TRUCKS AND BUSES

OPERATION AND
MAINTENANCE MANUAL
EE694 POWER GENERATION
ENGINE CPCB II

Pub. No. : M190514:02

July - 2016
 EE694 POWER GENERATION ENGINE
CPCB II - 100 KVA, 125 KVA & 160 KVA
CONTENTS
Section Details Page No.

Part I INTRODUCTION-OPERATION & MAINTENANCE MANUAL 01

Part II EICHER ENGINE - GENERAL INFORMATION 02

ENGINE FAMILIARIZATION 03
3 - GENERAL INFORMATION 03

3.1- Engine Identification 03

3.2- Engine Nomenclature 04

3.3- Engine Orientation and Parts Illustration 05

3.4- Engine Specifications 09

3.5- Engine Systems and Its Function 11

3.5.1- Air Intake and Exhaust System 11
Part III
3.5.2- Lubrication System 14

3.5.3- Fuel System 21

3.5.4- Cooling System 24

3.5.5- Hot EGR System 26

Part IV ENGINE ELECTRICAL SYSTEM 27

Part V ENGINES PRESERVATION AND RESTORATION FOR USE 29

Part VI SAFETY GUIDELINES 33

Part VII RECOMMENDED ROUTINE CHECKS BY USER 35

Part VIII ENGINE INSPECTION AND MAINTENANCE 37

Part IX TROUBLESHOOTING GUIDELINES 50

PART I - INTRODUCTION-OPERATION & MAINTENANCE MANUAL

We are glad to introduce us as VE Commercial Vehicles Ltd (VECV), manufactures of EICHER EE694
Power Generation Engine owned by you. VECV is committed to being the leader in customer satisfaction
in India and emerging markets. We put our best efforts to maintain global quality levels by understanding
and fulfilling customer needs.
This manual presented to you gives a comprehensive understanding on Construction, Operation
and Maintenance aspects of Engine for the intended application.
These Engines meets current prevailing emission norms.
Due care has been taken in preparing this manual. However due to Continuous improvements product
specifications and illustrations are likely to undergo change without any prior notice.
For any further information, please write to:

PRODUCT SUPPORT
NON AUTOMOTIVE ENGINES
VE Commercial Vehicles Limited
(A Volvo Group and Eicher Motors Joint Venture)
102, Industrial Area No. 1
Pithampur 454775
Dist. Dhar (M.P.)
India Phone: (07292) 402633
Fax: (07292) 402611

PUBLICATION NO: M190514:02 REVISION NO: 01

PUBLICATION MONTH: July-2016 REVISION DATE: Nov-2015

01
PART II - EICHER ENGINE GENERAL INFORMATION

EICHER EE694 Engines manufactured by VE Commercial Vehicles Ltd (VECV) are direct injection, four
Stroke, Four valve, Water cooled, Turbo charged, Intercooled Diesel Engines designed to suit various
applications.

The engines are eco-friendly, reliable and fuel efficient meets prevailing statutory emission
standards.

While we, at manufacturing and testing have taken due care to ensure trouble free performance, as an
engine owner and user, proper up keep of engine, use of genuine parts, use of Genuine oil and
Lubricants, use of Genuine Coolant and adherence to scheduled and preventive maintenance shall derive
the best out of your engine resulting in Value for Money.

02
PART III - ENGINE FAMILIARIZATION:
3. GENERAL INFORMATION
This part provides details about engine identification, engine Sl No nomenclature, Orientation, technical specifica-
tions and various Systems of engine.

3.1 ENGINE IDENTIFICATION

Engine is identified with the engine name plate fitted on flywheel housing on left hand side of the engine when
viewed from front. Engine name plate contains the information as shown in the figure below. Engine Sl No. is also
punched on the Cylinder block.

EE694 – 100 KVA

Engine Sl. No Punched on Cylinder Block

xxxx xxxx

EE694 – 125 KVA

Engine Sl. No Punched on Cylinder Block

xxxx
xxxx

03
 EE694 – 160 KVA

Engine Sl. No Punched on Cylinder Block

xxxx

3.2 ENGINE NOMENCLATURE

Engine Codifica on Nomenclature
EDS = Engine Descrip ve Sec on
EIS = Engine Indicator Sec on

EDS EIS
G/E - Non Auto Engines, G - Genset Engines,
E 6 1 3 C D C H XXXXXX G E - Industrial Engines
Running Serial Number
Month of Manufacturing (A to M), A= Jan & M = Dec. Note: “I” is omi ed

Year of Manufacturing (A to W), A= 2010 W=2028. Note: “I” is omi ed

Type of fuel [D=Diesel, C=CNG, L = LPG]

Version [N=NA, C=TCI, T=TC]

Emission Norms [Refer Table 1]

1-2 Valve, 0.83 Ltrs.
2-4 Valve, 0.94 Ltrs.
No. of Cylinder (4 or 6)
EICHER

Table - 1
CODES
Sr. No. Engine Type
1 2 3 4 5
1 Genset CPCB 1 CPCB 2 CPCB 3

2 Industrial CEV 1 CEV 2 CEV 3 CEV 4 CEV 5

04
3.3 ENGINE ORIENTATION AND PARTS ILLUSTRATION(EE694TCI -TURBO CHARGED INTERCOOLED ENGINE)
a) For 100 KVA & 125 KVA

Ĉ Assembly Air Cleaner 13 Radiator Hose W ater Inlet

2 Hose Air Cleaner Turbo Inlet 14 Intercooler Inlet Hose
3 Inlet M anifold 15 Radiator Fan
4 Inlet Manifold Connector 16 Alternator
5 High Pressure Pipe 17 Reservoir Tank
6 Intercooler Outlet Hose 18 Radiator Strip RH Support
7 TC Outlet Hose 19 Rear Pedestal for Transportation
8 Intercooler Pipe Inlet 20 Air Restriction Indicator
9 W iring Harness 21 Flywheel Assembly
10 EGR Valve 22 Flywheel Housing
11 Exhaust Bend 23 Engine identification Plate
12 Radiator Top Bracket 24 Oil Sump

6
13 12
4

10
14

5 8
3 34
15
9
17
1 16
31
11
2
29
7 26
20 27

32 33
23 25
30
18
28
21 22
24

19

25 Turbo Oil Supply Pipe 30 Front Pedestal

26 Oil By Pass Filter 31 Vacuum Pump
27 Turbo Oil Drain Pipe 32 Radiator Assembly L Bracket
28 Main Oil Filter 33 Support Assembly Bracket
29 Turbo Charger 34 Radiator Shroud
05
 35

54

53
41 42

36 37 52
39 50
49
51
43
45 38 47
40 48

44 46

ĊD Radiator Outlet Hose 45 Dip Stick

36 Engine Stop Solenoid 46 Breather Hose
37 Fuel Injection Pump 47 Fuel Injection Timing Inspection Cover
38 Feed Pump-FIP 48 Speed Sensor
39 Filter to FIP Pipe 49 Engine Control unit (ECU)
40 Fuel Filter 50 Fuel Return Pipe
41 EGR Valve Pipe 51 Air Cleaner Dust Cap
42 EGR Solenoid 52 Air Cleaner Assembly Bracket
43 Feed pump to Fuel Filter Hose 53 Oil Filling Cap
44 Starter Motor 54 Engine Lifting Hook

06
b) For 160 KVA

1 Assembly Air Cleaner 13 Radiator Hose W ater Inlet

2 Hose Air Cleaner Turbo Inlet 14 Intercooler Inlet Hose
3 Inlet M anifold 15 Radiator Fan
4 Inlet Manifold Connector 16 Alternator
5 High Pressure Pipe 17 Reservoir Tank
6 Intercooler Outlet Hose 18 Radiator Strip RH Support
7 TC Outlet Hose 19 Rear Pedestal for Transportation
8 Intercooler Pipe Inlet 20 Air Restriction Indicator
9 W iring Harness 21 Flywheel Assembly
10 EGR Valve 22 Flywheel Housing
11 Exhaust Bend 23 Engine identification Plate
12 Radiator Top Bracket 24 Oil Sump

13
12

6 17
33

10 14
8

5 9 15
3

1 16
30
11
2 28

7 18
20 26
31
25 32
23 29

21 27
22 24

19

25 Turbo Oil Supply Pipe 30 Vacuum Pump

26 Turbo Oil Drain Pipe 31 Radiator Assembly L Bracket
27 Combo Oil Filter 32 Support Assembly Bracket
28 Turbo Charger 33 Radiator Shroud
29 Front Pedestal

07
34 Radiator Outlet Hose 44 Breather Hose
35 E-Governor 45 Fuel Injection Timing Inspection Cover
36 Fuel Injection Pump 46 Speed Sensor
37 Feed Pump-FIP 47 Engine Control unit (ECU)
38 Filter to FIP Pipe 48 Fuel Return Pipe
39 Fuel Filter 49 Air Cleaner Dust Cap
40 EGR Valve Pipe 50 Air Cleaner Assembly Bracket
41 Feed pump to Fuel Filter Hose 51 Oil Filling Cap
42 Starter Motor 52 Engine Lifting Hook
43 Dip Stick 53 Spike Suppresser

34

52
51
40

53
35 47
36 50
38 45
48 49
37
41 44 46
43
39
42

08
3.4 ENGINE SPECIFICATIONS
Details
Parameters Unit 100 KVA 125 KVA 160 KVA
Engine Manufacturer Name VE Commercial Vehicles Ltd

