Workshop Manual DV Series

DV SERIES WORKSHOP MANUAL
4 December -2012
KIRLOSKAR OIL ENGINES LIMITED
1
Introduction
DV series well thought out engines
About us...
Kirloskar Engines: Prime mover to the Indian nation.
Kirloskar Oil Engines Limited, founded in 1946 and popularly known as KOEL is India's
leading manufacturer of the finest and widest range of diesel engines from 3 hp to 800 hp
and from 2400 hp to 11000 hp. The Kirloskar engines are manufactured in both air-
cooled and water-cooled version. Our engines (with annual manufacturing volumes
exceeding 320,000 engines) are manufactured in a most eco- friendly environment in
India at our Khadki – Pune, Kagal – Kolhapur, Rajkot and Nashik Plants. The
manufacturing plants are well equipped with most advance and high-tech machineries,
having state of the art cutting edge technology for machining of all the critical
components. Kirloskar engines are used as prime movers in Industrial, Agriculture,
Power generation as well as Marine Applications.
The engine manufacturing facilities are continually upgraded and improved to ensure the
requisite quality at competitive cost. Critical components like crankcases, crankshafts,
camshafts, gear casing, cylinder heads and connecting rod are manufactured in-house.
KOEL also manufactures for its exclusive use, Special Purpose Machines to achieve
critical degrees of precision that international specifications demand.
We pursue highest quality adherence for zero defect

"The certification demonstrates our commitment to excellence”
 ISO 9001 certification for Quality Management System since 1992 by

ABS QE, Inc.
 ISO/TS 16949:2009 for Quality Management System since 2007 by ABS
QE, Inc.
 ISO 14001 certification for Environment Management System since 1999
by TUV NORD.
 OHSAS 18001:2007 certificate for Health, Safety & Environment since
2009 by TUV NORD.
At Kirloskar, we believe that the industry and the environment can, and must, coexist in a
mutually beneficial way. Bringing this thought into practice is what has driven us to
manufacture engines that are not only eco-friendly, but are also manufactured in an
environment- friendly way.
Effective support to the product sold is available through the distributors selling the
product. Trained technicians and availability of spares at the distributor locations helps
minimize the engine downtime.
All pervasive IT in operations

Having foreseen the power of the IT to transform the businesses, way back in 1998
KOEL installed the world's leading Enterprise-wide Solution (ERP) - Oracle®. This
installation is noted to be one of the most comprehensive installations of Oracle in the
2
manufacturing industry. The installation of ERP in 1998 was followed up with net
enabled business processes in 2000. With this initiative, Kirloskar Service Dealers,
OEM's, Area Sales Offices, Suppliers and the Logistic providers form a digital
community that is ever ready to respond to each customer need efficiently. The Service
dealerships are able to respond to customer needs quickly and efficiently by accessing
round-the-clock the latest service information and parts availability over the internet, 24
hours a day, 365 days a year, including a leap year.
Customer Support:
Assurance through adequate product support is derived out of clear thought processes,
coupled with the most extensive service network in the country. Around 90% of Kirloskar
engines are within 80 km of a Kirloskar Service Dealer. 342 Service Dealership outlets
are operating efficiently to provide relentless service to customers. The dealership
locations and infrastructure is continuously assessed based on the Kirloskar engine
population build-up in each territory and the customer's emerging service needs. Out of
these, 210 Service Dealership locations provide 24-hour service as of December 2011,
with the number growing steadily. Add on, Kirloskar Service Managers, Service
Engineers and Technicians have been stationed at 14 Kirloskar Area and Regional
Offices. A well spread out service network manned by about 3500+ Kirloskar trained
engineers and technicians ensure prompt service and easy availability of genuine
consumable and spare parts, making sure that there's always the highest up-time for
Kirloskar engines.
DG Genset the Specific Anecdote:

We are recognized as one of the world‟s leading generating set manufacturers. “ Kirloskar
Green Genset “ is a major player globally, specialized in manufacturing of both air cooled
& water cooled Engines / Diesel Gensets with power output covering from 5 kVA to
625kVA & 1800kVA to 6300 kVA.
We have been instrumental in developing the latest technology driven products to suffice
power requirements of every individual customer from different market segments.
We provide reliable & high quality products at competitive cost.
We also provide variety of alternative fuel gensets, which efficiently run on Bio Diesel,
Bio Gas, SVO ( Straight Vegetable Oil ) and Natural Gas as per customer requirement.
DV Engine series, the Specific anecdote:

Design detail and performance delivery make every Kirloskar engine a well thought-out
engine. These engines go through painstaking scrutiny leaving minimal chances for any
kind of flaws or inadequacies before reaching the customer as a finished product. Making
every Kirloskar product to enjoy a strong presence in various fields of applications; such
as pumpsets, gensets, agricultural machinery, farm tractors, earthmoving and material
handling. The Indian Army, the Navy and the Air Force also accept them for arduous
applications in extremely demanding environs like deserts, snow-clad mountains, and the
blue sea, which is adequate proof for justifying the excellence of the well thought-out
engines.
3
DV Engine series, the Tech anecdote:
The DV series engines are 900 V series Liquid-cooled engines with direct injection. It is
Turbocharged and After-cooled engines.
Engine Features
 Four valve technology & Central injection system makes „DV‟ the most fuel
efficient engine in its class.
 Kirloskar „DV‟ engine is compliant to future emission norms of EU stage 2 level.
 Kirloskar „DV‟ engine can operate on 100 % bio-diesel giving 100 % power &
lower emissions.
 Lower lube oil sump capacity as compared to others, lower maintenance cost.
 Enhanced oil change period of 500 Hrs.
 Coolant change after 4000 Hrs.
 Light weight & strong crankshaft material, gives better strength and increases the
power train peak cylinder capability by 20 %.
 Gear cover & bell housing is a single piece design resulting in less leakage points
& less torsional vibration.
 'Belly Mounted' engine design reduces the vibrations and thus improves the
reliability o f engine.
 Most ideal for AMF application as well as for parallel operations.
 Provision of 'Auto Idle run' during start & stop gives time reduces initial friction
losses improving life of engine & Turbo charger.
 Indigenously developed fuel injection system, designed in collaboration with
'Bosch', with two feed pump units.
 'Double feed pump' increases tolerance for low level of fuel in fuel tank, resulting
in less chances of air locking.
 Air to air CAC results in less exhaust temperature, hence less load on cooling
system thereby improving the reliability of engine.
 Heavy duty Turbocharger, fully matched for varying load conditions.
 Rugged design to meet toughest operating conditions.
Gen-set Features
 Compact and aesthetically designed, CPCB approved canopy.
 Excellent transient response for sudden loading.
 State-of-art Engine and Gen-set monitoring system.
 Safety control for low coolant level in radiator, as standard feature.
 Engine health monitoring through internet and SMS to operator. (Optional)
4
Specifications
Sr. No. Topic Page

1.1 Foreword 6
1.2 General Instructions 6
1.3 Engine Description 7
1.4 DV Engine Photographs 9
1.5 General Specifications for DV Series Engines 11
1.6 Tightening High Tensile Fasteners 12
1.7 Tightening Torque Table for DV series engine 13
1.8 DV Series Engines nominal dimensions, clearances and 14
limits of important components.
1.9 List of special tools 19
1.10 List of Standard Tools 23
1.11 Consumables 24
1.12 Recommended Procedure for Engine Preservation 25
5
1.1) Foreword
This Workshop Manual has been prepared to assist KOEL authorised Distributors/
Dealers/Service workshops to recondition the DV series engine correctly. It contains
technical assistance and guidelines for correct dismantling and assembly of the DV series
engine during engine repairs. Detailed instructions about basic repairs have been omitted.
It is presumed that tasks will be carried out by trained engineers / technicians using
proper tools tackles and correct procedures taking responsibility for the engine's
operating life and their own personal safety.
When repairing / overhauling the DV series engine, use only genuine Kirloskar spares
towards maintaining engine quality and reliability.
For routine care and maintenance of the DV series engine, refer to the O & M Manual
DV0.066.02.0.00.
This manual is prepared from information available at the time of its publication.
However in accordance with the Company's policy of constant product up gradation,
continuous improvements will be carried out on the engine from time to time. These
improvements will be communicated through bulletins and subsequently included in the
workshop manual reprints.
When ordering spare parts, mention engine's designated model with the full engine
number as punched on the nameplate and, wherever possible, the spare part manual's
publication number. This will help us to supply correct parts within the shortest possible
time ensuring minimum engine downtime.
1.2) General Instructions

Before dismantling, it is necessary that the external part of the engine should be
thoroughly cleaned with pressurised water. Before cleaning the engine with pressurised
water ensure that all points of entry to the engine are closed so that water does not enter
the engine.
Cleaned and useable components must be properly stored in trays / containers to avoid
damage. Components likely to get rusted due to the weather must be treated with
recommended anti-rust oils, or even fresh engine oil. Machined and polished component
surfaces should be protected from scratching and damage by proper storage.
Use correct size standard and special tools. An adequate capacity lifting device should be
used to prevent accidents, injuries as well as damage to the engine.
For satisfactory results, the dismantling and assembly of the engine should be done in a
well lit, clean room.
Dismantling and assembly is convenient and quick if carried out on a DV service trolley.
The DV series engine may need top overhaul after about 10,000 hours and a major
overhaul after about 20,000 hours provided the engine is properly maintained as per the
instructions specified in the O&M manual.
6
1.3) Engine Description
The Kirloskar DV series engines are 900 V configuration with 8/10/12-cylinders, water-
cooled, four stroke diesel engines with direct injection, available in turbocharged after
cooled version, suitable for power generation, industrial, marine auxiliary applications.
The standard direction of rotation is counter clockwise when looking at the flywheel from
the flywheel-end side. The engine's cylinders are numbered in ascending order from the
flywheel-end side with cylinder No.1 being nearest to the flywheel.
The engine cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is
extended to a level below the crankshaft center line. The cylinder liners are wet and of
replaceable type. The engine has a unit construction design with individual cylinder liners
and heads with struck-in valve seat rings and replaceable valve guides.
The forged crankshaft has detachable counterweights (Balance weights) Radial oil seal is
on crankshaft at crank pulley and at flywheel end, oil seal is on crank gear.
The connecting rods are die-forged, diagonally split and can be removed through the top
of the cylinders together with the pistons. Crankshaft and connecting rods run in steel-
backed lead bronze ready to fit type bearings.
7
The Engine Nameplate
The engine number is punched on the nameplate. This is fitted on the crankcase at
alternator side.
Model Designation
DV 8.1002/0900001
Engine Serial No.

Year of manufacture 2009
Application code no.
No off cylinders
Engine series
DV 10.1002/0900001
Engine Serial No.

No off cylinders
Engine series
DV 12.1002/0900001
Engine Serial No.

No off cylinders
Engine series
8
1.4) DV Engine Photographs
9
10
1.5) General Specifications for DV Series Engines
Parameter Unit Engine Model
DV8 DV10 DV12
1 No. off Cylinders No. 8 10 12
2 Cylinder arrangement 90 Deg. V
3 Working cycle 4-stroke diesel engine
4 Combustion system Direct Injection
5 Cooling system Liquid-cooled
6 Direction of rotation Anticlockwise(looking at flywheel end)
7 Compression ratio 16.5:1
8 Bore x Stroke mm 130 x150
9 Displacement Lit. 15.93 19.91 23.89
10 Aspiration Turbocharged After-cooled
11 Firing Order 1-5-7-2-6-3-8-4-8 1-6-5-10-2-7-3-8-4-9 1-12-5-8-3-10-6-7-2-11-4-9
12 Engine starting arrangement Electric starting 24V(2 X12V)
13 Recommended Battery Capacity Ah 180
14 B.M.E.P at Rated Output bar 18.1 18 18.7
15 Rated Output Continuous- ISO 3046 kw 360 448 559
16 Rated Output kw 394 495 613
Standby- ISO 3046
17 Rated Speed rpm 1500
18 Injector Opening Pressure bar 250
19 Governor Electronic type

20 Fuel Timing Deg. 16 +/- 1
BTDC
21 Specific Fuel Consumption Under std. Gms/kw- 198.64 200
Test Conditions hr.
22 Lube Oil Sump Capacity lit. 38 42 48
23 Lube Oil System Capacity lit. 44 47 57
24 Lube Oil Pump Flow at 3,5 bar pressure lit. 130 145
25 Lube Oil Consumption max. Gms/kw- 0.2% of Fuel consumption
hr.
26 Recommended Lube Oil K Oil Super
27 Maximum Engine Inclintion Deg. 15
28 Valve Clearance Inlet, Exhaust mm 0.35
29 Bumping Clearance mm 1.4 to 1.55
30 Noise level at 1m dBA Less than 75
31 Exhaust Back Pressure Max. Mm of 50
Hg
11
1.6) Tightening High Tensile Fasteners
The purpose of every tightening is to obtain as uniform load as possible on the fasteners
which are tightened by pre-loading.
The high tensile fasteners are tightened by two methods. Some of the fasteners are
tightened in one or two stages. The initial tightening is known as pre-loading.
What is pre-loading ?
Pre-loading is the elongation of bolt or fastener under tensile stress.
Why pre-load?
To ensure a rigid and long lasting connection of two or more different parts(which cannot
be loosened) under operating conditions.
Reasons to pre-load fasteners

 Under tensile stress, a pre-stressed fastener will elongate less under stress thus
increasing the rigidity of the assembly.
 The risk of fatigue failure of the bolt under periodical variation of external forces
is reduced.
 Compression forces will not slacken the force.
 Frictional resistance of joint parts caused by pre-loading of bolts carries external
shearing force.
 No danger of loosening of connections under external loads and vibrations
Tightening High Tensile Fasteners by Torque Wrench
This is the most conventional method used wherein a torque wrench is used. Here the
wedge effect of the threads is used to produce the elongation of the bolt. The resulting
stress pattern in the bolt is both axial and torsional. Due to friction, occurring in the
threads and the mating surfaces; only a fraction of the applied effort results in bolt
elongation.
This method of preloading is not very accurate as many factors can offset the accuracy
The factors involved are:-
1 The torque wrench, which can have an error up to 7% or more depending on its
condition.
2 The proper cleaning and lubrication of threaded portion of the fastener as well as the
threads inside the component is very essential. Also the friction increases as the bolt
diameter increases. This is due to the increase in cross-sectional area coming in contact
with the threads.
3 The surface finish of the component and the fastener play a crucial part in increasing
the friction.
12
1.7) Tightening Torque Table for DV series engine
Sr.No. Description Initial Tightening Method Total torque

Totque (kgm/Deg) (kgm/Deg)
kgm Stage 1 Stage 2 Stage
3
1 Balance weight bolt 5 15 26 - 26
2 Main bearing cap bolt 5 15 30 35 35
3 Connecting rod bolt (M16X1.5) 5 85⁰ 85⁰
(22-26 Kgm)
4 Crank pulley bolt 5 10 20 - 20
5 Flywheel bolt 10 25 49 - 49
6 Flywheel Housing bolt 8
7 Injector stud nut - - - - 3.5
8 Fuel pump hub nut - - - - 20
9 Cylinder head bolt 5 15 26 - 26
10 All M8x1.25 Screws and bolts - - - - 2.5
11 All M10x1.5 Screws and bolts - - - - 3.5
 Threads and seating faces of fasteners are to be cleaned and wet with engine oil
before assembly.
 When replacing main or connecting rod bearings, during overhaul/piston seizures,

replace new bolts for main bearing caps and connecting rod.
 Apply initial torque and tighten the bolts according to the angles/torques in stages
as specified in the table above.
13
1.8) DV Series Engines nominal dimensions, clearances and limits of important
components.
Sr. No. Description Nominal Dimension
(For DV8, DV10 & DV12)
All dimensions are in mm
except for the angles
1 Cylinder Head
1.1 Valve guide (Inlet and Exhaust)
1.1.1 Valve guide outside diameter 15.040 to 15.056
1.1.2 Valve guide bore in cylinder head 15.000 to 15.018
1.1.3 Valve guide inside bore diameter 8.005 to 8.020
1.2 Valve stem diameter
1.2.1 Inlet & Exhaust 7.940 to 7.960
1.3 Valve stem clearance in guide normal
1.3.1 Inlet 0.045 to 0.080
1.3.1.1 Limit value 0.3
1.3.2 Exhaust 0.045 to 0.080
1.4 Valve seat insert
1.4.1 Valve seat insert bore in cylinder head (Inlet) 47.000 to 47.025
1.4.2 Valve seat insert outside diameter (Inlet) 47.054 to 47.070
1.4.3 Valve seat insert bore in cylinder head (Exhaust) 43.500 to 43.525
1.4.4 Valve seat insert outside diameter (Exhaust) 43.554 to 43.570
1.4.5 Depth of valve seat bore 12.000 to 12.100
1.5 Valve seat angle (Valve seat insert)
1.5.1 Inlet 29°.40' to 30°.10'
1.5.2 Exhaust 44°.50' to 45°.10'
1.6 Valve cone diameter
1.6.1 Inlet 45.900 to 46.100
1.6.2 Exhaust 41.900 to 42.100
1.7 Valve seat angle (valve)
1.7.1 Inlet 29°.30' to 29°.50'
1.7.2 Exhaust 45°.10' to 45°.30'
1.8 Rim thickness
1.8.1 Inlet 2.7
1.8.2 Exhaust 2.32
1.9 Valve recess (Distance between cylinder Head face
and valve face) - Valve stand-in
1.9.1 Inlet and Exhaust 0.000 to 0.200
1.9.1.1 Limit value 2
1.10. Valve spring
1.10.1 Total no. of coils 7
14
1.10.2 Valve spring , (free length) 59
1.10.2.1 Valve spring , (free length) limit value 57
1.12 Cylinder head bolt
1.12.1 Cylinder head bolt nominal length 188 to 188.500
1.12.2 Limit value 190
1.13 Rocker shaft and Rocker lever
1.13.1 Rocker shaft outer diameter for rocker lever 29.902 to 29.935
1.13.2 Rocker lever inside diameter with bush 29.955 to 29.984
1.13.3 Clearance between rocker shaft and rocker lever 0.020 to 0.082
1.14 Cylinder head surface flatness 0.04
1.15 Valve clearance (cold)
1.15.1 Inlet 0.35
1.15.2 Exhaust 0.35
1.16 Bumping Clearance 1.4 to 1.55
1.16.1 Gasket thickness 1 See note below
2 Cylinder liner
2.1 Cylinder liner bore, normal 130.000 to 130.035
2.1.1 Wear limit 130.2
2.2 Cylinder liner bore, ovality 0.01
2.3 Cylinder liner, projection over block (Liner
0.030 to 0.100
protrusion)
3 Piston
3.1 Piston pin bore in piston 55.003 to 55.009
3.1.1 Limit value 55.05
3.2 Piston pin outside diameter 54.992 to 55
3.3 Piston ring groove width
3.3.1 Tapered compression ring groove 3.240 to 3.270
3.3.1.2 Keystone Included angle 15°.15'
3.3.2 Scrapper ring groove 2.560 to 2.580
3.3.3 Oil control ring groove 4.020 to 4.040
3.4 Clearance between piston skirt & liner. 0.136 to 0.189
4 Piston rings
4.1 Piston Ring Land Clearance
4.1.1 Tapered compression ring 0.133 to 0.207
4.1.2 Scrapper ring groove 0.060 to0.110
4.1.3 Oil control ring 0.020 to 0.070
4.2 Piston Rings Butt gaps (As measured in liner bore)
4.2.1 Tapered compression ring 0.300 to 0.050
15
4.2.2 Scrapper ring 0.500 to 0.700
4.2.3 Oil control ring 0.400 to 0.750
5 Connecting rod
5.1 Big end bore diameter (without shell) 102.000 to 102.022
5.2 Big end bore diameter with standard shell 96.026 to 96.072
5.3 Number of under sizes 6 u/s in step of 0.25
5.4 Clearance between crankshaft pin and outside
diameter and connecting rod bearing inside 0.076 to 0.142
diameter
5.4.1 Limit value 2 0.3
5.5 Width of bearing 34.000 to 34.25
5.6 Connecting rod width 39.820 to 39.920
5.7 Connecting rod side clearance normal 0.360 to 0.647
5.8 Connecting rod small end bore
5.8.1 Connecting rod small end bore without bush 59.000 to 59.018
5.8.2 Connecting rod small end bore with bush 54.584 to 54.834
5.8.2.1 Limit value 54.984
5.9 Clearance small end bush and Piston pin, normal 0.048 to 0.076
6 Intermediate gear and support
6.1 Intermediate gear and support (Crank & cam)
6.1.1 Intermediate gear bore without bush bearing 80.000 to 80.035
6.1.2 Intermediate gear bore with bush bearing 75.030 to 75.060
6.1.3 Intermediate gear and Support journal diameter 74.971 to 74.990
6.2 Intermediate gear and support (Cam &fuel)
6.2.1 Intermediate gear bore without bush bearing 80.000 to 80.035
6.2.2 Intermediate gear bore with bush bearing 75.030 to 75.060
6.2.3 Intermediate gear and Support journal diameter 74.971 to 74.990
6.3 Clearance intermediate gear bush and journal 0.080 to 0.095
diameter , normal
6.4 Intermediate gear end play 0.190 to 0.280
6.5 Gear backlash
6.5.1 Intermediate gear to cam gear 0.070 to 0.400
6.5.2 LOP gear & LOP intermediate gear 0.070 to 0.260
6.5.3 Crank gear & LOP intermediate gear 0.070 to 0.260
6.5.4 Crank gear to intermediate gear 0.070 to 0.260
6.5.5 Int. gear to FIP intermediate gear 0.070 to 0.4
6.5.6 FIP gear to FIP intermediate gear 0.070 to 0.260
7 Camshaft
16
7.1 Cam bore diameter in crankcase without bushes
7.1.1 Bore 1 (flywheel-end) 75.000 to 75.035
7.1.2 Bore 2 75.000 to 75.035
7.1.3 Bore 3 75.000 to 75.035
7.1.4 Bore 4 75.000 to 75.035
7.1.5 Bore 5 75.000 to 75.035
7.1.6 Bore 6 75.000 to 75.035
7.1.7 Bore 7 75.000 to 75.035
7.2 Cam bore with bush bearing (finished)
7.2.1 Bearing number 1 Std. (flywheel-end) 70.125 to 70.215
7.2.1.1 Limit value 70.235
7.2.2 Bearing number 2 Std 70.125 to 70.215
7.2.2.1 Limit value 70.235
7.2.3.1 Limit value 70.235
7.2.4.1 Limit value 70.235
7.2.5.1 Limit value 70.235
7.2.6.1 Limit value 70.235
7.2.7.1 Limit value 70.235
7.3 Camshaft Journal diameter
7.3.1 Journal 1 (flywheel-end) 69.910 to 69.940
7.3.2 Journal 2 69.910 to 69.940
7.3.3 Journal 3 69.910 to 69.940
7.3.4 Journal 4 69.910 to 69.940
7.3.5 Journal 5 69.910 to 69.940
7.3.6 Journal 6 69.910 to 69.940
7.4 Clearance camshaft journal and bush 0.080 to 0.190
7.5 Camshaft end play 0.070 to 0.300
7.6 Thrust plate thickness3
7.6.1 Thrust plate 1 thickness 17.950 to 18.000
17
7.6.4 Thrust plate 4 thickness 18.150 tio 18.200
7.7 Valve cam lift
7.7.1 Inlet 8.750 to 8.850
7.7.2 Exhaust 7.150 to 7.200
8 Crankshaft
8.1 Crankshaft bore in crankcase
8.1.1 Crankshaft bore in crankcase without bearing 116.000 to 116.022
8.1.2 Crankshaft bore in crankcase with bearing (standard) 110.038 to 110.090
8.2 Crankshaft journal diameter 109.930 to 109.950
8.3 Number of under sizes 6 u/s in steps of 0.25
8.4 Hardness 56 ± 3 HRC
8.4.1 Limit value 50 HRC
8.5 Clearance (Crankshaft journal outside diameter and 0.088 to 0.160
main bearing inside diameter)
8.5.1 Limit value 2 0.3
8.6 Journal width 59.500 to 60.750
8.7 Fillet radius for journal 4.2 to 4.5
8.8 Fillet radius for pin diameter 4.2 to 4.5
8.9 Crank pin diameter 95.930 to 95.950
8.9.2 Number of under sizes 6 u/s in steps of 0.25
8.9.3 Hardness 56 ± 3 HRC
8.9.3.1 Limit value 50 HRC
8.10. Thrust washer thickness 2.855 to 2.905
8.11 Crank pin width 80.200 to80.287
8.12 Form tolerances for crankshaft
8.12.1 Roundness 0.003
8.12.2 Straightness 0.002
8.12.3 Parallelism between all pins and journal diameters 0.005
8.13 Crankshaft end play 0.070 to 0.260
9 Crankcase
9.1 Liner collar bore at top of crankcase 168.400 to 168.600
9.2 Bottom end bore for cylinder liner 153.000 to 153.040
9.3 Depth of liner collar supporting area 9.920 to 9.970
9.4 Tappet bore diameter 31.985 to 32.025
18
9.4.1 Tappet
9.4.2 Outside diameter of tappet 31.925 to 31.950
10 Lube oil pump
10.1 Lube oil pump speed (rpm) 2925 to 2945
10.2 Delivery pressure (bar) 3.5 ± 0.5
10.3 Delivery at 5 bar pressure (LPM) 190
11 Water pump
11.1 Water pump speed (rpm) 2325
11.2 Discharge (LPM) (at 80°C) 450
11.3 Delivery head (in meter) (at 80°C) 11
1. Check the present cylinder head gasket thickness used and replace with new
cylinder head gasket of same thickness.
2. Replacement of bearing is governed by lube oil pressure.
3. Select appropriate thrust plate to achieve the camshaft end play.
19
1.9) List of special tools
Engine Assembly Device
Camshaft Bush Fitting Tool (DV0.950.519) Camshaft Core Plug Fitting Tool
(DV0.950.515)
Engine Rotating Tool (DV0.950.524) FWE Oil Seal Pressing Tool

