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The design and development of a new four-stroke two-cylinder diesel engine family of 1.29 litre capacity for off road are discussed. The engine is in naturally aspirated and turbocharged and intercooled versions and rated from 11.9 kW/1500 rpm to 25.7 kW/2500 rpm. The engines were tuned for air and fuel flows, air utilisation, fuel air mixing, performance and emissions at steady state at a development lab and later certified in national labs. The high altitude capability of the TCIC was checked using a model. The engines rated at less than 19 kW satisfy India Generator set and off road norms of India and Europe equivalent to USTier4 standard, and at higher ratings, standard equivalent to US Tier4-interim. In the second part of the paper, the design of coolant and oil pumps, oil cooler for TCIC engine and the piston with steel oil control ring are discussed. The higher loaded TCIC engines use fillet hardened crankshafts of chromium molybdenum steel.

Breathing flow is the sum of blowby and pumping effect by the piston reciprocating in the crankcase. In a single cylinder engine or in an engine where the volume of the crankcase changes violently due to piston motion (e.g., a two cylinder engine where the two pistons reciprocate in phase) the fluctuating air flow through the breather would be high irrespective of engine speed but for a non-return valve. Oil slobbering through the engine breather is a function of breathing rate, oil loading and separation in the breather. Experiments showed three components of the crankcase pressure: high frequency acoustics due to the blowby jets, cyclic pressure due to the change in volume, and the pressure due to the mass flow from the cylinders and to the atmosphere through the breather valve. A model for the adiabatic pulsating flow is developed using the first law of thermodynamics.