Engine Make Make EICHER

Engine Model Model EE694TCI

Emission Compliance Standard CPCB II

No of Cylinders Nos. 6

Engine Configuration Configuration Inline / 4 Stroke/4 valve

Engine Aspiration Type Turbo Charged Inter cooled

Engine Fuel Type High Speed Diesel

Combustion Chamber Type Type Direct injection

Cylinder Bore X Stroke Mm 100 X 120

Engine Displacement Litres 5.65

Compression ratio Ratio 17.5:1 ± 0.5 mm

Engine Rated Output Kw @ RPM 95@1500 115@1500 148@1500

Ambient / Relative
Standard Operating Conditions 25°C / 40 % / 1000 mbar
Humidity / Altitude

2% for every 1000 feet 3% for every 1000

Engine Deration Applicability
above 3000 feet feet above 3000 feet
Rating Standard Standard IS10000

Overload Permissibility 10 % over load Permissible for 1 Hour in Every

12 Hours of Operation
Governing Standard Standard BS5514 / IS 10000 ISO 8528

Governing Class Class A1 G3

Engine Low Idling Speed RPM 700 ± 50

Engine Fly Up Speed RPM 1580 ~ 1615 1580 ~ 1615 1505

Engine Firing order Sequence 1-5-3-6-2-4

Direction of Rotation Direction Anti Clock wise when viewed from Flywheel End

Flywheel Standard SAE J 620 SAE 11.5

Flywheel Housing Standard SAE J 620 SAE 2

09
 Parameters Details
Unit
100 KVA 125 KVA 160 KVA
Lubrication Method Method Oil Pump Forced feed system

Oil Pump Type Gear Type

Oil Filter-Main Type / Nos. Paper Type / Single

Oil Filter-By Pass Type Spin on Type Paper Spin on Type Paper NA

Oil Cooler Type Shell Type

Engine Lubricating Oil Recommendation EICHER Premium Diesel Engine Oil

% of Fuel
Lubricating Oil Consumption < 0.15 %
Consumption

Minimum Lubricating Oil Bar 1.5

Pressure @ Low Idle
Max Lubricating Oil Pressure
Bar 5.5
@ Fly up Speed

Fuel Injection Pump Make/Type Bosch / Inline

Fuel Filter Type / Nos. Cartridge type / 2 Nos.

Cooling Method Method Liquid Cooling / Forced Circulation

Water Pump Type Centrifugal

Coolant Recommendation EICHER GENUINE RADIATOR COOLANT

Engine Cooling Fan Type Pusher

Electrical System V 12 V DC

Starter Motor Make / V Bosch / 12 V

Battery Charging Alternator Make / V Bosch / 12 V

Shut off Solenoid Type Energize to Stop Energize to Stop E-Governor

Controlled
Switch – Low Oil Pressure Applicability Yes
Switch – High Coolant
Temperature Applicability Yes

Switch- Air Cleaner Choke Applicability Yes (Mechanical)

Sensor-Water temperature Applicability Yes
Sensor-Lubricating Oil Pressure Applicability Yes
10
3.5 ENGINE SYSTEMS AND ITS FUNCTION
As we all know, Diesel engine is a prime mover developing useful power. Air and fuel is required to produce power.
Lubrication is necessary for the moving parts of the engine. Continuous cooling is required to dissipate heat generated
during combustion. Electrical system is required for engine starting, battery charging and sensing of critical engine
operating parameters.
The construction of EICHER Diesel Engine is divided in to five parts as below.
1. Air intake and Exhaust System
2. Lubrication System
3. Fuel System
4. Cooling System
5. Electrical System
The below section provides details of function, key components and working principle of respective system to
understand better about Engine aspects.

3.5.1 Air intake and exhaust system

TURBO CHARGED INTERCOOLED ENGINES
The function of air system is to supply clean, cool and sufficient quantity air required for proper combustion of the fuel
which results in designed power output of the engine and maintains emissions as per statutory norms.
Air intake system facilitates cleaning of air, induction of air, compression of air through turbocharger and cooling by
intercooler.

Air is sucked from atmosphere and passed through the Air filter to restrict dust and other foreign particles from entering
into air intake system. Clean air is then induced and compressed by the turbocharger compressor wheel. Turbocharger
increases the temperature of the air. This high temperature air is then passed through an intercooler which decreases its
temperature. As air inducted cools down its density is further increased. Due to more air with desired density of air inducted
into the engine there will be complete combustion resulting in:

11
• Increase in power and torque without increasing the size of the engine.
• Improves fuel economy.
• Reduce engine noise.
• More complete combustion resulting in cleaner emission
AIR FILTER
Air filter is fitted on the Suction Side. It is paper cartridge dry type air filter comprising of inner and outer element. Air filter
prevents dust and other foreign particles entering into the air inlet system. The restriction Indicator fitted on the filter
gives indication when air filter gets clogged.

Do not run the engine with clogged air filter. Clogged air
filter reduces power output, fuel efficiency; higher
exhaust emissions and affects engine performance.
Air filter outer element shall be cleaned whenever the
restriction indicator gives indication. There are limitations
for cleaning as frequent cleaning affects air filter filtration
efficiency. Follow the recommendation for cleaning
procedures and permissible number of cleaning. The
inner element should not be cleaned and it should be
replaced.
Never run the engine without air filter. Running without air filter will cause foreign object entering into air system and
results in turbocharger and engine failures.

TURBO CHARGER

The exhaust gases discharged from the combustion

chamber are driven out through the exhaust manifold into
the turbo charger and accelerated in the turbine housing
to turn the turbine wheel driving away the Exhaust gases
through the muffler to the atmosphere.
Simultaneously, the compressor wheel mounted on the
same shaft spins at the designed speeds. The centrifugal
action draws air from air cleaner and builds up the boost
pressure in the intake system.

12
SILENCER:

Silencer is used to reduce the noise of exhaust gas / Smoke. The

exhaust gas is sent through a number of small holes provided
inside the silencer which results in sudden expansion of
exhaust gases.

This results in reduction in exhaust noise.

INTER COOLER

Compressed Cooled Compressed hot air from turbocharger flows through

air out the tubes of intercooler.
Compressed Hot
air in
Pusher type radiator cooling fan charges Cold air
through the intercooler fins carries away the heat from
compressed hot air flowing through the intercooler
tubes thereby reducing the temperature of air to the
designed temperature levels. This compressed cold air
rushes in to the combustion chamber.

13
3.5.2 LUBRICATION SYSTEM
The engine has a forced lubrication system. The main functions of the Lubrication systems are as follows:

• Lubricates moving engine parts by forming a thin film of oil between components and prevents metal to metal contact
• This oil film is capable of absorbing shocks in Con-rod Bearings and Gear train
• Flowing oil absorbs heat and cools engine parts
• Oil also collects carbon & metal particles formed during engine operation and flows it to the oil pan
• Oil neutralizes the acids and alkali produced during engine operation & prevents corrosion
• Seals compression by forming a thin oil film on cylinder liner walls

ENGINE OIL FLOW PATH:

For 100 KVA & 125 KVA

3
4

10

1
2

1. Oil strainer 5. Engine oil pressure switch 9. To compressor

2. Oil pump 6. Bypass filter 10. Turbo charger
3. To oil filter 7. Piston cooling gallery
4. Main oil gallery 8. Oil jet for piston cooling

14
ENGINE OIL FLOW PATH:

For 160 KVA

3
4

1
2

1. Oil strainer 5. Engine oil pressure switch 9. To compressor

2. Oil pump 6. Turbo charger
3. To oil filter 7. Piston cooling gallery
4. Main oil gallery 8. Oil jet for piston cooling

15
SCHEMATIC DIAGRAM OF LUBE OIL FLOW
For 100 KVA & 125 KVA

5B 5 9A 9 11
8A
5A 7
18
4A 4 9B 12 13

8
3 9C 10 11A 14 17

2 2A 15 16

1 19

1. Oil strainer 7. Engine oil pressure switch 12. Rocker bushing

2. Oil pump 8. Bypass filter 13. Oil jet for piston cooling
2A. Relief valve 8A. Restriction orifice 14. Piston cooling gallery
3. Sub main oil gallery 9. Crankshaft main bearing 15. Conrod small end bushing
4. Oil cooler 9A. Crankshaft main bearing No.7 16. Piston
4A. Oil cooler bypass valve 9B. Idler bushing 17. FIP
5 Oil filter 9C. Timing gear 18. Turbo charger
5A. Oil bypass alarm 10. Connecting rod bearing 19. Oil sump
5B. Oil filter bypass valve 11. Camshaft bushing
6. Main oil gallery 11A. Thrust washer, camshaft gear

16
SCHEMATIC DIAGRAM OF LUBE OIL FLOW
For 160 KVA

5B 5 9A 9 11
5A 7
18
4A 4 9B 12 13

3 9C 10 11A 14 17

2 2A 15 16

1 19

1. Oil strainer 7. Engine oil pressure switch 14. Piston cooling gallery
2. Oil pump 9. Crankshaft main bearing 15. Conrod small end bushing
2A. Relief valve 9A. Crankshaft main bearing No.7 16. Piston
3. Sub main oil gallery 9B. Idler bushing 17. Compressor
4. Oil cooler 9C. Timing gear 18. Turbo charger
4A. Oil cooler bypass valve 10. Connecting rod bearing 19.Oil sump
5 Oil filter 11. Camshaft bushing
5A. Oil bypass alarm 11A. Thrust washer, camshaft gear
5B. Oil filter bypass valve 12. Rocker bushing
6. Main oil gallery 13. Oil jet for piston cooling

The oil required for lubricating the engine parts is sucked by the oil pump from the sump through the strainer.
The pressurised engine oil is then sent to oil cooler, where the oil is cooled and then it is sent to the oil filter for filtration.
The filtered oil is then sent to all engine parts through main oil gallery. By pass oil filter is provided for fine filtration.
LUBE OIL PUMP
The oil pump is of gear type and is driven by the skew
gear mounted on the camshaft.

