Vectra Fitness 175 User manual

ENGINE TECHNICAL
MANUAL

Page No. : 2

Page No. : 3
CONTENTS
Section Description Page No.
A GENERAL INFORMATION ... 5
B ENGINE VIEW … 6
ENGINE SERIAL NUMBER LOCATION … 8
THREADS AND TORQUE SPECIFICATION … 9
C TECHNICAL DATA … 10
MANUFACTURING DATA AND DIMENSIONS … 11
D OPERATION AND MAINTENANCE … 18
E PREVENTIVE MAINTENANCE … 21
F FUEL SYSTEM … 27
G COOLING SYSTEM – WATER PUMP … 33
H FRONT OIL SEAL … 35
I FLY WHEEL AND REAR END OIL SEAL … 37
J LUB OIL SUMP, BALANCER UNIT AND OIL PUMP … 40
K CYLINDER HEAD … 45
ASPIRATION SYSTEM … 58
L TIMING CASE AND DRIVE … 62
M PISTONS AND CONNECTING RODS … 67
N CRANKSHAFT ASSEMBLY … 71
O CYLINDER BLOCK AND LINERS … 75
P LUBRICATION SYSTEM … 78
APPROVED LUBRICATING OILS … 79
Q ELECTRICAL EQUIPMENT … 80
R TROUBLE SHOOTING … 81
S SERVICE TOOLS … 92

Page No. : 4

Page No. : 5
SAFETY PRECAUTIONS:
The safety measures that always should be
performed in order to avoid risks that is always
present.
All servicing normally be carried out with the
engine stationary.
Do not approach the running engine with loose
cloth or long hair. Keep away from the moving
parts during engine operation.
Warning: Some moving parts can not be seen
clearly while engine runs.
Be careful of hot surfaces.
Do not open the radiator ller cap when the
engine is hot.
Do not put fuel in the tank while the engine runs.
(unless it is absolutely necessary)
Avoid skin contact with oil, fuel or chemicals that
can cause burn. Long term contact with oil can
lead to the skin problem.
Run the engine only in a well-ventilated area.
When lifting the engine use the lifting eyes that
are tted to the engine.
Never work alone when removing heavy parts.
When cleaning the engine with high-pressure
washer, never direct the jet at seals, rubber
hoses or electrical components.
Always prevent diesel or oil from contacting
rubber parts or tubing
Caution: Warns of a risk of injury, serious
damage to the product or serious malfunctions
could occur if the instruction is not followed.
Important: Is used to draw attention to things
that could cause damage to or malfunction of
the product.
Note: It is used to draw attention to important
information to facilitate procedure or handling.
Section A
GENERAL INFORMATION
TOOLS AND MEASURING EQUIPMENT
Be sure that all necessary tools and
equipments are available before starting work.
Use special tools where they are
specied.
Never drop the tools.
Use specied tools only.
REMOVAL OF PARTS:
First nd the cause of the problem and then
determine whether removal or disassembly is
required before starting the job.
INSPECTION OF PARTS:
Each part when removed should be carefully
inspected for malfunction, deformation, damage
and other problems.
All disassembled parts required for reassembling
should be carefully stored.
Ensure to separate and correctly identify the
parts to be replaced from those that will be used
again.
CLEANING OF PARTS FOR REUSE:
All parts to be used again should be carefully and
thoroughly cleaned by an appropriate method.
PARTS
When replacing parts, use genuine parts.
Oil seals, Gaskets, O-rings, Lock washers, split
pins and plastic nuts should always be replaced
with new ones.
Standard values such as torque and adjustments
must be strictly observed in the reassembly of all
parts.
FITMENT
Use correct tools, gauges and testers for correct
tment of the parts to standard value.
ELECTRICAL SYSTEM
Be sure to disconnect the battery cables from
the negative terminal of the battery
Never pull on the wires when disconnecting
connectors.

