Is 10001 Final
Is 10001 Final
Is 10001 Final
December 2010
BUREAU OF INDIAN STANDARDS
(CENTRAL MARKS DEPARTMENT-III)
13 12 2010
(Ashok Narula)
Sc E (CMD-III)
Encl: As above.
Sc.F& H (CMD-III)
All ROs/BOs,
BIS LABS
ITSD - For hosting on the BIS Intranet
CC to i) CMD-1
ii) TED for arranging gazette notification
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All testing apparatus/measuring instruments shall be periodically checked and calibrated and
records of such checks/calibration shall be maintained.
1.2
Production gauges, inspection gauges, master gauges (plug and gauges) shall be checked /
calibrated after every 5000 applications or three months whichever is earlier. Slip gauges, dial
gauges, thread gauges and bore gauges shall be got calibrated once in three years.
1.3
Pressure gauges and pyrometers shall be checked with master gauges once in 6 months or be
replaced whenever not found in working order. Other Instruments / equipments / gauges shall be
checked / calibrated at a frequency decided in consultation and approved by the Bureau
2. The manufacturer shall maintain a system of works inspection at all stages of procurement and
manufacture to ensure that the individual working parts of engine are free from all manufacturing defects.
3. TEST RECORDS - All records of tests and inspections shall be kept in suitable forms approved by the
Bureau. For some tests and inspections, specimen Performas are given in Annexure I and IV. For other
tests and inspections, records shall be kept in suitable Performa approved by the Bureau.
3.1 Copies of any records or charts that may be required by the Bureau shall be made available at any time
on request.
3.2 QUALITY CONTROL - It is recommended that, as far as possible, statistical quality control (SQC)
methods may be used for controlling the quality during production as envisaged in this scheme.[see IS:397
(Part I) to IS 397(Pt. IV)
3.3 In addition, effort should be made to gradually introduce Quality Management system in accordance
with IS/ISO 9001
4. STANDARD MARK - The Standard Mark as given in Column 1 of the First Schedule of the licence
shall be applied on the data plate, provided always that each engine, so marked, conforms to every
requirement of the specification.
4.1 MARKING: In addition following shall be legibly and indelibly marked on the Engine:
a) Serial number of the engine;
b) Manufacturer name/Trade mark and code number;
c) Type of Rating
d) Rated speed in rev/min;
e) Rated Output in kW
f) Grades of oil & fuel to be used;
g) Specific fuel consumption g/kWh;
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h) Class of Governing; and
i) Made in India.
j) Licence No (CM/L )
4.2 Approval of the data plate(s) before use shall be obtained from the Bureau.
5. LEVELS OF CONTROL -The tests as indicated in Table 1 and at the levels of control specified
therein, shall be carried out on the whole production of the factory which is covered by this scheme and
appropriate records and charts maintained in accordance with para 1.1 and 3 above. All the production
which conforms to the Indian Standard and covered by this licence shall be marked with BIS standard
Mark.
6. DESIGN, DRAWINGS, DECLARATIONS AND MEASUREMENTS
6.1 The manufacturer shall submit and obtain approval of the design details and drawing of critical
components and flywheel (s) of each type and rating of engine from the Bureau in the beginning and
whenever there is a change.
6.2 Drawings should be prepared according to SP 46 (Code of practice for General Engineering Drawings)
and approval obtained from the Bureau. Drawings shall specify the material, hardness, tolerance, surface
finish and all other necessary details. Drawings of critical components and flywheel(s) shall suitably be
kept in the standards room for day today inspection and for reference when required.
6.3 Fuel consumption, rated power output (IS rating A (with overload), speed, lubricating oil consumption,
Mechanical efficiency and Class of governing shall be declared according to Section 1 of IS: 10000 (Part
IV) and Clause 4 of IS:10001:1981. Mechanical efficiency, in the absence of specific declaration based on
tests, shall be assumed to be 80%.