The oil pump cover also serves as the oil filter head,
requiring no oil pipe.
Engine oil is pressurized to the required pressure by the oil
pump and sent to various parts for lubrication and
From oil strainer cooling.

17
OIL COOLER

Shell type oil cooler facilitates heat dissipation from engine

lubricating oil and maintains engine lubricating oil
temperature and viscosity to the desired levels.
Water outlet
The Pressurized oil from oil pump is sent into the oil cooler for
cooling the hot engine oil. The coolant from the cylinder block
is passed through oil cooler element, which takes away the
heat from the engine oil.

LUBE OIL FILTER (Applicable For 100 KVA & 125 KVA)

The full flow barrel type paper filter removes carbon and
fine metal particles formed during normal operation of
engine. The filtered oil is sent to Main oil gallery.

BY PASS FILTER: (Applicable For 100 KVA & 125 KVA)

The Spin on type by pass filter mounted on engine block
through adopter which has a small orifice is used for fine
filtration of lubricating oil. The bypass filter allows a portion of
main gallery oil to flow through it & back to the oil pan through
an adopter having a small orifice. During replacement the
whole filter to be replaced

COMBO OIL FILTER : (Applicable For 160 KVA)

The full flow barrel type paper filter removes carbon and
fine metal particles formed during normal operation of
Unfiltered Oil
engine. The filtered oil is sent to Main oil gallery.

Filtered Oil

18
TURBO CHRAGER LUBRICATION

Bearing house Oil from oil main gallery flows through the oil tube to
Engine oil bearing housing of turbocharger to lubricate bearing and
is returned through the outlet tube at the bottom of the
bearing housing through the crank case and to the oil
pan.

To oil Piston ring

Piston ring
pan

Bearing

FUEL INJECTION PUMP LUBRICATION

Oil from oil gallery flows through banjo tube to FIP & lubricates
camshaft and governor mechanism and then drained to the oil
sump from the FIP gear side of FIP housing.

Pipe Lubrication - FIP

ELECTRONIC GOVERNOR

Electronic control
unit (ECU)
Electronic Governor controls the engine speed
Rotary automatically and runs using electronic power with
Actuator emission reduction technique (EGR). This system consist
of (1) Electronic Control Unit, (2) Magnetic Pick up Unit,
(3) Rotary Actuator with Linkage.
Linkage

ELECTRONIC CONTROL UNIT (ECU)

The ECU measures the speed from the frequency of the MPU
and compares this with the desired setting speed, and then
commanding the rotary actuator from FIP. It stops engine after
receiving STOP signal from Genset Control Panel.

19
MAGNETIC PICK UP UNIT (MPU)

The MPU is fitted on engine Flywheel housing. Main

function of MPU is to send the engine speed signal to

ROTARY ACTUATOR WITH LINKAGE

The rotary actuator is fitted on engine FIP's STOP lever. It
receives the command from ECU and changes the angle of the
mechanical linkage to the fuel valve to control the fuel flow
from FIP.

SPIKE SUPPRESSER

The Spike suppresser is an electrical device inserted in a

power line to protect ECU from sudden fluctuations in
current.

DO'S & DONT'S

Do's FUNCTION & WORKING PRINCIPLE
● Check the all connections are done properly, check for lose
FIP
connections.
● Check the “MPU, EGR & Actuator” connections are properly Engine Speed signal

connected as per the given sequence.

Command

● Check reverse spring is removed from FIP. MPU ECU

Engine Stop Signal
● Check for free movement of actuator linkage.
● Connect the Battery + ve on pin no #1 & Battery - ve on pin
no. #2 of ECU properly. Actuator
12V Power
Don't's Genset Control
EGR
Panel Battery
● Don't connect AC voltage to ECU's battery voltage pin's.
● Don’t remove 12V / 24V battery when the genset is ON.
● Don't modify the linkage length without permission from
OEM.
● Don’t wash, spray paint, Oil on linkage of Actuator.
● Don't apply any DC / AC voltage on actuator pin.
20
3.5.3 FUEL SYSTEM

The function of fuel system is to feed the engine with clean and sufficient quantity of fuel as per designed requirements.

For 100 KVA & 125 KVA

For 160 KVA

The fuel system consists of the injection pump, fuel filter, injection nozzle, injection pipe and other parts. Fuel is fed from
the fuel tank through suction pipe to the feed pump of the fuel injection pump assembly and then to the fuel filter, injection
pump and injection nozzle.
The excess fuel is returned from the Nozzle to injection pump and to the fuel tank.
21
FEED PUMP Priming pump

Piston
The feed pump is driven by the Fuel injection pump camshaft. Holder

Oil seal
The priming pump allows manual lift of fuel when the injection
pump is stationary. It may be used when bleeding the system.
Valve housing
The gauze filter removes large particles of dust from the fuel Gauze filter
lifted from the fuel tank, preventing the feed pump from
getting clogged. The filter must be washed in clean diesel Connector
periodically. Piston

FUEL FILTER

The fuel from the feed pump is supplied to fuel filter for filtration. The dual filter is of element type and replaceable individually

Filtered fuel
Un filtered fuel

Fuel inlet from

feed pump

Fuel filter element

fuel outlet to
injection pump Drain plug

Fuel from feed pump flows into the outer side of the filter housing and filtered by the element and supplied to the fuel
injection pump. The above diagram shows the flow path of fuel in fuel filter.

22
FUEL INJECTION PUMP

The Bosch in line type fuel injection pump is used. The injection
pump, that forces fuel into the injection nozzle under pressure
is provided with a mechanism to increase or decrease the
amount of fuel. It has one plunger and delivery valve for
each cylinder.

The plunger pushed up by the camshaft and pushed back by the

plunger spring, moves up and down in the plunger barrel on a
predetermined stroke to feed fuel under pressure. In doing so it
opens and closes the suction and discharge ports to adjust the
fuel injection rate.

The speed governor of the fuel injection pump is capable of holding any speed steadily between idling and maximum speed.

INJECTION NOZZLE

The injection nozzles are of the hole type. The fuel delivered
from the injection pump enters the nozzle holder. When it
reaches the specified pressure value, the fuel overcomes the
spring force to push up the needle valve of the nozzle tip,
spraying from the injection orifice at the end of nozzle into the
cylinder.

The injection pressure can be adjusted by increasing or

decreasing the number of washers in the spring.

23
3.5.4 COOLING SYSTEM:

The function of the cooling system is to absorb and dissipate heat generated during combustion thereby maintaining engine
coolant temperature as per designed parameters. To ensure the same the engine is cooled by forced circulation of coolant by
the water pump. Radiator cooling fan driven by the V Belt from the water pump pulley charges cold air through the radiator
fins which carries away the heat from the coolant. This continuous process of circulation and heat dissipation ensures the
operating temperature of the engine is maintained.

The coolant temperature around the combustion chamber should be maintained at optimum levels for satisfactory
performance of the engine. It takes more time to achieve the desired operating temperatures at low ambient temperatures,
engine warm up periods and light loading conditions. Hence a thermostat is installed in the cooling system which controls the
coolant temperature around the combustion chamber to the desired level all times during engine operation.

WATER PUMP:
The water pump is of centrifugal type and it is driven by
the V-belt from the crankshaft pulley. A unit seal is
installed between the impeller and Water pump to
prevent leakage of coolant. There is drain hole provided at
the bottom of the water pump case which ensures that
coolant, should it leak from the unit seal, does not enter
the bearings. The water pump is mounted on the timing
gear case provided with a suction pipe and swirl chamber.
Pressed into one end of the water pump shaft is the
impeller with backward blades which feeds coolant under
pressure into the engine.

24
THERMOSTAT:
The thermostat is of a bottom bypass configuration, has a valve
controlled by a special wax enclosed in a pellet. The wax
changes from solid to liquid as it is heated, involving volumetric
change for regulating the flow of coolant.

The changes in the valve position with varying coolant

temperatures regulate the flow rate of coolant into the
radiator and water pump (bypass side), thus controlling
coolant temperature

RADIATOR:

Pressure cap
The radiator, with a tube-and-corrugated-fin type core,
not only cools the engine coolant but also separates
vapour from liquid water and regulates pressure in the
cooling system.

The radiator is of simple closed type, equipped with a

Reservoir tank pressure cap. The reservoir tank is open to atmosphere.
The coolant overflowing from the radiator is therefore
Radiator stored in the reservoir full with coolant at all times.

RADIATOR PRESSURE CAP:

The pressure cap regulates the pressure in the cooling system. When the pressure builds up exceeding the predetermined
level, the pressure valve compresses the pressure spring relieving the excessive pressure to the atmosphere. As the coolant
temperature falls forming a vacuum in the radiator, the vent valve opens to admit air into the radiator, thus preventing the
radiator from being deformed by the vacuum.