Page No. : 6
Section B
ENGINE VIEW

Page No. : 7
ENGINE VIEW

Page No. : 8
ENGINE SERIAL NUMBER LOCATION
The Engine Number is stamped on the Camshaft Tunnel of the Block
When requesting information regarding the engine, please quote complete engine number.
T SJ436 E 00027
T SJ 4 3 6 E 000 27
Turbocharged Serial Number
Simpsons Export
'J' Series
4 Cylinder 3.6 Litres
Engine Cubic Capacity

Page No. : 9
SIMPSONS ‘SJ’ SERIES DIESEL ENGINES
ALL THREADS USED IN T SJ436 E ENGINES ARE
METRIC SERIES
Except for the components indicated below :
1. Bolt and Nut, connecting rod ... ... 7/16" – 20 UNF
2. De-aerator plug on water outlet body … … 1/4" – 18 NPSI
3. Water temperature sender on water outlet body (RHS) ... 3/8" – 18 NPSI
4. Lub oil pressure gauge tapping on cylinder block (LHS) ... 1/8" – 27NPSI
RECOMMENDED TIGHTENING TORQUES
Nm Kg.m. Thread Size
Cylinder head setscrew (Camshaft tunnel side) 65 6.6 (M10 x 1.0)
Cylinder head setscrew (Refer Section K) X X (M12 x 1.5)
Connecting rod nuts 80 8.3 (7/16" - 20 UNF)
Main bearing setscrews 155 15.9 (M14 x 2)
Idler gear hub nut (lower and upper) 28 2.9 (M10 x 1.25)
Camshaft gear retaining setscrews 75 7.6 (M12 x 1.75)
F.I. pump adaptor to F.I. pump camshaft nut 92.5 9.3 (M12)
F.I. pump gear to adaptor setscrew 21 2.2 (M8 x 1.25)
Flywheel setscrews 110 11.1 (M12 x 1.25)
Crankshaft pulley retaining setscrews 150 15.2 (M22 x 2.5)
High pressure fuel pipe cap nuts 20 2.1 –
Atomiser xing nut 60 6.1
Sump drain plug 45 4.5
Oil lter / fuel lter 16 1.6
Glow Plugs (leakless tightening) (M6 x 1)
Balancer Mounting Setscrews 55 5.6

Page No. : 10
Section C
TECHNICAL DATA
Engine Type : 4 Cylinder, 4 Stroke, Inline, Water Cooled
Aspiration : Turbo Charged
Combustion : Direct Injection
Bore (Nominal dia.) : 3.74 inch (95.0 mm)
Stroke : 5.00 inch (127 mm)
Cubic Capacity : 0.952 gal (3.6 Lts.)
Compression ratio : 18.3 : 1
Rotation : Anti-clock wise from the ywheel end
Firing order : 1, 3, 4, 2
Valve Tip Clearance : 0.012 inch (0.30 mm) inlet and exhaust
Atomiser setting pressure : 250 + 8 bar (7 Holes)
Inlet valve opens : 26.8° B.T.D.C.*
Exhaust valve closes : 25.3°A.T.D.C.**
Total inlet open period : 250.6°
Total exhaust open period : 266.6°
Fuel Injection Pump : Bosch VE (Rotary) fuel injection pump mechanical
governor
Injection timing : 0.009 inch (0.22 mm) plunger lift.
When No.1 piston at TDC compression stroke.
Fuel feed pump : Electrically operated tted on Fuel Filter mounting
Bracket by Tractor Manufacturing
Provision for plunger type fuel lift pump tted on
cam tunnel, driven by engine cam shaft also is
available
Application : Tractor
RATING :
Maximum Gross Rating Ps (kW) *** : 74.8(55) @ 2200 rpm
Maximum Gross Torque Nm/lbs ft. : 295 @ 1500 rpm / 217 lbs ft. @ 1500 rpm
Rating Standard : ISO 14396
*** 1 kW = 1.341 hp = 1.359 Ps : 1 lbs ft = 1.36 Nm
DE-RATING FOR ALTITUDE :
Where engines are called upon to operate in very high atmospheres occasioned by altitude. Such engines should
be derated. Please refer to our technical department for such applications.
APPROXIMATE ENGINE WEIGHTS :
Basic weight (with alternator but without starter motor, ywheel & ywheel housing) :590.8 lb (268 Kg). Typical
installed weight (with starter motor, ywheel & ywheel housing) : 758 lb (345 Kg).
ENGINE DIMENSION :
Height : 31.90 inch (810 mm). Length : 30.62 inch (778 mm). Width : 20.00 inch (508 mm).
* B.T.D.C. – Before Top Dead Center ** A.T.D.C. – After Top Dead Center

