuumloaderhasanin_builtcyclonicseparationchamber
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DIESEL E,NGINE
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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
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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.
06. CONTROLDEVICES
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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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
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ffinroCc FILTEB
E HOPPER
l. OIESEI ENGINE
eNT=-wteRAnoN PAD
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VERTICAL SILENCER
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T]SING
INSTRUCTIONS
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following characteristics
) Do not suck material with
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Inflamn-rable
\- ExPlosive
. ChenicallYaggressl\'e
l\- . Dangerous to Health
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' Make sure that sucked
matelials such as unslaked lime and
water' or naphthalene
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compal tnlent 1o avoid
nttxttlg'
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\\rrh ternpcrar'irlet
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n-raterials to avoid blocking
of flaps
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hygrosglnil
to tcsidues'
or sticky
L seals due
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Suction Unit
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ATTDN'IIONI
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
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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
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l.. FINAL INSPECTION & START- UP
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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more than 450mmhg' free air must
be sucked
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TPS ilanufaeturin$ &Jonstruction
suclon uru-l
V CTRALERvacuum
U-coJPlhg
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iranspod L'ail6r
al cholce Cca.,1ectlcn hose \aiL\
2 1,1 cc Jplings
C6necl,on
v end M
flo56 xllrl
c.uplhg
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Si/aj-chl m€lal rlPo
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a.\ll IIAINTIN 45CIt }{.']'f{I.''tI
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OPEruTION
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rt pipework system with K and-SK suction tools and EH piping elemenis
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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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condensole droin
lilter canridge
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li ccni:mirrciei tr'/ cil'
Chec!. rubber sec i'
Llse sccp wcier ( I cle'r'irrq ::i;ci'
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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
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i. Do ,-rot suck inflammable, explosive, chemically aggressive
material dangerous to
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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
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Ber-,ier-,e etc.should be inlmediately discharged from
the container of the machine
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CHECKLIST
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equiPment.
5 LiJk;;,ure drop indicating equipment for plugged
lines'
MonthlY checklist
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2.
Inspect and lubricate appropriate
item'
Check for cartridge filter cleaning'
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4.
Check all clamPs'
lnsPect housing lor corrosion'
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1* QuarterlY checklist
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1. lnsPect baffle Plate for wear'
2. Thoroughly inspect Cartridge lilter'
3. Check duct for dust build-uP'
l.- 4. InsPect Paint'
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3.
Check welds
hrsPect hoPPer for wear'
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t: VACUUN{ PUN'IP
Seruo sYstem12o or
L- oilGueilloC
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DIESEL ENCINE
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i F i it.,
Diesel Filter Condition
c ond it i on
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MiiV".*u',, A.t,Iq!g!
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05
oI Release Valve
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C Alft.kLscffirum loss from rubber
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of flllinq level Probe
ine of ull Nuts o,d bolts
acstxe srABT u!
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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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SERVICE ENGINEER
I CUSTOMER
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DATE:
DATE:
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f-- Check level TYPE OF OIL
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L. FILTER CLEANING/CHANGE
L. Vacuum SYstem
Suf"ty fiIt"r (Cartridge
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Moistu.e seParator fi lter
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TROUBLE - SHOOTING FOR ENGINE
l{ ENGINE
lJ, Contact on: Engine Not Battery discharged. Recharge or change
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Engine Fails to Stat Shut-down control not Pushed
hack (drawback sPring broken)
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L. In winter, oil too viscotts
Clean feed PurnP. tilter
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Leakage or Presencc 01 alr
fuel supplY lines
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cartridge.
Check and tighten all
connections.
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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
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L. Contact Engine
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Piston fungs seized or broken
L. Manufacturer
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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
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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-
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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]
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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
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IerIC
"rateriat
Adrust the oil level
to be suctioned cool off'
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L. Excessive bearing clearances
Roturv Van"s torch chambe| walls or eacl]
Rebuild vacltum PumP
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RotarY Vanes out of balance'
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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'
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"di,rst
Tai leaks
Check the belt tension.
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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
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filter.
E"d .orr..tio" ,rlves on cet.ttralized
ineline
Close the valves.