25
3.5.5 HOT EGR Sytem
Exhaust Gas Recirculation (EGR) is a nitrogen oxide (NOx) emissions reduction technique used in petrol/gasoline and
diesel engines.
The ECU controls the solenoid to shut off vacuum to the EGR valve at cold engine temperatures, idle speed, and wide-open
throttle operation. EGR is usually not required during the following conditions:
a) Idle speed
b) When the engine is cold
c) At wide-open throttle (WOT)

For 100 KVA & 125 KVA For 160 KVA

2 1

1. EGR Valve
2. EGR Solenoid

Caution :
The piping connections from alternator vacuum pump
to EGR valve must be routed through solenoid switch
with proper wiring connections, failure of connections
can cause black smoke.

EGR Valve:
EGR valve controls a small passageway between the inlet
and exhaust manifold. When vacuum is applied to the EGR
valve, the diaphragm pulls the valve and opens it allowing
exhaust gas to pass from exhaust manifold to inlet
manifold.
1. Spring 2. Diaphragm 3. Valve

26
PART IV- ENGINE ELECTRICAL SYSTEM:
12 V, Negative Earthing Electrical systems is used on the engine. Electrical systems consist of the following and its usage is
discussed as below.

Operating Usage Illustration

S/N Name of component
voltage

1 Starter motor 12V Engine Starting

Battery charger Battery Charging / W Point

2 12V
alternater Signal for RPM Sensing

Signal to Engine Control Unit / Gauge oil

3 Pressure sensor 12V pressure for oil pressure indication

1. Signal to Engine Control Unit / Stop

Relay for Stopping the engine in the
4 Pressure switch 12V event of Low Lubricating Oil Pressure
NC-Normally Closed

Signal to Engine Control Unit /

Temperature
5 12V Temperature Gauge for Coolant
sensor
temperature indication

Engine Normal stopping through Key Switch/

Stops the engine based on the command
6 Engine Stop 12V received from Stop relay in the event of Low
Solenoid Lubricating Oil Pressure, High Coolant
Temperature and High Air restriction

27
S/N Operating Usage Illustration
Name of component
voltage

EGR ECU commands the EGR solenoid

E Governor with switch to activate results in opening of
7 12V
EGR ECU vacuum passage to operate the EGR valve

EGR Solenoid switch activates and open the

8 EGR Solenoid Switch 12V Vacuum Passage based on the command
received from EGR ECU

Speed sensor is mounted on the

flywheel housing which is used to
9 Speed Sensor 12V sense the signal from the flywheel
of the engine

Signal to Engine Control Unit /Stop Relay

Temperature 12V
10 for Stopping the Engine in the event of
switch
Coolant Temperature

The ECU measures the speed from the

frequency of the MPU and compares this
11 ECU 12V
with the desired setting speed, and then
commanding the rotary actuator from FIP.

It receives the command from ECU and

12 Rotary Actuator 12V changes the angle of the mechanical
linkage to the fuel valve

The Spike suppresser is an electrical

13 Spike Suppresser 12V device inserted in a power line to protect
ECU from sudden fluctuations in current.

Proper earthing, recommended Voltage, proper Crimping of wiring connections and avoiding loose connection is
mandatory for satisfactory performance of electrical system.

The basic engine is supplied with the above features for integration to Engine control unit / Instrumentation. The
Equipment manufacturers are requested to refer engine manufacturer for necessary details.

28
PART V - ENGINE PRESERVATION AND RESTORATION FOR USE
The procedure for the engine preservation & restoration for use is provided in flow chart for necessary adherence.

Engine Receipt of Decision of

Engine by Engine Integration
dispatch
OEM/ Storage of engine on
By VECV
Dealer equipment

YES
Follow
Procedure - Engine
Engine Month Follow Procedure Engine Decision of
NO Use of Engine Engine Preservation
of Mfg. <180 NO Do Due for
- Preservation of Preparation Report -
Days (Less than Preservation Re-Preservation for integration
Engine for Use Submission
180 Days) on Equipment to VECV
After Preservation

YES

Follow
Preservation
Procedure Send back
not carried
- Engine engine for
out by
Preparation Refurbishment
OEM/ Dealer
for use

PROCEDURE – PRESERVATION OF ENGINE

a) Confirm engine preservation expiry month & remove identification TAG.
b) Remove the Poly cover wrapped around the engine and sealing of all openings before carrying out preservation.
c) Remove rust preventive additives from un-painted surfaces as given (Table: 1) and clean the surface by using NC thinner.
d) PRESERVATION GUIDELINES FOR COOLING SYSTEM:
1)Drain Engine coolant and store it in safe place with proper sealing and it can be reuse up to its shelf life.

NOTES :
Place ensure while filling coolant, it must be filtered and free from dust and foreign particles

2) Seal the water pump inlet connection by using a fabricated plate or hose. (Ensure no leakage should happen).
3) Remove the thermostat to facilitate filling of engine preservative coolant.
4) Fill the Engine with Clean Water + Preservative as per ratio through water outlet opening up to full level.
5) Keep the engine coolant preservative in the engine for 5 minutes and then drain it completely.
6) Cover the water pump inlet connection by plastic cap to avoid dust entry.
7) Install the thermostat & cover the water outlet opening.
e) PRESERVATION GUIDELINES FOR FUEL SYSTEM:
1) Prepare solution of clean HSD+ preservative oil in the ratio 5:1 in separate tank
2) Connect the tank to the engine fuel injection pump using priming pump.
3) Circulate solution of HSD+ preservative in fuel system to ensure this solution reaches to all moving parts.

29
f) PRESERVATION GUIDELINES FOR LUBRICATING SYSTEM:
1) Drain & discard Engine lubricating oil as applicable.
2) Use lubrication oil priming pump for priming.
3) Ensure lubrication oil priming pump delivery is connected to engine main oil gallery.
4) Prime the engine with preservative oil (As given in Table :3)
5) Circulate the engine lubrication preservative oil & ensure the lubrication pressure gauge shows min. 1kg/cm² pressure.
Bar the engine during the process.
6) Drain the engine lubrication preservative oil from the oil pan.

NOTES :
Guideline for reuse of Oil & Coolant preservative - It can be used up to maximum 10 times.

g) OTHERS CHECKS:
1) Loosen the belt tension on fan belt, water pump belt and other accessories driven by belt.
h) STORAGE AFTER PRESERVATION
1) Confirm & ensure that the engine is wrapped with poly cover, sealing of all openings with protective caps, tapes &
availability of rust preventive additives on unpainted ferrous surfaces (As given in Table : 1).
2) Keep the engine in clean, dry place & protected from rain water & dust.
3) Re - TAG engine with revised engine preservation expiry details.
4) For Engine codification details refer (3.2 ENGINE NOMENCLATURE)
i) REPEAT THE PRESERVATION PROCESSES EVERY SIX MONTHS IF NOT PUT ON USE.

PROCEDURE – ENGINE PREPARATION FOR USE AFTER PRESERVATION

a) Remove engine identification TAG.
b) Remove the poly cover wrapped around the engine & sealing of all openings.
c) Remove rust preventive additives from un-painted surfaces as given in Table 1 & clean the surface by using NC thinner.
d) Unfasten engine from packing case as applicable.
e) Always use engine lifting hook for movement of engine.
f) Upon integration of engine on the equipment, proceed for further mentioned activities.
g) Connect all peripherals connections as applicable
h) Replace with new EICHER genuine engine main lubricating oil filter.
i) Replace with new EICHER genuine engine by pass filter.
j) Replace with new EICHER genuine fuel filters.
k) Replace with new EICHER genuine engine coolant as per recommended ratio.
l) Restore the belt in its position & ensure its alignment & for proper tension.
m) Start the engine, run at idle and check for any oil, coolant, air leakages. Correct if required.
n) Stop the engine after 15 minutes running (Warm up) to ensure all engine lubricating oil gets collected in oil sump. Check
30
engine lubricating oil level & top up to high level mark on the dip stick if required.
o) Check engine coolant level & top up to desired level if required.
p) Start the engine. Apply load on the engine gradually as per standards & perform performance checks.

Table No. -1 Rust Preservation details

Manufacturer Rust Preservative

IOCL (Indian Oil) Servo RP 125

HPCL (Hindustan Petroleum) Rust Top 274

BPCL (Bharat Petroleum) Bharat Rustrol 152

Castrol India Russtilo DW 904 or DW901

Table No. -2 Engine Coolant Preservation details

Manufacturer Engine Coolant Preservative

IOCL (Indian Oil) Servo Cut S 20% Emulsion with water

HPCL (Hindustan Petroleum) Kool Kit 40.5 % Emulsion withWater

BPCL (Bharat Petroleum) Bharat Sherol B Emulsion with water ratio 1: 20

Tide water oil co (India Ltd - Veedol) Veedol Amulkut 4 Emulsion with water 1:15

Table No. -3 Engine Lubricating Oil Preservative details

Manufacturer Engine Lubricating Preservative

IOCL (Indian Oil) Servo Preserve 30 or Servo Run-N oil 30

HPCL (Hindustan Petroleum) Autoprun T120

BPCL (Bharat Petroleum) Bharat preserve oil 30

Tide water oil co (India Ltd - Veedol) Veedol 30/40

31
OEM / Dealer Report No OEM / Dealer Report Date : OEM / Dealer Report Date :
OEM / Dealer Name: OEM / Dealer Location :
OEM / Dealer Location : Engine Month of Manufacturing :
OEM / Dealer VECV Customer Code :
Engine Sl No :
Engine Month of Manufacturing :
ENGINE PRESERVATION ADHERENCE RECORD
Detail 1 Detail 2
Month Date Month Date
CHECK LIST (TICK AND CONFIRM)
Ė ÒǾintake & Exhaust System LUBRICATION SYSTEM

