Table of Contents
Advertisement
Sr.
Topic
No.
1
1.1
1.2
1.3
Safety
2
2.1
Engine Name Plate
2.2
2.3
2.4
Lube oil system
2.5
2.6
2.7
3
3.1
Commissioning
3.2
3.3
Stopping
3.4
3.5
Running-in period
4
4.1
4.2
5
Service and Maintenance
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Maintenance of Electrical Equipment
5.8
6
6.1
6.2
6.3
6.4
7
Instruction Manual for Electronic Governor
8
8.1
8.2
8.3
9
Tightening Torque, Settings
9.1
Tightening Torque
9.2
10
Fuel timing
R1040 MAINTENANCE MANUAL
Index
Page 1 of 48
Page
Nos
2
2
2
2
2
2
3
4
5 – 8
9-10
11
12
13-16
16
17
18
19
20
20
21
21
21 - 27
28
29-30
31-34
35
36
37
37
38
38
40
41
41
42
43
43
43
44
45
45
46
47
Advertisement
Table of Contents
Troubleshooting
Related Manuals for KIRLOSKAR 6R1080T
Summarization of Contents
1 General Information
Service and Maintenance Principles
Outlines sound service and maintenance practices for engine longevity and performance.
Maintenance and Repair Precautions
Details safety measures and essential steps for performing maintenance and repair work on the engine.
Safety Instructions and Regulations
Emphasizes adherence to all safety instructions and legal regulations for engine operation.
2 Engine Details
PCV/CCV Arrangement
Mentions the PCV/CCV arrangement specific to the COM stage II engine.
Engine Nameplate Interpretation
Explains the details found on the engine's nameplate for identification.
Engine Number System Explained
Details the format and meaning of the engine serial number.
Model Designation Interpretation
Clarifies how to interpret the engine model designation based on its components.
Engine Component Illustrations
Provides labeled diagrams illustrating various engine components for visual reference.
Engine Lifting Device Usage
Describes the engine lifting device and provides instructions for safe lifting operations.
Bare Engine Lifting Instructions
Offers specific guidance for lifting bare engines of the R1040/R1080 series.
2.4 Lube Oil System
Lube Oil Circuit Description
Explains the engine's lube oil circuit, including lubrication methods and components.
Lubrication System Schematic Diagram
Illustrates the schematic diagram of the lubrication system for water-cooled engines.
Lube Oil Pump Specifications
Details the delivery rate and pressure specifications for the lube oil pump.
Lube Oil Temperature Limits
Specifies the maximum permissible lube oil temperature for the engines.
Lube Oil Consumption Guidelines
Provides information on lube oil consumption under normal operating conditions.
Oil Sump Capacity and Change Intervals
Lists oil sump capacities and recommended oil change periods for the engines.
Lube Oil Specifications and Recommendations
Recommends specific lube oil grades, viscosity, and detergency for engine use.
2.5 Fuel Supply System
Fuel Circuit Diagram and Explanation
Describes the fuel circuit, including the fuel lift pump, filters, and injectors.
Approved Fuel Specifications
Lists the approved specifications for diesel fuel to ensure engine performance.
Fuel Oil Storage Best Practices
Provides guidelines for storing fuel oil properly to prevent operational issues.
2.6 Cooling System
Radiator Cooling System Operation
Explains the working principle of the radiator-type cooling system.
Coolant Mixture and Additive Recommendations
Advises on coolant mixtures and rust preventive compounds for different seasons.
Radiator Flushing Procedure
Describes the process for flushing the radiator to remove impurities.
Thermostat Function and Maintenance
Explains the thermostat's role and how to check its operation.
2.7 Electrical System
Alternator and Starter Specifications
Details the specifications for the alternator and starter motor used in the engines.
Battery Capacity and Voltage Requirements
Specifies battery capacity ratings and recommended capacities based on ambient temperature.
Battery Cable Sizing Guidelines
Provides recommendations for battery cable lengths and core sizes based on current.
Engine Wiring Specifications
Outlines the required wire gauges for various engine electrical connections.
3 Engine Operation
Commissioning New or Overhauled Engines
Details the essential steps before starting a newly installed or overhauled engine.
Fuel Tank Filling Procedure
Instructs on correctly filling the fuel tank with diesel fuel.
Fuel System Air Bleeding Procedure
Describes how to remove air from the fuel system for proper operation.
Cooling System Filling Procedure
Guides on filling the engine's cooling system with the appropriate coolant blend.
Belt Tension Check and Adjustment
Explains how to check and adjust the tension of the engine's V-belts.
Valve Clearance Check and Adjustment
Covers the necessity and method for checking and adjusting valve clearances.
Pre-Start Preparations and Checks
Lists final checks and preparations before commencing an engine trial run.
3.2 Starting and Stopping
Electric Engine Starting Procedure
Details the steps for starting the engine using the electric starter.
Correct Engine Stopping Procedure
Outlines the recommended method for shutting down the engine safely.
3.4 Operating Conditions
Winter Operation Considerations
Covers specific adjustments for running the engine in cold winter conditions.
Deration Chart for Naturally Aspirated Engines
Provides a power correction chart for naturally aspirated engines based on altitude and temperature.