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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
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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
IJ 4
7.5M LONG
COUPLING SET l5ONB
IJ
2
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CATALOGUES
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EDITION :3HVp_2001 OPERAIING INSTRUCilONS
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TRT LOBES
I ROTARY TRt LOBE
VACUUM PUMP
t
INSTALLATION
OPERATION
II4AINTENANCE
IIIANUAL qm
SERIES
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,#
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Sanoelc
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Fax:oBC 10. 15
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It: MESSAGE
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Vacuum PumP. We believe that You
have bought the best.
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We appreciate your purchase of a Kay ?rod':t l-!:l
,i["llf & catering to your future equipment needs.
""-."r"ice
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Yours trulY,
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Sd. xxx
K. L.Arora
Chairman Cum Managing Director
L.
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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
+
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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_-
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L.
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L
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L.
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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-
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J
Fa:
.J
n
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l.. Fig.-2 (CHECKING THE ALIGNMENT OF COUPLING)
l* shafi parallelism is confirmed when the thread or a rule is in contacl with the pulley at points A, B, C & D'
L-
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L
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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)
> 250-355
1.60
-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
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;
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POSITION V
L
L
\ l ,l tr"t".
f
1-
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l{. ,r"t"" l POSt_flON H
nFnon /'
A Y
\ """''"
L. z::R
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l-
lniection
\ ?
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.strl_Y_l)
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Dis.
lnjection
--v
-<
SLlction
[[ -,-/J
\+/
>
.:
Dis.
lnjection
t- POSITION V
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lnlection
\
\ A
/
V
rnjection
--l
f.-. f".!tfl
f- \-q-t-
{--rl )
I
L. Y
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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' {
4.5
formountingallmon]toringinstrumentsaswellassafetydevice(SUChaSSafetvreliefValve)
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
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]: 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
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
BASE FBAME
r- MANIFOLD 7 l\ilOTO B
2
V. BELT
r-
SUCTION SILENCEB B
3
L.
L.
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h
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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'
L
l-
Wn.n ,Jo piston comes to bottom line' filter
l-
L.
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L.
L.
L.
L.
L.
L.
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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'
-.=,===-'J
I
't
L-
L.
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L
l;
S.NO. NATURE OF TROUBLE
a) Excessive vacuum at
R EMEDY
t;
is too low suction side
b) The clearances are too high b) Overhaul the Vacuum Pump
L
L 6. Too high power input.
do not complies with the data
given on specifications
l;
data. check the lntake
resistance due to filter chocktng
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-
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't1
9. CROSS SECTIONAL DRAWING & SPARE PARTS LIST
FOR TRI-LOBE VACUUM PUMP SERIES 3HVP
I
I
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I
{
I
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1- (List of Spares)
L
1-
01 01 CASING ( D
t- 02 02 SIDE PLATE
L
L
a4 0'1 DRIVEN SHAFT FITTED WITH LOBE
E::
l* 08 01 HELICAL GEAR FOR DRIVEN SHAFT G. h1/
r* 09 01 HUB FOR DRIVEN GEAR /ffi)
aN4/
L.
f-.
18 01 OIL FLINGER
r-
L.
'19
20
o4
04
OIL PREVENTING DISK
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
{
{
{
{
{
:{
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(Authorised Signirtory) J
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r; II. FORIVIAT FOR DEMANDING SPARES
li
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l; X International Limited
I/s Kay
Date :
IJ Dclhi-ll0 033
l-
l;l- Kinrl Attn. : IVlarketing Ilanager
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Dcur Sir-.
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L. .\uthorised S ignator) )
f-.
\.utre
Jc:ignation
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f Note : To be lilled lbr cach vxclluln purrlp separately
15
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CORPORATE
Delhi-110033 (lndia)
HEAD OUARTERi :205'206' Lusa To"ver' AzaclpuJ' 7220491
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l- GENSETIIVTAR! NE ENGE E\$ ffi
l- Service Manual
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GENSET/MARINE ENGINE
Service Mamual
ALGP68OTC.E4i,I
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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
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L
Engines. This manual contains technical specifications, service data and instrucrions
on the correct methods of carrying out maintenance and repair work.
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L.
Chapter - I gives Technical specifications, Preservation & pre-commissioning
procedure, Genset installation & Testing, Marine Engine lnstallation, lnstruments &
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Control, Operating lnstructions, Maintenance Schedule, Filling Capaciries,
Recommended coolant/Lu b r icant Tables & Tightening Torques for AL6g0 series
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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.