(DV0.950.521)
Pushrod Tube Spring Pressing Tool Guide Sleeve for inserting Piston S/A
(DV0.950.530) into Liner (DV0.950.501)
Mandrel for Pressing Dowel Crankshaft Mandrel for Pressing Dowel Cylinder
(DV0.950.511) Head (DV0.950.512)
20
Mandrel for Pressing Dowel Flywheel Housing Mandrel for Pressing Dowel Oil Seal Hsg
(DV0.950.513) (Pulley end) (DV0.950.514)
Tool for injector removing (DV0.950.507) Tool for Pressing Oil Seal Pulley End
( DV0.950.522)
Tool for cylinder liner removal (DV0.950.04) Mandrel for Pulley end oil seal pressing
(DV0.950….)
Mandrel for cam bush pressing (DV0.950.519)
Cylinder liner clamping tool (DV0.950….) Bumping clearance checking gauge

(DV0.950….)
21
Following Special Tools are also required foe assembly which are not illustrated
DV0.950.502 Tool for Liner Pressing

DV0.950.505 Tool for Fitting Collets
DV0.950.506 Tool for Fitting Stem Seals
DV0.950.517 Mandrel for Pressing Dowel Plug FIP
DV0.950.518 Mandrel for Pressing Dowel Plug Header
DV0.950.523 Guide Stud for Crank Pulley
DV0.950.524 Guide Stud for Crank Rotation
DV0.950.525 Guide Stud for Flywheel
DV0.950.526 Guide Stud for Cylinder Head
DV0.950.529 Lock for Flywheel rotation
DV0.950.531 Tool for Measurement of Liner Distortion
DV0.950.533 Tool for TDC Indicator
DV0.950.535 Tool for Rack Insertion into FIP Hsg.
DV0.950.537 Tool for Liner Lapping
22
1.10) List of Standard Tools
Sr. No. Tool Description Tool Specification

1 Double ended spanner 10x12 mm
2 Double ended spanner 13x 17 mm
5 Ring spanner 12x13 mm

8 Box Spanner 13 mm
9 Box Spanner 17 mm
10 Box Spanner 27 mm
13 Adjustable wrench 150 mm
14 Speeder wrench 600 mm
15 Extension 100 mm long

16 Extension 225 mm long
17 Ratchet 300 mm long
18 Screw Driver 150 mm long
19 Ball Hammer 1 kg
20 Teflon Mallet 40 mm diameter
21 Internal circlip pliers 150 mm
22 Cutting pliers 200 mm
23 Torque Wrench EVT600RR 0-7 kgm

24 Torque Wrench 8-30 kgm
25 Allen Socket 17mm
23
26 Feeler gauge set 150 mm long
27 Micrometer 0-100 mm
28 Vernier 250 mm
29 Depth gauge 150 mm
30 Dial bore gauge 120 mm
1.11) Consumables
Sr. Use
No. Consumable
1 Engine fuel
High Speed diesel oil
Confirming to: -IS 1460 1995 or
-BS: 2969-A1 & A2*
(* Note sulphur content)
-ASTM D 975-81:1D and 2D
-W-F-800C:DF-A and DF-2 W-F-800C : DF-A. DF
-DIN 51 601
(Sulfur content less than 0 .25%)
2 Lubricating Oils
„K‟oil Super 15W40 or equivalent recognized brand Engine Lubricating oil
of oil meeting below specifications
Indian American European Standard Engine DV8 DV10 DV12
Standard Model
IS 13656:1993 U.S.Military API CCMC First 47 50 57
EDL-2 MIL-L-5199B CD/CD+ - Fill
- MIL-L-2104C GE/CF+ - Sump 41 45 50
EDL-3 MIL-L-2104C CF-4 D4 capacity
Plus
EDL-4 - Higher D5
grade
3 Coolant: Addetives to be mixed with water in Engine Coolant
- K-Kool Radiator to improve cooling and to Engine DV8 DV10 DV12
Super protect water jackets from rusting. Model
Plus Coolant 105 135 146
Capacity
In Lts.
4 Thread lock: Prevents low torque bolts from Thread sealant.
- Loctite getting loose. Should be use on
242 a) Oil sump bolts. b) Oil seal
- Anabond housing. c) Gear cover.
d) Rocker cover.
5 Sealing Sealing compound to prevent water For proper sealing
compound: or oil seepage between to metallic
- Zeelac joints.
- Loctite - Liner fitting in crankcase.
24
6 Gasket To be used where chances of Gasket sealant
sealing leakages is there due to splashing
compound: etc.
- Silastic - Sump joint
- Permatex - Water pump and Volute casing
Ultra
Blue
1.12) Recommended Procedure for Engine Preservation
SCOPE :
Following preservation procedure is recommended for both water cooled and air cooled engines
to be supplied overseas and also when the engines are to be kept idle (out of use) for prolonged
period (more than 12 months).
1) Using H.S.D. fuel, run the engine at approx. 70% of max. rated speed with no load for
approx. 5 minutes to warm up the engine (In case of 'fixed speed' engines like engine for
Genset, it can be run at rated speed).
2) After stopping the engine, drain lub.oil from sump and refill with suitable preservative oil
(Ref. Annexture I).
3) Run the engine on no load for 3 minutes (for engine speed ref. Point 1). During this time the
preservative will be circulated throughout the lub.oil system of engine. Stop the engine and
disconnect diesel fuel supply to fuel pump inlet.
4) Prepare a solution of Diesel + Preservative oil (5:1 ratio) in a separate tank, and connect fuel
line from tank, directly to fuel pump inlet ensuring gravity feed (by-pass fuel filter).
5) FOR WATER COOLED ENGINES WITH CLOSE CIRCUIT COOLING

SYSTEM
Drain coolant from cooling system and thoroughly flush with clean water. The system then
should be filled with mixture of water and any of the cooling system preservatives mentioned
in Annexure I.
6) Electrically crank the engine till it fires (In case of purely Hand Start engines, hand crank the
engine using decompressor lever, till it fires) and let it run for 30 seconds (during this time
the diesel in fuel pump gallery and high pressure pipes will be displaced by Diesel +
Preservative oil mixture) stop the engine.
Engine speed during above running:

- In case of variable speed engines, the engine should be run approximately at 800 to 1000 rpm.
- In case of fixed speed engines, i.e. for Genset, Pump set etc., the engine should run at no load
and rated speed.
7) Close the Air Inlet Manifold (or the Air cleaner inlet) and crank the engine by starter for 5 to
10 seconds (In case of only hand start engines, it should be hand cranked using the
25
decompressor for 5 to 10 seconds). This will ensure coating of Diesel + Preservative oil on
the combustion chamber surfaces.
8) Drain preservative oil from oil sump, reinstall drain plugs and reconnect fuel filter into the
fuel pipeline.
9) FOR WATER COOLED ENGINE WITH CLOSE CIRCUIT COOLING SYSTEM

Drain emulsion of water and preservative from cooling system.
10) Treat all unpainted external ferrous metal parts with two coats of suitable rust preventor (Ref.
Annexure I attached), allowing sufficient time for the first coat to thoroughly dry before
applying second coat.
11) All vents i.e. engine inlet pipe, exhaust pipe, air cleaner inlet, coolant inlet/outlet, crankcase
breather etc., to be carefully sealed with waterproof paper and waterproof adhesive tape.
12) Dipstick on engine to be sealed in place, with waterproof adhesive tape.
13) IMPORTANT "DO NOT ROTATE CRANKSHAFT AFTER ABOVE MENTIONED

OPERATIONS".
14) Loosen 'V' Belt tension.
15) Battery for engine starting, if provided, should disconnected and stored in a cool, dry place
after ensuring the electrolyte level (Refill with distilled water if necessary).
It is recommended to recharge the battery every 30 days.
16) Tag engine to indicate that it has been treated with preservatives, and should not be turned
over until ready to run, due to possible reduction of protective film. The tag should show the
date of treatment and validity date.
17) With above preservation procedure, the engine can safely be stored for a period of 12 months
maximum. It is preferable to wrap the engine in polyethylene bag and store in dry shade. If
the engine is to be stored unused for more than 12 months, the preservation procedure
mentioned above should be repeated every 12 months.
18) Periodically inspect the engine for rust or corrosion and take corrective action if any.
Commissioning of 'Preserved' Engine
1. Remove all the sealing tapes/papers from various openings.
2. Remove the rust preventive coating from those unpainted-machined surfaces, which are
interfacing surfaces for the driven equipment. This can be done by using NC Thinner.
3. Fill recommended grade of lub.oil in the oil sump upto the 'top' mark of the dipstick. Add 0.5
lit further for lub.oil filter.
4. In case of water-cooled engines, fill the cooling system with fresh water.
It is recommended to use Anticorrosion/Descaling additive in the fresh water.
26
The recommended additives are -
- Aquat 720 (2 cc per litre)
- Nalcool 2000 (35 cc per litre)
In case of low ambient temperatures (below +5oC) it is necessary to add antifreeze mixture to the
fresh water in 1:1 proportion.
5) Readjust the V belt tension after checking the condition of V belts(s). Replace the V belt(s) if
necessary.
6) Reconnect a fully charged battery of recommended voltage and Amp hr capacity ensuring
correct polarity connection (where applicable).
The engine is now ready for reuse.
ANNEXURE 1 : RECOMMENDED PRESERVATIVES
Manufacturer Preservative for --

Engine Lub.Oil and Fuel *Engine cooling system Unpainted ferrous metal
system parts
VEEDOL TIDE WATER Veedol 30/40 Veedol Amulkut 4 Veedol Ruspro IT
OIL CO. Emulstion with water in
ratio 1:15
CASTROL INDIA Rustilo DW 904 OR
DW 901
HINDUSTAN Autoprun T 120 Koolkit 40 5% Emulsion Rustop 274
PETROLEUM with water
INDIAN OIL Servo Preserve 30 OR Survo Cut S 20% Servo RP 125
Servo 'RUN-N' Oil 30 Emulsion with water
BHARAT PETROLEUM Bharat Preserve Oil 30 Bharat Sherol B Emulsion Bharat Rustrol 152
with water ratio 1:20
* Alternatively 'Suprabha VCI 302' of Suprabha Products can also be used.
27
Top Overhauling
Sr. No. Topic Page

2.1 Dismantling Instructions 2
2.2 Cleaning & Inspection 17
2.3 Engine Assembly 18
2) Top Overhauling
 The recommended Top Overhaul period is 10000 working hours of the engine.
 The Top Overhauling should be done by the authorised service dealer only.
 Before dismantling the engine, start the engine and run it on full load for about 45
minutes till the lube oil is warm.
In case of open generating sets

 Drain the lubricating oil from the
sump.
 Discard the 'O' ring of the drain
plug.
In case of generating sets with canopy

 Operate the hand drain pump to
drain the lube oil.
1
2.1) Dismantling Instructions
 Disconnect the battery. Remove
negative (-ve) connection first.
 Remove the battery and store it in a
dry place on a wooden plank.
Refer to Inspection & Service
procedure, Section 4, 4.43.1
 Disconnect wiring from the

alternator terminals.
 Disconnect wiring from the starter

terminals.
 Remove starter and send it to the
authorised service dealer for
servicing. Refer to Inspection &
Service procedure, Section 4, 4.43.3
2
 Disconnect the fuel supply pipe and
the fuel return pipes on the fuel tank
at bottom .
 In case of open generating sets
 Disconnect the fuel supply pipe and
the fuel return pipes to the fuel
tank.

 Disconnect the fuel pipes from the
fuel tank at bottom.
Remove the radiator pressure cap.
In case of open generating sets

 Drain coolant from the radiator.
 Collect coolant in a packed
container for reuse.
3
 Drain coolant from the radiator
drain pipe connection provided on
the base plate.
 Collect coolant in a packed
container for reuse.
 Remove the breather pipe

connection.
 Disconnect the rubber hoses on

charge air cooler inlet and outlet
pipes.
 Discard the rubber hoses
4
 Disconnect all the water inlet and
outlet connection hoses on radiator.
 Discard the old hoses.
 Remove the venting pipe.
 Disconnect hose bend from both air

cleaners.
5
 Remove both air inlet pipes
(Turbocharger to CAC)
 Remove Heat shields from both

sides.
 Remove the injector leak-off pipes

from both sides.
 Discard the copper washers.
 To avoid the ingress of dust, cover

the nozzle leak-off pipe openings
with a clean plastic sheet and tie the
ends. Alternatively use plastic caps.
6
 Disconnect the high pressure pipes
on injectors on both sides.
 Disconnect the high pressure pipes

on the fuel pump.

the HP pipe openings with a clean
plastic sheet and tie the ends.
Alternatively use plastic caps.

the fuel pump openings with a clean
plastic sheet and tie the ends.
Alternatively use plastic caps.
7
 Disconnect the expansion bellow.
 Discard the joints.
 Disconnect and remove both the

exhaust bends.
 Remove the rocker covers.

 Remove the rocker assemblies with

the pedestals from cylinder heads.
8
 Remove valve bridges.
 Remove the push rods.

 Refer to Inspection of Valve Rocker
Assembly & Push Rod, Section 4,
4.29.
 Remove the fuel filter.

 Discard the fuel filter elements.
 Refer to Replacing the Fuel Filter
Element, Section 4, 4.36
9
 Remove both Air pipes.
 Remove both Turbo compressor

outlet pipes.
 Remove both the Lubricating spin-

on oil filter cartridges with a strap
tool.
 Refer to Replacing the spin-on type
Lubricating Oil Filters, Section
4,4.35
 Discard both cartridges.
10
 Remove the injector fork.
 Remove injectors from the heads. If

the injector is stuck in the head,
remove it with the help of an
injector extracting tool.
 Send the injector to an authorised
BOSCH/MICO dealer for
reconditioning.
 Remove the sealing washer in the
nozzle bore in the cylinder head.
Discard the nozzle sealing washers.
Remove and discard the ‘O’ rings.
 Remove the oil filling body,
11
 Disconnect the lube oil inlet pipes
to turbochargers.
 Disconnect the lube oil drain pipes
to turbochargers.
 Disconnect the turbochargers from

the exhaust manifold.
 Refer to Inspection & Servicing of
Turbocharger, Section 4, 4.33
 Discard the joints
 Caution Protect lube oil inlet and
outlet ports on turbocharger
properly to avoid ingress of dust.
 Loosen cylinder head bolts.

 Check the bolt length.
 If length of cylinder head bolt is
increased beyond limit value,
replace the cylinder head bolts.
Refer to Specifications, Section 1,
1.7
 Disconnect the exhaust manifolds

from both sides.
 Remove the exhaust manifolds..
 Separate the two pieces of exhaust
manifold.
 Disconnect and remove the air inlet
manifold.. Refer to Servicing the
Air Inlet & Exhaust Manifold,
Section 4, 4.32
12
 Mark cylinder head numbers on
each head with paint / a permanent
marker.
 Remove cylinder heads.
 Refer to Inspection & Servicing
procedures in Section 4, 4.22
 Discard the cylinder head gaskets.
 Remove the centrifuge filter.

 Discard the joint.
 Remove the oil filling body.
 Discard the ‘O’ rings.
 Remove the Centrifugal Lube Oil

Filter and carry out the servicing.
Refer to Servicing of Centrifugal
Lube Oil Filter, Section 4, 4.37
 Remove the oil sump.
13
 Dismantle and remove the suction
tube assembly with bracket. Fig.
 Remove the delivery pipe. Fig.

