Eicher EE483TC Operation And Maintenance Manual Download Page 1

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Pub. No : M190456 : 01

Nov 2012

OPERATION AND MAINTENANCE MANUAL

EE483TCI Power Generation Engine

EE483TC &

Summary of Contents for EE483TC

Page 1: ...Pub No M190456 01 Nov 2012 OPERATION AND MAINTENANCE MANUAL EE483TCI Power Generation Engine EE483TC ...

Page 2: ... Parts Illustration 6 to 8 3 4 Technical Specification Engine 9 to 10 3 5 Engine Systems and Function 11 3 5 1 Air Intake and Exhaust System 11 to 13 3 5 2 Lubrication System 14 to 17 3 5 3 Fuel System 17 to 19 3 5 4 Cooling System 20 to 21 Part IV Engine Electrical System 22 to 23 Part V Safety Guidelines 24 to 25 Part VI Recommended Routine Checks By user 26 to 28 Part VII Engine Inspection and ...

Page 3: ...tion 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...

Page 4: ...er cooled Turbo charged Intercooled Diesel Engines designed to suit Power Generation application 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...

Page 5: ...E IDENTIFICATION Engine is identified with the engine nameplate 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 1 2 and 3 Engine Sl No is also punched on the Cylinder block as shown in the figure 4 Fig 1 EE483TC 38 Kw Fig 2 EE483TC 48 Kw Fig 3 EE483TCI 59 Kw Engine Sl No Punched on Cylinder Block Fi...

Page 6: ...M Dec Note I is omitted Year of production A to W A 2010 W 2028 Note I is omitted Type of fuel used D Diesel Version N NA Naturally aspirated C TCI Turbo Charged intercooled T TC Turbo Charged Swept Volume per cylinder 83 0 83 Litres No of Cylinders 4 or 6 EICHER G Identification for Power Generation Engine ...

Page 7: ...an Radiator 4 Tank Condenser 17 Fan Cooling Radiator 5 Bracket Radiator Support 18 Pipe Fuel filter to Fuel injection pump 6 Cushion Radiator Support Bracket 19 Stop Solenoid 7 Cap Oil Filler 20 Feed pump 8 Pipe Turbo to Intake Manifold 21 Pipe fuel Feed Pump to fuel filter 9 High Pressure Pipe 22 Fuel injection Pump 10 Rocker Cover 23 Oil Sump 11 Hose Turbo out 24 Starter Motor 12 Hose Breather 2...

Page 8: ...leaner 38 Hose turbo charger in 29 Pipe Lubrication Turbocharger 39 Turbo charger 30 Manifold Exhaust 40 Filter Oil Main 31 Cooler Oil 41 Bend Exhaust 32 Manifold Intake 42 Filter By Pass 33 Switch Cum Sensor Water Temperature 43 Pedestal Front 34 Pipe Air Cleaner to Turbo 44 Sensor oil Pressure 35 Housing flywheel 45 Alternator Battery charging 36 Engine Identification plate 46 V Belt Engine Alte...

Page 9: ...ED INTERCOOLED ENGINE 1 2 3 4 5 6 7 8 1 Hose Air Filter to Pipe TC in B 5 Intercooler Assy 2 Pipe TC in B 6 Hose Thermostat to Radiator 3 Hose Intercooler Outlet 7 Pipe Turbo Charger to Intercooler inlet 4 Pipe TC in A 8 Hose Pipe Intercooler inlet to Intercooler in ...

Page 10: ...Conditions Ambient Relative Humidity Altitude 25 C 40 1000 mbar Engine Deration Applicability Above 4000 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 Governing Class Class A 1 Engine Low Idling Speed RPM 700 50 Engine Fly Up Speed RPM 1560 10 Engine Firing order Sequence ...

Page 11: ... Type Centrifugal Coolant Specification Recommendation JIS K 2234 94 EICHER GENUINE RADIATOR COOLANT Engine Cooling Fan Type Pusher Electrical System V 12 Starter Motor Make V Kw Bosch 12 1 9 Kw Bosch 12 3 2 Battery Charging Alternator Make V Amps Bosch 14 49 Shut off Solenoid Type Energise to Stop Switch Low Oil Pressure Applicability Yes Switch High Coolant Temperature Applicability Yes Switch A...

Page 12: ...ve 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 ...

Page 13: ... 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 effi...

Page 14: ...sidential mufflers are used to achieve reduction in noise levels INTER COOLER APPLICABLE FOR TURBO CHARGED INTERCOOLED ENGINES Compressed hot air from turbocharger flows through the tubes of intercooler 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 o...

Page 15: ...etal 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 line...

Page 16: ...il sump 4A Oil bypass alarm 8B Idler bushing 14 Pressure control valve 22 Fuel Pump 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...

Page 17: ...formed during normal operation of engine The filtered oil is sent to Main oil gallery BY PASS FILTER 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...

Page 18: ...f fuel as per designed requirements Fuel Tank Feed pump Fuel Filter Fuel Injection Pump Injection Nozzle Return line Diesel tank 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 no...

Page 19: ...s Do not top up fuel in fuel tank when the engine is under operation as the process will allow sediments and water to float and gets carried away along with fuel Always top up fuel in fuel tank when the engine is not in operation Wait for few minutes and allow sometime for sediments and water to settle at the bottom of the fuel tank before starting the engine FEED PUMP The feed pump is driven by t...

Page 20: ...ves 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 Constant speed governor of the fuel injection pump is capable of holding rated speed steadily irrespective of variation in loads INJECTION NOZZLE The injection nozzles are of the hole type The fuel delivere...

Page 21: ... 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...

Page 22: ...lso separates vapour from liquid water and regulates pressure in the cooling system The radiator is of simple closed type equipped with a pressure cap The reservoir tank is open to atmosphere The coolant overflowing from the radiator is therefore 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 press...