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L. Chapter - 3 givs5 Maintenance & Overhauling procedure of Marine Accessories.
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ln accordance with Ashok Leyland Limited (the company's) policy of continuous
product improvements, the company reserves the right to change the procedures,
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material, specifications, dimensions or design referred to in this Booklet, at any
time and without prior notice. Relevant changes would be updated through our
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service circulars, if found necessaD/.
care has been taken to include as much useful information as possible. Every
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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
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and
not binding.
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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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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 :
L.
l-- CONTENTS
L.
rr GENSET/MARINE ENGINE SERVICE MANUAL
rf-. General
L. Marin e Accessories
L. r Network
L.
Deale
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E Ghapter - o{
GENERAL
f.-,-
f- GENERAL OI.OI
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E.
CONTENTS
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CHAPTER
I
GENERAL
f 'r"..,on--*1...-
Section bject5u Page No.
at.7. preservarionandpre-comnrissioningprocedure........
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0l I Genset tnstaltation and resting""""""" 0t.
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Marine Engines lnstallation lnstructions
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01.21
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Maintenance schedure ..................
Filling caPacitv
0 t.26
0l .29
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01.12 Tightening Torques
0
0
t.10
t.30
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L ]OI.O ATTENTION OWNERS
GENERAL O I .03
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.
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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 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
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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
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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
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or
. _, :.rr:nt, f'larine gearbox, pTO. Tur-bocharger. otherwise rn relailn to all engines, \,,hether
.-..:. Alternator etc. the warranty terms of the
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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
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
(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 legiona O--ce
600 il15. I
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of
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AL Service D--':]cr - ( io be aclreilci to f-i-: conce|nea Senvice Dealer and End Uiers Locatlon n case
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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
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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
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@ ,"orat",oa to*aR
INDUSTRIAL ENGINE POWER
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ENGINE [iODEL
]NVO CE \O & DT J
CUSTOMEtr CODE
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CATEGOaYOF INSTALLAI'1ON: 1) llEW
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NAN,E OF OE END USEB
1)ENGG, D 5I CONSTN. 8) TRANSPORI f :
3) LEATHER E
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7) CHEM CAL t-- Io) OTHET' I
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4) ;ENSET I PIN CODE J
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rl-- MARINE POWER UNIT REGISTRATION FORM
MARINE POWER UNIT REGISTFATION FORM
GENERAL
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TO BE FILLED BY ASHOK LEYLAND LTD,
lj AD DFi ESS
ADDRESS:
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L CUSTOMER CODE
L AI ENGINE I\4ODEL
DA-E ]F SALE BY DEALER
L ESCRIPTION OF EQPI
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BEING POWERED
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FAI]LTS OBSERVED WHILE COI'4M ISSIO^''NG NEW INSIALLATION
REPLACEMENT tr
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OTHERS"
(PLEASE SP EC FY) .
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PLEASE USE THIS SPACE TO
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GIVE DETAILS OF OTHSRS
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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
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L. ASHOK LEYLAND LTD.
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ENGINE
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MAX. CONT
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N,EA4E P!A7E SAMPIE
the io quote
L. relerring to any problems or while ordering sPare Pads, operators are requested alwaYS
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01.0.4 Leyparts
Leypan: is the brand nanre for Ashck Leyiand
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
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Cylin<Jer bore r siroke )l lilin ^ lic
P ston displacen-rent
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Output Data
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Alternator range (KVA)
Electrical Systern
I75 KVA
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flanne Heat
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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
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suitable for single
(:) 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
).
::".,'"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
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
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
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.
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.
rt 01.3 GENSET
TESTING
INSTALLATION
t: Diesel Genset.
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.
r,
SAE 3 ORrvE END = 0.06
r
L.
housing and set the indicator perpendicular
to the flywheel face with the stem riding on
the face.
l- TESTING
u
l{
lnstallation Procedure for
Coupling to Alternator
Engine
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
Face out
L. of flywheel housing
L.
rotated.
L. Runout
L.
riding on the bore of the fly"wheel housing.
LI
rr-r Flywheel Alignment
Faceout
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
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
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
clearance
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
fr
f-
Ensure lan belt tightness'
Genset Testing
Ir- achieved.