 Discard the joint. Discard the ‘O’
Ring.
 Inspect the end play of connecting

rod in assembled condition. If no
end play is found, connecting rod
must be checked for bend and twist.
 Loosen connecting rod cap bolts a
few threads.
 Gently tap with a plastic hammer

on the bolts head to dislodge the
cap from the connecting rod. Fig..
 Remove the connecting rod cap
with the bearing shell.
Do not disturb the

bearing shells seating position in the
connecting rod shank and cap.
 Rotate the crankshaft to a
convenient position, push the piston
and connecting rod assembly out
from the top of the cylinder liner
14
 Check numbers on connecting rod
and cap and reassemble the
connecting rod and cap of the same
no.
 Remove piston rings from the
piston. Discard them.
 Check the condition of piston &
connecting rod if necessary. Refer
to Inspection & Servicing
procedure in Section 4, 4.15 and
4.16
 Inspect the cylinder liner condition

visually for wear, step and scratch
marks etc. and also with a dial bore
gauge. Refer to Inspection and
Service procedure in Setion 4, 4.14
.Discard the cylinder liner if bore
has reached the wear limit.
 If cylinder liner is required to be

removed from the block use tool no
DV0.950.04 as per list of special
tools, section 1.9.
 Discard the liner ‘O’ rings.
 Inspect the liner externally and also
check the condition of liner bore in
the block.
15
 Dismantled parts are to be kept on
trolley. Fig.
 All the parts removed from the
engine are to be stacked properly on
the trolley / tray. Ensure that the
parts will not be damaged.
16
2.2) Cleaning & Inspection
To ensure satisfactory performance of the engine after top overhauling, all components should be
cleaned and decarbonised.
During cleaning avoid using sharp instruments, emery paper, steel wool or
steel brush. These will damage the machined surface and finish of the components.
 Inspect the cleaned components for cracks, erosion and pitting marks.
 Discard unserviceable components. The components which can be reconditioned must be
retrieved.
 Check retrieved components for dimensional accuracy. Refer to Section 1, 1.8 ‘Nominal
dimensions, clearances and limits’ for important components.
 Replace all bushes to avoid later complications and performance deterioration.
 If dish type core plugs are removed during cleaning and inspection, replace and fit again
with a proper mandrel to avoid leakages. Apply sealant.
Special attention should be given to components like cylinder head, piston, connecting rod and
cylinder liner during servicing and inspection. Refer to Section 4, 'Inspection & Servicing
procedures of major components, sub-assemblies' for adjustments and settings.
Refer to Tightening Torque Methods & values given in the table in Section 1,
17
2.3) Engine Assembly
Following components are recommended to be replaced during a Top Overhaul.

 Piston ring set
 Inlet and exhaust valves
 Valve guides
 Valve seals
 Valve collets
 Valve springs
 Connecting rod bolts
 Cylinder head bolts
 Set of joints
 Set of 'O' rings.
 Set of copper washers
 Set of hoses and hose clips
 V Belts
 Anti-vibration mountings for radiator, engine and alternator, control panel
If found damaged any other part which is not mentioned above, is to be replaced.
Precautions for Assembly

 Check all the components for damage cracks, normal/abnormal wear, scale formation,
rust formation and foreign particles present inside the galleries and surface. Treat
accordingly.
 Ensure that the components are properly cleaned before assembly.
 If a delay is expected in assembly, all usable casting and steel components should be
coated (with rust proof oil), duly labeled and stored properly to avoid damage to the
machined surface.
 Ensure a dust-free atmosphere around the engine assembly.
 Ensure that the assembled parts are adequately lubricated.
 Ensure that all joints, gaskets, 'O' rings and copper washers are replaced with new ones
while assembly. Remove the old joints by scraping them with a blunt tool.
 Ensure that all the fasteners are tightened as per the recommended torque values.
 Ensure that all the parts are checked for their limit dimensional values. Replace/Repair if
abnormal.
 Ensure that proper gauges are used to check the dimensions, end plays and backlashes.
 Ensure that proper tools are used for engine assembly and dismantling.
 Be aware of the particular reason for engine failure.
 All rubber components are to be replaced while assembling the engine.
 Ensure that oil is not spilling on the assembly floor.
 Ensure that a cotton duster is not used as it would leave cotton dust in the assembled
parts.
 Proper engineering adhesive should be used for a leak-proof assembly.
 Ensure that the engine is fitted on an Engine assembly device
 Spare parts should be stacked properly on the component trolley. No component should
lie on the floor.
 Ensure that the tools trolley is used for stacking tools.
 Ensure that assembler wears a boiler suit while assembling the engine.
18
 Ensure the use of a proper lifting tackle and correct practice of crane handling while
lifting the engine.
 Ensure that the tools and materials are properly stacked on respective trolleys before
leaving the place.
 Ensure cleanliness of the workplace while working and before leaving the place.
19
Major Overhaul
Sr. No. Topic Page

3.1 Engine Dismantling Instructions 1
3.2 Cleaning, Inspection and Servicing of Sub-Assemblies and parts 15
3.3 Engine Assembly as carried out on the assembly trolley 17
3.4 Engine Testing 33
3) Major Overhaul
The recommended Major Overhaul period is 20,000 working hours of the engine.
Before dismantling the engine, start the engine and run it on full load for about 45
minutes till lube oil is warm. Drain the lube oil from the engine.
For the engine dismantling procedure for the upper half of the engine, refer to Engine
Top Overhauling, Section 2.
3.1) Engine Dismantling Instructions

The additional points are as below
 Remove the magnetic pick up

probe on the flywheel housing.
 Disconnect the radiator and charge

air cooler assembly from the engine
base frame.
1
 Remove the radiator and charge air
cooler with the help of crane.
Radiator and CAC and Radiator
Cleaning Procedure with 'K Clean',
Section 4, 4.41& respectively.
 Remove the air cleaner mounting

bracket from the base plate.
 Remove both the air cleaner
assemblies from the mounting
bracket. Fig. Refer to Servicing the
dry type air cleaner, Section 4.38
 Discard the old hoses.
2
 Remove the earthing connection
from the alternator.
 Remove the main wiring from the

alternator.
 Disconnect the engine foundation

bolt at front end.
3
 Disconnect the alternator
foundation bolt.
 Remove the engine and alternator
assembly from the base plate.
 Remove the alternator cover.
 Decouple the alternator from the

engine. Mount the engine on the
engine assembly device.
4
Remove the radiator fan.
 Remove the fan driving arrangement.

 Refer to Servicing the Fan Driving
Arrangement, Section 4, 4.42
 Remove the fan belts.

 Discard fan belts.
5
 Loosen the alternator belts.
 Remove the alternator belts.

Discard alternator belts.
 Remove the header assembly for

lube oil cooler, water pump.
Discard ‘O’ rings and joint.
6
 Remove thermostat cover and
elements.
 Normally thermostat does not
require any maintenance. Refer to
Inspection of Thermostat element,
Section 4, 4.39
 Remove water pump assembly.

 Discard water pump assembly.
7
 Remove alternator
 Send the alternator to the authorised
service dealer for servicing. Refer to
Inspection of Auto Electricals, Section
4, 4.43.2
 Dismantle the crank pulley with

Damper.
 Remove cylinder liner from the block

with special tool DV0.950.04 and
inspect the liner externally and also
the block condition.
 Discard the cylinder liners.
8
 Remove the breather assembly with
the pipe.
 Dismantle gear, adaptor and flange

from the fuel pump
 Disconnect and remove the oil supply

line to the fuel pump.
 Discard copper washers.
9
 Remove the fuel pump from the
engine.
 Send the fuel pump for recalibration
to the authorised Bosch/ MICO
service dealer or to KOEL,Khadaki
Pune.
 Remove the lube oil cooler cover &

lube oil cooler from the Lube Oil
cooler header.
 Discard the joint
 Dismantle and separate the oil-
cooling element from the assembly.
Fig
Lube Oil Cooler, Section 4, 4.3
 Loosen and remove the flywheel.

Inspect the condition of the starter
ring.
 Replace the starter ring if teeth are
damaged.
10
 Remove the flywheel housing.
 Discard the oil seal and joint.
 Check the gear backlash. If backlash

found more than specified, replace
the gear in the assembly stage. Refer
to Checking Gear backlash, Section
4, 4.16
 Remove the intermediate double gear

for crank gear and cam gear.
Intermediate double Gear Assembly,
Section 4, 4.9
 Discard thrust washer.
 Remove the intermediate gear hub
and ring assembly.
11
 Remove the intermediate gear for
cam gear and fuel pump gear.
Intermediate Gear Assembly, Section
4, 4.9
 Discard thrust washer.
 Remove the intermediate gear hub
and ring assembly.
 Check the camshaft end play to

establish the condition of the thrust
plate. Refer to Specifications,
Section1, 1.8, 7.5. If the camshaft end
play is more than specified limit,
replace the thrust plate.
 Unscrew the bolts of the thrust plate.

Fully press tappets in their bores and
pull out the camshaft, guiding it out
from the central bearing zone through
the opening in the crankcase.
Camshaft, Section 4, 4.7
 Dismantle the lubricating oil pump

assembly.
 Discard the lubricating oil pump
assembly.
12
 Check the crankshaft end play to
establish the condition of thrust
washer and crankshaft.
 Refer to Specifications, Section 1,
1.8, 8.13
 Loosen and remove the main bearing

caps.
 Remove the crankshaft from the

crankcase.
 Remove and discard the bearings and
thrust washers from the crankcase and
caps.
Crank shaft, Section 4, 4.4
13
 Unscrew and remove oil spray
nozzles from the crankcase.
 Discard oil spray nozzles.
 Remove the core plugs, screw plugs
from the crankcase.
 Discard the sealing washers
14
3.2) Cleaning, Inspection and Servicing of Sub-Assemblies and parts
To ensure satisfactory performance of the engine after Major Overhauling, all components
should be cleaned and decarbonised.
During cleaning avoid using sharp instruments, emery paper, steel wool
or steel brush. These will damage the machined surface and finish of the components.
 Inspect the cleaned components for cracks, erosion and pitting marks.
 Discard unserviceable components. The components which can be reconditioned must be
retrieved.
 Check retrieved components for the dimensional accuracy. Refer to Running Dimensions,
Clearances & Limits, Section 1, page ----, for important components.
 Replace all bushes to avoid later complications and performance deterioration.
 If dish type core plugs are removed during cleaning and inspection, replace and fit again
with a proper mandrel to avoid leakages. Apply sealant.
 Special attention should be given to components like crankcase, crankshaft, camshaft,
cylinder head, piston and connecting rod during servicing and inspection. Refer to
Inspection & Servicing procedures of major components & sub-assemblies, Section 4, for
adjustments and settings. Refer to Tightening Torque Methods & Values given in Section
1, 1.7.
Precautions for Assembly

 Check all the components for damage, cracks, normal/abnormal wear, scale formation,
rust formation and foreign particles present inside the galleries and surface. Treat
accordingly.
 Ensure that the components are properly cleaned before assembly.
 If a delay is expected in assembly, all usable casting and steel components should be
coated (with rust proof oil), duly labeled and stored properly to avoid damage to the
machined surface.
 Ensure a dust-free atmosphere around the engine assembly.
 Ensure that the assembled parts are adequately lubricated.
 Ensure that all joints, gaskets, 'O' rings and copper washers are replaced with new ones
while assembly. Remove the old joints by scraping them with a blunt tool.
 Ensure that all the fasteners are tightened as per the recommended torque values.
 Ensure that all the parts are checked for their limit dimensional values. Replace/Repair if
abnormal.
 Ensure that proper gauges are used to check the dimensions, end plays and backlashes.
 Ensure that proper tools are used for engine assembly and dismantling.
 Be aware of the particular reason for engine failure.
 All rubber components are to be replaced while assembling the engine.
 Ensure that oil is not spilling on the assembly floor.
 Ensure that a cotton duster is not used as it
 would leave cotton dust in the assembled parts.
 Proper engineering adhesive should be used for a leak-proof assembly.
 Ensure that the engine is fitted on an Engine Assembly device.
15
 Spare parts should be stacked properly on the component trolley. No component should
lie on the floor.
 Ensure that the tools trolley is used for stacking tools .
 Ensure that the assembler wears a boiler suit while assembling the engine.
 Ensure the use of a proper lifting tackle and correct practice of crane handling while
lifting the engine.
 Ensure that the tools and material are properly stacked on respective trolleys before
leaving the place.
 Ensure cleanliness of the workplace while working and before leaving the place.
16
3.3) Engine Assembly as carried out on the assembly trolley
 Use the serviced crankcase. Refer to
Inspection & Servicing of Crankcase,
Section 4, 4.1
 Press a new set of cam bushes into the cam

bores with a special mandrel after aligning
the cam bush oil holes with those of the
crankcase.
 Fit core plugs and screw plugs with new
sealing washers using flange sealant.
 Lubricate the cam bushes.

 Insert the checked camshaft. Refer to
Inspection & Servicing of Camshaft,
Section 4, 4.7
17
 Fit the oil spray nozzle dowels.
 Fit new piston cooling spray nozzles.
 Insert the new main bearing shells on
crankcase and bearing caps matching oil
holes correctly with those of the crankcase.
Refer to Checking Main Bearing Shell
Internal Diameter, Section 4, 4.2
 Fit a new thrust washer set in the grooved
cavity provided in the crankcase and cap.
 Fit the new cylinder liners with new ‘O’

rings. Apply 'Sealant' to the liner collar
cavity in the crankcase. This seals any
uneven machined surface and avoids
coolant leakage from the joint.
 In case of Top overhaul, if old cylinder
liner (which is within specified limit) is to
be used. Check piston ring butt clearance.
Refer to Checking Piston Ring Butt
Clearance, Section 4, 4.17
 Apply oil to the lower part of the cylinder

liner
 Insert the new/checked cylinder liners in
the crank case
18
 Apply fresh engine oil to the installed main
bearings and thrust washer.
 Use the checked crankshaft. Refer to
Inspection & Servicing of Crankshaft,
Section 4, 4.4. Lower the checked
crankshaft into crankcase. Refer to Fitting
crankshaft in crankcase, Section 4, 4.5
 Fit the main bearing caps and torque the
bolts as specified. Follow the tightening
torque sequence given in Section 4, 4.5.
 Check whether crankshaft is rotating freely.

 Check the balance weight bolts for proper
torque.. Refer to Tightening Torque table,
Section 1, 1.7
 Check that crankshaft end play is within

permissible limits. Refer to Section 4, 4.6
19
 Fit the checked crank gear. Refer
inspection and servicing of crank and cam
gear, Section 4, 4.8
 Lubricate cam bushes and camshaft journal

diameters.
 Insert the checked camshaft . refer to
inspection and servicing of camshaft,
Section 4, 4.7
 Fit the checked cam gear with checked/new
thrust plate. Refer inspection and servicing
of crank and cam gear, Section 4, 4.8
 Check camshaft end play.
20
 Slightly lubricate the bearing surface of the
checked intermediate gear support and fit
the checked intermediate gear
 Slightly lubricate the bearing surface of the
checked intermediate gear double gear
support and fit the checked intermediate
gear double gear
 Slightly lubricate the bearing surface of
checked intermediate gear and new thrust
washer. Refer to Inspection & Servicing of
Intermediate Gear Assembly, Section 4,
4.9; then fit gear to the hub, ensuring the
correct meshing of teeth. Assemble the
retaining plate
 Slightly lubricate the bearing surface of
checked intermediate double gear and new
thrust washer. Refer to Inspection &
Servicing of Intermediate Gear Assembly,
Section 4, 4.9; then fit gear to the hub,
ensuring the correct meshing of teeth
Assemble the retaining plate
 Apply oil to the tappets, fit them in the

bores and check that tappets are free.
 Take the Piston and connecting rod

assembly. Refer to Assembly of Piston and
Connecting Rod, Section 4, 4.19
 Apply lube oil to the large end bearing
shell.
 Apply lube oil to the piston rings and
piston.
 Apply lube oil to the liner bore.
21
 Rotate the crankshaft and bring the
respective cylinder crank pin to 'top dead
center'. Wipe and lubricate a crank pin of a
cylinder.
 Wipe and lubricate the cylinder liner bore.
 Separate the connecting rod cap from the
connecting rod shank. Fit and lubricate the
bearing shells. Ensure that the notch on
connecting rod and bearing shell matches.
 Insert the piston and connecting rod
assembly in the piston with the use of liner
inserting sleeve tool.
 Tap piston down with a wooden / plastic
handle, at the same time guiding the
connecting rod large end bore towards the
crank pin till it fits snugly on it. Fit the cap
after ensuring that the bearing notches are
on the same side
 Fit correct connecting rod cap after
lubricating the bearing shell and tighten the
bolts as specified. Ensure that the
connecting rod is matched with correct cap
by matching the numbers on connecting rod
with those on cap.
 Torque the connecting rod bolts evenly and

firmly. Refer to Tightening Torque table,
Section 1, 1.7
 Check that the connecting rod is free in its
end play.
22
 Fit the new dowels for cylinder head gasket
on the block
 Fit the new oil and water ferrules.
 For Bumping clearance checking

procedure Refer Section No. 4, 4.20
23
 Fit the serviced cylinder heads with new
gaskets onto their respective cylinders.
Refer to Inspection & Servicing
procedures, Section 4, 4.22
 Fit the new cylinder head bolts in their
respective positions and tighten them by
hand only
 To align the heads, it is essential to first
fit the serviced exhaust manifold and inlet
manifold to the cylinder head with new
gaskets. Refer to Servicing the Air Inlet
& Exhaust Manifold, Section 4, 4.32
Tighten the fasteners for inlet manifold
and exhaust manifold with torque. Refer
to Tightening Torque table, Section 1, 1.7
 Tighten the cylinder head bolts to the
prescribed torque. Refer to Tightening
Torque table, Section 1, 1.7
 Insert the push rod cover tube assembly

with new top and bottom rubber bushes
with the help of special tool.
24
 Press the new pulley end oil seal with the
pressing mandrel. Refer to fitting the
pulley end oil seal Section 4, 4.11 and
4.13
 Insert the checked push rods in the

correct position. Refer to Inspection of
valve rocker assembly and push rods
Section 4, 4.29
 Fit the crank pulley with the Damper and

tighten the bolts as specified. Refer to
Tightening Torque table, Section 1, 1.7
 Assemble the serviced oil cooler sub-

assembly. Fit the assembly to the engine
with a new joint and ‘O’ rings.
Refer to Inspection & Servicing of Lube
Oil Cooler, Section 4, 4.3
 Fit the new water pump with a new joint.
 Install new / checked thermostat elements
with new joints. Refer to Inspection of
Thermostat Element, Section 4, 4.39
Fasten the thermostat cover.
25
 Fit the checked valve rocker assemblies.
Refer to Inspection of valve rocker
assembly and push rods Section 4, 4.29
 Install reconditioned / repaired injectors

with new nozzle sealing washers and new
‘O’ rings and lock in place (with the
injector fork) to the specified torque.
Refer to Tightening Torque table, Section
1, 1.7
 Set and adjust tappet clearance.

.Refer to Valve Tappet Setting, Section 4,
4.34
26
 Fit rocker covers with new joints and
tighten.
 Fit the serviced radiator fan drive

arrangement and pulley. Refer to
Servicing the Fan Driving Arrangement
Section 4, 4.42
 Fit the alternator mounting-arrangement
with the serviced charging alternator and
pulley. Refer to Inspection of Auto
Electricals, Section 4, 4.43.2
 Fit the new V belts for water pump and
apply tension as specified.
 Fit the new V belts for fan drive
arrangement and apply tension as
specified.
 Fit the reconditioned turbochargers

having the new gasket to the exhaust
manifold flange. Refer to Inspection &
Servicing of Turbocharger, Section 4,
4.33
 Connect the turbocharger oil inlet and oil
drain-pipes with new joints.
27
 Mount the fuel pump cap on the crank
case.
 Mount the serviced fuel pump with new
joint and new flat seal for oil seal
housing.
 Fit the fuel pump gear to the adaptor after
matching the timing marks of the fuel
pump gear to the intermediate gear bolt it
and tighten the bolts.
 Connect the oil supply to the fuel pump
from the crankcase.
 Install the flywheel housing to the

crankcase, with a new joint.
 Check the concentricity of oil seal bore.
 Check the flywheel housing bore.
concentricity and face run out.
 Torque the bolts as specified. Refer to
Tightening Torque table, Section 1, 1.17
 Press a new flywheel-end oil seal to the

flywheel housing, the flat surface of the
seal facing the flywheel. Use seal
pressing mandrel to press the oil seal.
Refer to Fitting the Flywheel-end Oil
Seal, Section 4, 4.11 and 4.12
28
 Mount the flywheel. Tighten the bolts as
specified. Refer to Section 1, 1.7.
Tightening Torque table
 Fit the serviced fuel filter assembly to the

engine. Refer to Servicing of Fuel Filter
Element, Section 4, 4.36
 Fit new fuel pipes between the fuel pump
and filter using new copper washers.
 Fit the new lubricating oil pump

assembly.
29
 Insert the delivery tube into the oil pump
outlet port and fasten the other end to the
crankcase with a new joint.
 Fit the suction tube to the oil pump inlet
with a new joint. Fit the clamping
bracket.
 Fit two diagonally opposite studs in the

crankcase for proper positioning of sump
while fitment.
 Apply a uniform layer of sealant on the
oil sump mating face.
 Fit the sump on the crankcase.