Engine oil sump filled to correct level and With

Air filter Element sealing EICHER GENUINE Lubricating oil

Hoses for any Cracks Engine Oil Sump Drain Plug tightness
Main Lubricating oil Filter replaced With New EICHER GENUINE
Hose Clamps-Tightness
Main oil filter
By Pass filter replaced With New EICHER GENUINE By Pass
Proper sealing of gaskets and intake manifold bolt tightness filter

Proper sealing of gaskets in Exhaust system

flanges/Joints / Welded portions Proper tightness of Turbo Charger Hose connections

COOLING SYSTEM Proper tightness of Hose connections to Fuel Injection Pump

Engine filled to Correct Level and With EICHER
GENUINE coolant as per recommended ratio Hose clamp tightness

Proper Sealing of Radiator Cap Engine breather pipe installation and proper tightness

Proper Tightness of Radiator Drain Plug PERFORMANCE CHECKS

Proper Connection and tightness from

Radiator to Tank Condenser Engine Starting and Stopping

Hose for any Cracks Proper Functioning of Sensors and Switches

Hose Clamp Tightness Inlet air & Exhaust Leakages

Radiator Cooling Fan tightness and Fan to Shroud alignment Lubricating Oil Leakages
Belt Condition, Alignment and tension Coolant Leakages
FUEL SYSTEM Fuel Leakages

Hose Connection for cracks and tightness LOAD CHECKS @ Rated Load

Fuel Filter replaced With New EICHER GENUINE fuel filter High Idle Rated Speed
ELECTRICAL
Engine Speed (RPM)
SYSTEM
Proper Tightness of Sensors ,Switches and ECU etc. Engine Oil Pressure Kg/cm² Engine Coolant Temp in ° C
Proper Clamping of Wiring Harness and Tightness

PRESERVATION OF ENGINES INSTALLED IN EQUIPMENT

Many times, the engine are installed and commissioned on the equipment but not put in service by end user for a longer
period. Periodic running of engine is a mandatory requirement.
Run the engine once in every week for 5 to 10 minutes on idle rpm. Scheduled maintenance to be carried out as per
recommendations
32
PART VI-SAFETY GUIDELINES
This section laid guidelines for safety of personal and equipment. Safety should be the utmost priority during installation,
operation and maintenance of the engine and equipment.

General safety instruction, accident prevention regulations and safety precaution defined by law must be observed.

Use of personal protective equipment must be worn during installation, operation and maintenance of the engine and
equipment.

ACCIDENTAL STARTING

Accidental starting of the engine can cause severe injury or death when working on engine. Safety must be observed when
working on engine.

Disconnect the battery before start of work negative (-) lead first. While reconnecting battery leads connect negative (-
) last.

Use lock out/tag out procedures when doing maintenance work on the engine In case engine is under remote start/ stop
operation.

ROTATING PARTS

Never operate equipment without guards and electrical enclosures. Rotating parts like Flywheel, Pulleys and radiator fan can
cause severe injury or death.

ELECTRICAL SHOCK

Never touch electrical terminals with bare hands or metal tools, always cut off the power and use insulated handled tools.
Electric shock can cause severe injury or death.

Always open the outgoing circuit breaker or isolator before starting any maintenance work on engine. Never make contact
when standing in water or wet shoes.
Never ground live terminals. It can cause electrocution.

Loose wiring is a hazard for spark and short circuit. Electrical wiring should be done properly using gland and cable harnesses.

33
HOT SURFACES

While running engine and exhaust system surface are at elevated temperature contact with them can cause severe burn
injury.

Always wear personnel protective equipment (PPE's) when working on hot surfaces. Start working on engine when it cools
down.

HANDLING ENGINE FLUIDS

Most Chemicals used in engines such as old engine oil, corrosion inhibiters; coolants and adhesives are hazardous to health.
Direct contact to Skin will cause allergy. Use of personnel protective equipment (PPE's) is recommended when using. Storage
of the same should be done as per suppliers recommendations. Oral consumption of these fluids can cause death.

Exhaust emitted from the engine exhaust is poisonous and inhalation of the same can cause harm. Always provide proper
ventilation of exhaust gases to the atmosphere.

Never smoke or permit flame near flammable fluids.

High pressure fluids can cause severe injury when pipes burst. Care should be taken when working with high pressure fluids.
Always release pressure before working on pressurized systems. Use safety goggles and personnel protective equipment's
(PPE's) while working.

HEAVY EQUIPMENT HANDLING/LIFTING

During handling heavy equipment always use proper lifting techniques. Lifting hooks should always be used. Unbalanced load
can cause injury to personal and damage to equipment.

Always use proper lifting arrangements. Check slings condition and capacity before using them. Do not stand
under the lifted loads.
Always lift load from the specified lifting points of the equipment.

Use soft/nylon slings of adequate capacity to prevent damage of equipment. Always check
operation of the crane/lifting tools before start of work.

34
PART VII - RECOMMENDED ROUTINE CHECKS BY USER
While all due care has been taken to ensure trouble free performance of the engine, a few simple routine checks by the
actual user will help to identify and fix the issue at right time which will avoid major breakdown and down time of the
equipment. It is recommended to monitor as below at regular intervals and immediately report to authorized service
center if any abnormality noticed for necessary rectification.

Details Activity

Engine Lubricating Oil Inspect for Leakage and Correct / Top up if required

V Belt Inspect for Looseness, Cracks / Damage and Correct if required

Inspect for Leakage and correct if Required

Coolant
Inspect for Level and top Up If required

All Rubber Hoses Inspect for Cracks / Damage and Correct If required

Instruments & Gauges Inspect for Proper Operation and correct if required

ENGINE LUBRICATING OIL CHECKING:

LOW FULL

A B

Ensure the equipment is placed on flat surface before checking the oil level. Do not check the oil level immediately after
stopping the engine. Allow 15 minutes after stopping the engine so that all the oil is completely drained to the oil sump. The
Engine oil level shall be checked through DIPSTICK of the engine. Always ensure the level is maintained to the full level
mark. Do not mix up different brands of oil.
Never operate the engine with oil level at Low level marks.
If any oil leakages noticed from any parts or location of the engine, report to the authorized service centre and
correct the same.

35
COOLANT CHECKING AND TOPPING UP:

Keep observing the reservoir tank coolant level and top up with
genuine recommended coolant to the maximum Level mark.

RUBBER HOSES:
Perform visual checks of all rubber hoses for cracks / damage. Report to the authorized service centre and correct if
necessary.

INSTRUMENTS & GAUGES:

All the instruments and gauges are critical for monitoring the operating parameters of the engine. The Hour meter feature
records the operating hours of the engine which is critical for planning scheduled maintenance.
Any abnormality shall be immediately reported to the authorized service centre and corrected as required.

V BELT:
V BELT Main which connects Engine Crank pulley/Battery charging alternator/water pump/ Fan Radiator is used for driving
water pump for effective Coolant circulation, battery charging alternator for delivering Battery Charging DC out Put and W
Point Signal to Engine Control Unit for RPM and Hour Indication and driving radiator cooling fan for keeping the coolant
temperature within designed parameters.

Operating the engine with belts in loose condition will result in belt slippage affecting coolant circulation, Engine cooling
performance, and battery charging alternator output and improper RPM and Hour reading.

Excessive tension will result in cracks/damage to belts and more stress on bearings affecting components reliability.
Whenever any abnormality is observed, it is recommended to correct the defects through the authorized service centre.

ENGINE STARTING CARE:

During Starting of the engine, long cranking and holding the ignition key in on condition keeping starter motor engaged with
flywheel ring gear for longer period will affect the life of starter motor. The precautions are as below.
· Release the ignition key immediately once engine firing noise is heard.
· If engine does not start, do not hold the ignition key more than 10 seconds.
· Re crank after 1 minute. If Engine does not start in three attempts, Check and correct the issue.

36
PART VIII - ENGINE INSPECTION & MAINTENANCE
Needless to say, any equipment needs scheduled and preventive maintenance care. Engine being a prime mover also needs
attention at right time in order to ensure trouble free performance of the equipment. By strictly adhering to the following
Scheduled & preventive maintenance, use of genuine spares, Lubricants and coolant will deliver satisfactory performance
of the engine and avoid down time of the equipment

DO'S AND DON'TS

GENERAL
Do's
• During Engine maintenance work and any welding work ensure that engine parts are covered properly.
• During any Engine maintenance work cover all the ports of TC and inlet system/ Exhaust system/water pump in and
out so that foreign particles would not enter.
• Cleanliness of the parts to be maintained during any service work.
• Ensure engine oil level before starting the Engine.
• Ensure coolant level on recovery tank and leakages if any.
• Ensure all engine harness connectors assembly for proper fitment and damages if any.
• Follow the engine service schedule.
• Use diesel fuel only, as engine is designed to operate on diesel only. Any deviation in fuel can affect the engine
performance, emission and durability.
Don'ts
• Do not apply external load on TC.
• Don't crank the starter with the external battery.

TURBOCHARGER
Do's
• Ensure protective caps on all openings of turbocharger.
• Ensure pre-lubrication of turbocharger.
• Ensure leak proof joints for oil & air. Check periodically.
• Run engine at idle RPM for approx.1min. Before stopping & after starting.
• Ensure all turbo connection hoses are properly clamped for no leakages.
Don'ts
• Do not expose turbocharger to dust & dirt.
• Do not add any additives in lubricating oil unless until specified.
• Do not raise the engine RPM immediately after starting.
• Do not run the engine at idle for long periods (more than 20 – 30 mins).