OI.I4 GENERAL
LOAD TEST REPORT
shift:
Set 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
rl
ol.4
INSTRUCTIONS
I
General
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
rrl
I
l+'I I
stern gear is t.ken through the gearbox'
til I
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
L.
Chapter 3.
rL
\
lf the clutch does not pull, overheated or
operating lever jumps out, the clutch must
r
be adjusted.
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
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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
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
|
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
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
u
tT
FOR GENSET AND MARINE ENGINES
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
lJJ.
u: Temperature Gauge
r.
ri
may be indicated ln the case of overheating
an indicated fault should be lnvestiSated
L
f-
engine to cool for several minltes'
r.
Look
does not droP StoP the engine' Check drive
belt condition and coolant leveL, if fault ls not
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.
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.
No. of
Batteries used - 2 nos.
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
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
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
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
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,
(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
Il temperature,
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
II General
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
recommended.
Marine Engines
Clean sea cork fllter atleast once a week'
TheperiodsunderwhichtheVariousitemsareli{edareintendedtoapplytoengineengagedonnorn^:
oPeratingcondiiions.MorefreqUentattentionwillbenecessarytoenSineworkingunderadver::
th"t"fot"' b"
conditions. The regular *uint"n"inl" p"'ioo'' 'hould 'll'
_--u
Oil in FIP
jelly
Battery terminals & apply petroleum -'i
First 50 Hours also. I
b) Fan belt ard tighten if necessary
h) Engine mounlings
and cowl
nuaiutoi.,g. t uy & gap between fan
(ior Industrial/Genset application)
I Turbochargermounting
IL
TE Run the engine, check and record
Elj
Elj
Elj d) l'4aximum RPM
!
ElI 4.
u;
Check leakage from
fu"t piPing & injector hlgh pressure lines
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
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
E- 8. Lubricate
f;
r,
Ir;
:
:
Throttle linkaSes
]i
OI .28 GENER.AL
-- ALc?680rcE4lt
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
H,
I; Gulf Oil CorPoration Limited'
LLrbricants Division
u
r
57, lYaruthi lndustr al Area
Sector I S Curgaon I 22
SS lndustrial CorPoration
0l5 FlaD'arra'
Ltd'
harat Petroleum CorPoration
L. ECE House,28A Kasturba
Gandhi Marg'
L. - I l0 001 '
New Delhi
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'
RECOI.IMENDED LUBRICANTS
saE 20W.40
OiIEP
oil80 80w
oirEP 9C
oil 90
i
OTE: Do no, ai>< lubrican!s of different
brands/grades'
i
Kgm tb. ft Nm
or.r2, TIGHTENING TORQUES
lr.-r 86 1
)94 304
l0 ; I 217 )24
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
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IL:
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L,*
LI AL68O SERIES ENGINE O2.O r
LI CONTENTS
LI CHAPTER . 02
L] 02.0
2.0.
0 Engine Type and Sl. No. .................
Description...........
02.05
02.05
L]
0 I
Ll :- r
.:U
lnspection and Fitment..
Boll and Rol!er
. .........
beorin9......................
02.7)
2.2
Lr
0 t
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
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
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
a7.3.t.7 0)! |
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
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
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 .
07.9.4.a
To Refit ... 02.81
07.9.5
Description 07.86
Operation a2.87
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
I: Lu brication 02.t 07
I: Trouble Shooting 02. t08
O2.O GENERAL
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
I
t
I
I
T
t
II
E
AL68O SERIES ENGINE 02.07
i
I 1093 cc (680 cu in )
Cubic caPactY of all cylinders
l5l PS net cont @ 193 PS max @ 172 PS max @
84Okg
Engine weight (Dry weight)
: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,
>_
02.08 AL58O SERIES ENGINE -
ALGp6s0rc.E4lllALMUTc5so/l lALx!!99!
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 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
u
75.433 55.880 BB.I
u
rtl
rice 7.200 55.880
u
87.643
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)
!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
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
Technical Data
ALGP68OTC.E4l I
3.430/3.460 mm
4.0)A14.A40 mm
0.030 / 0.070 mm
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
I-l
I: Leaded gun metal
I.i
02.I2 AL68O SERIES ENGINE
Technical Data
ALG P68OTC.E4l I
ALGP68OTC.E4IllALMUTC680/llALMU680/7
head after refacing
l4 I .7 mm (5.58")
mm (0.43425" I 0.43475')
mm (0,43275" / 0.43375")
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
L]
frf
- .-.-:= :'
-:.-: :.-. -:
alve head to cYlinder
;urface (above the
0.38 mm (0.0145')
LJ 0.76 mm (0.0299')
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")
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
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")
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")
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)
L. :^::
"z a
:-
..a-
lh
^.2
of oil filter by Pass
: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
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
M ECHANICAL LOSS OF
NOISE / POWER.