Page No. : 11
MANUFACTURING DATA AND DIMENSIONS
The following data of clearances and tolerances are given as a guide for personnel engaged in major overhauls
and the gures are those used in the factory for production purposes.
Cylinder Block
Height of cylinder block (Top to bottom faces) … 13.743 / 13.740 inch (349. 085 / 349. 009 mm)
Parent bore dia. for Cylinder Liner … 3.8583 / 3.8580 inch (98.022 / 98.000 mm)
Depth of Recess for Liner Flange (C.I. Liners) … 0.157 / 0.155 inch (3.99/3.94 mm)
Dia Recess of Liner Flange (C.I. Liners) … 4.0476 / 4.0437 inch (102.81/102.71 mm)
Main bearing parent bore … 2.9175 / 2.9164 inch (74.105 / 74.080 mm)
No. 1 Bore for Camshaft … 1.884 / 1.883 inch (47.865 / 47.840 mm)
No. 2 Bore for Camshaft … 1.875 / 1.874 inch (47.625 / 47.600 mm)
No. 3 Bore for Camshaft … 1.865 / 1.864 inch (47.375 / 47.350 mm)
No. 4 Bore for Camshaft … 1.855 / 1.854 inch (47.125 / 47.100 mm)
No. 5 Bore for Camshaft … 1.845 / 1.844 inch (46.865 / 46.840 mm)
Cylinder Liners – Cast Iron
Type …Production liner … Dry – Interference t
Service liner … Dry pre nished transition t.
Outside diameter of liner … 3.861 / 3.860 inch (98.075 / 98.047 mm)
Interference t of liner in Cylinder Block … 0.003 / 0.001 inch (0.075 / 0.025 mm)
Inside dia. of nished liner in Cylinder Block … 3.741 / 3.740 inch (95.022 / 95.000 mm)
Outside dia. of liner ange … 4.040 / 4.037 inch (102.64 / 102.54 mm)
Flange thickness … 0.158 / 0.157 inch (4.02 / 4.00 mm)
Liner protrusion above cylinder block
machined surface (Above top face of block) … 0.003 / 0.0011 inch (0.080 / 0.030 mm)
NOTE : Reboring to oversize is not recommended
Pistons :
Type … Aln Piston with re-entrant bowl and valve pockets on
crown. O󰀨set of combustion bowl in piston crown
should be to the FI Pump side while assembling piston
in engine. (O󰀨set of valve pockets towards camshaft
side)
Piston Height above cylinder block top face … 0.006 / 0.001 inch (0.150 / 0.025 mm)
(Above block surface)
Bore Dia. for Gudgeon Pin … 1.2503 / 1.2501 inch (31.758 / 31.753 mm)
Top ring Groove Width … 0.118 inch (3.0 mm) – Half Keystone ring
2nd ring Groove Width … 0.080 / 0.079 inch (2.05 / 2.03 mm)
3rd ring Groove Width … 0.159 / 0.158 inch (4.05/4.03 mm)