37
INTAKE & EXHAUST SYSTEM
Do's
• Ensure that air intake hoses are free from punctures, cuts and damages.
• Check the connection between the air cleaner and air intake manifold especially. Tighten loose clamps, if any.
• Check the air filter clogging indicator (air restriction indicator), replace the filter in case it shows the red indication.
Don'ts
• Do not touch the exhaust parts after just stopping the engine. It may cause personal injury.
• Don't disassemble the exhaust parts just after stopping engine.

FUEL SYSTEM (LOW PRESSURE)

Do's
• Replace the filter elements as per its maintenance schedule. Refer the service manual for replacing the filter elements.
• Before replacing any of the fuel system parts; disconnect fuel connections from fuel tank to avoid fuel leakages. Make
sure engine is off and cool to touch. Ensure high level of cleanliness while replacing fuel system parts.
• Operate priming pump in main filter to remove trapped air from the fuel system. Keep priming until fuel spills out of the
air vent. Whenever the fuel system has been opened up for service (lines disconnected or element replaced), it is
necessary to bleed the air from the system.
• Before priming; make sure complete fuel lines are assembled properly. Also ensure drain plug of main & primary filter
is in closed condition. Any air leakage within the fuel system will never allow successful priming. As soon as you see
any leakage of fuel in the engine, get it attended.
Don'ts
• Do not use kerosene as fuel, it reduces engine life and performance.
• Never allow the engine to run out of fuel, which results in misfiring of the engine.
• Don't crank the engine before priming of the fuel system or after any part replacement in fuel line.

FUEL SYSTEM (HIGH PRESSURE)

Do's
• Clean direct environment/ no particle or liquid contamination and ensure high level of cleanliness during parts
replacement.
• Clean hands (do not use fiber gloves) & tools. No particle or liquid contamination should be present.
• Handle parts with care and Do not use parts with impact stress(e.g. dropped, hit).
Don'ts
• Don't use same high pressure pipe again if it has to be reused. Each time replace with a new high pressure pipe.

38
LUBRICATION SYSTEM
Do's
• Ensure that oil filter element replace as per maintenance schedule. Replace with only genuine EICHER Oil. Check oil
level in engine on regular interval.
• Check (on level ground) the oil level and top up if necessary, before starting or at least 5 minutes after the engine is
shutdown.
• Use care to keep dirt and debris from entering the crankcase through the oil filler port when adding engine oil.
• Recommended to replace O-Ring whenever open the filter cap.
• As soon as you see any leakage of oil in the engine, get it attended.
Don'ts
• Do not mix different grade of lubricants during top up
• Do not overfill engine oil in sump. This may cause engine smoking and high engine oil consumption.
• Do not use of thicker engine oil for higher engine oil pressure, it will only reduced engine life.
• Be careful not to spill oil. When the exhaust system is still hot, spilled oil on the hot exhaust system can cause personal
injury and/or property damage due to fire.
• Do not spill oil on electric system. If oil is spilled, carefully wipe it off with a cloth.
• Do not drive the vehicle with the oil level below the “LOW” mark on the oil dipstick. An insufficient quantity of engine oil
can cause engine seizure.

COOLING SYSTEM
Do's
• Ensure use of genuine EICHER Coolant(50:50 ethylene glycol and distilled water)
• Check the engine, radiator, hoses and pipes daily. Repair any leaks. Replace swollen and worn hoses and tighten loose
clamps.
• Ensure to fit genuine radiator cap for pressurized cooling system.
Don'ts
• Do not top up radiator by pouring cold coolant in hot engine. The cylinder head may crack.
• Do not open the radiator filler cap while the engine is hot; wait until it cools.
• Be extremely careful when opening the radiator filler cap. Place a thick cloth on the cap and slowly loosen it to allow a
reduction in pressure in the cooling system.
• Do not add water without adding ethylene glycol antifreeze to the engine cooling system, except in an emergency. If
plain water is added in an emergency, restore the proper mixture EICHER coolant as soon as possible.
• Don't run the engine by removing the thermostat.

39
CONTROL SYSTEM
Do's
• When servicing the electrical system, be sure to off the cut off switch.
• Check battery indicator and top up electrolyte, if necessary. Keep battery terminals clean and cable joints tight. Apply
Vaseline/petroleum jelly on terminals.
• Ensure proper connectivity of ECU/sensor connectors with wiring harness in EGR.
• Reverse polarity protection: care needs to be taken while battery connection
• Ensure the right connections of power cables like starter and alternator connections.

Don'ts
• Do not allow any unauthorized person to tamper with engine settings or to carry modifications on the vehicle.
• Electrical tapping not allowed. Tapping should not be taken as this can severely affect the performance of ECU and
sensors.
• Do not run the alternator without battery connection.
• Mounting position of the ECU should not be changed.
• While removing the connector from sensor don't pull with the wires and do unlock in the connector and remove it.

40
 INSPECTION & MAINTENANCE SCHEDULE

LEGEND: C-CLEAN / D – DRAIN / I – INSPECT, ADJUST, CORRECT, REPLACE, TOP UP IF REQUIRED /

L – LUBRICATE / R – REPLACE / T – TIGHTEN TO SPECIFIC TORQUE

Every 1400 Hrs

Every 2100 Hrs

Every 2800 Hrs

Every 3500 Hrs

Every 4200 Hrs

Every 4900 Hrs

Every 700 Hrs
SL NO PART NAME ACTIVITY

1 Engine Oil Replace at specified interval / 12 Months R

whichever occurs earlier
Replace at specified interval / 12 Months R
Oil Filter (Main)
whichever occurs earlier
Replace at specified interval / 12 Months R
Oil Filter (Bypass) whichever occurs earlier
2 Replace at specified interval / 12 Months R
Fuel Filter (Main)
whichever occurs earlier

Fuel Feed Pump Gauze Filter Clean C

Clean Primary Cartridge whenever Choke Indicator provides alarm

3 Air Cleaner Element (Primary)
Replace with new Primary Cartridge after two cleanings or 24 Months whichever occurs earlier

Replace with new Safety Cartridge during 3rd replacement of Primary Cartridge or 24
Air Cleaner Safety Cartridge
4 Months whichever occurs earlier
(Secondary)
Caution: Safety Cartridge Should not be cleaned

5 Coolant Replace Coolant at Specified Interval / 24 Months I R

whichever occurs earlier

6 Engine – V Belt Inspect for Cracks / Damage and replace if required I

7 Valve Clearance Inspect and Adjust Valve Clearance if required

Inspect and retighten Cylinder Head Bolts
I

Rubber Hoses-Air intake

8 / Turbo Charger /Intercooler/ Inspect for Cracks / Damage and replace if required I
Radiator

9 Fuel Hoses Inspect for Leakage. Correct and Replace if required I

It is always recommended to carry out the above maintenance activities at the authorized service centre as it needs skilled,
trained manpower to perform the job.

41
MAINTENANCE ACTIVITY CARE
Before starting the scheduled / preventive maintenance activity, ensure the engine is started and run for around 15
minutes to confirm the engine starting ability, abnormal noise, vibrations, oil leakage, fuel leakage, function of
electrical instruments and gauges. This will facilitate in better understanding of the engine before proceeding for the
maintenance activity.
ENGINE LUBRICATING OIL REPLACEMENT
Always perform engine lubricating oil replacement when the engine is in warm condition to ensure complete draining
of lubricating oil from oil sump.

The following steps shall be followed:

Ensure equipment is positioned on flat surface. Unscrew

the oil drain plug and drain the oil in tray. Install and
retighten the Drain Plug.

Ensure to replace the Copper Gasket of the drain plug with

new.

Fill with recommended quantity of EICHER GENUINE

lubricating oil through the Filler Cap.

Allow 10 Minutes to facilitate oil to reach the oil Sump.

Reconfirm the oil level through dip stick after starting and
stopping of the engine. If found less top up to the level.
Ensure sufficient time is allowed as discussed above
before checking the oil level.

! CAUTION :
Necessary care shall be taken while working as high
temperature will result in burns.
Do not mix different brands of oil.
Clean the surface thoroughly.
Do not dispose the used oil on the ground as it is
hazardous to environment safety. Always collect,
store and dispose the old used oil in a container and
dispose as per safety rules.

42
ENGINE LUBRICATING OIL RECOMMENDATION
Details Engine
Specification EICHER EE694TCI

EICHER genuine oil & lubricants EICHER PREMIUM DIESEL ENGINE OIL
Quantity required for replacement
during scheduled maintenance 21.8 liters (including filters)

ENGINE MAIN OIL FILTER REPLACEMENT

Unscrew the drain plug and remove oil from main oil filter casing.

After draining retighten the drain plug. Ensure to replace the Copper gasket.

Unscrew the centre bolt and remove the filter casing along with element.

Remove the used main oil filter element and clean the housing.
Damage and discard the same to avoid misuse.

Insert the centre bolt in its location of the casing. Ensure to replace O'ring.

Secure the spring and spacer driving through the centre bolt.
Locate the new filter element driving through the centre bolt.

Secure main oil filter o'ring with new and ensure its seating in its location.

! CAUTION :
Cleaning and reuse of element is not
recommended.

ENGINE BY PASS FILTER REPLACEMENT:

Remove used spin on type by pass filter by using bypass

filter wrench (Part No153801).

Damage and Discard the same.

Apply oil film on the bypass filter gasket before fitment

Fit the new bypass filter by fully tightening with the hand and
then using bypass filter wrench.

After ensuring complete tightness tighten filter by rotating 90°.