FAILURES,
ENGINE
OVERHAULING
rJ INSUFFICIEHT GAP
L]
IMPROPER VALVE LEAK ON
BETWEEN SUMP &
SEATING TOO LOW
rl
STFAINER
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
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
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
0 t 03006
Compressor Valve SPring
4 68t8
0 r 03008
Extractor lYain Bearing CaP
5 6836
0 ! 03009
Etractor Crankshaft Gear
6 6848
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
LJ
rollers
E
f=l Outer races:
fit in their
Examination of seals before fitting:
r-l replaced.
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.
to be retained.
Fig - I I & 12
[I
of oit
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
It is not
engagement'
Iil
Etr
4 Covers and Housings
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
L.
f--
Cleaning KeY to Success
No operation in gasketing is more lmPortant
ihan thorough cleaning of the cylinder
head
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
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
.
tr
ft
lr6\ten rasLener'
i*"""rt then
Complete last stage with final
torque 02.0.5,I .6 Shims
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
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'
ft
EI
,.J."""
rhanPes
":ii ::
i: ;;::11^':::,iilIi- : ff :
indu.iion s/ stem uit
t1"unl^l^,1,
f.
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
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
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.
I, '
recommendations.
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.
u
u
lmproPer valve timing
and adjust 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
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.
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
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
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.
t{
lr
After lubricating the air comPressor, oil
:eturns back to the sumP.
P:De connection to the oil Pressure
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
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
Fig-2&3
. Unscrew the mounting nuts of the oil pump
and remove them'
/.
Iift it out
I
a
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" 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- -**
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
ru>uct/) Jr.Lt>uldt/)
EOOYUIE EC)c)YU-rC
(DE<oYurF IDd<()YLIJF
EC)(JYIU.! EO(JYLIJd
>-oorur >-oo_Jut
I
Lcxozl-
ILIl<T]
ELU<d
ILU<O
I
o>-J-ZOl,llcts o>-r-zouJE
I
I
I
I
€
,- t
'n
I
(9<JJurc!>
I
=<-z
I
E
e I
o
I
I
I
n I
I
I
I
I
l
I
l
I
I
j
j
AL68O SERIES.ENGTNE 02.39
WATER OUT
I ET PIPE
CYLINDER
HEAD
FRONT
sea water
-
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.
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
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
f.
1
E.OLLER BEARIN6 18 NUT 5/I6" BSF 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
leakage.
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
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'
L. I
cliP.
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.
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
::'.J:l::
L. rhal 2 ) ol 're olade rt-e
'n'
in
the ca p
case of martne
[.
L. enPines'
i',tan" -'o'""'neat exLhanBe' hoses
ai'th
L.
E
;;,;" "n-gin" 'nd
in the cooling sY*em'
check for anY lcakage
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
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
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
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
,.'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
;;;;;
"'
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:: ,
:
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.
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.
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
: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
f.
m,
I
f. I
I
BTDC for Genset, 26" BTDC for
l'4arine) of the flywheel with the tinring
L.
I INJ
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.
I-.
4. Tighten the
couPl ng Plate
2 bolts securing
and FIP flYwheel'
the {lange
L.
r--
CAUTION: DisassemblY' servicing or
overhauling of FIP should be
carried out onlY through Ashok
Fig-I
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
$-a
L2l
x,l 'u-B
11-g
L.l
E.
E I Lx\taded iew CYI''d"! !:"d
"f
22 DOWEL FOR ROCKER BRKT
L.
