KIRLOSKAR HA Series Manual

1. Foreword 1 - 6
2. Engine Description 7 - 22
3. Engine Operation 23 - 34
4. Operating Media 35 - 38
5. Routine Maintenance 39 - 44
6. Service & Maintenance 45 - 68
7. Faults, Causes & Remedies 69 - 72
8. Engine Preservation 73 - 76
9. Technical Specifications 77 - 86
INDEX

1
1. FOREWORD
Dear Customer,
We are happy to provide you with latest revision of HA
series O & M manual.
The HA series air cooled engines are developed and
supplied for wide range of application meeting your
requirements.
We assure you that all necessary safety precautions and
regulations have been adhered to in the design, material
and manufacturing of HA Series engines. All the engines
under go stipulated performance test before being
delivered to customers.
This manual provides specifications and operations
guidelines for of HA series engines, routine maintenance,
services maintenance procedure. The performance of
engine largely depends on its proper maintenance and up
keep. Hence, please maintain your HA engine properly as
per the guidelines and schedules given in this manual.
We recommend that only trained manpower should perform
the operation and maintenance tasks on the engine. Always
use the genuine Kirloskar spare parts whenever required
for periodic maintenance as well as for engine repairs.
We maintain the facility for operators training for
maintenance of Kirloskar diesel engines. Please contact
our authorized service dealer / distributors nearest to you
to avail this facility.
Continuous improvements in the product design are
incorporated from time to time which may not be included
in this manual
The manual is updated periodically to include such changes
in the latest editions.
Should you have any queries, fully equipped and trained
team from Kirloskar Customer Support will be happy to
provide the help.
In case of any difficulty please contact
KIRLOSKAR OIL ENGINES LTD
Customer Support
Laxmanrao Kirloskar Road, Khadki
Pune 411 003 (INDIA)
Help Desk – 1800 2333344, 020-66084608
Help Desk ID – [email protected]
Visit us at : www.kirloskar.com

2

3
STANDARD WARRANTY FOR KOEL HA SERIES
ENGINE OPERATING IN INDIA
This warranty applies to the HA Series KOEL Diesel
Engine.
Duration of Warranty
For Industrial Application (Engines working for Earth
moving equipment, material handling equipment and
liquid handling pumps, e.g. Backhoe Loader, Vibratory
Compactor, Concrete Pump, Transit Mixer,
Excavators, Pick and Carry Crane, Fork Lift Truck, Fire
Fighting Pumpsets etc.) - Within 18 Calendar Months
from Date of Dispatch from KOEL or 3600 operating
hours or 12 calendar months from date of installation
or within six calendar months where the machinery
has run continuously day and night, Whichever
occurs first.
Scope of Warranty
After the Engine has been taken delivery by you, we
expressly guarantee, in lieu of any warranty implied
by law, to make good any defective parts in machinery
of our own manufacture, which defect develops
under proper use and necessary maintenance
practices as written in this manual and arises solely
from faulty material or workmanship, provide always
that such defective parts are promptly returned
carriage paid to our works and provided that Fuel
and lubricants approved by us, have been
continuously used. The repaired or (at its option) new
parts will be delivered free of cost, EX-works.
At the termination of such period of 12 calendar
months (or six calendar months as the case may be)
all liability on our part ceases.
In the case of goods not of our manufacture (e.g.
Fuel Injection Equipments, Electrical Components like
Starter, Alternator, Turbocharger), you are entitled
to the benefits of respective manufacturers warranty
given to us. In respect there of and our liability in
respect of such goods is limited to the warranty given
by the respective manufacturer. In no case shall we
be liable for the fitting charges of replacement parts
of thereof.
The defective parts replaced by us shall become our
property. All goods are supplied on the Condition
that we shall not be liable for any loss incurred

4
through stoppages or any consequential damages.
Warranty for rubber parts like AVM’s, Belts, Hoses, O
rings etc will be six months from date of installation.
Limitations and Exclusions
This warranty does not apply to
1. To fair wear and tear or to damage due to
negligence or improper handling or incorrect
application or incorrect installation by the
purchaser, or his employees or agents or in the
case of repairs or alterations carried out by the
purchaser without our knowledge and written
approval.
2. To reconditioned or second-hand combination sets
or Engines. The Engines will be deemed to have
been taken over by the customer upon dispatch
from our works, in the case of direct deliveries EX-
Factory and from the godowns of our authorized
Dealers viz. Distributors and Dealers, in the case
of supplies from their stock and this warranty will
come into effect from that time.
3. The cost of maintenance or regular service of the
engine.
4. Any damage due to idle storage of engine beyond
period of 6 months without treatment of long
storage.
5. Any damage due to use of lubrication oil, fuel
quality and grade not recommended by Kirloskar
Oil Engines Ltd.
6. Any damage resulting from improper shutdown.
7. Any failure to meet its obligations hereunder which
are due to circumstances beyond its reasonable
control including but not limited to industrial
disputes, fire, severe weather conditions,
government decisions, material shortage, power
or machinery breakdown or failure or war.
8. Gradual reduction in operating performance
commensurate with the age, kilometers covered
or operating hours, including but not limited to,
gradual loss of engine compression or gradual
increase in oil consumption due to normal
operating functions.