Deration Chart for Turbocharged Engines
Offers a power correction chart for turbocharged engines considering altitude and temperature.
Deration Chart for Turbocharged/Aftercooled Engines
Details power correction for specific turbocharged and aftercooled engine models.
3.5 Running-In Period
First 100-Hour Maintenance Schedule
Lists crucial maintenance tasks to be performed after the initial 100 hours of operation.
4 Routine Maintenance
Comprehensive Maintenance Intervals
Presents a detailed schedule of routine maintenance tasks based on running hours.
5 Service and Maintenance
5.1 Maintenance of Lubrication System
Details the maintenance procedures for the engine's lubrication system.
5.2 Maintenance of Fuel System
Covers maintenance procedures for the engine's fuel system.
5.3 Maintenance of Cooling System
Details maintenance procedures for the engine's cooling system.
5.4 Maintenance of Dry Type Air Cleaner
Covers the maintenance of the dry type air cleaner.
5.5 Belt Drives Maintenance
Explains how to inspect and maintain V-belts.
5.6 Adjustments
Covers engine adjustments, particularly valve clearance.
5.7 Electrical Equipment Maintenance
Details maintenance for electrical components like the starter motor.
5.8 Fastener Checks
Lists fasteners that require regular checking and tightening.
5.1 Maintenance of Lubrication System
Oil Change Intervals
Specifies when to change the engine oil, considering grade and running hours.
Engine Oil Level Checking Method
Describes the correct procedure for checking the engine oil level using a dipstick.
Engine Oil Changing Procedure
Provides step-by-step instructions for draining and refilling engine oil.
Lube Oil Filter Replacement Guide
Details the process for replacing the spin-on lube oil filter cartridge.
Centrifuge Lube Oil Filter Maintenance
Explains the maintenance requirements for the centrifuge lube oil filter on specific models.
Centrifuge Servicing Instructions
Offers guidance and precautions for servicing the centrifuge cleaner assembly.
Centrifuge Cleaner Servicing Steps
Details the step-by-step procedure for cleaning and servicing the centrifuge cleaner.
Centrifuge Cleaner Assembly Precautions
Lists important points to ensure proper assembly and sealing of the centrifuge cleaner.
Centrifuge Cleaner Operation Restrictions
Highlights critical actions to avoid and restrictions for operating the centrifuge cleaner.
5.2 Maintenance of Fuel System
Fuel Strainer Cleaning Procedure
Describes how to clean the fuel strainer located at the feed pump inlet.
Fuel Filter Cartridge Replacement
Explains the procedure for replacing pre-filter and micro-filter cartridges.
5.3 Maintenance of Cooling System
Radiator Coolant Level and Fin Cleaning
Details how to check coolant level and clean radiator fins for optimal cooling.
5.4 Maintenance of Dry Type Air Cleaner
Air Cleaner Construction Overview
Shows the construction of typical dry type air cleaners with plastic and sheet metal housing.
Air Cleaner Regular Maintenance Checks
Outlines daily checks and maintenance essential for protecting the engine from dust.
Filter Element Cleaning Process
Details the steps for cleaning the air cleaner filter element when restricted.
5.5 Belt Drives Maintenance
V-Belt Inspection and Tensioning
Guides on inspecting V-belts for damage and checking/adjusting their tension.
5.6 Adjustments
Valve Clearance Adjustment Procedure
Provides the detailed procedure for adjusting the valve clearance using feeler gauges.
5.7 Electrical Equipment Maintenance
Starter Motor Brush Maintenance
Details checks and replacement procedures for starter motor brushes and springs.
Alternator Brush and Slip Ring Care
Explains how to clean and maintain the alternator's brushes and slip rings.
5.8 Fastener Checks
Critical Fasteners for Regular Inspection
Lists key fasteners on the engine that require regular checking and tightening.
6 Troubleshooting
Common Engine Problems and Solutions
Presents a chart detailing common engine troubles, their causes, and corrective actions.
Turbocharger Operational Tips
Offers useful tips for the satisfactory operation of the turbocharger.
Turbocharger Periodic Inspection for Gensets
Specifies periodic inspection requirements for turbochargers used in generating set applications.
6.4 Turbocharger Operation and Maintenance
Recommended Turbocharger Practices
Provides operational and maintenance recommendations for turbochargers to ensure longevity.
7 Electronic Governor System
Electronic Governor Troubleshooting Guide
Guides on diagnosing and resolving issues when the electronic governing system is inoperative.
8 Engine Preservation
Recommended Engine Preservatives
Lists recommended preservative oils and compounds for different engine parts during storage.
Engine Preservation Procedure Steps
Details the comprehensive procedure for preserving an engine for long-term storage.
Commissioning a Preserved Engine
Explains the steps required to recommission an engine after it has been preserved.
9 Tightening Torque and Settings
High Tensile Bolt Tightening Torque
Provides information on tightening torque values and methods for high tensile bolts on the engine.
Tappet Clearance Specifications
Specifies the correct tappet clearance for inlet and exhaust valves in cold conditions.
Bumping Clearance and Fuel Timing
Covers bumping clearance values and the procedure for setting engine fuel timing.
Need help?
Do you have a question about the 6R1080T and is the answer not in the manual?
Questions and answers