2
Is-v or cvr HEAD & vALVES - collPLETE 23 BUSH
2
I S/A OF CYLINDER HEAD I 14 CIRCLIP
VALVE SEAT KIT - INLET WELCH WASHER FOR SHAFT
L.
c l 2
E VALVE SEAT KIT. EXHAUST I 17 SPRING LONG t1
C.E COMPOSITE VALVE SEAT KIT l
'28 LOCKNUT 2
D INLET VALVE KIT I 19 BALL END l2
G VALVE KI-T - EXHAUST 11 t9A SiA OF ROCKER LEVER( WITH BUSH ) 6
VALVE GUIDE I l0 ROCKER BRACKET t2
SETSCREW FOR CYL HEAD COVERS ! ll WASHER FOR SPRlNG 2
CY,HEAO COVER 1 l2 SPRING LONG ')
R.)'(ER
Ei
ROCKER COVER GASKET 3l SHAFT
OIL FILLER CAP
I
L.l
LIFTING EYE 1 35 BSF PLAIN
6
CYLINDER HEAD GASKET t0 31 NOZZLE SLEEVE
6
SPECIAL NUT 3/8' NUT I/2' BSF . SIIlI'IONDS SPECIAL
L.
t1 l8 6
VALVE COLLAR LOWER l2 l9 CLAI1P FOR !NJECTOR 8
3 VALVE SPRING INNER t1 40 NIIT 3/8'BSF. PLAIN 6
L-
VALVE SPRING OUTER WASHER I/2'DIA KOLOK
a
VALVE SPRING COLLAR ' UPPER
t2
iiJi] l,)j,i,'ii t qocF t q BR/ ro t Nozzr E -AvD 6
t2 42
VALVE STEM SEAL -.]WFI FOR CYLINDER HEAD COVER5
L.
3 74 8
) VALVE CONE t7 45 i,t e i] ,iL o x " I oNG Lrr- I INC Pr a'I E
.: VALVE CAP
BRACKET
6
JOINT FOR ROCKER ln
L,, oil waYs drilled the
two veftical
2.6 CYLINDER HEAD a."nt arr", cyllnder heads and middle
rocker
E.
O
L.
r--
interchangeab e Replaceable
inlet
seat
L.
L
on"
"u.f,
corresponding to the cylinder
head. These are rnounted on each cylinder
head seParately by means of three supPor-t
side of the cylinder heads lnjectors
fitted ln the cylinder head by holdlng
nuts
E b.ackets.
*w$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
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:
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.
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
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
Fig-8
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
Fig - 9 & l0
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
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.
L. Fig - 13
L. ;";;;;.:;
,ui"ir- ,"i "g ca:e ln' l'-
c:
LoP rn3lt prn'hed
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
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
Fig - 14
as
filur" ,n" rocker shaft sub assembly
follows:
Fig' 15
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
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
",""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
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
',]
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 '
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. 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.
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
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
f.
f.
exceed I 50"C (302'F)'
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.
-a."ii,ion.o,nln"d quclgecn prrr bc '''
L.
f--
liSton ring e'(Dander as
describec
Fig 9
l'"e url"'-
E.
I.
nas lof' ma,-k
ar,"r,,ol7 Top mark shouid
ie
over its surface' Durlng
{ace
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
engine oil.
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'
I
I
nrp the nut.
E. -16C
oso ttllntile eNctNe
E
E.
f,
f.
E r1
r. io21
Fig. I Exlloded View of Crcnkshoft
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
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
L. 0 2.8.0 DescriPtion
The crankshaft is supported
in seven Lead- connected equiprrents in the
:ase of marin
L. engine bearings'
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
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
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
marks on the
Fig'2
Fig-3
II
I
02.8.4 To Remove Crankshaft
I
I
Pla.: the enq nc on a:'-rtable sta.l
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
I,l ;"y
.;;;;,. overheating
1n casethere : n: appr-=riaL-'le lear'i Canri-!e
f.
LnC .: F ._ '
r-l
a.i ,, a:
Fig
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
a. i;.
.,. , ,n. e'- Le r -' ' r
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.
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
4.
L ft and c:refu / p ace lhe cranl<shafi
P
c sitio n
trl:
f]
?:l::",J::'.::"",
15. Remove
b!ock.
the filter head from the cylinder
|-] 1 l"o in" i'" 18. Loosenthe alternator adiusting link and
rnoLnted on the engine'
remove the water PumP belts
and
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.
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
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
llll
07.g.7 lnsP e ction
l'
lecrea:e .-,1 lr: il trr:ln'' ed colrrpon'
irllrrt,, En.. : the ,',11E,. ''vaY: and '' i
oPening er:1
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
rl
r.
crankcase.