5
9. We will not be responsible for loss or damage to
goods beyond the delivery stated in our tender
and we will repair or replace free of charge goods
damaged in transit upto the point of delivery by
us, as specified above.
This warranty is the only document given by us
warranting the Kirloskar HA series engine. No other
document giving any warranty terms conflicting these
contents shall be considered and entertained.

6

7
2.1 Model
2.2 Engine Illustration
2.3 Lube Oil System
2.4 Fuel System
2.5 Engine Cooling System
2.6 Air Inlet System
2.7 Exhaust System
2. Engine Description

8

9
2.1 Model 2. Engine Description
The engine model and engine serial no. are stamped on nameplate along with engine
rating, rpm and referred standard. The nameplate details must be given while ordering
spares and asking for service.
2.1.1. Rating plate 2.1.2. Rating Plate Location.
For Genset For Industrial
ENGINE TYPE
Sr No.
RATING kW/hp rpm
RATING STD.
DATE OF MFG.
KIRLOSKAR OIL ENGINES LTD. INDIA
ENGINE TYPE
ENGINE No.
RATING kW/hp rpm
RATING STD.
GOVERNING CLASS
KIRLOSKAR OIL ENGINES LTD
INDIA
The nameplate is fixed on engine
crankcase as shown.

10
2. Engine Description 2.1 Model
2.1.3. Cylinder Numbering. 2.1.4. Direct Injection
Cylinder are numbered consecutively,
beginning at the flywheel end.
Engines are with direct fuel injection to
meet high performance and pollution
regulations
1234 56

11
1. Cooling Blower
2. Lifting Hook
3. Fuel Injection Pump
4. Flywheel Housing
5. Crank Pulley
6. Belt Tension Unit
7. Oil Filler Neck / Cap
8. Lube Oil Sump
9. Lube Oil Filter
10. Fuel Filter
11. Air Cowling
12. V-Belt
13. Feed Pump
14. Lube Oil Drain Plug
2.2 Engine Illustration 2. Engine Description
2.2.1. Service Side.
HA694 NA

12
15. Charging Alternator
16. Starter
17. Crankcase
18. Crankcase Breather
19. Flywheel
20. Rocker Cover
21. Air Intake Manifold
22. Exhaust Manifold
2. Engine Description 2.2 Engine Illustration
2.2.2. Exhaust Side.
HA694 NA

13
1. Cooling Blower
2. Lifting Hook
3. Fuel Injection Pump
4. V-Belt
5. Crank Pulley
6. Belt Tension Unit
7. Oil Filler Neck
8. Lube Oil Sump
9. Lube Oil Filter
10. Fuel Filter
11. Air Cowling
12. Rocker Cover
13. Feed Pump
14. Lube Oil Drain Plug
2.2 Engine Illustration 2. Engine Description
2.2.3. Service Side.
HA694 TC

14
15. Exhaust manifold
16. Charging Alternator
17. Starter
18. Crankcase
19. Crankcase Breather
20. Flywheel Housing
21. Flywheel
22. Turbocharger
23. Air Intake Manifold
2. Engine Description 2.2 Engine Illustration
2.2.4. Exhaust Side.
HA694 TC

15
1 Lube Oil Sump
2 Suction Pipe
3 Lube Oil Pump
4 Pressure Relief Valve
5 Delivery Pipe
6 Lube Oil Cooler
7 Lube Oil Filter
8 Relief Valve (not shown)
9 Oil Gallery
10 Main Bearing
11 Large End Bearing
12 Camshaft Bearing
13 Tappet with groove for pulse fed
rocker arm lubrication.
2.3 Lube Oil System 2. Engine Description
2.3.1. HA694 NA
879
11
19 110 12 2
3
4
5
18
14
17
13
16 15
21
6
22
20

16
14 Push Rod
15 Rocker Arm Bearing
16 Metering Plug
17 Push Rod Cover Tube
18 Restrictor ( for lubrication of gears)
19 Spray Nozzle for Piston Cooling
20 Connection for Pressure Gauge
21 Oil Pressure Gauge
22 Fuel Pump Connected to Lube Oil
Circuit
2. Engine Description 2.3 Lube Oil System
2.3.1. HA694 NA
879
11
19 110 12 2
3
4
5
18
14
17
13
16 15
6
22
21 20

17
1 Oil Sump
2 Suction Pipe
3 Oil Pump
4 Pressure Valve
5 Delivery Pipe
6 Pipe to Oil Cooler
7 Oil cooler plate type
8 Lube Oil Filter
9 Safety Valve
10 Oil Gallery
11 Main Bearing
12 Big-End Bearing
13 Camshaft Bearing
2.3 Lube Oil System 2. Engine Description
2.3.2. HA694 TC
621 16
17
14
1
5
4
3
13
11
12
19
2
7
8
22
23
24
9
18
15
20
10