 Fit the bolts and tighten them.
 Insert O-ring in the drain plug, fit the
sump and tighten the drain plug.
30
 Fit the serviced centrifugal filter
assembly with a new joint on oil filter
header body. Refer to Servicing of
Centrifugal Lube Oil Filter, Section 4,
4.37
 Fit the new lubricating oil filter

cartridges.
 Set the fuel timing by ‘spill cut-off’

method. Refer to Fuel Timing setting for
Fuel Pump, Section 4, 4.30
 Connect nozzle leak-off pipe with new copper washers. Connect fuel return line.
 Fit the high pressure pipes after cleaning them externally and internally with dry
compressed air only.
 Fit the main air pipe and bracket from the turbocharger to the charge air cooler unit with
new hoses and clips.
 Install the air pipe from charge air cooler to the air inlet manifold bend with new hoses
and clips.
 Fit exhaust outlet bend manifold arrangement and expansion bellow with new joints.
 Align and fit exhaust outlet pipe to the bellow with a new joint.
31
 Fit the reconditioned starter. Refer to Inspection of Auto Electricals, Section 4, 4.43.3.
 Fit the serviced air cleaner assembly. Refer to Servicing of Dry Type Air Cleaner,
Section 4, 4.38.
 Connect the air cleaner assembly to the turbocharger with new hose and clips.
 Fit and tighten the flywheel-end and gear-end foot.
 Remove the engine from the service trolley.
 Set the engine on its base frame.
 Couple the engine with the alternator and carry out the alignment.
 Check the end play of the crankshaft of the complete unit after assembly.
 Fit the radiator fan.
 Fit the heat shields on both sides.
 Fit the serviced Radiator and Charged Air Cooler assembly to the base frame. Refer to
Inspection & servicing of Radiator Charge Air Cooler (CAC) Radiator, Section 4, 4.40
 Connect fuel line between fuel tank and feed pump.
 Connect fuel overflow return line.
 Bleed the fuel system. Refer to Bleeding the Fuel System, Section 4, 4.31.
 Reconnect the electrical connections to the starter, alternator and the safety system.
 Fill the oil sump with fresh 'K' oil.
 Refill radiator with 'K-Cool Super Plus’ coolant.
 Connect the serviced battery. Refer to Inspection of Auto Electricals, Section 4, 4.43.1.
32
3.4) Engine Testing
 After starting the engine, run the engine at low idle speed of between 650-700 rpm and
check the following:
 Oil pressure
 External oil and water leakage
 Battery charging
 Charge air leaks from joints. (Rectify any leaks noticed.)
 Engine is ready for testing.
 Engine testing:
Start the engine, warm it and load it in steps at 25%, 50%, 75% and 100% load at
intervals of 30 minutes each. During this period check and log oil pressure and water
temperature at regular intervals.
33
Inspection, Servicing & Installation of Major Sub-Assemblies & Components
Sr. No. Topic Page

4.1 Inspection & Servicing of Crankcase 2
4.2 Checking Main Bearing Shell Internal Diameter 3
4.3 Inspection & Servicing of Lube Oil Cooler 4
4.4 Inspection & Servicing of Crankshaft 5
4.5 Fitting Crankshaft in Crankcase 9
4.6 Checking Crankshaft end-play 9
4.7 Inspection & Servicing of Camshaft 10
4.8 Inspection & Servicing of Crank Gear and Cam Gear 10
4.9 Inspection & Servicing of Intermediate Single & Double Gear Assembly 10
4.10 Checking Gear backlash 11
4.11 Oil Seal Fitting 12
4.12 Fitting the Flywheel-end Oil Seal 12
4.13 Fitting the Pulley end Oil Seal 13
4.14 Inspection & Servicing of Cylinder Liner 13
4.15 Inspection & Servicing of Connecting Rod 14
4.16 Inspection & Servicing of Piston Assembly 15
4.17 Checking Piston Ring Butt Clearance 16
4.18 Fitting of Piston Rings on Piston 17
4.19 Assembly of Piston & Connecting Rod 17
4.20 Bumping clearance checking procedure 18
4.21 Inspection of Valve Recess in Cylinder Head 18
4.22 Inspection & Servicing of Cylinder Head, Valve and Valve Spring 19
4.23 Inspection of Cylinder Head surface flatness 20
4.24 Replacing Valve Guides 20
4.25 Replacing Valve Seat Inserts 20
4.26 Valve Lapping 21
4.27 Checking Valve Seat by Pencil Erase Test 22
4.28 Valve Checking by Diesel Leakage Test 23
4.29 Inspection of Valve Rocker Assembly & Push Rod 23
4.30 Method of adjusting the fuel timing 24
4.31 Bleeding the Fuel System 24
4.32 Servicing the Air Inlet & Exhaust Manifold 24
4.33 Inspection & Servicing of Turbocharger 25
4.34 Valve Tappet Setting 34
4.35 Replacing the spin-on type Lubricating Oil Filters 35
4.36 Replacing the Fuel Filter Element 35
4.37 Servicing of Centrifugal Lube Oil Filter 36
4.38 Servicing the dry type Air Cleaner 38
4.39 Inspection of Thermostat Element 41
4.40 Inspection & Servicing of the Radiator and Charge Air Cooler (CAC) 42
Radiator External Checking
4.41 Radiator Cleaning Procedure with 'K Clean' 43
4.42 Servicing the Fan Driving Arrangement 44
4.43 Inspection of Auto Electricals 44
1
4) Inspection, Servicing & Installation of Major Sub-Assemblies & Components
4.1) Inspection & Servicing of Crankcase
 Clean the crankcase. Visually inspect the crankcase for damages and cracks. If damage is
irreparable and will affect the engine's performance, replace the crankcase.
 Match the numbers on the bearing cap and crankcase.
 Inspect the crankcase main bearing bore. There should be no fretting marks on the loading
surfaces of the crankcase/M.B.Cap cavity or heavy scratches on the polished face.
 Inspect the thrust washer groove cavity (in the crankcase and bearing cap) for damage or
heavy scratching.
 Inspect the hollow dowel condition. Replace damaged dowels.
 Clean the bores and oil passages with a brush using clean diesel. Blow dry with compressed
air.
 Clean the threaded holes of the main bearing caps by running correct taps. Where holes are
blind, apply grease to the tap while running it.
 Inspect the main bearing bores with a dial bore gauge. Refer to Specifications, Section1, 1.8,
8.11.
 To check the bore diameter with a dial bore gauge.
 Set dial bore gauge to the bearing's correct bore size with a micrometer. Measure the bores at
two planes and at angles. Fig. 4.1 and 4.2
 Record and check the values with Specifications, Section 1, 8.11. Record on a chart as shown
in the manual.
 If required, check old bearing inside diameter after refitting bearings dry in their respective
bores and caps in the main bore Refer to Specifications, Section 1, 8.12. Tighten main
bearing cap bolts with washers to the prescribed torque. Refer to Tightening Torque table in
Section 1, 1.7
 During tightening, take care that :
a. Oil is applied to bolt threads and head bottom surface.
b. Initial torque, stage 1 and stage 2 torque is applied with a torque wrench.
 Inspect the liner collar cavity in the crankcase.
 Check the internal diameter of the cam bushes with a dial bore gauge. Record and compare
values with the specification. Refer to Specifications, Section 1, 1.8, 7.2. If the values are
beyond the limit, replace the cam bushes. Fig.
2
 After bushes are removed, inspect the
internal diameter of all cam bush bores
with a dial bore gauge at two planes and at
a right angle. Refer to Specifications,
Section 1,1.8, 7.1. If any of the cam bores
are damaged, recondition the damaged
bore (with KOEL's guidance) or replace
the crankcase. Fig.
 Clean the water passages in the

crankcase.
 Inspect the liner collar resting face
bore in the crankcase .
 Check the condition of the liner bore
where the liner joint rings sit. If deep
grooves are noticed, recondition or
replace the crankcase.
Thrust Washers
 KOEL recommends replacing the thrust washers during a major overhaul.
 Fit the old thrust rings onto the
crankcase and cap. Measure total
thickness with micrometer W1. Fig.
Measure the distance (W) between
the thrust faces of the thrust journal
of the crank shaft. Refer to point 4.4.
 Calculate clearance and check the

corresponding specification. Refer to
Specifications, Section 1, 1.8, 8.10
and 8.13. If the calculated clearance
exceeds the specified limit, then
carry out the above exercise with a
new set of standard thrust rings, and
also check the crankshaft end-play.
4.2 ) Checking Main Bearing Shell Internal Diameter

 Main bearings are available in two halves, in a finished condition.
 These are available in 6 under-sizes, in steps of 0.25 mm.
 As these are thin-walled, trimetal bearings, they have to be pre-loaded in the main
bearing bore.
 While fitting the bearing, do not touch, rub or polish the bearing-lining surface.
 Bearings should be cleaned only
with clean diesel, dabbed dried with
a soft cloth, and then fitted.
3
 While fitting the bearing, ensure an
adequately free spread. Do not install
bearings with negative free spread as
this will lead to premature bearing
failure.
 Fit bearing caps and torque the bolts. Refer to Tightening Torque table in Section 1, 1.7.
 Set the dial gauge to the correct size (standard or under-size) with a micrometer and measure
the bearing inside diameter at two planes-near the bearing parting line and in the vertical
plane. Record the values and check with the specification data. Refer to Specifications,
Section1, 8.1.2. Fig…
4.3) Inspection & Servicing of Lube Oil Cooler

 The plate-type cooler is mounted on the lube oil cooler header. Under normal operating
conditions, the oil cooler does not require any servicing. However when the cooler is
removed during an engine overhaul, it is advisable to service it. Fig. 4.9
Servicing
 Dismantle the cooler from the cooler
header and service both the oil side
and the water side of the cooler as
below.
Cleaning the Oil Side (Internally)
 Immerse the cooling element in
clean diesel and shake it vigorously
till all the carbon and dirt comes out.
OR
 Direct compressed air very slowly from the oil outlet of the element with the element dipped
in fuel oil. This will clean the inside of the element by agitation method. Rinse the element in
fresh clean diesel and flush it with fresh lubricating oil.
Cleaning the Water Side (Externally)

 Seal the oil inlet and outlet openings of the cooler.
 Clean the cooler unit externally with soap, solution and brush. Remove rust and scale.
Do not use acid /alkaline-based cleaners. Do not use any sharp

instrument to scrape off rust as this can damage the cooler element.
 Dry the lube oil cooler either with compressed air or by keeping it open in a dust-free
environment.
 Re-assemble the lube oil cooler with new ‘O’ rings and joint on the lube oil cooler
header. Apply the torque as specified for the fasteners. Refer to the Tightening Torque
table in Section 1, 1.7.
4
4.4) Inspection & Servicing of Crankshaft
The crankshaft is subjected to a lot of stress during engine operation and gets worn out /
damaged over time. Before servicing the crankshaft, a thorough inspection of the crankshaft is
essential. To recondition the crankshaft a good reconditioning facility is imperative.
Visually inspect the crankshaft for wear, damages and discoloration. Assess the state of the
crankshaft- whether it can be reconditioned or it should be replaced.
Crankshaft Inspection:
 Thoroughly clean the crankshaft before inspecting it.
 Support the crankshaft on 'V' blocks on journals as per the table shown in Section 4, page
--.
Visual Damage Check
Visually inspect the crankshaft for damage such as hit marks, discoloration of pins or journals,
cracks, etc. If cracks are detected on the fillet radius, replace the crankshaft. In case of other
damages, crankshaft can be salvaged by reconditioning.
Inspection of Diameters of Journals and Pins
Check the journal and pin diameters for wear and ovality with a micrometer. Note and compare
the readings with the specified values. Refer to Specifications, Section 1, 1.8, 8.2 and 1.8, 8.9.
Fig..
Inspect the locating journal width (W) where the

thrust washers come in contact. Calculate the
clearance considering the bearing cap with standard
thrust washer width (W1).Refer to Section4, 1.8, 8.6
and 1.8, 8.10. If the clearance has exceeded the
limit value of crankshaft end play, refer to Section
1, 1.8, 8.13. Replace the crankshaft.
Inspect pulley end journal flange at the oil seal contact zone.
If wear and deep grooving is noticed, replace the crankshaft.
Fig…
Check Case Hardness of Journals and Pins
Check the surface hardness of the journals and pins with a
non-indenting type hardness tester, (Rockwell 'C' scale.) Note
and compare the values with the specification. Refer to Specifications, Section 1, 1.8 and 1.8,
8.9.3.
Crack Detection
Journals and pins should be checked for cracks.
This can be done by various crack detection
methods. KOEL recommends using the Magna
flux crack detection method. If cracks are noticed,
under-size the crankshaft till the crack disappears.
Fig…
5
If the crack is deep and reaches the soft core, it is advisable to replace the
crankshaft.
Checking Crankshaft for Bend

Procedure to be followed, to check crankshaft for bend.
 Support crankshaft on two journals as mentioned
in the table below. Fig. ----
To check one particular journal run-out, refer to
the table below. The run-out is to be checked by a
dial gauge for the specific journal or flange as
mentioned.
Sr. To check ‘run-out’ Support the crankshaft Permissible

No. of journal no. on 'V' block journal no. max. run-out
1 FWE flange diameter Journal dia. 1 and 0.05 mm
Journal dia. 2
2 Journal 1 Journal dia. 2 and 0.055 mm
Journal dia. 5
Journal dia. 5
Journal dia. 5
Journal dia. 5
6 Crankshaft nose (90 Journal dia. 1 and 0.05 mm
dia.) and nose at pulley Journal dia. 2
end
If a bend or twist is observed, do not try to rectify it as this will further damage the crankshaft
and main bore of the crankcase. KOEL recommends replacing the crankshaft.
Check for proper fillet radius on Crankshaft

 For the details of fillet radius, refer to
Specifications, Section 1, 1.8, 8.7 and Section 1,
1.8, 8.8.
 Grind all journals and pins uniformly to the same
under-size limits, within the tolerance prescribed.
 Fillet radius of journals and pins must be
maintained as specified.
 Remove all sharp corners / edges from the
journals and pins.
 Ensure that there is no mismatch of fillet radius
with diameter or face. Fig…
6
Sharp edges developed due to mismatch will lead to stress being
concentrated in a sharp-edged area thereby leading to breakage of crankshaft (through fillet
radius) in a running condition. This is the main reason for crankshaft failure.
Reconditioning work should be carried out at a good machine shop wherein proper machining
practices are followed. Proper tooling and inspection facilities should be available.
Procedure to be followed before Reconditioning
Before sending the crankshaft for machining, remove balance

weights. All the balance weights are balanced at their respective
location and hence should be numbered before removing.
Numbers must be marked by paint or permanent marker
only at site in the ascending order starting with No. 1 balance
weight which is nearest to the flywheel side. Fig. ---. For
convenience of refitting the weight exactly, all numbers should
be marked on the camshaft side of the balance weights as well
as on the crankshaft web.
Precautions during Machining:

All journals and pins must be ground uniformly to the same
under-size diameter and within the specified tolerance limits.
Maintain the specified fillet radius of journals and pins. There
should be no sharp corners / edges to the journals and pins. The
sharp corner / edge should be removed by polishing and
rounding off. Fig. ---
 There should be no visible tool marks / scratches on the fillet radius or the polished
surface areas.
 Sharp corners of oil holes should be rounded

off and blended with the pin's curvature. Fig. -
---
Note: If crankshaft requires extensive rebuilding, please contact KOEL Pune for assistance.
After grinding:
 Check journal and pin diameters for cracks.
 Check thrust journal width.
 Inspect the journal and pin diameters with a
micrometer for correct reading. Refer to
Specifications, Section 1, 1.8, 8.2 and 8.9
 Check surface hardness of the newly ground
journals and pins. Refer to Specifications,
Section 1, 1.8, 8.4 and 8.9.3
7
 Inspect and ensure that the fillet radius of the ground journals and pins are maintained as
specified. Refer to Specifications, Section 1, 1.8, 8.7 and 8.8.
 Check the straightness, out-of-roundness parallelism between journals and pins. Refer to
Specifications, Section 1, 1.8, 8.12.1, 8.12.2 and 8.12.3. Fig…
 Inspect and ensure that there are no visible tooling marks / scratches on the fillet radius
and the finished surfaces of the crankshaft.
 Use the correct size tap to clean the threaded holes in the crankshaft where the balance
weight bolt fits.
 Clean the crankshaft and oil passages with clean diesel and remove all traces of abrasive
material from the oil passages. Blow-dry with compressed air.
 Balance weight bolts should be replaced at every major overhaul.
 Refit the correct numbered balance weights to their respective webs and tighten bolts as
per the specified tightening torque. Refer to the Tightening Torque table, Section 1,1.7.
Use the following format to record the dimensions of crankshaft after re-grinding. Fig. ---
Plane/ Diameter Hardness (RC) Remarks
(All dimensions in mm)

Journal No. &
A1 A2 B1 B2 A1 A2 B1 B2
Pin No.
Journal 1 Journal Standard diameter: 109.930 to
109.950
Journal 2 6 Nos. under-sizes in the step of 0.25 mm
Journal 3 Journal Standard Hardness: 56 ± 3 HRC

Journal 4
Journal 5
Journal 6
Journal 7
Pin 1 Pin Standard diameter: 95.930 to 95.950

Pin 2 6 Nos. under-sizes in the step of 0.25 mm
Pin 3 Pin Standard Hardness: 56 ± 3 HRC

Pin 4
Pin 5
Pin 6
Locating Journal width 44 Note: No.1 Journal is the thrust journal
8
 Calculate the clearance between
crankshaft journal and main bearing
inside diameter.
Compare the readings. Ensure the
clearance is within the limit value.
Refer to Specifications,
Section 1, 1.8, 8.5 and 8.5.1. Fig.
4.5) Fitting Crankshaft in Crankcase

 Clean and wipe the main bearing bores in the crankcase.
 Install the cleaned new bearings in the crankcase bore and caps.
Bearings are fitted dry. (Do not apply oil to the bearing back or the bore.)
 Bearing shells must fit tight with a spring action in the bore cavity. (Adequate free
spread)
 Fit the thrust washers in the grooves provided in the first bearing cap and bore.
 Wipe the crankshaft journals with a soft cloth.
 Apply fresh oil to crankshaft journals, installed bearings and thrust washers.
 Lower and settle the crankshaft in the
crankcase gently.
 Ensure the free rotation of the crankshaft by
hand.
 Fit bearing caps after checking that the cap
numbers and locating notch on crankcase and
bearing cap are both on the same side.
 Ensure the free rotation of the crankshaft by
hand.
 Apply torque to main bearing cap bolts as per the Tightening Torque table given in
Section 1, 1.7. Ensure the free rotation of the crankshaft by hand after every torquing
step.
 Inspect the crankshaft end-play as below.
4.6) Checking Crankshaft end-play

Crankshaft end-play must be checked with a dial gauge.
4.6.1) Checking with Feeler Gauge
 Shift the crankshaft towards the flywheel-end with a lever.
 Insert the maximum permissible limit thickness feeler gauge in the gap between the thrust
washer and the crankshaft locating journal face. If the feeler gauge slides freely, this
indicates that the end-play limit is exceeded. If the feeler gauge does not go in, this shows
that the thrust clearance is within limits. To establish correct end-play, keep on checking
the gap with thinner and thicker feeler gauges till the gauge slides in firmly and smoothly.
4.6.2) Checking with Dial Gauge
9
 Fit a dial gauge on the crankcase with the
pointer touching the crankshaft hub.
 Push the crankshaft away from the dial gauge
with a lever.
 Press dial gauge stylus against crank gear
face.
 Set the dial needle at '0'.
 Again shift the crankshaft towards the dial gauge. Fig. ----
 Note the reading and confirm whether the end-play is within the specified limit. Refer to
Specifications, Section 1, 1.8, 8.13.
4.7) Inspection & Servicing of Camshaft
 Check the cam journal diameter with a

micrometer. If journals are worn, recondition
/ replace the camshaft. Refer to
Specifications, Section 1, 1.8, 7.3. Fig. ----
 Calculate the clearance between camshaft
journal and bush. Compare the readings.
Ensure the clearance is within the limit value.
Refer to Specifications, Section 1, 1.8, 7.4
and 7.4.1.
 Check cam profile for excessive wear.
 Replace camshaft if the cam toe or cam profile is damaged.
Do not try to recondition the camshaft's cam profile, as this will affect
the engine performance.
 Check that the oil gallery along the length of the camshaft is clean and open.
 Check camshaft end-play and also check thrust plate condition. If end gap exceeds the
specified limit, replace the thrust plate with a new one. Refer to Specifications, Section 1,
1.8, 7.6.
4.8) Inspection & Servicing of Crank Gear and Cam Gear