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.
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,-
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
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
I
VisuallY check sumP
ends for anY damage or I
crack.
f. "-"1"
Cne!t rrdnL.hafl pulle, lo' anl damage and
f ex-essl\e ^edr
ard roF a ' 'l necessa_v
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
L.
r_.
pernaLoc 50'
f; Lru l-.
L.
E
. . ./ ^,( c " "cl'
'n c ,' '^ "ne
bor
"r
d
e dnd
P'ac'
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
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.
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
E Fig - ll
'.vire
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.
t
same.vidth.
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
-.. I
tl' II . lee ""i, o"
" laou]o
il--tjl I
g
I ronnectinB
uia
rod as alreadY e<Ptat "!'',ti
-."#.ting Rod section'
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
@
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
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
L pin.
L
f.
Fig
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<
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 ': --
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'
'.'' : 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
1''-)'
E*o,", tlrl ^ zr". -
E
E ::i,::;" il';."il*1.t.";-::;'i l: sumP
E
lJ. :-'
r_ :: r::'_":",";;; o;;,,,. r::r
tr ''
' ,L
'
" a';'';Y:.:".1::l' "
i"
l-. ,"1-l;l:"i','':': . ou''',.
'
la "- '
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
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
II
fl.
5. Tighten FIP mounting bolts
the
bottom suPPort brackets'
FIP to iniectors
at the
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
\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.
L.
hose cliP
E.
I
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' .
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. "".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' <
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
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
L.
E.
f
I.- _
R.
1540 36-8
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
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. Fig'4
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
E .-hall and
cables
STABTER
-::ass3ry' SWITCH
L-'
f
Fig-7
Test 6 (Voltage drop insulated line)
Fig a
CRANK
Alternator ENGINE
S :
Recommended test eguipment
:
D.C. lvlo,/ing coil vo tmeter Scale 0-24 V
40v
d be 6 mm (l/. ")
The fan belt teosion shou :
;nder moderate finger pressure. ll it s
oose, rectiry.
1
AL68O SERIES ENGINE 02'85
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
rl
-et''rc.
,iu",i'"*"tt ano a'1err alo' ano
defective unit' @
l:l Fig ' 17
L.l """
,;' ,r;;; I ordl ' o'rase o-oP sr uurd
EI
LAMP TEBT TNAL
Control) CONNECT-TO WABNING
Test 7 (Alternator
'"'";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
02.10.3.1 DescriPtion
machine of the
The alternator is a 3 phase
armature tyPe'
revolving freld and stationary
Its output fr-om the' stator windings
rs
Terminal Arrangement
The alternator has three terminals
i'e'
'\
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-\ srar,ona,
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
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
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
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
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 ^",
"" "' 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 "'
L. ";:;"
r ':*J:,,
Diodes
lest eacr'
.
Fig -
:i""
"',.';:'"";19 & 20
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:
: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'
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'
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
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.
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
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
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
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
6 e"aultng
,n; rime \DenL ^
.::".:' Remove lubricating Plug'
: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
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
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'
l? tf,""ot'"t Yoke
$rt;'"T; "',,'i*"* be to '"1
:i": i";* *1i,1;,:;:t
,.""' -' '^r1< ol the bearrng
Turn 'or.)''',^
" ";:i;i flusn wtt' ' '' -
f2qs5 sf rhe casltng
t he
tll"Y' i'"T""J:"" - ' nr LtSe d
Ptnton'
wh"n f'tri:i. ^u-j1".n"" pinion and Dnarrns
Bearings in the dr''e
clearance u""1.- o
;|.,T"il';' o os
to ^,n
ro -m mm r
CE bruch
'.11.'o'l
"i,* 'il"';;','e
,.he rnsulation
Clutch a rnultrolc d
lh,*'*,."$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
'
^ 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:":.::. '
,,''
ne\^ r
Padq
, - ^,,, .n
should nol be PUt
I
;';" ,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
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.
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
L
sealing ring and shims.
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. the pinion so as not to damage the oil seal' Fit solenoid switch5) to commutator end
( I
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
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
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
tautty'
the insulatron is
overheating
*age conLdLL'
I.: AL68O SERIES ENGINE O2;I
T-
f o7.l o.4.4 Solenoid Switch
f D esc ri ptio n
E
E.
raised.
