KIRLOSKAR R1040 User manual

R1040 MAINTENANCE MANUAL
Page 1 of 48
Index
Sr.
No.
Topic Page
Nos
1 General 2
1.1 Service and Maintenance 2
1.2 Maintenance and Repairs 2
1.3 Safety 2
2 Engine details 2
2.1 Engine Name Plate 2
2.2 Engine illustrations 3
2.3 Engine lifting device 4
2.4 Lube oil system 5 – 8
2.5 Fuel supply system 9-10
2.6 Cooling System 11
2.7 Electrical System 12
3 Engine operation
3.1 Commissioning 13-16
3.2 Starting 16
3.3 Stopping 17
3.4 Operating conditions 18
3.5 Running-in period 19
4 Routine Maintenance 20
4.1 Maintenance Schedule 20
4.2 Top Overhaul and Major Overhaul Periods 21
5 Service and Maintenance 21
5.1 Maintenance of Lubrication system 21 - 27
5.2 Maintenance of Fuel System 28
5.3 Maintenance of Cooling System 29-30
5.4 Maintenance of Dry type air cleaner 31-34
5.5 Belt drives 35
5.6 Adjustments 36
5.7 Maintenance of Electrical Equipment 37
5.8 Checking of Fasteners 37
6 Troubleshooting and Remedial measures 38
6.1 Troubleshooting 38
6.2 Useful tips for Turbocharger 40
6.3 Periodical Inspection of Turbocharger for Generating set application 41
6.4 Recommendation for Turbocharger operation and maintenance 41
7 Instruction Manual for Electronic Governor 42
8 Engine preservation 43
8.1 Recommended Preservatives 43
8.2 Preservation Procedure 43
8.3 Commissioning of Preserved Engine 44
9 Tightening Torque, Settings 45
9.1 Tightening Torque 45
9.2 Settings 46
10 Fuel timing 47

R1040 MAINTENANCE MANUAL
Page 2 of 48
1 General
Your engine needs
•Clean High Speed Diesel oil.
•Lubricating oil of specified quality and viscosity grade.
•Fresh air for combustion of fuel, for cooling of engine.
•Proper ventilation of engine compartment to avoid re-circulation of hot air.
•Genuine spare parts for its maintenance.
1.1 Service and Maintenance
Sound service and maintenance practices will ensure that the engine continues to
meet your requirements. Recommended service intervals must be observed. The
service and maintenance work should be carried out conscientiously.
Special care should be taken under abnormally demanding operating conditions.
1.2 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 catch the moving parts.
Never fill the fuel tank while the engine is running.
Observe all industrial safety regulations when engines are operating in enclosed
spaces or underground.
Please contact your Distributor for Spare parts enquiry. Use only genuine spare parts.
1.3 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.
2Engine details –
2.1 PCV / CCV Arrangement –
 PCV / CCV Arrangement only for COM stage II engine.
2.2 Engine Name Plate
Fig 2.1.1

R1040 MAINTENANCE MANUAL
Page 3 of 48
Engine no is punched on the Name Plate which is fixed on the engine Crankcase.
Fig. No 2.1.1 show the engine nameplate
2.2.2 Engine Number System
4H 3002 / 06 00001
Engine serial No
Year of Manufacturing
Application code No. (i.e. build of the engine)
2H for 2R1040
3H for 3R1040
4H for 4R1040NA or 4R1040T or 4R1040TA
6H for 6R1080T or 6R1080TA
Please furnish the complete engine number so that matter concerning Customer Service and
Spare Parts can be more easily dealt with.
2.2.3 Model Designation
The engine model is punched on nameplate in column ‘TYPE’. The information about engine
series, No off cylinders, Piston displacement in liter per cylinder and Aspiration is
mentioned. The examples are stated below will clarify the matter.
3 R 1040
Indicates Piston displacement 1.04 Lit. /Cylinder as 1040
Indicates series of engine as Rseries
Indicates No.off Cylinders as 3
6 R 1080 TA
Indicates engine aspiration TA as ‘Turbocharged After cooled’
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 Rseries