6.3.1 The technical literature supplied with the engine shall have the following information:
a) Information given on the data plate (see Clause 4 of STI)
b) Accessories supplied with engine.
c) Operating instructions including operating temperatures and lubricating oil pressure(s)
d) Servicing schedule and information as per Clause 3 of IS: 10000 (Part XI)
e) Preferably exploded view of engine / sub-assemblies giving all the parts of engine would also be given.
6.4 The measuring instruments shall be of accuracy as indicated in IS:10000 (Part III). The units of
measurement shall preferably be as per the IS: 10000 (Part III).
6.4.1 Observations and test results shall be recorded as per IS: 10000 (Part VI) and Clause 3 of this scheme.
Performance curves shall be plotted in accordance with appendix D of IS: 10000 (Part VI).
6.4.2 Power of the engine shall be determined during the performance test. Specific Fuel Consumption
(SFC) of an engine shall be the value reported from the fuel consumption test (Ref. Clause 3.5.3 of
IS:10001:1981) and SFC observed during full load condition, during 8 hour rating test shall not exceed
SFC at full load in fuel consumption test by more then 5%. Measured values shall be compared with the
declared values given in the licence applying the adjustment factors and tolerances as per Section 1 of IS:
10000 (Part IV) and clause 4.1.1 and 4.2.2 of IS: 10001-1981.
7 RAW MATERIAL/COMPONENTS INSPECTION
7.1 RAW MATERIAL All raw materials shall be according to company standards approved by the
Bureau. Manufacturers test certificates should be procured for the raw materials. Checks for physical and
chemical requirements shall be done on lot-wise basis.
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7.2 COMPONENTS For all components either purchased from outside sources or manufactured by
licensee /vendor , the following details should be available: The vendor shall submit the test report of all
the critical components, and will be supplied along with the engine.
a) Complete specification and drawing of each component will be supplied by the manufacturer to the
vendor.
b) Inspection sheet for each component laying down the various characteristics to be checked along with
their requirements according to drawings and the type of gauges to be used (a list of gauges, measuring
instruments etc. is given in Annexure VI to VIII).
c) Sampling plan for each component For critical components, as far as possible, inspection shall be
100% for critical dimensions whereas for non-critical dimensions of critical components and the other
components sequential sampling method with an AQL between 1 to 4% be adopted by the vendor and
supervised by manufacturers representatives.
d) Test certificates shall be obtained for physical and chemical properties for each lot of components
received by the licensee. The material of Crank shaft, Connecting Rods and Valves shall also be
periodically tested for chemical composition and where possible, for physical properties, as per the
declaration in the drawings. Such testing may preferably be done for every lot of the components but at
least once in three months at the vendors premises and countersigned by manufacturers representatives
posted in vendors premises. However, the complete responsibility lies with the manufacturer (licensee).
7.2.1 Various critical components as given in Annexure V shall be procured from manufacturers whose
quality has been established. A change in the material design / Size of the critical components should be
brought to the notice of this Bureau immediately and used for ISI marked engines only after approval by
ISI. In case components carry the ISI Mark no further approval is necessary but intimation to that effect
shall be sent to the Bureau. The licensee shall ensure as far as possible that the components conform to the
Indian Standard Specification, if any and through their periodic checking by the manufacturer (licensee).
7.3 Colour codes or any other suitable method shall be used to indicate the decision after inspection and
testing (For example Reject Red, Rework-Yellow, Accept-Green).
8. INSPECTION OF CASTING
8.1 FOUNDRY Where a licensee is having his own foundry and he is casting important components like
Cylinder head, Cylinder block, Cylinder liner and Crank case, the following controls are necessary:
a) There should be a control on the chemical composition of the melt. The firm must have arrangement of
chemical testing. Samples for tensile strength and transverse strength shall be tested in licensees factory or
in an outside laboratory if properties do not match with the licensee. For this purpose, separate test bars
shall be cast and tested as per IS: 210 and IS: 6331 respectively. Chill test is normally carried out during
casting.
b) Equipments for said testing like rapid moisture tester, strength tester (green and dry), permeability tester
and core hardness tester shall be available for ensuring the use of good quality sand in the moulds.
c) A metallurgical microscope to check the micro structure of the casting is recommended.
d) The grade of the cast iron to be used for various components shall be specified. Minimum of grade FG200 is recommended.
