KIRLOSKAR R1040 Manual

R1040 / R1080 / K1080 SERIES ENGINES
OPERATION & MAINTENANCE MANUAL

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1. FOREWORD
Dear Customer,
We are happy to provide you with latest revision of
R1040 / R1080 series O & M manual.
The R1040 / R1080 series liquid 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 R1040 / R1080 Series
engines. All the engines under go stipulated
performance test before being delivered to customers.
This manual provides specifications and operations
guidelines for services maintenance procedure.The
performance of engine largely depends on its proper
maintenance and up keep. Hence, please maintain
your R1040 / R1080 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.
KIRLOSKAR OIL ENGINES LTD
Customer Support
Laxmanrao Kirloskar Road, Khadki
Pune 411003 (INDIA)
Help Desk – 1800 2333344, 020-66084608
Help Desk ID – [e-mail]
Visit us at: www.kirloskar.com
www.koel.co.in
Visit us at : www.koel.co.in

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STANDARD WARRANTY FOR KOEL R1040 / R1080 SERIES
ENGINE OPERATING IN INDIA
This warranty applies to the R1040 / R1080 Series KOEL
Diesel Engine for power generation application.
Duration of Warranty
For Power Generation Non Cellular Application
Within 18 Calendar Months from Date of Dispatch from
KOEL or 3600 operating hours or 12 calendar months
from date of installation, Whichever occurs first For
Power Generation Engines for Non Cellular Customers,
OR
30 Calendar Months from Date of Dispatch from KOEL
or 5000 operating hours or 24 Calendar months from
date of installation, whichever occurs first.
The extended warranty as below will be applicable if
customer source the filters, K-Oil Super, K-Cool Super
Plus and avail the services from KOEL Authorised
Service Dealer.
For Power Generation Cellular Application
Within 24 Calendar Months from Date of Dispatch from
KOEL or 2500 operating hours whichever occurs first
if customer source the filters, K-Oil Super, K-Cool
Super Plus and avail the services from KOEL Authorised
Service dealer.
Industrial Engines
Within 18 Calendar Months from Date of Dispatch from
KOEL or 3600 operating hours or 12 Months of hours
date of installation whichever occurs first if customer
source the filters, K-Oil Super, K-Cool Super Plus and
avail the services from KOEL Authorised Service dealer
for off Highway application.
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.

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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 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. Incorrect operational & maintenance practices,
lapse in scheduled maintenance or maintenance
done by other than KOEL - Authorised dealership.
4. The cost of maintenance or regular service of
the engine.
5. Any damage due to idle storage of engine beyond
period of 6 months without treatment of long
storage.

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6. Any damage due to use of lubrication oil, coolant,
fuel quality and grade not recommended by
Kirloskar Oil Engines Ltd.
7. Any damage resulting from improper shutdown.
8. 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.
9. 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.
10. 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.
11. Any modification in engine without KOEL consent,
use of engine other than designed application or
changes in engine performance related settings
without KOEL consent.
This warranty is the only document given by us
warranting the Kirloskar R1040 / R1080 series engine.
No other document giving any warranty terms
conflicting these contents shall be considered and
entertained.
* KOEL recommends use of K Oil Super, K Cool
Super Plus Coolant & Kirloskar genuine filters to
be used in engine.
* KOEL will provide 2 free service checks (Namely
G1 & G2) for power generation application &
5 free service checks (Namely C1, M1, M2, M3
& M4) for off highway application. For availing
free service checks contact nearest KOEL
authorised service dealer or call us on toll free
number 1800-233-3344
* Consumables & spares required for free service
checks will be on chargeable basis.

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Your engine needs :
* Clean high speed diesel oil.
* Lubricating oil of specified quality and viscosity
grade.
* KOEL recommends use of K Oil Super.
* Fresh air for combustion of fuel, for cooling of
genset / radiator.
* Genuine spare parts for its maintenance.
* K - Cool Super Plus Coolant to avoid rust formation.
Service and Maintenance
* Sound service and maintenance practices will ensure
that the engine continues to meet your requirements.
Recommended preventive maintenance at regular
intervals must be observed. The service and
maintenance work should be carried out
conscientiously.
* Special care should be taken under abnormally
demanding operating conditions.
Maintenance and Repairs
* Shut down the engine before carrying out
maintenance or repair work.
* When the work is complete, be sure to install safety
devices that may have been removed.
* If you have to work on a running engine, ensure that
all clothing is tight fitting and cannot entrap the
moving parts.
* Observe all industrial safety regulations when engine
are operating in enclosed spaces or underground.
* Please contact your Kirloskar Dealer for Spare parts
enquiry. Use only genuine spare parts.
Safety
* All Safety instructions (for both engine and operator)
in this manual are designed by the accompanying
symbol. Please follow them carefully.
* The attention of operating personnel should be
drawn to these instructions.
* General safety and accident prevention regulations
laid down by law must also be observed.
General