Inspect the crank gear and Cam Gear for abnormal wear or damage. If found worn out or
damaged, replace crank gear / Cam Gear. Check condition of the crank gear and cam
Gear dowel pin. If damaged, replace it.
4.9) Inspection & Servicing of Intermediate Single & Double Gear Assembly
 Inspect the intermediate single & double gear for wear and damage. If wear or damage is
severe, replace the gear along with the bush.
10
 Check intermediate single &
double gear's bushes inside diameter
at two planes and at right angles in a
pressed condition.
 Inspect the intermediate single & double gear support outside diameter with a micrometer
at two places and at right angles. Refer to Specifications, Section 1, 1.8,
 Calculate the clearance between the intermediate gear bush and intermediate gear support
journal and compare the clearance. Refer to Specifications, Section 1, 1.8,. If the
clearance exceeds the limit value, replace the intermediate gear bush.
 Replace all the thrust washers.
4.10) Checking Gear backlash
Backlash is the gap between the meshing gear teeth. To check gear backlash, a dial gauge is
used.
 Attach the dial gauge pointer to one tooth of a
gear whose backlash is required to be
checked.
 Press dial gauge stylus against the gear.
 Set the dial to '0'.
 Hold the corresponding gear firmly with one
hand. (Do not allow it to move while checking
backlash).
 Lightly oscillate the required gear back and
forth within its free movement range.
 Check the reading on dial gauge.
11
 Repeat this procedure at four points of the gear. The average reading will be the backlash.
 Compare the reading with the recommended gear backlash values given in table on the
next page.
Recommended Gear Backlash
Intermediate gear to cam gear 0.070 to 0.400
Crank gear & LOP int. gear 0.070 to 0.260
LOP gear & LOP int. gear 0.070 to 0.260
Crank gear to int. gear 0.070 to 0.260
Int. gear to FIP Int gear 0.070 to 0.4
FIP gear to FIP Int gear 0.070 to 0.260
4.11) Oil Seal Fitting
These seals are 'Double Lip Oil Seals'. One lip prevents dust entry and the second lip prevents oil
leakages.
If installed properly, the oil seal is effective and will reduce wear and tear on engine components.
However the seal will leak profusely if the right tooling is not used for fitting. For fitting
instructions, refer to Inspection & Service Procedure No. 4.12 and 4.13 Section 4.
Procedures must be strictly followed to avoid problems.
4.12) Fitting the Flywheel-end Oil Seal

Use FWE Oil seal Pressing Tool (DV0.950.521)
Pressing Tool Guide Tool
Do not apply oil to the seal or shaft. Oil seal should

be installed dry.
 Clean the oil seal locating bore in the flywheel housing with a clean dry cloth.
 Mount the guide tool on the crank gear and crankshaft flange with the help of two bolts
provided with the tool.
 Remove the oil seal from its packaging and install immediately.
12
 Place flywheel-end oil seal squarely on the guide tool. The entry chamfer will help to
expand the oil seal lips evenly.
 Locate the pressing tool on the guide tool.
 Tighten the centre bolt on pressing tool.
Do not tamper with the seal's lips by inserting a screwdriver or any

other pointed instrument. This will permanently damage the seal lips.
Do not fit the oil seal by hammering on the oil seal face.
4.13) Fitting the Pulley end Oil Seal
 Assemble the oil seal housing on crank case and
hand-tighten the screws.
 Fit the Oil seal housing locating mandrel on
crank shaft.
 Tighten first the two nos. screws of oil seal
housing (where dowels are provided) Then tighten all
other screws with torque.


 Mount the oil seal guide piece on the crank shaft.
Do not apply oil to the seal or
the pulley. Oil seal should be
installed dry.
 Clean the Oil seal housing oil seal bore with a clean dry
cloth.
 Remove the oil seal from its packaging and install immediately.
 Guide the pulley end oil seal into the oil seal housing bore squarely.
 Use Oil Seal pressing mandrel pulley end
(DV0.950.522)
Do not tamper with the seal's lips by

inserting a screwdriver or any other pointed instrument. This
will permanently damage the seal lips.
Do not fit the oil seal by hammering on the oil seal face.
4.14) Inspection & Servicing of Cylinder Liner

 Visually inspect the liner from inside for excessive wear, step, scratch marks or seizing.
 Discard the liner if any step, scratch or seizing mark is noticed.
 Inspect the liner externally for pitting and erosion.
 Check liner bore with a dial bore gauge for ovality and taper wear at three levels 1 to 3 and at
position A and at position B (right angle to position A)
13
 Compare readings with the specification Data. Refer to Specifications, Section 1, 2.1. If
the wear limits are reached, replace the cylinder liner.
Also check the liner collar face under the collar for fretting or uneven wear marks.
Discard the liner if any of the above faults are noticed or if the tolerances are not within
the recommended limits. Refer to Specifications, Section 1, 1.8, 2.1.1 and 2.2.
Note: Whenever refitting an old liner or replacing it with a new liner, always fit new liner
joint rings as specified.
Fit new joint rings as under:

 Apply fresh oil to the liner area, which comes in contact with the joint ring.
 Apply recommended gasket adhesive to the liner collar resting face on crankcase. This
seals the uneven machined surface if any and avoids coolant leakage from the joint.
 Insert the liner properly in the crankcase and tap it down or press it down with liner
pressing tool .
4.15) Inspection & Servicing of Connecting Rod

 Thoroughly clean the connecting rod assembly. Inspect the ‘I’ section of the connecting
rods for notches or hit marks. If notches or hit marks are observed, replace the connecting
rod.
 Inspect the connecting rod for bend or twist. This can be checked on the parallelism
fixture. Replace the connecting rod if bend or twist is noticed.
 Visually inspect the large end bore for discoloration and damage.
If the large end bore is found discolored or damaged, replace the
connecting rod.
 Tighten the connecting rod bolts as per the torque specified in
Tightening Torque table, Section 1, 1.7.
 Check the large end bore diameter with a dial

bore gauge. Refer to Specifications, Section 1,
5.1
14
 Check inside diameter of the small end bore
with a dial bore gauge. Refer to
Specifications, Section 1, 8.If any of the
above defects are noticed, replace the
connecting rod.
 When pressing the new small end bush, take care to match the profile of the bush with
that of the small end bore of connecting rod.
Important : Irrespective of the condition of the connecting rod bolts, the bolts should be
replaced during a major overhaul.
4.16) Inspection & Servicing of Piston Assembly
Remove carbon from the piston's crown with a blunt tool or with an old piston ring.
Do not use sand paper or a wire brush to clean the piston.
 Visually inspect the overall condition of the piston and check the piston crown for
cracks, burn marks, pitting and erosion. Check the piston outside diameter for seizure or
scoring marks.
 Remove carbon from the ring groove with old

discarded piston rings.
 Inspect the piston ring grooves for damage and other deformities.
15
 Checking the Land Clearance
 Check land (side) clearance between groove and
piston ring.
 Use a new ring for checking clearance.
 Use filler gauge for checking.
 Follow the same procedure for all three piston rings.

 Compare the readings with Specifications, Section 1, 4.1
 Inspect piston pin bore diameter for wear and damage. Refer to Specifications, Section1,
3.1.
Piston Pin
 Inspect piston pin outside diameter at the center, where

the small end bush fits. Refer to Specifications,
Section 1, 8.
 Replace piston and pin assembly if any of the
above defects are noticed.
4.17) Checking Piston Ring Butt Clearance

The purpose of checking the piston ring butt clearance is to
check that the cylinder liner bore size is within the specified
limits.
Butt clearance, also known as end clearance, is the gap
between piston ring ends. This gap is crucial and should be
maintained as specified. Butt clearance should always be
checked with new piston rings.
Method:
 Insert one ring at a time in the cylinder liner.
 Push ring down squarely with the help of piston to about
40-50 mm.
 Measure the gap between ring ends with a feeler gauge.
Follow this procedure with the next set of the rings in
another liner.
 Repeat the procedure with the rest of the rings in
the set.
16
 Retain the checked rings as a set with the respective liners only. Refer to Specifications,
Section1.8
4.18) Fitting of Piston Rings on Piston
 Install piston rings with a ring expander to prevent
damage and premature failure of the rings.
 Before installing piston rings, ensure that the
piston ring grooves and rings are spotlessly clean.
 When installing piston rings, ensure that the
manufacturer's name or 'TOP' stamped on the ring
is facing the piston crown.
 Install rings dry and in their correct sequence.
 Ring gaps to be spaced at 120°. Gaps should not be
set along the axis of the piston pin.
Do not set the ring gaps along piston pin's axis.

4.19) Assembly of Piston & Connecting Rod
The procedure for assembling the piston and connecting rod is as below.
 Take the checked connecting rod. Refer to Inspection & Servicing
of Connecting Rod as per procedure no. 4.15.
 Take the checked piston. Refer to Inspection & Servicing of Piston
Assembly as per procedure no. 4.16 Installed the piston rings.
Refer to procedure no. 4.18.
 Fit the circlip to one side of the piston pin bore groove.
 Apply fresh engine oil to the piston pin and the con-rod small end
bush.
 Position the connecting rod in correct orientation to the piston. Fig.
 Fit the piston pin with the help of mallet.
 Lock the second circlip in place.
The ends of the circlips to be installed should

face upwards. Fig…
17
4.20) Bumping clearance checking procedure
 Tighten the cylinder liner by liner pressing tool no.

 Take the corresponding piston to TDC.
 Set both the dials at 0-0 on a flat surface/surface plate.
 Mount the
bumping
clearance
checking gauge
no on the
corresponding
liner.
 Rest the
dial gauge stylus
on piston top on both the dials.
 Measure the dial readings on both the dials.
 Select the correct cylinder head gasket to adjust the
bumping clearance. Refer section 1, 1.8, 1.16.
4.21) Inspection of Valve Recess in Cylinder Head

 Before removing the valves from the head, check the valve recess. Valve recess is the
distance between the cylinder head face and the valve face.
 This gap can be checked with the help of a 100 mm long straight edge and a feeler gauge
set or with the help of a dial gauge. Fig…
 The valve recess is different for inlet and exhaust valves.
 Insert the maximum specified thickness feeler gauge between the valve face and the
straight edge. If the gauge slides through the gap effortlessly, the gap is said to be more
than specified. Refer to Specifications, Section1, 1.9. In such a case, replace the valve,
the valve seat insert or both. Fig…
18
4.22) Inspection & Servicing of Cylinder Head, Valve and Valve Spring
 Before dismantling the valve assembly from the head, check the valve recess. Refer to
procedure No. 4.21 above.
 Mark the respective cylinder number on the valve face. The inlet valve has a bigger cone
diameter than the exhaust valve.
 Place the cylinder head on a flat surface with base support to inlet and exhaust valves.
 Press valve spring assembly with until the valve

collets are free.
 Remove valve collets by hand.
 Remove valve spring cup and springs.
 Remove valve from the bottom.
 Remove valve steam seal from valve guide.
 Discard valve steam seal.
 Remove carbon from the bottom face of the cylinder

head. Avoid scuffing and nicking the head's
machined surface while removing the carbon.
 Check the head face for pitting marks.
 Check the valve seat inserts in the head for burn
marks, heavy pitting and other defects.
 Recondition / Replace the seat if required or damaged.

 Check the inlet and exhaust port faces (where the manifolds fit) for damage.
 De-carbonize the exhaust and inlet ports

 Replace the old valve guides. Refer to Inspection & Service Procedure No. 4.24.
 Inspect the valve cone for cracks, burns, erosion, etc. Replace valves if found damaged.
 Inspect valve stem diameter at four to five places

for wear in both axis. Replace valves if stem is
worn out. Refer to Specifications, Section 1, 1.2.1.
19
 Check valve springs for pitting marks, cracks
and other defects. Measure the free length of
springs. Fig… Refer to Specifications, Section
1, 1.10.
 Replace spring if required.
4.23) Inspection of Cylinder Head surface flatness

 Remove carbon and clean the flat surface of the head.
 Check the surface flatness at three places. Fig…

 Use a 100 mm straight edge and a feeler gauge to
ascertain the flatness of the head.
 Put the straight edge on the surface of the head and put
the feeler gauge between the straight edge and the head.
(Not under the valve cavities.)
 If a feeler gauge passes through the gap, the face of the head is damaged and requires
repair / replacement. Refer to Specifications, Section1, 1.14.
 Correct the flatness by re-facing the head in a machine shop.
4.24) Replacing Valve Guides

 Punch out the old valve guide from the cylinder head top.
 Clean the guide bores in cylinder head with a dry cloth.
 Inspect the bores for scoring or other damage.
 Insert new valve guides by pressing them from the cylinder head top. Use mandrel for
pressing valve guide.
 After valve lapping press new valve stem seals with tool no. DV0.950.506 on the guide.
4.25) Replacing Valve Seat Inserts

 DV Series cylinder heads are fitted with replaceable valve seat inserts. KOEL
recommends replacing valve seat inserts during a major overhaul.
 Use Puller for valve seat insert for removing valve seat insert from cylinder head.
 In absence of puller for valve seat insert, the valve seat inserts can be removed with a
chisel without damaging the insert bore in the cylinder head. Alternatively the insert can
be removed by cutting it on an appropriate lathe in a machine shop.
 Clean and inspect the condition of the bore.
Note: The outer diameter of the inlet valve seat insert is more than that of the exhaust valve seat
insert.
20
 After removing the seat inserts, remove old valve guides and clean the valve guide bores.
 Cool the valve seat inserts in dry ice for about 30 minutes. OR cool in liquid nitrogen for
about 10 minutes. OR heat the head in an oven up to 130°C (not direct fire). Fit the insert
in its bore and press it immediately with a suitable tool taking the reference of the newly
fitted guide. Ensure the seat fits squarely and completely in the bore.
When using liquid nitrogen, avoid direct contact with it to prevent injury to
the body due to its sub-zero cooling effect. KOEL recommends wearing gloves while working.
Refer to Material Safety Data Sheet of liquid nitrogen.
4.26) Valve Lapping

Ensure that all inspection and servicing procedures related to the cylinder head are correctly
carried out. Refer to point nos. 4.21- 4.25,
Valve lapping should be carried out to ensure proper sealing of valves to avoid compression
leakages so as to achieve good combustion. If new valves and seats are fitted, then only a light
lapping with the 'fine' lapping compound will ensure a good sealing, but if seat/s and the valve
cones are to be refaced, then the complete valve lapping procedure is required.
Burnt and cracked valves should be replaced.
Valves with reduced rim thickness should be replaced. Refer to Specifications, Section1, 1.8.
 Check condition of both the valve face and the valve seats in the head.
 If the valve face is in a relatively good condition only light lapping with a fine lapping
paste will be required to ensure a good seating.
 If valve face is damaged, the face will have to be refaced to the correct angle without
reducing the rim thickness.
 If the valve rim thickness is already reduced, replace the valve.
 If valve seat is damaged beyond repair, replace valve seat.
 Thoroughly de-carbonize and clean the valve and cylinder head before proceeding for
valve lapping.
 Apply a small quantity of coarse lapping compound all around the valve seat.
 Dip the valve stem in fresh clean oil and insert the numbered valve in the respective valve
guide.

Ensure that no valve grinding paste touches the valve stem or valve guide.
This will damage both the valve guide and the valve stem.
 Lap the valve and seat by rotating the valve back and
forth in a half turn with gentle but firm pressure with
the help of a cupped valve-grinding tool.
21
 After every few turns, lift the valve off slightly from
the seat, give it a half-turn and tap gently. This is essential
to uniformly spread the grinding paste. Keep grinding
until the rough gritty feeling of the coarse compound turns
relatively smooth.
 Remove the valve, wipe the compound from the valve and seat and check for a contact
pattern. When a relatively good flawless pattern is achieved, lap the valve again with the
fine lapping compound.
Maintain a separate cloth and small quantity of diesel for wiping off the
compound from the valve cone and seat inserts. This prevents accidental damage to the valve
stem and guides.
 After lapping, visually inspect both the valve face and seat. The finished contact pattern
on both should be even, without flaw or break, scratch or depression marks.
Note: If a shining line or scratches are visible on the seats after lapping, it is possible that the
lapping was carried out with a heavy hand. Such valves will have to be lightly re-lapped again
with the fine compound.
 Wash the valves and cylinder head with clean diesel to remove all trace of the harmful
abrasive material and dry with compressed air.
 Before assembling the lapped valve assembly, confirm that the seating is good. This can
be done by a pencil erase test. Refer to Inspection & Servicing Procedure No. 4.27
 Wipe and lightly lubricate the valve stem. Assemble valve in its original seat with valve
spring and new stem seal and lock it in position.
 After locking the valve, check sealing of the seats. This should be checked by carrying
out the fuel leakage test. Refer to Inspection & Servicing Procedure No. 4.28
4.27) Checking Valve Seat by Pencil Erase Test

The pencil erase test is a simple test. It should be carried out before assembling the valve
to the cylinder head. This test ensures proper valve seating.
Method
 Draw a zigzag line on the lapped valve's seat surface
with a soft lead pencil. Fig….
 Fit the valve in its place in the head and turn it once
to 900 or 1/4 turn with a gentle but firm pressure.
 Pull the valve out and inspect the pencil line. The lines should be completely erased from
the seats. This proves proper seating and good sealing.
 If the pencil marks are not erased fully, repeat the lapping process as per procedure no.
4.26
22
4.28) Valve Checking by Diesel Leakage Test
Ensure the pencil erase test is carried out and sealing is ok.
 Assembling the lapped valves, lock the collar,
spring and cone in position with the valve collets.
Pour clean diesel into the air inlet and
subsequently exhaust gas ports.
 Check if the diesel leaks out between the valve
face and seat.
 No diesel should leak out between the seats for the next 30 seconds. This ensures that
the sealing is effective.
 If sealing is ineffective, diesel will leak out between a valve and seat. This diesel leak
may be due to dirt on the valve seat. Tap the valve lightly on the stem with a hammer to
remove the leak.
4.29) Inspection of Valve Rocker Assembly & Push Rod

Measure the inside diameter of the rocker lever bush.
 Measure the outside diameter of the corresponding rocker shaft.
 Calculate the clearance between rocker bush and
shaft. Compare the reading with Specifications,
Section 1, 1.1 3.3. If the clearance is more than
the specified limit, replace the rocker lever bush.
KOEL recommends replacing the rocker lever
bush set during a major overhaul of an engine.
 Inspect push rods for bend or other damages.

 Note: Concentricity of push rod can be checked
by rolling them on a smooth flat surface or surface
plate with the palm of the hand.
 Check the push rod cup and cone for damage.

Replace damaged rods.
23
4.30) Method of adjusting the fuel timing
The fuel timing is required to be adjusted when the fuel pump is removed from the engine during
engine major overhaul or for calibration.
 Bring 1st cylinder piston (from flywheel side) to 'top

dead center' in compression stroke. This can be
checked with the ‘T’ mark on the flywheel coinciding
with the pointer punched on the flywheel housing.
 Connect external diesel pump trolley to fuel pump.
 Start the pump and adjust delivery pressure to 15
bars.
 Rotate the fuel pump shaft until fuel spill is cut-off
for cylinder no.1
 Assemble the fuel pump gear and tighten the bolts.
 Disconnect the external diesel pump trolley.
 Assemble the H.P. Pipes and overflow pipes.
Fuel pump timing (BTDC static)
Engine Model Fuel

Timing*
DV8/DV10/DV12 160 +/- 10
* Subjected to change as per emission norms and engine rating.
4.31) Bleeding the Fuel System

Bleed the fuel system thoroughly to avoid an 'air lock' in the fuel circuit. This will eliminate
operational problems like engine starting trouble, engine hunting and engine not taking load.
To bleed the system:

 Operate the hand-priming pump provided on the Pre-line filter
 Unscrew the vent screw provided on the filter's header

till the fuel flows out freely without any air bubbles.
 Tighten the screw.
 Vent screw is provided on the fuel pump body, carry out
similar operation. After the bleeding operation is carried out, the
hand-priming pump will become hard to operate.
4.32) Servicing the Air Inlet & Exhaust Manifold

 Remove the old joint from the manifold face with the help of a blunt metal piece.
 Before cleaning the air inlet manifold check for

presence of oil or dust (Oil indicate; faulty
turbocharger seals, whereas dust indicates, faulty
air cleaner, hose and connections).
 Clean the manifold from inside with clean diesel.
24
The exhaust manifold is in two parts, joined by a expansion bellow. The joint requires attention
as exhaust gases leaking from the joint can hamper engine performance.
 Separate two manifolds from the joint.

