ENGINE TRAINING PROGRAM

MAHINDRA 2185 GM

CHROMELITE ONE DAY TRAINING 1

 Engine Nomenclature
Engine Number:
• Please furnish the complete engine number so that,
questions concerning Customer Service, Repair and
Spare Parts can be more easily dealt with.

Model Designation:
• The engine model is punched on name plate in column
“MODEL”.
• The first one digit indicates number of cylinder of
engine (3) i.e. 3 cylinder engine.
1 • After two digits indicate HP of engine (30) i.e. Engine
power is 30HP.
• Remaining last digit is the unique number (5) i.e. it is
2 Mahindra Unique Number.
3 • First alphabet indicates the application (G) i .e. i t is
Geneset application.
4 • Last alphabet indicates the location of manufacturing
(M) i.e. Mumbai.

1. Engine Serial Number Engine Serial Number

• First Digit indicates number of cylinders (3) i.e. 3
2. Engine Model Designation cylinder engine.
3. Month & Year of Engine Manufacturing • Next alphabets indicates production month (Refer
in Factory Month Coding system).
• Next digit indicates production year.
4. EngineRPM • Next alphabet indicates product code.
• Remaining digits indicates engine manufacturing serial
number.

CHROMELITE ONE DAY TRAINING 2

Product Range :Liquid Cooled
Engines
Description Unit 2185GM
No Of Cylinders Qty 2
Aspiration Natural
Engine bhp (gross) hp 18
Cont with 10% overload hp 15
Stroke 4 Stroke
BORE / STROKE 88.9 x 110
Displacement cc 1365
Compression Ratio mm 19.5 : 1
Firing Order Seq 1-2
Electrical systems Volts 12
Required Battery Capacity A.H. 75
Engine Cooling System
Lit. 5.5
Coolant Capacity
Fuel Pump MICO
No of filters 2

CHROMELITE ONE DAY TRAINING 3

Product Range :Liquid Cooled
Engines
Description Unit 2185GM
Lub Oil system capacity
lit 6
(with filters)
Lub Oil Pressure normal 1.8 to 3.0 kg/cm2
Spin-On Filter +
Lub Oil filter Type
Paper element
Number Of Lub Oil Filters 1
Fuel Shut-Off solenoid type
RICO / 30 mm
& Travel
Low Lub Oil Pressure Shut-
bar 1.8
Off
High Water Tempo Shut-Off deg.C 110
Flywheel Housing SAE SAE 3/ SAE2
Flywheel Dimensions SAE SAE 10/ SAE 11.5
Noise on Full Load at 1 m dBA 94

CHROMELITE ONE DAY TRAINING 4

 Systems of Diesel Engine

 Air Intake System

 Exhaust Gas System

 Cooling System.

 Lubricating System.

 Fuel & Governing System.

 Electrical & Safety System

CHROMELITE ONE DAY TRAINING 5

 Air Intake System
AIR Ventilation ( Engine + Alternator + Control Panel )
Natural Draft

Combustion Forced
Sufficient Volume
Supply clean cool & dry air to the engine
without excessive restriction Clean

Right Temperature
Dirt is no.1 enemy – so aircleaner is the hero
Dry Range-15 to 350C
Types Wet (oil-bath)
Crankcase Breather
Heavy
Normal
Function-relieves crankcase pressure Light
Types-Dry, Oil bath and Screen
System-Open type and Closed type
CHROMELITE ONE DAY TRAINING 6
 Functions

Air System-

 To draw fresh and cool air into combustion chamber by

natural aspiration or by turbo charger.

 Purify the intake air.

 Mahindra Powerol: The only DG manufacturer to use heavy duty

duel Combo air filter which allows 100% clean air to engine.

CHROMELITE ONE DAY TRAINING 7

 Air Filters

CHROMELITE ONE DAY TRAINING 8

 Cooling System
Cooling Air Proper ventilation

Water

Vital for Engine Performance & Durability

Design Components
Radiator (plate or shell & tube)
Radiator Fan (blower or sucker)
Important Factors Deaeration system and time
Design & Selection of cooling type Top tank & Coolant filling arrangement
Temperatures, flows & pressures Pressure cap & valve
Restrictions Piping
Coolant quality Temperature control (thermostat)
Top-up Gauge and Safeties
Coolant Conditioner
Mounting
CHROMELITE ONE DAY TRAINING 9
Cooling System Flow diagram

CHROMELITE ONE DAY TRAINING 10

 Cooling System

CHROMELITE ONE DAY TRAINING 11

 Cooling System
Thermostat operating temperature is 82°C.

Engine ranges between 85 C to 105 deg. C

Allowable maximum temperature is 110 deg. C.

Radiator cap valve opening pressure - 13 psi.

Cooling System Coolant level should be 2" below the radiator neck.

Radiator should be drained and cleaned by

washing soda solution every 1000-1500 hrs.

Add 500 ml of ZERO-R Coolant to 10-lit water

Replace "Zero-R" solution after every

1000 hr. or one year whichever earlier.
Use clean water for Radiator.