R1040 MAINTENANCE MANUAL
Page 4 of 48
Indicates No. off Cylinders as 6
2.1 Engine illustrations
Fig. 2.2.1 Air Inlet side Fig. 2.2.2 Exhaust Manifold side
Inlet Manifold Side Exhaust Manifold Side
1 Air inlet manifold 13 Stop solenoid
2 Air cleaner 14 Breather (Positive crankcase ventilation)
3 Oil filling body 15 Alternator (for battery charging)
4 Fuel pump 16 Crankcase
5 Fuel Feed pump 17 Starter
6 . Spin-on Lube oil filter 18. Engine mounting foot (Gear end side)
7 . Spin-on Fuel Filter 19. Engine mounting foot (Flywheel end side)
8 . Dipstick 20. Exhaust manifold
9 . Lube oil sump with drain Plug 21. Rocker cover
10 . Gear casing 22. Flywheel housing
11 . Radiator 23 . Flywheel
12 . Balance Water Tank
2.3 Engine lifting device
2.3.3 For bare engine for ’R1040/R1080’
Before lifting the engine first fix the lifting hooks on the engine and then lift the engine
(see Fig. 2.3.1). The lifting hooks provided on the engine are meant for lifting bare engine
only. Use of engine lifting hooks for lifting of generating set must be avoided as it can
cause damage to engine or generating set in the event of breakage.
18
15
16
17
19
23
22
21
20
2
7
8
9
1
6
4
10
5
3
11
12
13
14

R1040 MAINTENANCE MANUAL
Page 5 of 48
Fig. 2.3.1
For Canopied generating set lifting is shown below. Use proper sling/tackle arrangement for
lifting the generating set.
2.4 Lube oil system
Lube oil circuit
Force feed lubrication is provided by a ‘G’ rotor type pump to main bearings, large end
bearings, camshaft journals and to the valve gear, fuel pump and turbocharger (incase of
turbocharged engines). Other components like connecting rod small end bushes, cylinder
liners and gear train are splash lubricated. Piston cooling nozzles are provided for piston
cooling for turbocharged engines only. 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. For 6R1080 series engines twin
filter cartridges are provided and a centrifuge Lube oil filter is also provided. 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.

R1040 MAINTENANCE MANUAL
Page 6 of 48

R1040 MAINTENANCE MANUAL
Page 7 of 48
2.4.2 Lube oil pump: -
Lube oil pump Delivery
Engine type 2R/3R/4R1040 4R1040T/TA 6R1080/T/TA
Engine rpm 1500 1500 1500
Lube oil pump rpm 1680 1680 1680
Delivery Liters/min.
at 4kg/cm
2
pressure
20.5 30 32
Lube oil pressure: -
At low idling speed Minimum 1.5 Kg/cm
2
In normal working condition when engine is warm 2.5 Kg/cm
2
At loaded condition in operating range 2.5 to 5.5 Kg/cm
2
If the pressure at any time drops, at engine idling rpm or below 1.5 kg/cm
2
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 Distributor.
2.4.3 Lube oil Temperature: -
The maximum lube oil temperature for ‘R1040/R1080’ series engines is ambient temperature
plus 70
0
C. For example if ambient temperature is 40
0
C, the maximum lube oil temperature
should be 110
0
C
2.4.4 Lube oil consumption: -
Lube oil consumption for well run in
engine & under normal load condition.
0.3 % of fuel
consumption
Note: -
1. 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. During the running in period the oil consumption is slightly more than the above
figure.
3 The lube oil consumption varies according to engine operating conditions. The value
mentioned above is for the normal engine operating condition.
2.4.5 Lube oil sump capacity and oil change period: -
The lube oil sump capacities and oil change period of ‘R1040/R1080’ series engines are as below: -