Page No. : 12
Piston Rings
Top Compression … Chromium inlaid, Half Keystone (Symetric barrel on
periphery)
2nd Compression … Cast Iron, Taper land
3rd Oil Control … Conformable oil control ring
Piston Ring Width
Top ring width … 0.118 inch (3.0 mm) (Nominal)
2nd ring width … 0.078 / 0.077 inch (1.99 / 1.97 mm)
3rd ring width … 0.157 / 0.156 inch (3.99 / 3.97 mm)
Ring Clearance in Piston Groove :
Top ring clearance in Groove … Nil (since keystone)
2nd and 3rd ring clearance in Groove … 0.003 / 0.0015 inch (0.08 / 0.04 mm)
Ring Open End Gaps
Ring Gap – Top … 0.0216 / 0.011 inch (0.55 / 0.30 mm)
Ring Gap – 2nd … 0.0393 / 0.0314 inch (1.00 / 0.80 mm)
Ring Gap – 3rd … 0.0216 / 0.011 inch (0.55 / 0.30 mm)
NOTE : The ring open end gaps given above are for when checking in the unworn portion of the cylinder bore.
When checking ring gaps in a worn bore. 0.003 inch (0.08 mm) should be added to these ring gaps for every
0.001 inch (0.03 mm) increase in bore diameter
Gudgeon Pin
Type … Fully Floating
Outside dia. of gudgeon pin … 1.2497 / 1.2500 inch (31.74/31.75 mm)
Fit in piston boss … Transition
Clearance t in Small end Bush … 0.0005 / 0.0017 inch (0.013 / 0.044 mm)
Small End Bush
Type … Steel Backed. Lead Bronze Lined
Outside Dia … 1.3785 / 1.3800 inch (35.014 / 35.052 mm)
Length … 1.057 / 1.0381 inch (26.87 / 26.37 mm)
Inside Dia after reaming … 1.2505 / 1.2515 inch (31.763/31.788 mm)
Connecting Rod
Type … “H” Section
Big end Parent Bore Dia … 2.3948 / 2.3956 inch (60.83 / 60.85 mm)
Small end Parent Bore Dia … 1.3748 / 1.3763 inch (34.92 / 34.96 mm)
Big end Width … 1.5503 / 1.5523 inch (39.38 / 39.43 mm)
Big end side clearance on Crankpin … 0.009 / 0.0147 inch (0.236 / 0.375 mm)
Length between bore centers … 8.813 / 8.812 inch (223.85 / 223.82 mm)
NOTE : The numbered side of connecting rod and cap should be on the fuel injection pump side.
Connecting Rod Bearings
Type … Pre-nished, Steel Backed Aluminium Tin (or)
Copper lead
Inside Dia. … 2.250 / 2.252 inch (57.19 / 57.21 mm)
Bearing Running Clearance … 0.0023 / 0.0039 inch (0.06 / 0.10 mm)
Recommended sizes in service … 0.010" (0.25 mm); 0.020" (0.51 mm); 0.030" (0.76 mm)

Page No. : 13
Crankshaft
Refer Figure from Page No. 70
A – Main Journal Dia. (Std.) … 2.748 / 2.749 inch (69.81 / 69.83 mm)
B – Crank Pin Dia. (Std.) … 2.248 / 2.249 inch (57.11 / 57.13 mm)
C – Main Journal length Nos. 2 and 4 … 1.2145 / 1.2228 inch (30.85 / 31.06 mm)
D – Crankpin length … 1.5168 / 1.57 inch (39.67 / 39.88 mm)
E – Main Journal Length – Rear … 1.8425 / 1.8456 inch (46.80 / 46.88 mm)
F – Main Journal Length – No. 3 … 1.840 / 1.848 inch (46.73 / 46.94 mm)
R1 – Main Journal llet radii Nos. 1, 2 and 4 … 0.125 / 0.140 inch (3.17 / 3.56 mm)
R2 – Main Journal llet radious No. 3 and 5 … 0.156 / 0.166 inch (3.97 / 4.22 mm)
R3 – Crankpin llet radii … 0.172 / 0.156 inch (4.37 / 3.96 mm)
Surface nish (all Pins and Journals) … 0.4 microns (Maximum)
Crankshaft end Float … 0.002 / 0.015 inch (0.05 / 0.38 mm)
Crankshaft rear end Seal … Cassette type
Regrind Under sizes. Main and Pins … 0.010" (0.25 mm); 0.020" (0.51 mm); 0.030" (0.76 mm)
NOTE: When regrinding the crank pin length should not exceed 1.5748 inch (40.00 mm) and the rear main
journal length should not exceed 1.861 inch (47.27 mm) and Nos. 2 and 4 main Journals length should not
exceed 1.2275 inch (31.1785 mm) maximum. The maximum permissible undersize is 0.030 inch (0.76 mm)
Crankshaft main and connecting rod journals are nitrided and requires nitriding when reground to
undersize beyond 0.010” (0.25 mm)
Crankshaft Thrust Washers
Type … Steel Backed, Aluminium Tin (or) Copper Lead
Position in engine … Cylinder Block Rear Main Bearing Housing
Thickness-Standard Size … 0.121 / 0.123 inch (3.07 / 3.12 mm)
Thickness-Oversize … 0.128 / 0.130 inch (3.26 / 3.31 mm)
NOTE : While locating the Thrust Washers ensure that the plain surface/Steel back is towards the block and the
rear main bearing cap.
Main Bearings
Type ... Pre-nished. Steel Backed. Aluminium Tin or Copper
Lead
Inside Dia. (tted) … 2.7519 / 2.7535 inch (69.90 / 69.94 mm)
Running clearance … 0.0027 / 0.0051 inch (0.07 / 0.13 mm)
Recommended size in service … 0.010" (0.25 mm); 0.020" (0.51 mm); 0.030" (0.76 mm)
Camshaft
Type … Polydine with internal EGR (Part No. 14SG 4008) (Hollow
shaft located with thrust washer) Journals are pressure
feed lubricated.
No. 1 Journal Dia. … 1.8700 / 1.8694 inch (47.50 / 47.48 mm)
No. 2 Journal Dia. … 1.8602 / 1.8596 inch (47.25 / 47.23 mm)
No. 3 Journal Dia … 1.8503 / 1.8497 inch (47.00 / 46.98 mm)
No. 4 Journal Dia … 1.8401 / 1.8395 inch (46.74 / 46.72 mm)
No. 5 Journal Dia … 1.8301 / 1.8295 inch (46.50 / 46.48 mm)