CHROMELITE ONE DAY TRAINING 12

 Lube Oil System
Major Components
• Oil Pan
• Oil Pump
• Oil Filter
• Pipes / Hoses
• Oil Cooler
• Dipstick & Dipstick tube
• Oil temperature gauge & safety control

Watch & Maintain

• Lube oil Specifications, Quality & Performance
• Temperature, Pressure and Flow
• Restriction
• Filter location, Operation & Maintenance
• Filter and Oil change period
• Oil Level
• Plug Leakage

CHROMELITE ONE DAY TRAINING 13

 Clogged
Bypass valve
Filter bowl Filter element
open

Lubrication System MDI Lower hole

filter cover

Lower hole Upper hole

crank case filter cover

Clogged

Main gallery of
Valve stem Relief valve
crank case

Open

OIL
Push rod cups
PUMP Oil pressure
gauge
FIP

Oil pump
strainer

Between C/C
Push rod
OIL SUMP front cover &
cavity
plate
Rocker arms

Rocker arm
Rings Rings Rings Rings
bushes Timing gears

4th liner & 3rd liner & Valve lever 2nd liner & 1st liner & small
small end bush small end bush shaft small end bush end bush Idler gear shaft

Rocker arm
Crankshaft pin Crankshaft pin Crankshaft pin Crankshaft pin
bracket

Crankshaft Crankshaft Crankshaft Cylinder head Crankshaft Crankshaft

journal journal journal gasket & head journal journal

5th main 4th main 3rd main 2nd main 1st main
3rd cam bush 2nd cam bush 1st cam bush
bearing bearing bearing bearing bearing

CHROMELITE ONE DAY TRAINING 14

 Lube Oil System
Functions of Lube oil

Cleans : Carbon particles and metal wear particles float in oil and are
washed to the pan.
Cools : As it moves over hot engine parts, it absorbs heat
Absorbs Shocks : It absorbs shocks & prevents metal to metal contact (Con-rod)
Seals : It seals the combustion chambers & valve stems (Cyl. Heads)
Lubricates : Reduces metal to metal contact and hence reduces friction.

Types
Single Grade : SAE 30 / SAE 40
Was in use earlier, had lesser additives, not so effective

Multi-grade : API CD; SAE 20 W40 / API CF4; SAE 15W40

Currently in use, More additives, keeps engine clean, well
lubricated and healthy

CHROMELITE ONE DAY TRAINING 15

 Lube Oil System

 Recommended Oil
Pressure – 3 to 1.8 Bar
 Tripping Pressure – 1.8
+/- 0.2 Bar
 Oil – Valvoline Power
gen Excel 15W40, CH4

CHROMELITE ONE DAY TRAINING 16

 Fuel System

CHROMELITE ONE DAY TRAINING 17

 Fuel System

Fuel System High Pressure fuel system

System Major Components

Fuel pump
Injector
Fuel Feed (forced or gravity)
Governor
Fuel tubing
System Function Filtration
Supply Fuel at Fuel piping
Right Quantity Fuel Gauges and controls
Right Pressure Diesel
Clean Fuel

CHROMELITE ONE DAY TRAINING 18

 Functions

Fuel System –

 To feed clean diesel fuel through twin filters from fuel

tank to Injection Pump.

 Mahindra Powerol Uses: Twin fuel filters of Coil

construction to ensure dirt free fuel to Injection
equipments. Also the replacement schedule of pre &
micro filter is scientific based to ensure maximum
quantity & cleanliness of fuel.

CHROMELITE ONE DAY TRAINING 19

Valve Clearance Operation & Maintenance

CHROMELITE ONE DAY TRAINING Firing Order 20

 Exhaust System
Functions Major Components
• Carry combustion gases • Manifold
• Discharge at right location • Turbocharger
• Pipes / Hoses
• Support
• Muffler / Silencer
Watch & Maintain • Flexible Connection/s
• Maintain emission pollution norms • Connecting Flanges
w.r.t. constituents & their quantities
Muffler / Silencer
• Temperature & Noise Control
• Controlling restriction is must Types
• Piping Material & Flexibility Industrial
• Location of muffler/ silencer Residential
Hospital

CHROMELITE ONE DAY TRAINING 21

 Functions

Electrical System –

 Start & Stop the engine with the help of battery.

 Recharge the battery through Charging alternator while

the engine is in motion.

 To keep the safety controls live & to actuate when any

abnormality.

CHROMELITE ONE DAY TRAINING 22

Sectional View of an Engine

CHROMELITE ONE DAY TRAINING 23

 Do & Don’t
Do’s:
 Get the DG Set health checked above 4000Hrs & follow recommendations of M&M
service network.

 Always use M&M recommended tractor plus coolant in proper mixture.

 Ensure PIU / Electrical vender is duly conversant / trained about the DG Set electrical /
safety systems etc.

 Always consider de-ration factor if the site location/ condition is different than NTP
conditions.

 Ensure rated voltage at No Load at 52 Hz (Engine speed for 1560 RPM)

 Ensure that engine speed is never below 50 Hz. (1500 RPM) from no load to full load.

 Ensure that Alternator neutral is earthed properly.

CHROMELITE ONE DAY TRAINING 24

 Do & Don’t
Don’t:-
 Never allow building owner to take power from DG Set. This can overload DG Set.

 Never allow unauthorized person to attempt for repair / maintenance.

 Do not use DG Set with unbalance load above 10% (Max to Min). This can cause alternator
failure.

 Do not allow anyone to do welding with DG Set & do not overload the alternator.

 Do not bypass safety for any reason.

 Don’t disturb AVR potentiometer setting except voltage point.

 Don’t operate DG Set on less than 1500rpm (50 Hz). This may leads to alternator failure.

 Do not allow PIU vender to temper original wiring harness provided with DG Set.

CHROMELITE ONE DAY TRAINING 25