R1040 MAINTENANCE MANUAL
Page 8 of 48
These capacities are for the standard cast iron and standard sheet metal sumps.
Engine type 2R1040 3R1040 4R1040/T/TA 6R1080/T/TA
Oil sump type S.M. S.M. S.M. S.M.
Initial fill
(lit.)
5.5 9 11.5 15
Refill (lit.) 4.5 7.5 9.5 13.5
Oil Specifications Oil change period (Hours) To be used for
MIL-L-2104 C PLUS
CF4, D4, D5
400 Naturally aspirated as well
as Turbo charged engines
The oil must be changed at least once in a year. This is applicable to the engines, which are
running for standby duty application.
The above oil change period is subject to following conditions.
• The minimum ambient temperature should not less than – 10
0
C.
Please contact your distributor for change in the ambient temp condition.
Note:
 First fill = Sump capacity + Gallery capacity + Lube oil filter capacity
 Fill the oil Lube oil filter before fitting on the engine.
 Do not forget to fill the Lube oil filter whenever you replace the filter.
 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.
2.4.6 Lube oil Specifications and recommendations
The chart below shows the nomenclature of lube oil in different standards. Lube oils of
correct viscosity and detergency grades should be used. For detergency, oil should comply
with the following specifications
US Military
Specifications
American
Petroleum Institute
classification (API)
CCMC
MIL-2104C CD/SE -
MIL-2104C Plus
CF4 D4
For viscosity, the recommended SAE number should be used. SAE J 30 specifies the viscosity of
Lube oils for each SAE No.
Always use oil brands of reputed oil companies. Too viscous oil causes starting difficulties. The
ambient temperature prevailing at the time of starting the engine should be governed the choice of the
viscosity grade, during winter operation.

R1040 MAINTENANCE MANUAL
Page 9 of 48
It is recommended to use ‘multi grade oil’ considering the maximum and minimum ambient
temperatures.
No guarantee claims will be entertained on the grounds of engine damages due to use of unsuitable
engine Lube oils.
Atmospheric
Temperature range in C
Viscosity no
-20
0
to +20
0
SAE 10W30
-10
0
to +50
0
SAE 15W40
-5
0
to +45
0
SAE 20W40
Note:
The anticipated lowest temperature at the time of engine starting should be used as reference
in winter. While in summer the highest anticipated temperature of the day should be used as
reference.
2 . 5 Fuel supply system
2.5.1 F uel Circuit
Fuel is supplied to the block type fuel pump by a fuel lift pump (feed pump) incorporated in the
fuel pump itself. A dual type spin-on fuel filter consisting of efficient pre and micro paper
filter cartridges ensures the supply of clean fuel to the fuel pump. The schematic diagram (Fig.
2.5.1) shows the fuel circuit of the engine.
Fig. 2.5.1
NOTE: It the fuel tank is to be installed below the fuel pump level, and then the bottom level
of the fuel tank should be less than 1 meter below the feed pump inlet
2.5.2 Fuel Specifications
The performance of the engine depends upon supply of clean and correct grade of
fuel. The fuel injection equipment is manufactured to very close tolerances and
slightest amount of dirt in fuel can cause wear on the injection equipment. Following
points are important in use of fuel on Kirloskar R1040/1080 series engines.
The following specifications are approved: -
• BS: 2869-A1&A2 (In case of A2, note sulphur content)

R1040 MAINTENANCE MANUAL
Page 10 of 48
• DIN 51 601
• ASTMD 975-81:1D&2D
Winter Grade Fuel-
 At low temperatures, waxing may occur and clog the fuel system, thus causing
operational troubles.
 In the case of ambient temperature below 10° c, use ‘Winter Grade’ diesel fuel,
mixed with Kerosene.
Fig.2.5.2
 Proportion of Kerosene to be mixed in Diesel, depends on the ambient temperature
as shown in the graph (Fig.2.5.2). (Maximum proportion limited to 50%) For cold
starting aid see 3.4.1
PREPARE THE BLEND IN THE TANK ITSELF. FILL IN THE NECESSARY AMOUNT
OF KEROSENE FIRST, THEN ADD DIESEL FUEL.
2 .5.3 Storing Fuel Oil
 The storage of fuel oil is of utmost importance since many engine problems are
traced to dirty fuel or fuel stored for too long a period. Store fuel in a
convenient place outside the building.
 It is recommended that the fuel tank should be filled in at the end of the day’s
work. This keeps moisture out of the tank.
 To eliminate water from the fuel, drain out small quantity of fuel from fuel
tank through a drain plug every day before starting the engine.