Page No. : 14
Running Clearance – All Camshaft Journals … 0.004 / 0.0055 inch (0.10 / 0.141 mm)
Oil way for rocker shaft lubrication … From head to 1st rocker bracket top face
Cam Lift – Inlet … 0.251 inch (6.3814 mm)
– Exhaust … 0.292 inch (7.4169 mm)
Gear–Spigot dia … 1.378 / 1.377 inch (35.00 / 34.98 mm)
Camshaft end oat … 0.016 / 0.004 inch (0.40 / 0.10 mm)
Cylinder Head
Cylinder head total height … 4.645 inch (118 mm)
Skimming allowance on head face … A maximum of 0.0118 inch (0.30 mm) may be removed
from the Head Face provided the atomiser nozzle
protrusion does not exceed 0.147" (3.75 mm) after
skimming
Leak Test … 4 Bar for 1 minute
Valve seat angle … Inlet 30° / Exhaust 45°
Tappet bore in cylinder head … 0.6306 / 0.6299 inch (16.02 / 16.00 mm)
Valve guide bore in cylinder head … 0.5125 / 0.5118 inch (13.02 / 13.00 mm)
Permissible cylinder head bow
Transverse and Longitudinal … 0.00314 inch (0.080 mm)
NOTE : Cylinder Head for this engine has provision for tment of glow plugs to each cylinder to aid engine from
cold Starting
Valve Guides (Sintered) – Inlet and Exhaust
Inside Dia. … 0.311 / 0.312 inch (7.90 / 7.92 mm)
Outside Dia … 0.5127 / 0.513 inch (13.023 / 13.034 mm)
Overall Length … 2.323 / 2.315 inch (59.00 / 58.80 mm)
Guide Protrusion above Cyl. head Top Face … 0.392 / 0.396 inch (9.95 / 10.05 mm)
Interference t of guide in head … 0.0013 / 0.0002 inch (0.034 / 0.005 mm)
NOTE : Valve stem seal (with Sintered metal insert) is tted in both inlet and exhaust valves.
Inlet and Exhaust Valves
Valve Stem Dia (Inlet) … 0.310 / 0.309 inch (7.88 / 7.86 mm)
Valve Stem Dia. (Exhaust) … 0.310 / 0.309 inch (7.86 / 7.85 mm)
Clearance t of valve in guide (Inlet) … 0.001 / 0.0025 inch (0.023 / 0.052 mm)
Clearance t of valve in guide (Exhaust) … 0.0014 / 0.0025 inch (0.036 / 0.065 mm)
Valve face Angle (Inlet) … 29° 40’ ± 15’
Valve face Angle (Exhaust) … 44° 40’ ± 15’
Valve depth above or below cylinder head face … 0.008 inch (0.203 mm) (Inlet and Exhaust)
Valve Seat Insert (Sintered)
Outer Dia. Inlet … 1.660 / 1.659 inch (42.17 / 42.15 mm)
Exhaust … 1.522 / 1.521 inch (38.67 / 38.65 mm)
Thickness Inlet … 0.242 / 0.238 inch (6.15 / 6.05 mm)
Exhaust … 0.257 / 0.253 inch (6.55 / 6.45 mm)
Valve Spring
Free length … 1.771 inch (45.0 mm)
Fitted length … 1.496 inch (38.0 mm)
Load at tted length … 111 lbf.ft (150 Nm)
Tappet
Outside Dia. of Shank … 0.6292 / 0.6288 inch (15.984 / 15.973 mm)
Clearance t in Cylinder head ... 0.0006 / 0.0017 inch (0.016 / 0.045 mm)