43
ENGINE FUEL FILTER REPLACEMENT:

Unscrew the drain plug and drain diesel in a clean container.

Pour back the fuel in the fuel tank.

Unscrew the centre bolt and remove the fuel filter casing along
with filter.

Remove the old O'ring from its location and discard the same.

Clean the fuel filter casing with clean diesel.

Install the drain plug and tighten to 0.8 to 1.5 Kgf m (8 to 15

Nm) torque. Replace the copper gasket with new.

Install the fuel filter O'ring with new in its location. Install new

fuel filter element in the filter housing.

Secure the fuel filter housing on the filter head and tighten to
2.5 Kgf m torque (25 Nm).

Ensure the copper gasket is replaced with new.

Bleed the fuel system through Hand primer of feed pump. Wipe and clean any spilled diesel fuel as it can cause fire.

ENGINE FUEL FEED PUMP GAUZE FILTER CLEANING:

Since the fuel from fuel tank is passed first through feed
pump, due to suction process foreign particles / dust
from Fuel if allowed through the fuel system affects the
reliability of Fuel injection pump components. Hence a
gauze filter (Baby Filter) is provided at the inlet side of
fuel pump which filters any foreign particles/dust that is
being is passed through it.

Remove the filter by unscrewing the Banjo Bolt and clean

with diesel as per recommendation.

Feed Pump Gauze Filter

44
ENGINE AIR FILTER ELEMENT INSPECTION AND CLEANING:

Remove the Air cleaner assy cover.

Loosen the nut and remove the Primary air filter element.

Remove air cleaner safety cartridge.

Visually inspect both the filters for clogging / tear of element.

If there are thin portions in the filter paper, replace the

element. If the sealing of the air filter element is found
damaged, replace element.

If there is dry dust on the element, clean the dust by

blowing 7 Kg/cm² or lower compressed air against the
element.

Blow the compressed air from inside the element up and

down along the frills of the filter paper and clean the
whole element evenly.

After the element has been cleaned, put an electric lamp

inside the element to check for damage and pin holes.

If the element is contaminated with moist soot, replace it

regard less of the specified replacement frequency.

! CAUTION :

· Do not strike the element or strike it against a hard

object to remove dust.
· Primary Element Should be removed for cleaning only
when Choke switch provides alarm.
· Clean only the primary filter element. The safety
Element should never be cleaned but only replaced
at the recommended intervals.
· Frequent cleaning of elements will only result in
damage to the paper, sealing washers and rings and
wing nut which will ease the entry of unfiltered air
into the engine. It will thus reduce the air cleaning
efficiency of the element leading to serious engine
damage.

45
AIR FILTER RESTRICTION INDICATOR:
Air filter restriction
The choke indicator functioning shall be confirmed after indicator

starting the engine and closing the inlet port of air cleaner assy
gradually to increase negative pressure. The air filter
restriction indicator will show red band when air filter is
clogged.

ENGINE COOLANT REPLACEMENT:

In order to prevent corrosion of the cooling system, it is

recommended to add coolant at a ratio 50:50 of
quantity of water.

A drain cock is provided at the bottom tank of the

radiator for draining coolant from the engine.

Unscrew the drain cock and drain the coolant. Secure

the drain cock in its position after draining.

Remove Pressure cap and fill the recommended coolant

as per ratio through the Pressure cap opening.
Allow sufficient time for the coolant to get filled as air
will be removed from the engine slowly during the
coolant refilling process.

With pressure cap removed from the radiator, allow the engine to run at idle with coolant temperature of 90°C to bleed the
system completely.

After the system is bled with air, add recommended coolant to radiator as required.

46
ENGINE COOLANT RECOMMENDATION
Details Engine Coolant

Eicher genuine oil & lubricants EICHER genuine radiator coolant

Usage recommendation 1: 1 by volume i.e. 50% coolant & 50 % water

Coolant capacity ( liters) 100 KVA, 125 KVA & 160 kAV
23

! CAUTION :
· Be sure to use EICHER Genuine Coolant
· Never Mix it with any other coolant, anti-freezes
or anti rusts.
· Ensure that the caps of the radiator assembly
and that of coolant are tightened.

47
INSPECTION AND ADJUSTMENT OF VALVE CLEARENCE
Valve clearance adjustment should be performed when the
engine is cold. The engine was warm while performing the
maintenance activities as the engine was started before
starting the maintenance activities. The engine will become
cooler by the time lubricating oil and filter replacements were
completed.

Inspect and adjust the valve clearance when the engine is cold
by using the following procedure.

Before Starting the inspection and adjustment procedures,

remove the breather rubber hose, rocker cover and
inspection cover.

Using the crankshaft damper pulley installation bolt, secure the cranking tool on to the crankshaft pulley.

Turn the crankshaft in the direction of normal rotation (Anti clockwise when viewed from Flywheel side) of the engine to
align the pointer of the inspection window of the flywheel housing with the marking “0” of the flywheel.

At this time, the piston in either the No 1 or No 6 cylinder is at TDC of the compression stroke, whichof these two pistons at
TDC can be known by the position of rocker arms of intake and exhaust valves.

When the piston in the cylinder is at TDC on the compression stroke, both rocker arms are not pushed up by the Push rods
(With both intake and exhaust valves closed) and free to rotate.

When the Piston No 1 cylinder is at TDC on the compression stroke, Check and adjust clearance of valves marked with “I” in
the following table.

When the Piston No 6 cylinder is at TDC on the compression stroke, Check and adjust clearance of valves marked with “X” in
the following table.

Cylinder no. 1 2 3 4 5 6

Valve arrangement In. Ex. In. Ex. In. Ex. In. Ex. In. Ex. In. Ex.

Valve no. 1 2 3 4 5 6 7 8 9 10 11 12

No. 1 at TDC on compression stroke 0 0 0 0 0 0

No. 6 at TDC on compression stroke X X X X X X

48
Install the specified thickness gauge between the rocker and
Valve clearance
valve cap to check for clearance. (both intake and
exhaust, when
cold). NV : 0.35
If the valve clearance is out of nominal value, loosen the lock NV....Nominal value
nut and turn the adjusting screw to the extent that the
thickness gauge moves slightly tight.

After adjustment hold the adjusting screw in position with a

screw driver and tighten to secure the lock nut.

Recheck the valve clearance with the thickness gauge.

Slotted screw driver Rotate the engine one full turn and adjust clearance
of other valves.
Assemble the rocker cover, Breather Hose and
inspection cover.

ENGINE STARTING AFTER MAINTENANCE

Before starting the engine, ensure tightness all fasteners, Lubricating oil level and coolant level. The fuel systems needs
bleeding of air and proceed as below.
The feed pump has a hand primer arrangement for the
purpose. Turn the feed pump primer counter clockwise
until it becomes loose. Loosen the air plug of the fuel
filter.
Move the hand primer up and down by hand to feed fuel
until air bubbles do not come out from the fuel filter air
plug.

When no air bubbles come out along with fuel, tighten

the air plug. Press the hand primer down and turn
clockwise until it fits into its position.
Wipe out spilled fuel around the fuel filter and floor.

Actuate Starter to discharge air from Fuel Injection Pump.

After bleeding the air check for performance of engine on load, Oil leaks, Coolant leaks, Engine noise level and for any other
abnormalities before handing over to the end user.

49
PART IX - TROUBLESHOOTING GUIDELINES
Sl no Symptom Probable Cause Remedy
Inadequate fuel quantity Add Fuel

Poor Quality of fuel or oil used Change fuel or Oil

Bleed the system.

If trouble persists Check for

Air trapped in fuel system Loose

Water trapped in fuel system
· Piping & Connectors
Restriction
· for fuel flow due to blockage in fuel pipes
Possibility
· of air being sucked in from the feed pump
Drain water from fuel tank, fuel filter

Fuel leakage from injection Repair/ Replace Cracked or loose pipes and other parts
Pump piping

Feed Pump defective Repair

Fuel Pipes, feed pump gauze

Clean/Replace
filter, fuel filter, air cleaner
clogged
1 Engine Difficult to Start Incorrect fuel injection timing Reset
Incorrect Valve Clearance Reset

Injection Nozzles not clean Clean

Injection pressure not ok Rectify

Injection Spray Pattern Poor Repair / Replace Nozzle

Low engine Compression
(Worn out piston and
Repair / Replace worn out parts
sleeve/valve seat leakage/
cylinder head gasket leakage)
Ignition key defective Replace
Starter Motor defective Repair / Replace

Check for:
Fuel injection Pump defective · Starting delivery
· Variation between cylinders

Battery Discharged Recharge Battery

Incorrect fuel or oil used Change fuel or oil

Idling speed setting not ok Adjust idling stopper bolt

Bleed the system.
If trouble persists Check for

2 Air trapped in fuel system Loose

· Piping & Connectors
Idling Not Smooth
Restriction
· for fuel flow due to blockage in fuel pipes
Possibility
· of air being sucked in from the feed pump