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2. Engine Description
2.1 Engine numbering system
2.2 Engine illustrations
2.3 Engine lifting device
2.4 Lube oil system
2.5 Fuel system
2.6 Cooling system
2.7 Electrical system

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2. Engine Description

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2. Engine Description
2.1 Engine numbering system
2.1.1. Engine name plate
Engine no is punched on the Name Plate which is fixed on the engine crankcase.
ENGINE TYPE
ENGINE No.
RATING kW/hp rpm
RATING STD.
GOVERNING CLASS
KIRLOSKAR OIL ENGINES LTD
INDIA
YEAR OF MANUFACTURE
RATED VOLTAGE
RATED POWER FACTOR
SERIAL NO.
RATED FREQUENCY
RATED CURRENT
RATING
KIRLOSKAR OIL ENGINES LTD.
INDIA
V
HZ
A
KVA
Genset nameplate Engine nameplate

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2. Engine Description 2.1 Engine numbering system
2.1.2 Engine number system 2.1.3 Model designation
Please furnish the complete engine number, so that matter
concerning Customer Service and Spare Parts can be more easily
dealt with.
The engine model is punched on nameplate in column ‘TYPE’.
The information about engine series, No of cylinders, Piston
displacement in liter per cylinder and Aspiration is mentioned.
The examples are stated above will clarify the matter.
3 R 1040
Indicates Piston displacement
1.04 Lit. / Cylinder as 1040 cc
Indicates series of engine
as R series
Indicates No. of Cylinders as 3
4H 3002 / 10 00001
Engine serial No
Year of Manufacturing
Application code No.
(i.e. build of the engine)
2H for 2R1040
3H for 3R1040
4H for 4R1040
6H for 6R1040
6 R 1040 TA
Indicates engine aspiration TA as
‘Turbocharged Aftercooled’
engine.(In case of Naturally
aspirated engines this
denomination is not mentioned.)
Indicates Piston displacement
1.08 Lit. / Cylinder as 1080
Indicates series of engine as
R series
Indicates No. of Cylinders as 6

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2. Engine Description
2.2 Engine illustration
2.2.1 Air inlet manifold side
1. Air cleaner
2. Aircleaner hose
3. Adaptor plate
4. F. W. E. Mtg. foot
5. Crank case
6. Dipstick
7. G. E. Mtg. foot
8. Spin-on lube oil filter
9. Stopping lever
10. Feed pump
11. Gear casing
12. Fuel pump
13. Air inlet manifold
14. H. P. Pipes
15. Fuel filter - Pre
16. Fuel filter - Micro
17. Restriction indicator
4
3
2
7
8
6
5
11
12
13
1
14
9
10
15 16 17

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2. Engine Description 2.2 Engine illustration
2.2.2 Exhaust manifold side
18. Thermostat / Thermostat Hsg.
19. Radiator cooling fan
20. Tension adjusting lever
21. V - Belt
22. Crankpulley
23. Lube oil sump
24. Breather tube
25. Starter
26. Flywheel housing
27. Charging alternator
28. Vacuator Valve
29. Exhaust manifold
30. Rocker cover
31. Lube Oil filling point
26
29
27
25 21
30
18
19
22
23
24
31
20
28

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2. Engine Description
2.3 Engine lifting device
2.3.1 For bare engine – R1040 / R1080
Before lifting the engine first fix the lifting hooks on the engine
and then lift the engine. The lifting hooks provided on the engine
are meant for lifting bare engine only. Use of engine lifting hooks
for lifting engine + equipment must be avoided as it can cause
damage to engine or equipment in the event of breakage.
Fig. above shows the recommended lifting device

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2. Engine Description 2.4 Lube oil system
Force feed lubrication is provided by a ‘G’ rotor type pump to main
bearings, large end bearings, camshaft journals, valve gear etc.
Other components like connecting rod small end bushes, cylinder
liners and gear train are splash lubricated. Oil supply to valve gear
is achieved through rocker shaft core hole; the oil supply is
controlled to the valves and rocker arm by oil metering screw, which
results into lower oil consumption and lower carbon deposition.
The system includes adequate filtering by replaceable
‘Spin-on’ filter cartridge. The water-cooled lube oil cooler is
provided to maintain the oil temperature within limits. A relief valve
controls the maximum oil pressure, which is provided on delivery
side of the lube oil pump.
2.4.1 Lube oil circuit 2.4.2 Lube oil pump
Lube oil pump delivery
Engine type 2R/3R/4R1040/6R1080 4R1040T/TA
Engine rpm 2200 2200
Lube oil pump rpm 2464 2464
Delivery Liters/min. 30.5 44
at 4kg/cm2pressure
Engine type 6R1080T/TA
Engine rpm 2200
Lube oil pump rpm 2464
Delivery Liters/min. 47
at 4kg/cm2pressure

