SAFARI

106 4 DLT ENGINE ENGINE TESTING After assembly of the engine, mount engine on test bed. Prepare engine for starting and testing in the following manner : Connect gear box to the dynamometer flange with suitable coupling or propeller shaft Connect oil pressure gauge and temperature gauge. Connect water hoses to and from radiator. Fill coolant (water and anticorrosive agent) in the cooling system. Fit radiator cap. Fill required quantity of recommended oil in the oil sump. Mount air cleaner assembly on test bed suitably. Connect hoses from air cleaner out let to turbocharger, turbocharger to intercooler and intercooler to engine intake. Make suitable linkage of controlling accelerator lever. Connect exhaust pipe to exhaust manifold. Connect battery cables to starter motor. Ensure that -ve terminal is earthed. Make suitable connection from +ve terminal of battery to the FIP solenoid switch. Crank engine with accelerator lever in idling position. Allow oil to be circulated through the system. Check and ensure that oil pressure indicated by gauge is satisfactory. Slightly raise the engine speed and check for any oil, fuel, water and air leakages. Rectify if any. Check colour of the exhaust gas. Check for any unusual noise from the engine. Connect engine to dynamometer and run for running-in test as per schedule. Engine running in test schedule Engine Speed Time Torque (rpm) (minutes) (mkg) 900 5 - 1500 5 3.5 2000 5 5.9 2500 5 7.1 3000 5 8.8 3500 5 9.0 4000 5 9.5 4300 5 10.0 4300 5 13.0 After running-in test of the engine, reduce dynamometer load to zero and allow engine to run at idling speed for about 5 minutes and then stop it. To prevent the entry of dirt/debris into the Turbocharger, the following procedure is to be followed during testing. 1. Remove inlet adaptor from turbocharger and preserve it in a clean place for refitment after the test. 2. Fit assy. connector using new & clean filter sieve. 3. Fit assy. oil line inlet ensure that this line is internally clean. 4. Complete engine testing. 5. Remove assy. oil line & assy. connector. 6. Remove used filter sieve & the strainer. Do not use the oldfilter Sleeve & Strainer again. Fit a new sieve & strainer and the sealing washer and keep the assy. connector ready for next eng. 7. Fit the original Adaptor on the turbocharger (refer sr. No. 1) after ensuring that it is clean. 8. Connect the cleaned standard assy. oil line. 9. Run engine to ensure no oil leakage.