Page 23: ...otor 12V Engine Starting 2 Battery Charging Alternator 12V Battery Charging W Point Signal for RPM Sensing 3 Temperature Sensor Cum Switch 12V 1 Signal to Engine Control Unit Temperature Gauge for Coolant temperature indication 2 Signal to Engine Control Unit Stop Relay for Stopping the Engine in the event of High Coolant Temperature 3 NO Normally open 4 Pressure Sensor 12V Signal to Engine Contro...

Page 24: ...12V Engine Normal stopping through Key Switch Stops the engine based on the command received from Stop relay in the event of Low Lubricating Oil Pressure High Coolant Temperature and High Air restriction 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 ...

Page 25: ...le 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 ...

Page 26: ...m 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 equipments PPE s while working HEAVY EQUIPMENT HAND...

Page 27: ...akage and correct if Required 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 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...

Page 28: ...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 O...

Page 29: ...th 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 ...

Page 30: ...ter Fuel Replace at Specified interval 6 Months Whichever occurs earlier R Filter Gauze Feed Pump Clean C 3 Filter Air Primary Clean Primary Cartridge Whenever Choke Indicator Provides alarm Replace with new Primary Cartridge after two cleanings or 24 Months Whichever Occurs earlier 4 Filter Air Safety Replace with new Safety Cartridge during 3rd replacement of Primary Cartridge or 24 Months which...

Page 31: ...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 ...

Page 32: ...rain 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 Secure the spring driving through the centre bolt Locate the new filter element driving through the centre bolt Secure main...

Page 33: ... 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 eleme...

Page 34: ...er 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 cm or lower compressed air agains...

Page 35: ...to NC and send signal to the stop relay there by commanding the stop solenoid to shut off the engine If it does not stop the engine then replace the Choke switch 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 th...

Page 36: ... 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 BELT TENSION CHECKING AND ADJUSTMENT As shown in figure press the V belt and check whether there is a deflection of 10 15 mm In case the deflection is less or more than the above value then loosen two bolts of ...

Page 37: ...emove the inspection cover on the flywheel housing You will observe a pointer is fitted on the flywheel housing and also access to the flywheel periphery 2 Remove the Rocker cover 3 Crank the engine with cranking handle Standard tool in the direction of engine rotation Anti clockwise when viewed from Flywheel End 4 Align the TDC Mark with the pointer 5 Check the cylinder no 1 valves for freeness T...

Page 38: ...able given above 12 Assemble the rocker cover assembly 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...

Page 39: ...38 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 ...

Page 40: ... injection Pump piping Repair Replace Cracked or loose pipes and other parts Feed Pump defective Repair Fuel Pipes feed pump gauze filter fuel filter air cleaner clogged Clean Replace 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...

Page 41: ...ng 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 sleeve valve seat leakage cylinder head gasket leakage Repair Replace worn out parts Incorrect Engine control adjustment Reset 3 Loss of Power Output Air trapped in fuel system Bleed the system If ...

Page 42: ...ke system Rectify Turbo Charger Gas leak at turbine inlet exhaust manifold joint Overhaul at Manufacturer authorized service centre Excessive dirt built up on turbo charger compressor wheel or diffuser vanes Overhaul at Manufacturer authorized service centre Insufficient oil supply to turbo charger Check and rectify 4 Black Smoke Air cleaner Muffler not in good condition Correct or replace defecti...

Page 43: ...e Foreign body damage on compressor or turbine Find out the cause of entry of foreign particles and rectify Turbine housing flap damaged Find out the cause of entry of foreign particles and rectify Overhaul at manufacturer authorized service centre Insufficient oil supply to turbocharger Check and rectify Air filter clogged Clean Replace Restricted turbo charger oil drain line Rectify Check Qualit...

Page 44: ...ve Spring set Worn or damaged piston ring Excessive clearance between piston and cylinder sleeve 6 Engine Over Heating Fan belt loose Adjust belt tension Check for damage and cracks Coolant level incorrect Add Coolant and if level continues to reduce inspect for leakages loose hose clamps and damaged hoses Radiator fins Clogged Clean and correct core bends if any Thermostat defective Replace Radia...

Page 45: ...ring deteriorated or damaged Replace Valve and Valve seat contact improper Rectify Oil Supply to rocker shaft inadequate Rectify Injection opening pressure low Repair Replace Injector spray pattern poor Repair Replace Noise comes from Gear case Neighbour hood Timing gear backlash not ok Replace gear Noise comes from cylinder head Crank Case Excessive ply in camshaft Rectify Piston Piston ring and ...

Page 46: ...d out the cause of entry of foreign particles and rectify 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 8 Oil Pressure too low Oil cooler defective Repair Incorrect oil level Check for leaks or oil trapped in Repair trouble spot and restore oil level Oil Viscosity not Ok Change oil wi...

Page 47: ...ace Piston rings or Piston Piston and sleeve worn Replace Piston or sleeve Turbo charger bearing housing sludge or coked Overhaul at manufacturer authorized service centre Excessive dirt build up on turbocharger compressor diffuser vanes Overhaul at manufacturer authorized service centre Turbo charger sealing defective Overhaul at manufacturer authorized service centre Turbo Charger Bearing defect...

Page 48: ... Nozzles defective Check for Injection Pressure Spray Condition Seat tightness Clean Nozzle Adjust injection pressure if incorrect Replace nozzles tip or Nozzle if required Engine Overloaded Avoid overloading Defect in FIP Repair Calibrate FIP from Bosch authorized service centre ...

Page 49: ...Regd Office Works 102 Industrial Area No 1 Pithampur 454 775 Distt Dhar M P India Tel 91 7292 402633 Fax 07292 402611 Website eicher in eth ...

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