Page No. : 15
Rocker Shaft
Outside Diameter … 0.748 / 0.747 inch (19.000 / 18.979 mm)
Rocker Lever
Bush Bore Diameter … 0.748 / 0.750 inch (19.01 / 19.06 mm)
Running clearance of Bush on Shaft … 0.004 / 0.003 inch (0.01 / 0.08 mm)
Timing Gears
Crankshaft gear – Steel … 26 Teeth
Idler gear (Lower) – Steel … 48 Teeth
Idler gear (Upper) – Steel … 43 Teeth
Camshaft gear – C I … 52 Teeth
Fuel Pump gear – Steel … 52 Teeth
Camshaft Gear
Gear Bore Diameter … 1.379 / 1.378 inch (35.02 / 35.00 mm)
Clearance t of Gear on Spigot … 0.000 / 0.002 inch (0.00 / 0.05 mm)
Idler Gear and Hub (Upper / Lower)
Bore Dia of gear … 2.001 / 2.000 inch (50.82 / 50.80 mm)
Diameter of hub … 1.997 / 1.996 inch (50.72 / 50.69 mm)
Clearance of gear on hub … 0.005 / 0.003 inch (0.128 / 0.075 mm)
Gear width … 1.193 / 1.190 inch (30.31 / 30.24 mm)
Bearing length of hub … 1.602 / 1.594 inch (40.69 / 40.49 mm)
Gear end-oat … 0.008 / 0.003 inch (0.20 / 0.08 mm)
NOTE : The bore and faces of bushes should be nished to the specied dimensions by machining after pressing
the bushes in the gear bore.
Crankshaft Gear
Diameter of Bore … 1.499/ 1.501 inch (38.09 / 38.13 mm)
Spigot Dia of crankshaft … 1.5005 / 1.5000 inch (38.11 / 38.10 mm)
Transition t of Gear on Crankshaft … 0.011 / 0.0015 inch (0.03 / 0.04 mm)
Fuel Pump Gear
Diameter of Bore … 1.891 / 1.892 inch (48.03 / 48.05 mm)
Pump adaptor Dia. … 1.890 / 1.889 inch (48.00 / 47.97 mm)
Clearance t of gear on spigot … 0.004 / 0.002 inch (0.10 / 0.06 mm)
Timing Gear Backlash
All Gears … 0.003 inch (0.08 mm) (min.)
Balancer Unit & Lubricating Oil Pump (Mid Mounted)
Oil Pump type … Rotor
Number of teeth on drive gear … 13
Number of teeth on idler gear … 34
Backlash between idler and drive gear … 0.013 / 0.023 inch (0.325 / 0.575 mm)
Backlash between idler and C/S gear … 0.005 / 0.015 inch (0.125 / 0.375 mm)
Backlash between spar gears on balancer shafts … 0.003 / 0.008 inch (0.075 / 0.020 mm)
End ow at idler gear and hub … 0.003 / 0.011 inch (0.075 / 0.275 mm)
Lubricating Oil Pump Clearances
Inner Rotor to Outer Rotor … 0.0004 / 0.0023 inch (0.01 / 0.06 mm)
Inner Rotor end clearance … 0.0015 / 0.0031 inch (0.04 / 0.08 mm)
Outer Rotor end clearance … 0.0004 / 0.0023 inch (0.01 / 0.06 mm)
Outer Rotor to Pump Body … 0.011 / 0.013 inch (0.28 / 0.33 mm)