 Remove carbon and clean the manifolds from
inside.
 Check the manifold's flanges flatness with a
straight edge.
 Check the flatness of the face where the
turbocharger sits with a straight edge.
4.33) Inspection & Servicing of Turbocharger
S300 TURBOCHARGER
Introduction
These Service Instructions cover the recommended procedures for
overhauling Schwitzer model S300 turbochargers.
These instructions should be used in conjunction with the latest
issue of the "Hundred Series Turbocharger Service Limits and
Torque Values"Data Sheet.
Always use a Schwitzer Overhaul Kit when servicing a Schwitzer

turbocharger and ensure that any replacement parts used are the
correct Original Schwitzer parts as specified in the appropriate
Turbocharger Parts List.
Please note that unless specialist dynamic balancing equipment is available no attempt should be
made to service the cartridge assembly of the turbocharger.
WORKSHOP EQUIPMENT
To service a Schwitzer S300 turbocharger it is necessary to have the tools and equipment listed
below.
In addition you will need a clean work area and the appropriate Schwitzer Overhaul Kit.
 Securely mounted vice.
 Stiff natural or wire brush
 Plastic scraper
 A source of clean compressed air
 Non-flammable solvent
 Squirt can of clean engine oil
 Internal circlip pliers (0° tip angle.)
 Internal circlip pliers (90° tip angle.)
 Snap-action torque spanner
 Vee block
 Vapour blasting equipment
 Sand blasting equipment
 Dynamic balancing equipment
25
• Shaft stretch measurement equipment
• 2 x Box end spanner:- 13mm (112 ins) and 14mm ( 9/16 ins)
• T-handle wrench (prevents bending in the shaft during stretch):- 14mm (9116 ins)
• Two standard, flat ended, screw drivers.:- 305mm length (12 ins)
• Plastic tipped mallet:- 500gms (16oz)
• 2 x Dial indicator, range:- 0- 25mm (0- 1 ins) and 0- 2.5mm (0- 0.1 ins)
• 12 point socket:- 17mm (11116 ins)
• Torque wrench:- 35Nm (0- 300 lbs/ins)
5300 TURBOCHARGER
Parts List 8. Flinger sleeve 16. Clamp plate 4
1. Compressor cover 9. Oil deflector 17. Screw and washer assembly 8
2. Compressor locknut 10. Thrust sleeve 18. Piston ring (Turbine)
!: :i essor wheel ,.·.-. u_..l,b:.-.i.n

-
,-g.=g-_c.,i.r.c..l:,i.p----- .41,- : n:n:aw
: heel
5. Insert -
13
:-_ J,.o...urna-,1-:b-ea..r.,i.n-g''-------'------,2.- 21. Setscrew 6
6. Insert o,..r.in"g'::-- 1 14. Bearing housing 0 ring (optional) 22. Clamp plate 3
7_._ P_is_to_n_rin'g"- 1_ 15. Bearing Housing 23. Turbine housing
(,C
__omp,_r_
es_s_
or.:)....
Parts listed in red are contained in a full S300 Overhaul Kit 16 17
18 19 20 21 22 23 Fig. 1
DISMANTLING.
IMPORTANT: Disassembly nullifies Schwitzer warranty responsibility so it is important to
check that the turbocharger is no longer under warranty before dismantling.
26
1. Mark the relative positions of the turbine housing and compressor cover to the bearing
housing.
2. Check the motion of the shaft for excessive radial or axial play. Refer to the 'Service
Limits and Torque Values' Data Sheet.
3. Rest the turbocharger on the bench and unfasten the turbine housing clamp plates.
4. Lift off the turbine housing.
5. Repeat 3 for the compressor cover and carefully lift the cartridge assembly from the
compressor cover.
6. Clamp the 12 point socket wrench in the vice and place the hub of the turbine wheel
7. into the socket so that the shaft is in a vertical position. (Fig. 2)
8. Holding the cartridge in one hand release the compressor locknut.
NOTE: Left hand thread. Over tightening the nut may cause yield in the shaft.
9. Remove the nut and slide off the compressor wheel.
10. Carefully remove the shaft from the bearing housing assembly by gently tapping the
shaft with a small soft faced hammer.
TAKE CARE NOT TO BEND OR DAMAGE THE SHAFT.
10. Remove the turbine backplate and sit the bearing

housing on the turbine backplate.
11. Remove the insert circlip using the circlip pliers.

Remove the insert assembly using two levers and
remove the flinger sleeve from the insert. (Fig 3).
12. Remove the oil deflector, thrust bearing and thrust
sleeve from the bearing housing.
13. Using circlip pliers, remove the outer circlip from
both ends of the bearing housing.
14. Remove the journal bearings.
NOTE: New bearings should be fitted on reassembly.

15. Remove inner circlips.
PARTS CLEAN-UP PROCEDURE

Cleaning is generally done by soaking the components in commercially available non-caustic
solvent, wiping, brushing or scraping any residue off and then blow drying with clean
compressed air.
27
However, vapor blasting is a good alternative if available, providing the vapor blasting
equipment manufacturers instructions are carefully followed and critical surfaces are
appropriately protected (see details below).
If parts are to be stored for any length of time after cleaning then they should be stored in clean,
dry plastic bags and the surfaces of all potentially rusting parts should be oiled prior to storage.
1. Bearing Housing
a) Scrape, brush or wipe as appropriate, to remove accumulations of residue from the
exterior surfaces.
b) Immerse briefly in safety solvent to remove any oily residue.
c) Blow dry with compressed air.
N.B. If vapor blasting is used mask the bore with corks or rubber stoppers.
2. Compressor Wheel
a) Immerse briefly in safety solvent to remove any traces of oily residue.
b) Blow dry with compressed air.
N.B. If vapor blasting then take care to mask the bore with corks or rubber stoppers.
3. Shaft and Wheel

a) Immerse briefly in safety solvent to remove any traces of oily residue.
b) Blow dry with compressed air.
N.B. If vapor blasting then take care to mask the entire shaft section with either appropriately
sized rubber hose or adhesive backed cloth tape.
a. c. After cleaning mount the shaft and wheel between centres in a lathe and lightly polish
the journal section of the shaft at 300 to 600 rpm with 400 grit abrasive paper and clean
oil.
b. NOTE: If the shaft and wheel shows any evidence of imbalance (bearing material
smeared on only one side of the shaft) - do not attempt to reuse.
c. After polishing re-immerse briefly in safety solvent and blow dry with compressed air.
4. Compressor cover
a. Scrape, brush or wipe, as appropriate, to remove accumulations of residue from the
exterior surfaces.
b. Immerse briefly in safety solvent to remove any oily residue.
c. Blow dry with compressed air.
N.B. No masking necessary if vapor blasting.
5. Turbine Housing and Back plate

a. Blast with coarse sand or steel grit to obtain total interior and exterior cleanliness.
b. Immerse briefly in safety solvent to remove residues.
c. Blow dry with compressed air.
6. V Clamps
a. Immerse in safety solvent agitating moderately until foreign material deposits have been
softened or dissolved.
28
b. Blow dry with compressed air.
7. Small Internal Parts

a. Immerse briefly in clean safety solvent to remove oily residues.
b. Wipe dry with a clean cloth.
INSPECTION OF PARTS FOR RE-USE
It is recommended that all visual and dimensional checking of parts for re-use be done after parts
have been cleaned as described above. Critical dimensions mentioned below are given in the
latest issue of the ‘Hundred Series Service Limits and Torque Values' Data Sheet.
1. Bearing Housing
a. Inspect visually for evidence of cracks and fractures, pitting of gasket and other machined
surfaces, or distortion of the turbine end flange. Reject and replace if any of the above
conditions are severe.
b. Closely inspect the bearing bore visually for signs of damage or wear. The condition of
the removed bearings will be a good indicator of the bore condition. Refer to ‘Service
Limits Tables’
a) for maximum bore diameters. Reject and replace if bore condition is substandard.
c. Examine the turbine end seal bore for damage and replace bearing housing if wear is
excessive.
N.B. Do not mistake the machined step and relief groove for a wear ridge.
2. Compressor Wheel
Inspect visually for evidence of bent, burred, nicked or eroded blades and for evidence of
scuffing on the back face. Dynamically balance the Compressor wheel and reject and
replace if any damage has affected wheel balance. Do not attempt to straighten bent blades.
3. Shaft and Wheel

a) Inspect visually for evidence of bent, burred, nicked or eroded blades and for evidence of
scuffing on the back face. Very minor damage is acceptable but reject and replace if the
damage appears sufficient to affect wheel balance. Do not attempt to straighten bent
blades.
b) Inspect hub visually for evidence of smearing (as with high speed contact with the
bearing house bore) and for deterioration of the original rectangular configuration of the
piston ring groove. Reject and replace if the damage or
wear is excessive.
c) Inspect journal diameter for wear. If this appears
reusable the diameter should be checked with a
micrometer referring to the ‘Service Limits
Tables’.
29
e. Dynamically balance the shaft and wheel assembly, referring to the ‘Service Limits
Tables’. Do not attempt to straighten a bent shaft.
4. Compressor Cover
Inspect visually for evidence of contour damage (as from high speed wheel contact). Reject
and replace if damage is excessive. It is permissible to polish out minor surface damage in
the contour.
5. Turbine Housing and Back plate

Inspect visually for evidence of contour damage (as from high speed wheel contact) and for
evidence of over temperature damage such as cracking, pitting, distortion or erosion.
Reject and replace if damage is excessive.
6. Insert
Inspect the insert bore for evidence of surface damage. If there is evidence of contact
with rotating components or if the piston ring wear has created a ridge the insert should be
rejected and replaced.
7. Flinger Sleeve
Inspect visually for evidence of surface damage from contact with stationary parts. If piston
ring wear has caused the ring groove to deteriorate from its original rectangular configuration
reject and replace the flinger sleeve.
8. V Clamps
Inspect visually for evidence of cracks or distortion of the clamp and T-bolt threads.
Reject and replace if damage is excessive.
S300 ASSEMBLY.
When reassembling the turbocharger a Schweitzer Overhaul Kit should always be
used (see Parts List on the S300 Exploded View).
1. Re-use only parts complying with the "Inspection of Parts for re-use" guidelines.
2. Ensure all parts to be re-used have been thoroughly cleaned as described in the "Parts
Clean-Up Procedure".
3. Fit inner circlips to the bearing housing with the chamfered edge towards the bearing
(Fig. 5).
4. Lubricate the new journal bearings with clean oil and fit
into the bearing housing, using the outer circlips with
the chamfered edge towards the bearing. (Fig. 5)
5. Fit the new piston ring into the second groove in the
hub of the shaft.
6. Place the bearing housing on the bench turbine end uppermost and fit the backplate.
30
7. Lubricate both shaft and piston ring with clean oil and fit the
shaft and wheel assembly into bearing housing (Fig. 6).
TAKE CARE NOT TO DAMAGE THE PISTON RING.
7. Place the assembly into the turbine housing with the shaft vertically up.
9. Lubricate the new thrust bearing surfaces and fit the new thrust
sleeve.
10. Fit the thrust bearing assembly into the bearing housing
engaging on the locating pin, then fit the oil deflector with the
oil deflector tongue fitting into the cutaway section of the thrust
bearing (Fig. 7).
11. Fit the new 'O' ring onto the insert and a new piston ring into the
flinger sleeve.
12. Fit the flinger sleeve assembly into the insert. TAKE CARE NOT TO DAMAGE
THE PISTON RING.
13. Lubricate the insert 'O' ring and press the insert into the bearing
housing. Fit the circlip with the gap at 90 degrees to the cutaway
section in the thrust bearing (Fig. 8).
ENSURE THE BEVELLED EDGE IS UPPERMOST AND THE

INSERT IS PRESSED HOME FLAT.
14. Fit the compressor wheel and new locknut.
15. Using the appropriate equipment tighten the locknut in accordance

with the Fastener 'Torque Values' Table.
16. For turbochargers which have a compressor end 'O' ring, (see
turbocharger Parts List to check), fit this to the compressor end of
the bearing housing and lubricate with clean engine oil.
17. Place the bearing housing into the compressor cover and fix the
clamp plates, using the set screw and washer assemblies (Fig. 9).
18. Orientate the turbine housing and compressor cover to the desired
position and fit the clamp plates. Fasten in accordance with the values
given in the 'Fastener Torque' table.
31
Whilst every care has been taken to provide accurate information in this Data Sheet
Schwitzer cannot accept any liability for any inaccuracies. All rights reserved.
Schwitzer Turbocharger Service Limits and Torque Values.

All technical turbocharger service data provided in this section is to our original manufacturing
specifications. The service data sheets may be used as a reference when rebuilding Schwitzer
turbochargers. To avoid premature failure and possibly consequential Engine damage, use only
Genuine Schwitzer service parts.
Compressor Locknut Torque Values
Refer to Schwitzer Service data sheet for tightening values

There are 3 methods of specifying the tightening values of compressor locknuts and
these vary with model type.
1. The simple .Pure Torque. Method.
2. The .Snug Torque and Angle. Method. Where a torque figure together with an
angle, the torque value is the snug torque followed by a continued tightening of a
further specified angle.
3. The .Shaft Stretch. Method. The locknut tightness is measured by monitoring the
amount in mm [ins] that the shaft increases in length as the increased force is
applied to the threads. This is the most accurate method by illuminating the false
readings due to friction, sometimes experienced in torque methods.
Note:- specialist equipment is required for this method.
On Several models the shaft threads have changed recently from .Right Hand Thread.
to .Left Hand Thread.. When servicing care must be exercised to identify which thread is present.
When tightening to the specified value .Right Hand Threads. should be coated with 2
drops of Locktight adhesive of grade MS 8-7001 or similar. Left Hand Threads. should
be lightly oiled.
SERVICE LIMITS & TORQUE VALUES

Measuring Radial and Axial Play
Axial Play
1. Clamp the compressor end flange of the bearing
housing in a securely mounted vice, between soft
jaws.
2. Position the dial indicator parallel to the shaft (see
Fig. 1) putting the ball of the indicator onto the flat
of the turbine wheel hub.
3. Push the turbine wheel and shaft into the

bearing housing to the full extent of the play (A).
4. Zero the dial guage in this position.
5. From the compressor end (B), push the shaft until it reaches the full extent of the play in this
direction, being careful not to rock the shaft in the radial plane.
6. Record the dial indicator reading at this point.
32
Repeat the exercise to validate the result and compare with the specified maximum axial end
play given in the Service Data Table.
Measurement of Compressor End Radial Play
With cartridge assembly clamped firmly in the vice:
1. Reposition the dial indicator (D.T.I) to be
perpendicular to the shaft. Position the ball of
D.T.I so it is resting on the rounded surface of the
compressor locknut and as close to the flat face as
possible.
2. Take hold of compressor hub and press down (A)
until the lowest position is reached.
3. Zero the D.T.I in this position.
4. Lift the turbine wheel up (B) until the highest
position is reached and record the D.T.I reading.
5. Repeat the exercise to validate the readings and then compare your results
with the service data table provided.
WORKSHOP EQUIPMENT
The workshop requirements for measuring the axial and radial play of turbochargers are:
Securely mounted vice

2 x Dial indicator, range - 0 - 25mm ( 0 - 1 ins) and 0 - 2.5mm ( 0 - 0.1 ins )
Vee block
Schwitzer Turbocharger Service Data
TURBO MODEL C/Wheel C/Wheel Compressor Compressor Turbine Housing

Locknut Locknut Housing Bolts V‐Band Torque Bolts Torque
Torque Nm (lb. Torque
ins) shaft stretch Nm(lb.ins) Torque Nm(lb.ins) Torque Nm(lb.ins)
S200 13.56 (120) 0.12 (.0048) 13.55 (120) n/a 21.01 (186)
S300 20.34 (180) 0.14 (.0055) 13.55 (120) n/a 21.01 (186)
Rotor
Turbine Housing Radial Clearance/play Axial Clearance Balance Rotor Balance
V‐Band Torque compressor end or end play Turbine end Comp End
Torque Nm(lb.ins) mm (ins) mm (ins) gmm (oz ins) gmm (oz ins)
0.41 to 0.55 (.016 to
n/a .022) 0.05 to 0.1 (.002 to .004) 0.216 (.0003) 0.36 (.0005)
0.05 to 0.13 (.002 to
n/a 0.53 to 0.7 (.021to .027) .005) 0.36 (.0005) 0.36 (.0005)
TURBO MODEL Max Allowable b/hsg Min Allowable S&W Max Allowable
Journal Bore Journal diameter mm Shaft eccentricity
mm (ins) (ins) or runout mm (ins)
S200 18.171 (.7154) 10.566 (.4160) 0.0076 (.0003)
33
S300 19.202 (.7560) 10.566 (.4160) 0.0076 (.0003)
Turbocharger: Maintenance Periodical Inspection

The recommendations for the maintenance and the periodic inspection of different engine applications,
turbocharger rotor condition, etc. are given below.
Application Inspection interval

Genset Every 6 months Every 12 months Every 24 months
Items to be Inspected
Inspect Rotor Freeness
•
Inspect Rotor Play
•
Overhauling Turbocharger
• If required.
Replace Air Filter Element As per the Engine Maintenance Manual

Replace Oil Filter Element As per the Engine Maintenance Manual
Changing Engine Oil As per the Engine Maintenance Manual
4.34) Valve Tappet Setting

Tappet clearance setting is necessary to compensate for the expansion of heated valve mechanism
parts. These parts expand due to heat.
Valve Tappet setting

The tappet clearances are to be adjusted if
- Engine is overhauled
- The cylinder head is disassembled
- When abnormal noise is noticed in the valve train.
The valve clearance (in cold condition)
Engine Model For Inlet and Exhaust valves

DV8/DV10/DV12 0.35 mm
Method for setting the Tappet clearance

 Setting Valves with individual cylinder at ‘top dead center’.
 Bring 1st cylinder piston (from flywheel side) to 'top dead center' in compression stroke. This
can be checked with the ‘T’ mark on the flywheel coinciding with the pointer punched on the
flywheel housing. Check if both inlet and exhaust valves are free. This can be ascertained by
rotating the push rods by hand. If push rods are not free, rotate the crankshaft a full 3600 (Full
turn).
 Set valve clearance on both the inlet and the exhaust tappets as specified. Refer to
Specifications, Section1,
Note: The correct valve gap setting requires that the feeler gauge slides firmly but smoothly in
the gap between rocker arm and Valve Bridge
 Turn the crankshaft pulley in the clockwise direction till the next cylinder in firing order
comes to ‘top dead center’ in compression stroke.
34
 Continue with the process till all cylinder valves are set as per the firing order shown below.
Engine Model DV8 DV10 DV12
F.W.E. F.W.E. F.W.E.
Firing order
1-5-7-2-6-3-4-8
1-6-5-10-2-7-3-8-4-9
1-12-5-8-3-10-6-7-2-11-4-9
 Turn the crank shaft as per the table below for adjusting the valve clearance of the
successive cylinder.
Engine Model Rotate the engine by

DV8 900
DV10 720
DV12 600
4.35) Replacing the spin-on type Lubricating Oil Filters

The spin-on filter should be replaced at every oil change. Both filters should be replaced together.
 Remove the filter cartridge with a strap tool in the counter-
clockwise direction. (Strap Tool is commercially available).
 Remove the cartridges and destroy them.
 Remove the old sealing ring and destroy it.
 Wipe the sealing surface of the filter housing with a clean dry
cloth or brush.
 Apply a light film of oil on rubber seal of new cartridge. Fig.
 Do not pour the oil in the filter cartridge. Filter should be
installed dry. Screw-in new cartridge into place by hand till it
is evenly seated.
 Tighten the cartridge firmly by both hands and rotate it by
2700 further
4.36) Replacing the Fuel Filter Element

 Replace pre-filter element after 500 hours of engine operation. Destroy the old element.
35
 Replace the micro filter element after an interval of 500 hours of pre-filter element
change.
Do not change pre-filter element and micro-filter element at the same time. A
filter attains maximum efficiency after a layer of dirt has been deposited on the surface of filter
element.
 Bleed the fuel system before starting the engine.
The procedure for changing the micro-filter element is the same as the procedure for changing the pre-
filter element.
Replacing the Preline Filter Element

 Remove the filter cartridge with a strap tool in the counter-
clockwise direction. (Strap Tool is commercially available).
 Remove the cartridge and destroy it.
 Remove the old sealing ring and destroy it.
 Wipe the sealing surface of the filter housing with a clean dry
cloth or brush.
 Apply a light film of oil on rubber seal of new cartridge.
 Screw the filter cartridge by hand up to base.
 Tighten the cartridge firmly by both hands and rotate it by
2700 further.
BOWL
 Apply a light film of oil on rubber seal of new cartridge.
 Screw the filter cartridge by hand up to base.
 Tighten the bowl with mounting tool at 20Nm.
 Drain the water.