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8.2 When castings are obtained from outside sources, test certificates for the physical and chemical
properties should be obtained as per IS: 6331. For critical components like cylinder head, cylinder block,
cylinder liner and crankcase test bars shall be obtained with each lot and tested at least once in three months
or earlier whenever there is change of a manufacturer. If casting are not accompanied by test certificates the
test bars received with the lot shall be tested. Test bars, mechanical test, sampling, retests shall be as given
in IS: 210. Test results shall be as per Table 1 and A-1.1 of IS: 6331.
9. REJECTION - If an engine fails in any one or more of the requirements, if shall be considered as unfit
for the purpose of marking. Such engine shall be given a suitable identification mark to distinguish from
those passing.
9.1 The engines rejected as per 9 above may, however, be suitably repaired and defects rectified. Such
repaired engine when tested again should conform to all the requirements of the specification for being fit
for the purpose of ISI marking. Records for initial failure rework and retesting shall be maintained.
9.2 A separate record shall be maintained giving information relating to the rejection and the method of
disposal of engines which do not conform to the specification even after reworking. Such engines shall not,
in any case, be stored together with those conforming to the specification.
10 PACKING The engines shall be suitably packed so as to avoid damage during transits.
11 SAMPLES - The licensee shall supply, free of charge, the samples required in accordance with the
Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory
or godowns. The Bureau shall pay for the samples taken by it from the open market.
12 REPLACEMENT - Whenever a complaint is received soon after the goods with Standard Mark have
been purchased and used, and if there is adequate evidence that the goods have not been misused, defective
goods are replaced free of cost by the licensee, in case the complaint is proved to be genuine and the
warranty period (where applicable) has not expired. The final authority to judge the conformity of the
product to the Indian Standard shall be with the Bureau. The firm shall have its own complaint
investigation system as per IS/ISO 10002.
12.1 In the event of any damages caused by the goods bearing Standard Marks, or claim being filed by
the consumers against BIS Standard Mark and not conforming to the relevant Indian Standard, entire
liability arising out of such non conforming product shall be of licensee and BIS shall not in any way be
responsible in such cases.
13 STOP MARKING - The marking of the product shall be stopped under intimation to the Bureau if, at
any time, there is some difficulty in maintaining the conformity of their product to the specification, or the
testing equipment goes out of order. The marking may be resumed as soon as the defects are removed
under intimation to Bureau.
13.1 The marking of the product shall be stopped immediately if directed to do so by Bureau for any
reason. The marking may then be resumed only after permission by the Bureau.
14 PRODUCTION DATA - The licensee shall send to BIS as per the enclosed proforma- 1 to be
authenticated by a Chartered Accountant, a statement of quantity produced, marked and exported by him
and the trade value thereof at the end of each operative year of the licence.
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Table1..
CONSTANT SPEED COMPRESSION IGNITION (DIESEL) ENGINES FOR
GENERAL PURPOSE (UP TO 19 kW)
TABLE 1 - LEVELS OF CONTROL
Cl.
Test Details
3.1.1
Requirement
Critical
Components
FLY SHEEL
(s)
a) Size
b) Weight
c) Balancing
TESTS
3.6
Test Method
Cl.
Ref.
As per Clause 6,
7 & 8 of the
Scheme
As per Approved
Drawings
a) ROUTINE
TESTS
i)
Fuel
Consumption
ii)
Output
power
iii) Governing
b) Routine
Production
Acceptance
Test
i)Eight Hour
Rating Test
c)MEC
H. EFF.
IS
10000
(Part
VIII) &
IS
10000
(PartIV)
ii)Fuel
Consumption
Test
iii) Governing
Test
3.4
Diesel engines
of each
Rating once a
week OR From
a months
production of
each rating one
engine out of
every20 engines
to be tested
Samples shall be selected from the production line and preferably from
early production of the week / out of the first few of 20 engines, as
applicable. Before starting the test, each engine (selected at random) shall
be well run
for the period and manner pre-declared by the licensee and running in
period shall include 10% overloading (see Cl. 2.1 of IS: 10000 (Part-V).