Page No. : 16
Lubricating System Pressure
Lubricating Oil Pressure … 29.87 / 59.74 psi (2.1 / 4.2 kg per cm²) at maximum
engine speed and normal working temperature
Lub. Oil delivery at 800 pump rpm with pressure setting 40 lbf/ in² (2.8 Kg/cm²)
For Balancer type … 6.1 – 6.3 lpm
Lubricating Oil Relief Valve
Type … Spring loaded plunger type valve
Pressure Setting … 50 / 65 psi (3.52 / 4.57 kg/ cm²)
Lubricating Oil Filter
Type … Full Flow
Element … Replaceable Paper / Canister
By-pass Valve Setting … 13 / 17 psi (0.92 / 1.20 kg/ cm²)
Sump Capacity … 2.37 gal (9 lts). May vary according to application
Cooling System
Type … Thermosyphon-Pump assisted
Coolant capacity–Engine only … 1.585 gal (6 lts). (approximate)
Specic gravity of coolant with 50 : 50 … S.G. 1.060 at 40° C
Thermostat
Type … Wax, Single, By-pass blanking
Opening temperature … 167° ± 35.6°F (75° ± 2°C)
Fully open … 192.2° ± 35.6°F (89° ± 2°C)
Water Pump
Type … Centrifugal
Impeller to Body Clearance … 0.010 / 0.020 inch (0.25 / 0.51 mm)
Distance between impeller rear face to the
water pump pulley front machined face … 5.5310 ± 0.150 inch (140.5 ± 0.40 mm)
Fuel System
Fuel oil specication … Fuel oil should conform to IS : 1460 / 2000 grade-
special or grade-A specication or equivalent
Fuel Filter Type … BOSCH dual lter 0.132 gal (0.5 litre) capacity. spin on
type (primary and secondary)
Fuel Overow Valve … BOSCH orice type valve
Overow Valve Location … Fuel Injection Pump
Fuel Feed Pump … Electrically operated pump located on Fuel lter bracket.
Fuel Injection Pump
Make … BOSCH
Type … VE (Rotary)
Mounting … Flange mounted
Drive … Gear
Pump Rotation … Anti-clockwise
Governor … Mechanical governor with KSB solenoid (Cold starting
device) and LDA (Boost control device)
Alternator
Make … Lucas-TVS. India
Volts … 12 V
Max. Output … 36 Amps

Page No. : 17
Starter Motor
Make … Lucas-TVS. India
Type … 3SM114. 12 V Solenoid operated
No. of teeth on pinion … 10
Starter Cable Resistance … 0.002 ohms maximum
Rotation … Normally clockwise
NOTE : The above electrical data is general and can vary with individual application
Cold Starting Aid
Device … Glow plugs (tted in each cylinder)
Voltage … 12 volts
Location … Cylinder Head
Cylinder Block water heater provision is also available
Atomiser
Make ... Bosch
Type … 7 hole valve covered orice (VCO) Injectors
Opening Pressure ... 250 Bar
Sealing Washer Thickness ... 1.5 mm
Turbo Charger
Make ... Cummins Turbo Technology (HOLSET)
Type … H x 25 TD 04/8.5”
Location ... Exhaust Manifold Flange