Water trapped in fuel system Drain water from fuel tank, fuel filter

Fuel Pipes, feed pump gauze

Clean/Replace
filter, fuel filter, air cleaner clogged

50
Sl no Symptom
2 Idling Not Smooth
3 Loss of Power Output
Probable Cause Remedy
Incorrect fuel injection timing Reset
Incorrect Valve Clearance Reset
Injection Nozzles not clean Clean
Injection pressure not ok Rectify
Injection Spray Pattern Poor Repair / Replace Nozzle
Low engine Compression
(Worn out piston and
Repair / Replace worn out parts
sleeve/valve seat leakage/
cylinder head gasket leakage)
Incorrect Engine control
Reset
adjustment
Bleed the system.
If trouble persists Check for
Air trapped in fuel system Loose Piping & Connectors
Restriction for fuel flow due to blockage in fuel pipes
Possibility of air being sucked in from the feed pump
Water trapped in fuel system Drain water from fuel tank, fuel filter
Fuel Pipes, feed pump gauze
filter, fuel filter, air cleaner Clean/Replace
clogged
Incorrect fuel injection timing Reset
Incorrect Valve Clearance Reset
Injection Nozzles not clean Clean
Injection pressure not ok Rectify
Injection Spray Pattern Poor Repair / Replace Nozzle
Low engine Compression
(Worn out piston and
Repair / Replace worn out parts
sleeve/valve seat leakage/
cylinder head gasket leakage)
Air cleaner Clogged Clean/Replace
Air leakage in intake System Repair
Muffler or Exhaust pipe Repair/Replace
clogged
Feed Pump delivery quantity Rectify
and Pressure low
Air restriction in intake system Rectify
Turbo Charger - Gas leak at
turbine inlet / exhaust Overhaul at Manufacturer authorized service centre
manifold joint
Excessive dirt built up on turbo
charger compressor wheel or Overhaul at Manufacturer authorized service centre
diffuser vanes
Insufficient oil supply to turbo
charger Check and rectify
51
Sl no Symptom Probable Cause Remedy

Air cleaner / Muffler not in Correct or replace defective parts

good condition
Engine oil level is not Ok Restore Proper level
Incorrect fuel injection timing Reset
Incorrect Valve Clearance Reset
Improper fuel used Change fuel
Restricted Exhaust system Check and rectify
Clean nozzles and adjust injection pressure if required. Check
Injection Nozzles defective spray pattern and change Nozzle if required
Check / Correct or Replace.
Defective
· Cylinder head gasket
·Worn Valve and Valve Seat
Poor Compression Pressure
·Valve Spring set
·Worn or damaged piston ring
Excessive
· clearance between piston and cylinder sleeve
Restricted air duct from turbo
Rectify
compressor to intake manifold

Restricted air duct from air

cleaner to turbo charger Rectify

Air leak between Intake

manifold and engine Retighten manifold Nuts

4 Black Smoke Gas leak at Turbo charger

turbine inlet / Exhaust Retighten Mounting nuts
manifold joint

Excessive dirt build up on

compressor wheel and or Overhaul at manufacturer authorized service centre
diffuser vanes

Foreign body damage on

compressor or turbine Find out the cause of entry of foreign particles and rectify.

Find out the cause of entry of foreign particles and rectify.

Turbine housing flap damaged
Overhaul at manufacturer authorized service centre

Insufficient oil supply to

turbocharger Check and rectify

Air filter clogged Clean/ Replace

Restricted turbo charger oil Rectify / Check Quality of fuel
drain line

Turbo charger bearing housing

sludge or coked Overhaul at manufacturer authorized service centre

Worn Engine Piston rings or Replace

Liners
Burnt Valves and or Piston Replace
Turbo Charger Piston ring Overhaul at manufacturer authorized service centre
sealing defective
Turbo charger bearing
defective Overhaul at manufacturer authorized service centre

52
Sl no Symptom
4 Black Smoke
5 Improper Exhaust Colour
6 Engine Over Heating
Probable Cause
EGR Defective
Improper fuel used
Engine oil level not Ok
Full Load stopper on governor
control lever loose
Excessive Valve clearance
Incorrect fuel injection timing
Injection Nozzle defective
Air cleaner or muffler not in
good condition
Poor Compression Pressure
Fan belt loose
Coolant level incorrect
Radiator fins Clogged
Thermostat defective
Radiator Cap Pressure Valve
defective
Water Pump Impeller
damaged / Malfunction
Inferior Engine oil quality
Low engine oil level
Coolant Contaminated
Oil Cooler defective
Oil Pump defective
Cylinder head gasket leaky
Air cleaner or muffler clogged
53
Remedy
Check / Correct or Replace
Defective
· EGR valve
Defective
· Speed sensor
·EGR pipe clogged due to carbon deposition
·EGR Solenoid defective
·ECU defective
Change fuel
Restore Proper Level
Adjust and tighten the stopper bolt
Adjust
Reset
Clean nozzles and adjust injection pressure if required.
Check spray pattern and change Nozzle if required
Correct or replace defective parts
Check / Correct or Replace.
Defective Cylinder head gasket
Worn Valve and Valve Seat
Valve Spring set
Worn or damaged piston ring
·
Excessive clearance between piston and cylinder sleeve
Adjust belt tension. Check for damage and cracks
Add Coolant and if level continues to reduce inspect for
leakages,loose hose, clamps and damaged hoses
Clean and correct core bends if any
Replace
Replace
Replace
Change oil
Replenish
Flush Cooling system and change coolant
Repair
Repair
Replace
Replace
Sl no Symptom Probable Cause Remedy
Engine overloaded Avoid Overload

Check / Correct or Replace

Defective
· EGR valve
6 EGR Defective Defective
· Speed sensor
Engine Overheating
·EGR pipe clogged due to carbon deposition
·EGR Solenoid defective
·ECU defective
Piping’s and hoses not
Rectify
securely installed

Injection Pump, water Pump

and other auxiliaries not in
Check and adjust
good condition or improperly
Engine Noise- Comes
installed
from outside the engine
V Belt Loose or damaged Adjust belt tension and replace if damaged

Crankshaft pulley not installed

properly Rectify

Alternator bearing worn out Replace

Incorrect valve clearance Adjust
Valve Spring deteriorated or
damaged Replace

Valve and Valve seat contact

improper Rectify

Noise comes from rocker

Oil Supply to rocker shaft
cover and neighbourhood Rectify
7 inadequate

Injection opening pressure Repair/Replace

low

Injector spray pattern poor Repair / Replace

Noise comes from Gear
case & Neighbour hood Timing gear backlash not ok Replace gear

Excessive ply in camshaft Rectify

Piston, Piston ring and cylinder

sleeve worn out Replace

Connecting rod small end and

big end bush worn out Replace
Noise comes from
Main bearing worn out Replace
cylinder head & Crank
Case Excessive crankshaft end ply Correct by using correct thrust washer
Piston pin worn out Replace
Loose flywheel or crankshaft Rectify

Worn Cam and tappet Replace

Inferior quality of fuel (Low

cetane number) Use correct fuel

54
Sl no Symptom Probable Cause Remedy

Injection Pump Coupling loose Align timing marks and retighten bolts
Noise from around the
injection pump Injection pump piping cracked
or loose connection Rectify / Replace

Injection timing incorrect Reset

Clamping bolts & nuts of

Tighten
intake & exhaust System loose
7
Turbo charger bearing
defective Rectify through manufacturer’s authorized service centre

Foreign body damage on

Noise in Intake and Rectify through manufacturer’s authorized service centre
compressor or turbine
Exhaust System

Find out the cause of entry of foreign particles and rectify

Turbine housing / flap damage
the same
Insufficient Oil Supply to
turbocharger Check and rectify

Exhaust Pipe or muffler

damage Repair or Replace

Air leakage in intake / exhaust

system Rectify

Oil cooler defective Repair

Check for leaks or oil trapped in. Repair trouble spot and
Incorrect oil level
restore oil level

Oil Viscosity not Ok Change oil with correct viscosity

Oil Pressure switch / Gauge
defective Replace
Oil Pressure too low
Oil filter clogged Replace
Oil Strainer Clogged Clean

8 Oil Pump defective Rectify

Connecting rod bearing worn
out Replace

Oil Temperature high Rectify

Oil Pump relief valve faulty Repair/Reset
Oil Main gallery clogged Clean
Oil Pressure too high
Oil Pump Joints loose or Piping Repair/Replace
Cracked
Improper Engine oil Viscosity Use correct grade of oil
Check for oil Leaks – Oil
filter/Oil cooler/Oil Repair leaks

Pan/Piping’s/Rocker cover
9 Excessive Oil
Consumption
Lines in cooling system leaking Repair leaks of oil cooler, water jacket etc

Bearings worn Replace

Front or Rear Crankshaft oil Repair defective parts or replace
seals leaking
55
Sl no Symptom Probable Cause Remedy

Dirty air cleaner Clean

Valve stem seal worn Replace

Valve to Valve guide clearance
Replace
not ok

Piston ring and groove worn Replace Piston rings or Piston

Piston and sleeve worn Replace Piston or sleeve
9 Excessive Oil
Consumption Turbo charger bearing housing
sludge or coked Overhaul at manufacturer authorized service center

Excessive dirt build up on

turbocharger compressor / Overhaul at manufacturer authorized service center
diffuser vanes

Turbo charger sealing

defective Overhaul at manufacturer authorized service center

Turbo Charger Bearing

defective Overhaul at manufacturer authorized service center
Fuel leakage from Piping’s Rectify
Improper fuel being used Use correct fuel
Incorrect setting of idling
speed Reset

Incorrect Engine control

adjustment Reset

10 Excessive fuel Incorrect fuel injection timing Reset

consumption
Incorrect Valve clearance Adjust
Injection Nozzles defective.
Check for Clean Nozzle/Adjust injection pressure if incorrect/Replace
nozzles tip or Nozzle if required
Injection Pressure/Spray
Condition/Seat tightness
Engine Overloaded Avoid overloading
Defect in FIP Repair/Calibrate FIP from Bosch authorized service centre

56