4.37) Servicing of Centrifugal Lube Oil Filter
The centrifugal filter is fitted on the lube oil sump. It is only a by-pass filter. The centrifuge is a super
filter, removing minute harmful particles and sludge up to 4 microns (by centrifugal force from the
engine oil, when the engine is in operation). This filter increases the life of the oil as well as the engine
and maintains a constant lube oil pressure.
 It is a precision assembly. Consult authorised persons.
36
 Carry out servicing preferably when engine is still warm.
Centrifugal Filter Servicing Procedure
 Wipe the filter body from the outside with dry cloth.
 Unscrew top nut and remove cleaner cover. Lift rotor and drain oil from
it.

 Unscrew rotor nut by holding rotor assembly in hand. Remove rotor

cover and deflector inside.
 Remove the conical disc.

 Clean the conical disc with the
help of a wire brush and wash it
in clean diesel.
 Remove the cake of sticky dirt
formed inside the rotor cover
with a blunt knife. Wash in clean
diesel.
 Clean all rotor parts with proper detergent.

 Clean the rotor cover nozzles with a fine wire.
 Blow compressed air on the rotor cover nozzles.
 Check the 'O' rings on the rotor and the housing. If damaged, replace them…
 Clean the filter bowl from inside.
37
 Assemble all rotor parts in a proper order and close the rotor cover nut with a maximum torque
of 1.2 kgm.
 Match arrow narks on rotor and rotor cover.
 Confirm rotor rotates freely on the shaft.
 Tighten the center dome cover nut.
 Start the engine and let it run for some time till the oil turns warm.
Stop the engine. The humming noise of the rotor should be heard after the engine has stopped. This
shows that the centrifugal filter is working properly.
4.38) Servicing the dry type Air Cleaner
Dos and Don'ts of Dry Type Air Cleaner
Dos
 Service the filter element only if the restriction indicator shows a red band in engine
stopped condition.
 Check the condition and functioning of the restriction indicator regularly.
 Check the evacuator valve regularly and replace it if required.
 Clean the filter casing by wiping the dust from inside with a damp cloth.
 Clean the baffle dust cover with compressed air.
 Clean the main element with compressed air from inside-out, in the opposite direction to
air flow. The compressed air pressure should not exceed 3 kg/cm2. The air nozzle ID
should be not less than 8 mm and nozzle mouth at least 25 to 30 mm away from the
inside surface of the element.
 The element should be replaced only after cleaning the element twice.
 Check the element which has been cleaned with an inspection lamp for tear, perforations
or any damage. Replace the damaged element.
 Do not disturb or remove during servicing of the main element. Replace the safety
element at every replacement of the main element.
 Check and ensure that all connections, seals and joints are air-tight and leak-proof.
 Ensure that the exhaust and/or oil fumes are not sucked in by the engine induction
system.
 While re-assembling the air cleaner, ensure that :
 The sealing ring of the element is OK and the rubber grommet and washer are OK and in
position.
 The end cover seals the entire periphery around the air cleaner body.
 The element is clamped with the wing nut.
Don'ts
 Do not service / replace the element if the restriction indicator is not showing red band.
 Do not clean the element by rapping, tapping or pounding.
 Do not wash the element with hot water and soap or with petrol.
 Do not remove/disturb the safety element when the main element is removed for
cleaning/checking.
38
 Do not clean the filter elements unless the restriction indicator is showing red alert
signal.
 Do not clean the safety element.
 Do not fill oil or wet any part of the air cleaner with oil.
The Pre-cleaning (if provided) should be cleaned to remove the accumulated dust, after each
day’s work, when the engine is stopped.
Cleaning Procedure for Filter Element

 Cleaning of filter element is to be done only when the filter element is choked which is
indicated by a restriction indicator showing a red signal even after the engine has
stopped.
 Check the restriction indicator daily.
 Do not clean the main element unless it is choked.
 The cleaning procedure for the filter element is as below.
 Remove the wing nut of the element and take out

the element for checking and cleaning..
 Do not remove the inner (safety) element.
39
 Use a damp cloth to wipe all excess dust in the air
cleaner. Similarly clean the end cover.
 Thorough cleaning of the filter element with
compressed air is recommended. Clean the element
from inside-out, using the pressurised plug.
 The maximum air pressure should not exceed 3
kg/cm2. (Too much air pressure can break the fiber
paper and destroy the element.)
 The cleaning nozzle ID should be less than 8 mm.

 The minimum distance between the nozzle and the
filter element inner side should be 25 to 30 mm.
 Do not clean the element from outside
 Rapping, tapping or pounding dust out of the element is

dangerous. Serious damage to the filter can result.
 Do not wash the air cleaner element with hot water/soap or
petrol.
 Carefully check a new or properly cleaned element for damage before its installation in the
cleaner. Conduct the light test by passing a light bulb through the element as illustrated
below. If there is any crack in the element, the light will pass through it. In that case replace
the element.
 Inspect the rubber-sealing ring at the end cover of the element. If

damaged, replace it.
40
 Replace the main element after two cleaning intervals.
 Replace the inner or safety element every time the outer or main
element is replaced or after two years of duration or of the 3rd
replacement of main element whichever is earlier. Service /
Replace the element if the restriction indicator is showing the red
band.
 Re-set the restriction indicator by pressing the button on top.
Vaccuator Valve Maintenance
 The vaccuator valve at the bottom of the end cover

helps in expelling the accumulated dust. This is
achieved by opening and closing of the vaccuator
valve outlet due to the air flow fluctuations inside the
air cleaner.
 Make sure that the vaccuator valve is not damaged. If
necessary, change it.
 Check the condition of the cup joint sealing. Replace
if necessary.
 Before starting the engine it is recommended to manually tap out the dust.
To remove dust
 Press the vaccuator valve lip open. Tap lightly on the

valve till dust falls out.
 Release the lips. They will close automatically.
 If valve lips do not close properly replace
 the vaccuator valve.
4.39) Inspection of Thermostat Element
A thermostat element is required to bring up the working

temperature of the engine quickly and to maintain the desired
temperature of coolant during engine running period.
41
 Carry out a visual inspection of element resting face towards proper sealing of the
element.
 Fill a container with water. Heat the water more than 740 C.
 While water is heating, immerse the thermostat element in the container with a string so
that opening and closing of the element is clearly visible.
 Record the temperature readings for both stages i.e. when the thermostat element starts
opening and when completely opened, with the help of a thermometer.
 The thermostat element should start opening at 720 C to 740 C and be completely open at
880 C.
 The thermostat is in proper working condition if it satisfies the above conditions.
4.40) Inspection & Servicing of the Radiator and Charge Air Cooler (CAC) Radiator
External Checking
 Check the radiator cap for effective sealing and

correct pressure specification. Replace cap if
required.
Radiator and Charge Air Cooler

 Inspect the radiator tubes for leaks. If tubes are
leaking, repair at an authorised outlet only.
 Check for water leakage between the core and
header tank joints.
 Inspect radiator-cooling fins for damage. If fins
are damaged, get the fins repaired.
 Clean the radiator core externally by pressurised
air in the reverse direction of cooling air flow.
 Check the water inlet and outlet connections (to
and from header and bottom tank) for leakages.
If radiator tubes are choked internally due to scale or rust formation,

clean the radiator internally with 'K Clean'. Refer to procedure No. 4.41
 Clean the radiator core externally with

pressurised air in the reverse direction of
cooling air flow.
42
Charge Air Cooler
 Remove the plug at the bottom from the

charge air-cooler air outlet tank. Drain out
condensate.
 Always clean the cooler with pressurised air
in the reverse direction of the cooling air
flow.
4.41) Radiator Cleaning Procedure with 'K Clean'

 'K Clean' radiator cleaner is specially developed for KOEL water cooled engines.
How to use
 Drain and flush radiator and cooling system thoroughly with fresh water to remove loose
materials.
 Refill the radiator with water.
 Add 'K Clean' in the following proportions:
 For radiators with a capacity of less than 16 liters, add 375 ml of 'K Clean' to the cooling
system.
 For radiators with a capacity of more than16 liters, add 1liter of 'K Clean' per 40 liter of
cooling system capacity.
 Run the engine at a normal operating temperature for 1 hour.
 Completely drain the system. Flush with fresh water. Repeat the process till the drained
water is clean.
 Fill the system with Premix 'K-Kool Super Plus' immediately.
Advantages of 'K Clean'

 It is provided in a liquid, ready-to-use form.
 Designed to remove the contaminants commonly found in the engine cooling system in
the shortest possible time.
 Removes oil, grease, dirt and loose metal oxide.
 It protects the system while cleaning.
 'K Clean' is compatible with rubber hoses and other non-metallic parts of the cooling
system.
 'K Clean' cleans the radiator within 1-2 hrs while conventional cleaners need 25-50 hrs.
Warning
Contains strong alkaline fluid. Should be handled carefully. Avoid eye and skin contact.
Keep out of the reach of children.
First Aid
 In the event of contact with eyes, wash eyes with fresh water for 15 minutes.
43
 If swallowed see a physician. Don't induce vomitting. If conscious, give lemon juice or
vinegar in an equal volume of water.
Protect the Environment

 Dispose of the drum after triple rinse with fresh water.
 Engine coolant should not be disposed off into drains, soil, sewer systems or open water.
4.42) Servicing the Fan Driving Arrangement
 Unscrew the grooved nuts. Remove the adapter.

 Remove the pulley.
 Remove the internal circlip and pull out both the ball bearings.
 Check the shaft. If found worn/ damaged replace the unit.
 Replace both ball bearings. (Since 'sealed' ball bearings are used,
do not fill grease between both ball bearings.)
 Re-assemble the drive arrangement and tighten the groove nuts with a special spanner.
 Check freeness by rotating.
4.43) Inspection of Auto Electricals
4.43.1) Battery
 While disconnecting the battery from the engine, remove _ve connection first. Battery
Specific gravity should be checked with a hydrometer about 5 minutes after topping with
distilled water.
 Check and correct the electrolyte level as well as the specific gravity of battery cells.
 If the specific gravity is not as per the table below, charge the battery externally.
 Store the battery on a wooden plank in a dry and cool place.
 If the battery is to be stored for more than 8 days, charge the battery with a static battery
charger.
 Ensure that the battery top is clean and dry. Ensure that the battery vent holes are open.
Choked vent holes could lead to the battery bursting.
 Ensure that petroleum jelly is applied on all battery leads.
 Ensure that the lead taper is matched with the terminal taper.
Battery State:
State of Charge Specific Gravity Specific Gravity

(Normal) (Tropics)
Fully Charged Battery 1.28 1.23
Half-charged battery 1.20 1.12
Requires re-charging
Discharged Battery Must be 1.12 1.08
re-charged before use
4.43.2) Charging Alternator

Disconnect and remove the alternator from the engine and get it reconditioned by an Authorized
Service Dealer.
44
Do not 'short' the output leads of the charging alternator for checking the
output supply. This is to avoid failure of regulating diodes.
4.43.3) Starter
Disconnect and get the starter repaired / reconditioned by an Authorised Service Dealer.
Irrespective of the condition it is advisable to replace the bush bearings and brushes.
45
Engine Trouble- Shooting
No. Topic Page
5.1 Engine fails to rotate 2
5.2 Engine rotates slowly and will not start 2
5.3 Engine rotates freely but does not start / has starting difficulty 2
5.4 Engine starts but stops after some time 3
5.5 Engine mis-fires during operation 3
5.6 Engine starts but does not reach its desired speed 3
5.7 Engine speed does not remain constant 3
5.8 Mixing of diesel with lube oil 4
5.9 Excessive fuel injection equipment wear 4
5.10 Diesel knock 4
5.11 Mechanical knock 4
5.12 Excessive vibration 5
5.13 Battery runs down frequently 5
5.14 Engine not taking load 5
5.15 Engine overheating 7
5.16 Temperature rise in canopy 9
5.17 Low lube oil pressure 9
5.18 Engine emits black smoke 11
5.19 Excessive smoke at No Load 12
5.20 Excessive smoke at Full Load 13
5.21 Engine emits blue smoke 14
5.22 Engine emits white smoke 14
5.23 Water or oil leakage 14
5.24 Bearing wear 15
5.25 Wear / Seizure of liner, piston and piston ring 15
5.26 Excess blow-bye 17
5.27 High lube oil consumption 17
5.28 High fuel consumption 19
1
Sr. Complaint Cause Remedy
No.
5.1 Engine Battery discharged Charge the battery
fails to Defective Starter. Repair the Starter
rotate Loose/dislodged battery cable. Tighten the battery leads.
Engine used after a long period Service the engine
Engine seized. Carry out the engine overhauling with the
help of an authorised service dealer
5.2 Engine Battery weak Charge the battery
rotates Battery cable loose Tighten the battery leads.
slowly Faulty starter Repair the starter
and will Small capacity battery Use the battery as specified
not start Engine seized. Carry out the engine overhauling with the
5.3 Engine No diesel in tank Fill up the fuel tank with clean diesel, vent
rotates fuel system
freely, but Fuel tank cock closed/half closed Open cock on fuel tank
does not Poor quality of diesel Use the diesel as specified
start/ has Air in fuel line Bleed the fuel system
starting Leaking fuel line Remove the leakages
difficulty Fuel line chocked Clean the fuel pipes
Fuel Filter clogged Replace the fuel filter element
Fuel pump lever stuck Service the fuel pump
Fuel pump defective Service the fuel pump
Incorrect fuel timing Set the correct fuel timing with the help of
an authorized service dealer
Incorrect tappet setting Set the correct tappet setting with the help
of an authorized service dealer
Cylinder head gasket blown Replace the Cylinder head gasket
Engine not used for a long time Service the engine with the help of an
authorised service dealer
Worn/damaged piston rings Replace the piston rings as specified with
the help of an authorised service dealer
Clogged /Dirty air cleaner Clean the air cleaner and change the filter
element
Faulty/Choked fuel injector Check the nozzle spray, it should give the
“squeaking” noise. If necessary replace
the injector
2
Valve leakage Arrest the valve leakage
Broken / worn piston rings Replace the piston rings as specified ns
with the help of an authorised service
dealer
Engine needs de-carbonising De-carbonising the engine with the help
of an authorised service dealer
5.4 Engine Fuel vent hole blocked Clean the vent hole on fuel tank cap
starts but Choked air cleaner element Clean/Change the filter element
stops after No diesel in tank Fill up the fuel tank with clean diesel, vent
some time fuel system
Air in fuel line Bleed the fuel system
Choked fuel filter Replace fuel filter element
Faulty fuel pump Service the fuel pump with the help of an
No coolant in cooling system Fill the cooling system with coolant
Head Gasket blown Replace the Cylinder head gasket
Engine Piston / liner seized Replace seized Liner/Piston with the help
Engine bearing seized Replace the bearings with correct size
with the help of an authorised service
dealer
Engine needs overhauling Overhaul the engine with the help of an
5.5 Engine Engine used after a long lime Service the engine with the help of an
misfires authorised service dealer
during Air in fuel line Bleed the fuel system
operation Faulty/Choked fuel injector Check the nozzle spray, it should give the
“squeaking” noise. If necessary replace
the injector
Water mixed with fuel Clean the fuel tank and fill up diesel as
specified in the maintenance manual
Faulty fuel pump Service the fuel pump with the help of an
One or more cylinders not firing Service the engine through an authorised
service dealer
Incorrect tappet setting Set the correct tappet setting with the help
5.6 Engine Choked Fuel filters Replace fuel filter element
does not Choked fuel line Clean the fuel pipes
reach its Control lever setting incorrect Adjust the control lever setting
governed Engine overloaded Reduce the load on engine up to the full
speed load capacity
5.7 Engine Choked fuel line Clean the fuel lines
speed Faulty/Choked fuel injector Check the nozzle spray, it should give the
does not “squeaking” noise. If necessary replace
3
remain the injector
constant Faulty fuel pump Service the fuel pump with the help of an
Faulty governor adjustment Adjust the governor
Excessive governor linkage play Remove the play in governor linkage
One or more cylinders not firing Service the engine through an authorised
service dealer
5.8 Mixing of Dribbling Injector nozzle Clean the nozzle and check the spray. If
Diesel not proper replace the nozzle
with Lube Broken piston rings Replace the broken piston ring with new
oil piston ring set. (It is preferable to replace
piston ring set complete instead of a single
ring)
Worn piston and liner Replace the liner and piston
One or more cylinders not firing Service the engine with the help of an
Feed pump „O‟ ring damaged Replace the damaged „O‟ ring
Excess wear and tear of fuel pump Replace the fuel pump element with the
element help of an authorized service dealer
5.9 Excessive Poor quality of diesel Use diesel as specified
fuel Poor quality of filter element Use genuine filter element
injection Water contamination in diesel Clean the fuel tank and fill up diesel as
equipment specified in the maintenance manual
wear
5.10 Diesel Poor quality of diesel Use diesel as specified
Knock Fuel timing far advanced Correct the fuel timing with the help of an
Incorrect injector pressure setting Correct the injector pressure with the help
Incorrect calibration of fuel pump Re-calibrate the fuel pump with the help of
an authorized service dealer
High-pressure pipe of wrong Replace the high-pressure pipe set
specification fitted
5.11 Mechanic- Incorrect tappet setting Set the correct tappet setting with the help
al knock of an authorized service dealer
Broken piston rings Replace the broken piston ring with new
piston ring set. (It is preferable to replace
piston ring set complete instead of a single
ring)
Excessive clearance between the Replace the piston/piston pin or both with
piston pin and piston pin bore the help of an authorised service dealer
Excess clearance between piston Replace the piston and liner with the help
and liner of an authorised service dealer
Excessive clearance between Replace the connecting rod small end
connecting rod small end bush and bush and piston pin
piston pin
4
5.12 Excessive One or more cylinders not firing Service the engine with the help of an
vibration authorised service dealer
Faulty engine mounting Correct the engine mounting with the
Mounting bolts loose Tighten the mounting bolts
Improper exhaust clamping Repair the exhaust clamping with the
Mis-alignment with driven Align engine and driven machinery with
machinery the help of an authorised service dealer
5.13 Battery runs Poor condition of Battery Check the specific gravity of electrolyte
down Check the battery cell
frequently Fan belt loose Tighten the charging alternator belt
Charging alternator defective Service the charging alternator from an
Defective wiring Re-do the wiring with the help of an
5.14 Engine not Air and Exhaust System
taking load Choked air cleaner element Clean/Change the filter element
Worn out turbocharger bearings Replace the turbocharger
and shaft
Poor ventilation in engine room / With the help of an authorised service
hot air getting re-circulated dealer improve the engine room
ventilation. Avoid the re-circulation of
hot air
Hose from turbocharger outlet to Replace the cracked hose/ Remove the
inlet manifold is in cracked or twist on hose/ Tighten the loose hose
twisted condition and or hose clamps properly
clamps are in loose condition
After cooler is in chocked Clean the after cooler as specified
condition
After cooler drain plug in loose Tighten the drain plug / Assemble the
condition or missing new drain plug
Excess back pressure in exhaust Check whether the Exhaust pipe length,
system diameter and no off bends used are as
specified. If not correct accordingly
High carbon deposition in inlet De-carb inlet and exhaust ports
and exhaust port
Excess carbon deposition in Clean the exhaust pipe line properly
exhaust pipe line
Loose inlet / exhaust manifold Tighten the nuts on air inlet/ exhaust
nuts manifold
Choked exhaust silencer Clean/ Replace exhaust silencer
Lube Oil System
Wrong grade of Lube oil used Use specified grade of Lube oil
5
Prolonged oil change period Replace the Lube oil with new Lube oil
and observe the oil change period
Oil level not as per Maintain the oil level up to the high
recommendation level mark on dipstick
Lube oil supply to Turbocharger Remove the blockages or leakages in
is less Lube oil supply to Turbocharger
Fuel System
Fuel cock not fully opened Open cock on fuel tank
Stop lever on fuel pump is not Bring the stop lever on fuel pump to
fully in operating position or proper position with suitable remedial
touching engine parts measures
Air lock in system Bleed the fuel system
Fuel line chocked Clean the fuel pipes
Choked fuel filter Replace the fuel filter element
Button / swivel type filter choked Clean the Button / swivel type filter
Mud filter choked Clean the mud filter
Bend in / Excessive length of Use genuine High pressure pipe set
high pressure pipes leads to fuel
throttling
Smaller diameter fuel inlet pipe Recommended inside diameter for fuel
used inlet is 8 mm for power generation
application
Twisting of fuel pipes Remove the twists in the fuel pipes
Feed Pump not working properly Service / Replace the feed pump
Feed pump spring tension not Adjust the spring tension or replace the
proper feed pump
Defective fuel pump due to wear Service / Replace the fuel pump from an
and tear of fuel injection pump authorised service dealer
parts
Dribbling Injector nozzle Clean the nozzle and check the spray. If
the spray is not proper replace the nozzle
Fuel injection pump control rack Service the fuel pump from an
movement sluggish authorised service dealer
Incorrect fuel timing Set the correct fuel timing with the help
Faulty fuel injection pump Replace the overflow valve
overflow valve
Incorrect height of the fuel tank Correct the fuel tank height as specified
Poor quality of diesel Use diesel as specified
Mechanical System
Compression leakage Check the torque on cylinder head bolts.
Re-tighten cylinder head bolts. If
necessary replace the cylinder head
gasket
Cylinder head gasket torn Replace the cylinder head gasket
6
Defective nozzle washer Replace the defective Nozzle washer
Worn out or pitting marks on Replace the worn out valve/ valve seat
valve, valve seat and valve guides insert /valve guide or re-grind the valve
and valve seat
Incorrect tappet setting Set the correct tappet setting with the
Worn out liner, piston and piston Replace the worn out liner, piston and
rings piston rings
Sticking of piston rings Clean the piston and piston rings. If
necessary replace.
Engine requires major Carry out the major overhaul through an
overhauling authorised service dealer
Problem with A/C Generator like Replace the carbon brushes
voltage fluctuation because of
worn out carbon brushes.
5.15 Engine Air System
Overheating Poor ventilation in engine room / With the help of an authorised service
hot air
Choked air cleaner element Clean/Change the filter element
and shaft
Excess back pressure due to Clean/Replace the chocked silencer
Chocked silencer
Exhaust pipe length, diameter and Carry out the corrective measures as
bends are not as specified specified
After cooler is in chocked Clean the after cooler as specified in
condition the maintenance manual
Lube Oil System
Prolonged oil change period Replace the Lube oil with new Lube oil
Dirty or chocked suction tube Clean the suction tube strainer
strainer
Clogged oil passage Clean the clogged oil passage
Clogged Lube oil cooler Clean the clogged Lube oil cooler
Oil level too low Fill the fresh Lube oil up to the „high‟
mark on dipstick
Chocked oil filter Replace the Lube oil filter cartridges
Relief valve sticky Clean the sticky relief valve
Lube oil temperature gauge/ Replace the faulty lube oil temperature
Sendor unit faulty or not gauge/ sendor unit or use the lube oil
matching (Manufacturer is not temperature gauge/ sendor unit from
same) same manufacturer
7
Cooling System
Faulty water temperature gauge Replace the faulty water temperature
gauge
Coolant leakage Remove the coolant leakage
Less or no coolant in cooling Fill the cooling system with fresh
system coolant
Radiator type cooling system
Radiator core chocked Clean the radiator core as specified
After-cooler core chocked Clean the after-cooler core as specified
Heat exchanger type cooling system
Heat exchanger tubes chocked Clean the heat exchanger tubes as
specified.
After-cooler tubes chocked Clean the after-cooler tubes as
specified.
Pressure cap on balance water Replace the pressure cap as specified. If
tank is of incorrect specification missing or rubber seal is damaged,
or missing or its rubber seal is in replace the new pressure cap as per ct
damaged condition specifications.
Improper belt tension Properly adjust the belt tension
Worn out belt Replace the worn out belt
Wrong size of belt Use belt of correct size
Thermostat element sticky or not Replace the thermostat element
opening at required temperature
Air lock in water passage Remove the air lock in the water
passages
Excess scale formation on Remove the scale formed on the
cylinder liner due to bad quality cylinder liner. Clean the cooling system
of cooling water with „K‟ clean
Engine water pump
Leakage of coolant through seal/ Replace the water pump/ pump
pump mounting joint mounting joint
Excess water pump shaft play Replace the water pump
Sea water pump (in case of marine)
Excess water pump shaft play Replace the water pump
Fuel System
Delivery valve in fuel pump is Service the fuel pump delivery valve
sticky or worn out from an authorised service dealer
Faulty/Choked fuel injector Check the nozzle spray, it should give
the “squeaking” noise. If necessary
replace the injector
8
Mechanical System
Excessive load on engine Reduce the „excessive‟ load on engine
up to full load capacity
Bearing failure indicated by low Carry out the major overhaul through an
lube oil pressure and high lube oil authorised service dealer
temperature
In case of diesel generating set, Balance the load within the tolerance of
the load is not equally balanced 10 to 12% on 3 phases
on 3 phases
and shaft
Piston seizure indicated by Replace the seized piston and liners
increase in blow by through
breather tube
Stuck/Broken piston rings Replace the broken piston ring with new
piston ring set. (It is preferable to
replace piston ring set complete instead
of a single ring) If piston and liner are
damaged, replace them.
rings piston rings
5.16 Temperature Note the difference (delta T) Run the engine on full load for at least
rise in between the ambient temperature 1 hour with the canopy doors open. If
canopy and the temperature at air cleaner the engine temperature is still rising,
inlet. If delta T exceeds 5°C to check all the points mentioned in the
7°C, the defect is due to engine Engine Overheating, Sr. No. 5.15.
overheating.
5.17 Low Lube Air System