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2. Engine Description
2.4 Lube oil system
1 Lube oil sump
2 Suction tube
3 Lube oil pump
4 Pressure relief valve
5 Delivery pipe
6 Delivery body
7 Plate type oil cooler
8 Lube oil filter
9 Safety valve (not shown)
(In-built in lube oil filter)
10 Oil gallery (Main)
11 Main bearing
12 Large end bearing
13 Camshaft bearing
14 Tappet
15 Push rod
16 Rocker arm bearing
17 Metering plug
18 Rocker shaft
19 Oil passage in cylinder head
20 Oil spray nozzle for piston cooling
(Not shown) (Used on Turbo charged
& Turbo charged after cooled engines
only.)
21 Fuel pump connected to lube oil
circuit
2.4.3 Lubrication system for R1040 / R1080 Series engines
A schematic diagram, shown below, shows the lubricating oil circuit of a typical R1040 / R1080 series engines
The above parts are arranged in typical lube oil flow, as
observed in R1040 / R1080 series engine lube oil circuit.
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19

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2. Engine Description 2.4 Lube oil system
The maximum lube oil temperature for R1040 / R1080 series
engines is ambient temperature plus 700C. For example if ambient
temperature is 400C, the maximum lube oil temperature should
be 1100C
Note :- During the running in period of first 50 hours, never
exceed ‘full load’ even for a short duration; this is applicable for
stationary applications like power generation application.
2.4.4 Lube oil pressure 2.4.5 Lube oil temperature
At low idling speed Minimum 1.5 Kg/cm2
At loaded condition 2.5 to 5.5 Kg/cm2
in operating range
If the lube oil pressure at any time drops below 1.5 kg/cm2 at
operating speed of 1500 rpm, under loaded condition, then
replace the lube oil filter cartridge and check the pressure. If the
pressure is still low, then contact your Kirloskar Dealer.

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2. Engine Description
2.4 Lube oil system
The lube oil sump capacities of R1040 / R1080 series engines are
as below
These capacities are for the standard sheet metal sumps.
Engine type 2R1040 3R1040
Oil sump type S.M. S.M.
Initial fill (lit.) 5.5 9
Refill (lit.) 4.5 7.5
Engine type 4R1040/T/TA 6R1080/T/TA
Oil sump type S.M. S.M.
Initial fill (lit.) 11.5 15
Refill (lit.) 9.5 13.5
The oil must be changed at least once in a year. This is
applicable to the engines, which are running for standby
duty application.
Note :
*Initial fill = Sump capacity + Gallery capacity + Lube oil filter
capacity
*Fill the Lube oil filter with oil before fitting on the engine.
2.4.6 Lube oil sump capacity 2.4.7 Lube oil
*Whenever Lube oil filter is drained off, add approximately
0.5 lit. / 1 lit. extra Lube oil (as per the size of the Spin-on filter
cartridge) in the sump to maintain the correct oil level.)
*The oil level in the sump should be checked at room
temperature by using dipstick. Top up with fresh oil when the
level reaches the low level mark on dip stick, fill till it increases
to top level mark. Avoid over filling.
The engine should be lubricated only with the specified oil. This
specially blended engine oil designed for the best performance of
your genset.
Using the specified oil has the following advantages:
*Extra protection against corrosion and rusting
*Excellent performance at both high and low temperatures
*Reduced fuel consumption
Usage of improper lube oil could result in:
*Overheating of the engine
*Sluggish performance
*Excessive fuel consumption
*Increased wear of bearings and other parts
The specified oil is available only through KOEL’s authorized service
dealers in suitable packing.

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2. Engine Description 2.4 Lube oil system
2.4.8 Quality Grade 2.4.9 Viscosity
Lube oil of correct viscosity and detergency grades should be
used It is recommended to use ‘K Oil Super’ (SAE15W40). For
detergency it should comply with following specifications:-
Multi-grade oil should be used.
As the viscosity of lube oil is dependent on temperature. the
choice of SAE grade should be governed by the ambient
temperature prevailing at the engine operating site..
Optimum operating behavior will be attained if you take the
accompanying oil viscosity diagram as a guide Should be
temperature fall temporarily below the limits of the SAE grade
selected, cold starting may be affected but the engine will not be
damaged.
In order to keep wear to a minimum, do not exceed application
limits for extended period of time.
E - DL2 CF
CF+
E - DL3 MACK
T - 7 / T - 8A
E - DL4 CF4
Is 13656:2002 API
KOEL approved Lube Oils :-
Bharat Petroleum Bharat Ultra
Supreme 15W40
Hindustan Petroleum Hylube LL15W40
Indian Oil Corporation Servo Premium
XHP15W40
Manufacturing Co. Trade Name
Warranty is applicable on use of ‘K Oil Super’ engine
oil only.