-doIS
10000
(Part
VII)
Cl.6
Sec.1
IS
10000
(Pt.IV)
Fuel consumption test and governing test shall be carried out only after
twelve hour rate test, however sequence of fuel consumption test
governing test may be interchanged. In case any functional change in the
design of the critical components mentioned under cl.3.1.1 of IS
10001:1981 is made, the test shall be carried out according to IS 10000
(Pt.3) only.
Diesel engines This is optional test
of each type,
design and
rating once in
a year.
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IS: 10001-1981
CONSTANT SPEED COMPRESSION IGNITION (DIESEL) ENGINES FOR
GENERAL PURPOSE (UP TO 19 kW)
TABLE 1 - LEVELS OF CONTROL
(Para 6 of Scheme of Testing and Inspection)
Clause
Test Details
3.1
Requirement
Type Test
3.1 a)
3.1 b)
3.1 c)
3.1 d)
3.1 e)
3.1 f)
3.1 g)
3.1 h)
3.1 i)
i) Preparation for
Test
ii) Preliminary
Run
Test Method
Clause
Reference
Levels
Control
3.1
Whenever
there
is
functional
change in
type/design
of
the
engines [See
clause
3.1.2 of IS:
10001-1981]
or change in
any of the
critical*
components
(see
cls.3.1.1 of
IS
10001:1981)
or
when
asked
by
BIS
for
specific
reasons at
any time.
iii)
Initial
Performance
Test
iv)
Governing
Test
Sec.1
v)
Endurance
Test
vi)
Governing
Test
vii)
Final
Performance
Test
viii)
Final
Inspection Test
ix) Categories of
Test
Type Test
Sec.1
Performance
Test
Endurance Cycle
4.2
IS
10001:1981
IS 10000
(Part V)
IS 10000
(Part V)
IS 10000
(Part-VIII)
IS 1000 0
(Part VII)
Sec.1
of
Remarks
IS 10000
(Part IX)
IS 10000
(Part VII)
IS 10000
(Part-VIII)
IS
10000
(Part V)
4.1
IS
10000
(Part XIIII)
4.3
Annexure- 1
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ANNEXURE I
PROFORMA FOR RECORDING OBSERVATIONS / RESULTS OF ROUTINE TESTS (See Table 1 of STI)
Production Control Number: ________________________
kW ______________
Time of Run
(h)
Sr.
No.
From
To
Load
Rev/min
Note: 1.
2.
Change in Load
%
Water Temperature
Fuel
Consumption
Sec/50 cc
Kg
% of FOL
(See note 1 below)
Rev/Min __________________________
Inlet
(See note 2 below)
Observed
Remarks
(Including
action taken
incase engine
found failing)
Outlet
Declared
Temporary Change
Permanent Change
Result
Ref/Min
Rev/Min
Pass/Fail
Other
Observations
Steps of load may be suitably selected as per declaration by the licensee and shall necessarily include steps of 100% & 110% output power which is applicable for
Engines of IS rating A (with overload).
Recording Water temperatures will be optional provided it is ensured that declared temperature are maintained.
Annexure II
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ANNEXURE - II
LOG SHEET FOR FUEL CONSUMPTION AND 8 HR. RATING TESTS FOR CONSTANT SPEED INTERNAL COMBUSTION ENGINES FOR GENERAL
PURPOSES.
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Sr
No.
Time
(s)
1
Baro
meter
Reading
Temperatures
Wet
Dry
Bulb
Bulb
kPa
(mm
Hg)
Air
Intake
Exh.
(Ta)
(Tb)
Exh.
Back
Pressu
re
(Peb)
kPa
8
Rela
Hum
Obs.
Sp.
Brak.
Load
Cal.