Oil Pressure Choked air cleaner element Clean/Change the filter element
hot air
Damaged air cleaner Replace the damaged air cleaner
Air inlet hose connection loose or Tighten the hose clip/clamp on hose or
hose badly damaged replace the damaged hose
Restriction indicator damaged or Replace the damaged restriction
missing indicator
Air inlet manifold joints damaged Replace the damaged joints
Inlet manifold nuts in loose Tighten the nuts of air inlet manifold
9
condition with proper torque
Lube Oil System
Lube oil pressure gauge / Replace the defective Lube oil pressure
pressure sendor unit defective gauge / pressure sendor unit
Prolonged Lube oil change period Replace the Lube oil with new Lube oil
Lube oil dilution with diesel / Drain the diluted lube oil and fill the
coolant specified lube oil
Choked Lube oil filter cartridges Replace Lube oil filter cartridge
Relief valve sticky Clean the sticky relief valve
Suction tube strainer choked Clean the suction tube strainer
Suction tube joint damaged Replace the damaged joint
Delivery body 'O' ring damaged Replace the damaged „O‟ ring
Relief valve „O‟ ring damaged Replace the damaged „O‟ ring
Excessive backlash in lube oil Replace the lube oil pump
pump gears or worn out gears
Loose oil gallery plug/plugs Tighten the loose plug/plugs
Improper plugging of crankshaft Plug the crankshaft oil holes properly
oil holes
Clogged Lube oil passages Clean the clogged Lube oil passages
Lube oil leakages Remove the Lube oil leakages
Defective / chocked Lube oil Replace/clean the Lube oil cooler
cooler
Cooling System
Overheating due to defective Check all points as mentioned in Fault
cooling system 'Engine overheating'
Piston cooling oil spray nozzle Replace the oil spray nozzle
breakage
Dirty engine Clean the engine
Fuel System
Mechanical System
Incorrect bearing clearance Carry out the major overhaul through an
Worn out / Damaged main and Replace the main and connecting rod
con rod bearings bearings through an authorised service
dealer
10
rings piston rings
5.18 Engine emits Air System
black smoke Air cleaner choked / damaged Clean/replace the chocked element/
Replace the damaged air cleaner
Air inlet hose connections to air Replace the damaged hose, air inlet
cleaner, air inlet manifold manifold
damaged
Air leakage of after cooler hose Arrest air leakage of after cooler
connections or pipe pipe/hose connection
After cooler badly choked Clean the after cooler as specified
Turbocharger bearing, shaft worn Replace the turbocharger / Arrest the air
out / Turbocharger leaking leakages from the turbocharger
hot air
Restriction in air inlet manifold Clean the air inlet manifold
due to some foreign particle
Lube Oil System
Chocked/ cramped Lube oil Clean the chocked pipe or remove the
supply pipe to turbocharger cramp in the pipe
Fuel System
Fuel pump plunger and barrel Service the fuel pump from the
worn out authorised service dealer
Incorrect calibration of fuel pump Re-calibrate the fuel pump with the help
Smaller diameter fuel inlet pipe Recommended inside diameter for fuel
used inlet is 8 mm for power generation
application and 10 mm for other variable
speed applications
Return line blocked Clean the blockages in the return line or
if line is damaged replace
Delivery valve sticky or nylon Service the fuel pump from an
11
washer on delivery valve is in authorised service dealer
damaged condition
Exhaust System
Excess back pressure in exhaust Check whether the Exhaust pipe length,
system diameter and no off bends used are as
specified. If not correct accordingly
Mechanical System
Bearing failure Carry out the major overhaul through an
Piston seizure indicated by Replace the seized piston and liners
increase in blow by through
breather tube
of a single ring)
rings piston rings
gasket
Cylinder head valve seat face Reground the valve seat and valve with
damaged emery and carry the diesel leak test
before use
5.19 Excessive Choked air cleaner element Clean/Change the filter element
smoke during Incorrect tappet setting Set the correct tappet setting with the
'No Load' help of an authorised service dealer
Incorrect fuel injector pressure Correct the injector pressure with the
setting help of an authorised service dealer
Defective / Faulty fuel pump Service the fuel pump with the help of
an authorised service dealer
Low compression Check the cylinder liner bore and piston
ring condition. Replace cylinder liner/
piston rings if necessary
12
Incorrect valve timing Adjust the valve timing correctly with
the help of an authorised service dealer
Valve leakages Arrest valve leakages
dealer
Incorrect fuel pump setting Calibrate the fuel pump with the help of
Faulty turbocharger Replace turbocharger
Engine needs overhauling Overhaul the engine through an
5.20 Excessive Choked air cleaner element Clean/Change the filter element
smoke at full Deration due temperature As per the site conditions, calculate the
load resulting in engine overloading full load capacity of the engine and
accordingly reduce the load on engine
Overheating due to defective Check all parameters mentioned in
cooling system „Engine Overheating‟
Broken valve spring Replace the broken valve spring
Excessive crankshaft end play Replace the thrust washer set
13
dealer
Worn valves and valve guides Replace the worn out valve and valve
guides
Faulty turbocharger Replace turbocharger
After-cooler tubes chocked Clean the after-cooler tubes as
specified.
Engine needs overhauling Overhaul the engine through an
5.21 Engine emits Wrong grade of Lube oil used Use specified grade of Lube oil
blue smoke Excess oil Drain the excess oil from the engine
Damaged turbocharger seals Replace the turbocharger seals through
Worn valve stems and valve Replace the worn out valves and valve
guides guides
Worn out piston rings and liners Replace the worn out piston rings and
liner
5.22 Engine emits Water mixed with Diesel Drain the water-diesel solution, clean
white smoke the fuel tank and fill with fresh diesel
Water seeping into the Replace the cylinder head gasket
combustion chamber
5.23 Coolant or Coolant leakage
oil leakage Loosening of cylinder head bolts Tighten the cylinder head bolts with
proper torque in specified sequence
Coolant leakage from cylinder Apply araldite or replace the core plug if
head and crank case due to damaged
seepage from core plug on
cylinder head / crank case
Loose bolts of plate type Lube oil Tighten the bolts with proper torque as
cooler specified
Coolant leakage from water Replace the water pump/ pump
pump seal or pump mounting mounting joint
joint
Porosity in cylinder head/ crank Replace the porous cylinder head or
case crankcase
Lube oil leakage
Clamping bolts or nuts in loose Tighten the bolts or nuts with proper
condition torque as specified
Damaged rocker cover joint Replace the damaged joint
Improper fitment of Lube oil Re-fit the Lube oil filter cartridge as
filter cartridge specified
Damaged oil seal due to improper Replace the damaged oil seal as
14
fitment specified
In case of leakage check: Threading of the bolt or nut. Any cracks
near the hole or in threaded portion
Washer is missing or damaged
Uneven machining of seating portion
of bolt or nut
Condition of the joint / gasket
 Torn out
 Shifted from the position
 Reverse fitment
 Improper diameter of holes
5.24 Bearing Air System and Lube Oil Check all the points related to „dust
Wear System entry‟ in to the engine as mentioned in
Fault „Low Lube oil pressure‟
Mechanical System
Crank shaft oil hole chocked due Clean the oil passages in the crankshaft
to metal burr
Sludge formation because of bad Change the oil
quality of oil or foreign material
of a single ring)
rings piston rings
Excessive crankshaft end play Replace the thrust washer set
5.25 Wear or Air System
seizure of Poor ventilation in engine room / With the help of an authorised service
Liner, Piston hot air getting re-circulated dealer improve the engine room
and Piston ventilation. Avoid the re-circulation of
ring hot air. If necessary get the help of an
Dust entry Check all the points related to dust entry
in to the engine as mentioned in Fault
„Low Lube oil pressure‟
Lube oil System
Choked Lube oil filter cartridges Replace Lube oil filter cartridge
External and internal Lube oil Find the cause of oil leakage and take
leakages suitable action to avoid leakages
Defective Lube oil pump Replace the defective Lube oil pump
Chocked piston cooling nozzle Replace the chocked Piston cooling
nozzle
15
Less oil in the sump Fill the oil up to the high mark on
dipstick
Low Lube oil pressure and high Check all points related to „Low Lube
Lube oil temperature oil pressure‟ and „High Lube oil
temperature‟, as mentioned in Fault Low
Lube oil pressure
Lube oil pipe burst or chocked Replace the burst pipe or clean the
chocked pipe
Mechanical System
Crankshaft jammed or not Replace the main bearing ser to provide
moving due to less bearing proper clearance
clearance
of a single ring)
rings piston rings
and shaft
Cooling System
Engine Overheating Check all the points related to
overheating due to faulty cooling system
as mentioned in the Fault „Engine
Overheating‟
Fuel System
Diesel dilution due to damaged Replace the damaged „O‟ ring/seal with
feed pump 'O' Ring/ fuel pump new one and change the oil
seal damaged
Leaking cylinder head inlet valve Arrest valve leakage. Re-grind the valve
seat and valve with emery and do the
diesel leak test before use
16
5.26 Excess Blow Check the Running Hours of the Engine. Check the colour of the smoke
Bye Air System
Clogged / Dirty air cleaner Clean the air cleaner. Clean/replace the
chocked element
and shaft
hot air. If necessary get the help of an
Lube Oil System
Low Lube oil pressure Check all the points related to Lube oil
system as mentioned in the Fault „Low
Lube oil pressure‟
Mechanical System
and valve seat
Piston rings butt gap in one line Rotate the piston rings so as the butt gap
do not come in one line
Excess butt gap in the piston Check the butt gap. The butt gap must
rings be as specified in workshop manual. If
not, replace the piston ring set. Re-check
the butt gap. If the butt gap is still out of
limit value, check the bore size of
cylinder liner. If the bore size out of the
limit value as specified in workshop
manual, replace the liner.
Intermediate gear bush worn out Replace the intermediate gear bush
Cam bush worn out Replace the cam bush set
High Lube oil consumption Check all the points related to Fault
„High Lube oil consumption‟
Bearing worn out Carry out the major overhaul through
rings piston rings
Overheating Check all the points related to fault
„Engine Overheating‟
5.27 High Lube Air System
17
Oil Dust entry Check all the points related to dust entry
Consumpt- in to the engine as mentioned in Fault
ion „Low Lube oil pressure‟
Lube oil throw into the air inlet Clean the turbocharger lube oil drain
manifold due to restriction into pipe
the Lube oil drain pipe
Lube oil throw in the inlet and Replace the turbocharger
exhaust manifold due to
Turbocharger shaft and bearing
worn out
Lube Oil System
Excess oil in the sump Drain the excess oil from the sump
Oil level checked incorrectly Bring the equipment on leveled ground
(Equipment not on leveled and recheck the oil level. The excess oil
ground) should be drained
Short dipstick used Use correct dipstick and recheck the oil
level. The excess oil should be drained
Lube oil leakages Arrest all the lube oil leakages
Excess oil supply to rocker levers Reduce the excess oil supply to rocker
Wrong adjustment of oil metering levers Readjust the metering screw to
screw reduce the excess oil supply
Excess Lube oil pressure Adjust the relief valve in the system to
reduce the lube oil pressure as specified
Cooling System
Check all the points related to Refer Fault „Engine Overheating‟ and
cooling system which leads to Fault „Low Lube oil pressure‟
Low Lube oil pressure and High
Lube oil temperature
Mechanical System
and valve seat
Excessive clearance between Check all journal diameters and select
crank journal and bearing the main bearing set to keep proper
clearance between main bearings and
crankshaft
Excess butt gap in the piston Check the butt gap. The butt gap must
rings be as specified in workshop manual. If
not, replace the piston ring set. Re-check
the butt gap. If the butt gap is still out of
limit value, check the bore size of
cylinder liner. If the bore size out of the
limit value as specified in workshop
18
manual, replace the liner.
Piston rings become sticky Clean the piston and piston rings
Lube oil throw into the exhaust Increase the load on engine
manifold due to engine running
for longer period in under-load
condition (less than 30 % of the
full load capacity of the engine)
Overcooling of the engine. Check the thermostat element. Replace if
(Please confirm that the liquid in necessary
the exhaust manifold is Lube oil
and not un burnt diesel.)
rings piston rings
5.28 High fuel Air System
Consumption Clogged / Dirty air cleaner Clean the air cleaner. Clean/replace the
chocked element
Excess back pressure in the Check whether the exhaust pipe length,
exhaust system diameter and no off bends are as
specified. If not, correct accordingly
Fuel System
Fuel leakages Find the cause of fuel oil leakage and
take suitable action to avoid leakages
Faulty feed pump leading to lube Repair/replace faulty feed pump
oil dilution with diesel
Fuel injection pump elements Service the fuel pump from the
worn out authorised service dealer
Mechanical System
help of an authorized service dealer
19
gasket
20

Workshop Manual DV Series

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Workshop Manual DV Series

Uploaded by

Copyright:

Available Formats

DV SERIES WORKSHOP MANUAL

KIRLOSKAR OIL ENGINES LIMITED

We pursue highest quality adherence for zero defect

 ISO 9001 certification for Quality Management System since 1992 by

All pervasive IT in operations

DG Genset the Specific Anecdote:

DV Engine series, the Specific anecdote:

Sr. No. Topic Page

1.2) General Instructions

Engine Serial No.

Engine Serial No.

Engine Serial No.

19 Governor Electronic type

Reasons to pre-load fasteners

Tightening High Tensile Fasteners by Torque Wrench

Sr.No. Description Initial Tightening Method Total torque

 When replacing main or connecting rod bearings, during overhaul/piston seizures,

Engine Rotating Tool (DV0.950.524) FWE Oil Seal Pressing Tool

Mandrel for cam bush pressing (DV0.950.519)

Cylinder liner clamping tool (DV0.950….) Bumping clearance checking gauge

DV0.950.502 Tool for Liner Pressing

Sr. No. Tool Description Tool Specification

5 Ring spanner 12x13 mm

13 Adjustable wrench 150 mm

14 Speeder wrench 600 mm

15 Extension 100 mm long

17 Ratchet 300 mm long

18 Screw Driver 150 mm long

20 Teflon Mallet 40 mm diameter

21 Internal circlip pliers 150 mm

22 Cutting pliers 200 mm

23 Torque Wrench EVT600RR 0-7 kgm

25 Allen Socket 17mm

1.12) Recommended Procedure for Engine Preservation

5) FOR WATER COOLED ENGINES WITH CLOSE CIRCUIT COOLING

Engine speed during above running:

9) FOR WATER COOLED ENGINE WITH CLOSE CIRCUIT COOLING SYSTEM

12) Dipstick on engine to be sealed in place, with waterproof adhesive tape.

13) IMPORTANT "DO NOT ROTATE CRANKSHAFT AFTER ABOVE MENTIONED

14) Loosen 'V' Belt tension.

Commissioning of 'Preserved' Engine

1. Remove all the sealing tapes/papers from various openings.

It is recommended to use Anticorrosion/Descaling additive in the fresh water.

ANNEXURE 1 : RECOMMENDED PRESERVATIVES

Manufacturer Preservative for --

Sr. No. Topic Page

In case of open generating sets

In case of generating sets with canopy

 Disconnect wiring from the

 Disconnect wiring from the starter

In case of generating sets with canopy

Remove the radiator pressure cap.

In case of open generating sets

 Remove the breather pipe

 Disconnect the rubber hoses on

 Remove the venting pipe.

 Disconnect hose bend from both air

 Remove Heat shields from both

 Remove the injector leak-off pipes

 To avoid the ingress of dust, cover

 Disconnect the high pressure pipes

 To avoid the ingress of dust, cover

 To avoid the ingress of dust, cover