Page No. : 18
Section D
OPERATION AND MAINTENANCE
PREPARATION FOR STARTING
Check the coolant level with radiator.
Check the oil level in engine sump.
Check the fuel oil level in the tank.
Check the fan belt tension.
Check the battery is fully charged and that all
electrical connections are properly made and all
circuits in order.
STARTING THE ENGINE
If the engine is warm, turn starter switch in a clockwise
direction to the “Heat and Start” position.
As soon as the engine starts, release the switch to
the “ON” position.
If weather is cold, turn starter switch to the “Heat”
position and hold it there for 40 to 45 seconds.
By setting the starter switch to heat position ‘H’ the
heat wire in glow plugs preheats the air in combution
chamber / cylinders.
Then turn the starter switch to the “Heat and Start”
position, thereby engaging the starter motor.
If the engine does not start after twenty seconds,
return the switch to the “Heat” position for ten seconds
and then re-engage the starter motor by switching to
the “Heat and Start” position.
As soon as the engine starts, release the switch to
the “ON” position.
COLD STARTING AID
The cold start unit comprises four glow plugs
screwed in the cylinder head for individual cylinders
to aid engine from cold starting.
Glow plugs are connected to the engine starting
electrical system in parallel by a wiring harness which
is provided by Tractor Manufacturer.
Glow plugs wiring harness

Page No. : 19
TO STOP THE ENGINE
1. Turn start switch to the ‘O󰀨’ position.
Note : A mechanical stop lever is also provided in
the FIP as an alternative in case of fault in
electrical switch / solenoid to stop engine.
Always be sure that the starter pinion has
stopped revolving before re-engaging the
starter.
RUNNING-IN PROCEDURE
Caution: Do not operate the engine at high speed
without a load. Do not over load the engine.
It is not necessary to gradually run-in a new engine
and any prolonged light load running during the early
life of the engine will in fact prove harmful to the
bedding in of piston rings and liners.
Full load can be applied on a new engine as soon as
the engine is used, provided that the engine coolant
is rst allowed to reach a temperature of at least 140O
F (60OC).
POST-DELIVERY CHECKUP
After a customer has taken delivery of his diesel
engine, it is advisable, a general check-over of the
engine be carried out after the rst 25 hours in
service.
It is also recommended that the following procedure
be adopted where an engine has been laid up for a
considerable period before it is again put into service.
1. Drain lubricating oil sump and re-ll up to the full
mark on the dipstick with new clean oil (Do not
overll).
2. Renew the lubricating oil lter (canister).
3. Check external nuts for tightness.
4. Check / adjust valve tip clearances to 0,30mm
(0.012’’) to inlet and exhaust valve in cold.
5. Check fuel pipes from tank to fuel injection
pump for leaks.
6. Check for lubricating oil leaks and rectify if
necessary.
7. Check hose clips for tightness.
8. Check cooling system for leaks and inspect
radiator water level.
9. Check fan belt for tension.
10. Carry out test to check general performance of
engine.
11. Check engine mounting bolts for tightness.
12. Check the electrical equipment such as rate
of charge, e󰀨ectiveness of connections and
circuits, etc.
Thereafter maintenance periods should be in
accordance with the instructions given. (Ref. Section
E).
PRESERVATION OF LAID-UP ENGINES
It is recommended that the following procedure
be adopted and applied immediately the unit is
withdrawn from service:
1. Thoroughly clean all external parts of the
engine.
2. Run the engine until well-warmed. Stop the
engine and drain lubricating oil from sump.
Remove the oil lter.
3. Drain coolant from radiator and engine cylinder
block.
4. Replace the oil lter, ll sump to correct level
with clean, new lubricating oil or with a suitable
preservative uid.
5. Remove atomisers and spray into cylinder bores
150 ml of lubricating oil divided between the
cylinders.
6. Turn engine slowly over compression and
replace atomisers.
7. Remove air cleaner intake pipe and remove
exhaust pipe and seal opening in manifolds.
8. Disconnect battery and store in fully charged
condition. Before storing the battery, terminals
should be treated to prevent corrosion.
The fuel system be drained or charged with a suitable
preservative designed for the prevailing climatic
conditions or alternatively, it may be left primed with
normal fuel oil.
If the engine is laid for several months then the fuel oil
contained in the remainder of the fuel system should
also be dispelled and the fuel lter renewed, following
which the system may then be recharged with fresh
clean fuel oil.
Before starting, the engine should be cranked over
by the starter motor with the stop control in the ’o󰀨’
position until oil pressure is recorded or the oil warning