Break
Power
Total
Corr.
Factor
Corr
Brake
Power
()
(%)
9
rev/
min
10
kW
Kg
11
kW
12
Fuel Consumption
Fuel
Fuel
Fuel
Consd.
Cons.
Con
Rate
Time
g
s
g/h
()
13
Signature of Tester
Cal.
Spec.
Fuel
Cons.
g/k
Wh
14
15
16
17
18
Corr.
factor
for
SpecF
uel
Cons
()
19
Cooling Water
Temp
Temp
Inlet
Outlet
Lubricating Oil
Temp
Pr.
(Tcoo
l-1)
(T
cool-o)
(To)
g/k
Wh
20
21
Corr
Spec.
Fuel
Cons.
kPa
K
22
23
ANNEXURE III
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24
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ANNEXURE III
Name of Licensee: _____________________________________________
Size
Size of G Gauge
Size of No-Go Gauge
Nominal
Required
Actual
No-Go Gauge
Size
Error
Remarks
PERIODICAL INSPECTION
Date
of
Inspection
Temp.
OK
Go Gauge
Size
Error
Sign.
Of
Inspector
Annexure IV
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ANNEXURE - IV
PRODUCTION AND TESTING REGISTER
Name of Licensee: _____________________________________
Sr.
No.
Date
of
Production
Rating
kW
Rev/Min
Prod.
Control
No.
Date of
Testing
Nature of
Test
Result
Engine
Number
Allotted
ISI
Marked or
Not
Cumulative
total of ISI
Marked
Engine
Brand
Remarks
Sign.
Annexure V ..
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ANNEXURE V
LIST OF CRITICAL COMPONENTS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Cylinder Head
Crank Case
Cylinder Block
Cylinder Liner
Inlet and Exhaust Valves
Valve Guides
Rocker Arm
Tappets
Pistons
Piston Rings
Gudgeon Pin
Connecting Rod
Crankshaft
Main Bearings
Big end Bearing and Small end Bearing, Bush for Connecting Rod
Connecting Rod Bolts and Nuts
Camshaft, Cams and Timing Gears
Valve Springs and Governor Springs (Whenever applicable)
Fuel Injection Equipments, such as Fuel Injection Pump, High Pressure Pipe, Injector / Nozzle &
Nozzle Holder
Lubricating Oil Pump
Sealing gaskets and
Governor Weights
Annexure VI
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ANNEXURE VI
LIST OF INSTRUMENTS
1. Gauges:
a) Go & No-Go Plug Gauges
b) Go & No-Go Snap Gauges
c) Ring Gauges
d) Thread (Plug and Ring) Gauges
2. Inside Micro-Meters
3. Outside Micro-Meters
4. Vernier Calipers
5. Height Gauge(s)
6. V-Block & Magnetic Stand
7. Feeler Gauge(s)
8. Depth Gauge(s)
9. Dial Gauges
10. Slip Gauge Set
11. Comparator
12. Dial Bore Gauges and Master Rings
13. Surface Plates
ANNEXURE VII
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ANNEXURE VII
LIST OF EQUIPMENT FOR IN-PROCESS CONTROL
A.
1. Hardness Tester
2. Spring Tester
3. Crack Detector (recommendatory only)
4. Nozzle Tester
5. Lub-Oil Pump Tester
6. Fly-wheel Balancing Equipment(s)
7. Cam-Detail Checking Equipment
8. Hydraulic Pressure Testing Equipment
9. Connecting Rod Alignment & Twist Checking Rig
10. Crankshaft Alignment & Pin Parallelism Checking Rig
11. Balances (Preferably Self-indicating type)
12. High Pressure Fuel Pipe Flushing Equipment
13. Torque Wrenches
14. Compression Pressure Tester
15. Gear Marking Apparatus
16. Valve Timing Apparatus
17. Arrangement for Checking Bumping Clearance
Annexure VIII ..
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ANNEXURE VIII
LIST OF TESTING EQUIPMENT
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Page 16 of 16
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(TED 2)
Reprography
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