L. Fig - 3l
L Dismlntling
L. plrer:
L
L
WithCraw .ontact sPring
contact assemblY ( l0)
( l7) and moving
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
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
EI Solenoid Winding
ln- ,h" of the winding becomtng
LI it"r"" .l"u"nt
damaged the comPlete switch
L] should be rePlaced
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'
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
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
I-- MultiplePropellers........................... 03 05
03 05
L. Propeller Shafts....................
Reduction Gears...................... "" """ """ " 03 06
L.
L. Engine AliSnment to Propel er shaft ........... ..... """" 03'07
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
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
SafetY 03.1 7
03.4.1.0
Flushing 03,17
03.4,3. I
03.4.3.7
Piping connections 03.19
03.4.4.0
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
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
L
L,
angle of the propeller blade, known as
combine to form a thrust force on
propeller shaft. Thrtrst is transmitted
pitch'
the
ProPeller'
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.
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.
L
blade, or the diameter of the cir"cle scribed
by the tips of the blade
three blade ProPeller'
L
Li
a proper pitch ratlc for efficient propulslon'
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. Figl&2
L. A rotating prope ler tends to drift sideways
L. ln the direction of rotation ln a single
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
L
transmitting enSine torque io the propeller
and propeller thrust to the thrust bearing'
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
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
r. e. ./rwr 09 or Ll
5 Iot.o.c Alignment
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
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.
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
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'
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
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
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
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-
l-
1.
l;
\,
l(
\
f..
L.
E.
rr.
L.
I-
irr.
41
46
tlO. oesCnlertOt't
ffi;pE ',
JUBLIEE
CLIP
Fig.
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) !
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
lJ '
;T:":.'i:::
-'"
;'a'!:
5tlenl"':'"';""',
'. .,- rs i led :o '
?:',1:
tf 03.3.2.1.2
Back Plate ( l7).
tr,,i::
l-.
5:'i ".,i
"""''.11,""',","^""'o
(30) is attached to the Collrr through
lltting r3t1 The other 6n6 s{ the
r)
flexble
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. (3) sliding 5ee;e assemblY Nut anC Lock Washer' Pulle; s held bY
'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'
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
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.
k
r,
FrequencY of Adiustment:
1o l) can be reached'
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. When to Adiust: (e) Refix the name Plate after lhe adiustment
is over.
L
L.
,O
(d)
The P.T.O does not Pull the load
The Clulch overheats due to slippage
load'
L.
r-. wARNING:
Syi 'c' and 'd' will be observed rvhen
itorn,
the clutch starts sliPPing on load'
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
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
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
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
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
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
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
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"
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
!L I-
L \ every 2OO0 runnrng
hours'
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
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
Fax
Tel: 310184/315314 671 I 59
Fax:329004 Fax : 565710
L
1- INDORE;
l-.- 8. RNr
ihone :
Mart,'l^oli"^..,lt"L'',rrrr.u
2526i78 2522277
Fax :
rih',".'1,:li,lil' ;;'
L. [T,"lIj:,:: ^l"j:,abad 380 ooe
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'
ffi MarketinS & Services' L Road' Bekar Eandh Dhanbad 826 001'
Superex
Tel: (0126) 20s717
Road. Ranchi 834 00t.'ret: (05s1-208108.
@
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
GU'lARAT
Nri.h.ah Engitt"..ing Co" 403/l Balaji Estate, Narol
lsanPur
182 443 Tel: (079) 5731581 & 5731885 . Fax: 573 l68l
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.",""*-
Ill-[
PU RAM
rl
PALGHAT 5568'D
\. I
--aEn.o'p,i."',sC!1-!!9Y! <..r
=--+43
50t rel : 07622-55731'
t- INDORE
R--..-..-
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
\ 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
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
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
E, BLAIR
PoRT Branch Andaman Automobile ASencY' MB
Tel: (03192) 33788' Fax: 331 I8
'le As".a""n Bazar. Pod
R I'o^''*'* , -_.1""1
1] Irxosna PnaoesH
& General Atencies, P B \o. 36. \ j Ll'lr'ir
!tI
'et
Kak nada
\I u I
\\l llovall
Branch
34724v
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
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(,
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:
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
!.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
II
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