Table of Contents
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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
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Table of Contents
Troubleshooting
Related Manuals for KIRLOSKAR 6R1080TA
Summarization of Contents
1 General
1.1 Service and Maintenance
Guidance on maintaining the engine to meet requirements and recommended service intervals.
1.2 Maintenance and Repairs
Safety precautions and procedures for performing maintenance and repair work on the engine.
1.3 Safety
Essential safety instructions for engine and operator, emphasizing careful adherence to symbols and regulations.
2 Engine details
2.1 PCV / CCV Arrangement
Details on the PCV/CCV arrangement specifically for the COM stage II engine.
2.2 Engine Name Plate
Information regarding the engine's name plate, including type, rating, and manufacturer details.
2.2.2 Engine Number System
Explanation of the engine number system and its components for identification.
2.2.3 Model Designation
Details on engine model designation, covering series, cylinder count, displacement, and aspiration.
2.3 Engine lifting device
Instructions and precautions for safely lifting the bare engine using provided hooks.
2.4 Lube oil system
2.4.2 Lube oil pump Delivery
Specifications for lube oil pump delivery rates at different engine RPM and pressures.
2.4.3 Lube oil Temperature
Guidance on maximum permissible lube oil temperatures relative to ambient conditions.
2.4.4 Lube oil consumption
Information on normal lube oil consumption rates and factors affecting it.
2.4.5 Lube oil sump capacity and oil change period
Details on lube oil sump capacities and recommended oil change intervals.
2.4.6 Lube oil Specifications and recommendations
Recommendations for lube oil specifications, viscosity grades, and detergency.
2.5 Fuel supply system
2.5.1 Fuel Circuit
Schematic diagram and explanation of the fuel supply circuit, including filters and pumps.
2.5.2 Fuel Specifications
Approved fuel specifications and important points for fuel use to ensure engine performance.
2.5.3 Storing Fuel Oil
Recommendations for proper storage of fuel oil to prevent engine problems and maintain quality.
2.6 Cooling System
2.6.1 Radiator type cooling system
Description of the radiator type cooling system and its schematic water circuit.
2.6.2 Coolant
Guidelines for using fresh water with additives and ethylene glycol antifreeze for cooling.
2.7 Electrical System
2.7.1 Electrical Equipment
Details on the 12V electrical system, including alternator and starter specifications.
2.7.2 Battery
Information on battery capacity ratings and recommendations based on ambient temperature.
2.7.3 Engine wiring
Wiring specifications for starter coil, alternator connections, and other engine wiring.
3 Engine operation
3.1 Commissioning
Steps and precautions to follow before starting a new or overhauled engine.
3.1.2 Diesel
Procedure for filling the fuel tank with appropriate diesel grade and observing cleanliness.
3.1.3 Bleeding of fuel system
Instructions for bleeding the fuel system to remove air bubbles, ensuring proper fuel flow.
3.1.4 Cooling system
Procedure for filling the cooling water system with coolant and safety precautions.
3.1.5 Belts
Checks for belt position and tension, with instructions for adjustment if necessary.
3.1.6 Valve Clearance
Information on checking and adjusting valve clearance, especially after overhauling.
3.1.7 Other preparations
Pre-start checks including battery connections, cable security, and initial engine run.
3.2 Starting
Procedures for starting the engine, including electric starting and safety checks.
3.3 Engine stopping
Recommended procedure for stopping the engine, avoiding sudden shutdown under load.
3.4 Operating conditions
3.4.1 Operation in winter
Guidance on operating the engine in winter, including lube oil, fuel, and cold starting aids.
Deration Charts
Charts showing power correction factors based on altitude and ambient temperature for different engine types.
3.5 Running in period
Tasks to be performed after the initial 100 hours of engine running.
4 Routine Maintenance
4.1 Maintenance Schedule
Comprehensive schedule detailing routine maintenance tasks based on running hours and intervals.
4.2 Top Overhaul and Major Overhaul Periods
Estimated periods for top overhaul and major overhaul based on engine usage and maintenance.
5 Service and Maintenance
5.1 Maintenance of Lubrication system
Procedures for maintaining the engine's lubrication system, including oil changes and level checks.
5.1.3 Changing Engine Oil
Detailed steps for changing the engine oil, including draining, filling, and filter replacement.
5.1.4 Lube oil filter
Instructions for replacing the spin-on lube oil filter cartridge, including preparation and installation.
5.1.5 Centrifuge Lube oil filter
Maintenance instructions for the centrifuge lube oil filter, including cleaning frequency and identification.
5.2 Maintenance of Fuel System
5.2.1 Cleaning Fuel Strainer
Procedure for cleaning the fuel strainer, including steps for removal and reassembly.
5.2.2 Fuel Filter
Instructions for changing fuel filter cartridges (pre-filter and micro-filter) as per schedule.
5.3 Maintenance of Cooling System
5.3.1 Radiator
Maintenance tasks for the radiator, including checking coolant level, cleaning fins, and flushing.
5.3.3 Thermostat
Information on the thermostat's function and how to check its operation if deviations occur.
5.4 Maintenance of Dry type air cleaner
Maintenance
Regular checks and maintenance procedures for the dry type air cleaner to ensure engine protection.
Cleaning of Filter Element
Steps for cleaning the air cleaner filter element, including loosening, wiping, and compressed air cleaning.
5.6 Adjustments
5.6.1 Checking and adjusting valve clearance
Detailed procedure for checking and adjusting valve clearance using feeler gauges and tools.
5.7 Maintenance of Electrical Equipment
5.7.1 Starter Motor
Maintenance steps for the starter motor, including checking brushes, commutator, and springs.
5.7.2 Battery charging Alternator
Maintenance procedures for the alternator, covering brushes, slip rings, bearings, and belt tension.
6 Troubleshooting and Remedial measures
6.1 Troubleshooting
A guide to diagnosing and resolving common engine operating troubles and their probable causes.
6.2 Useful tips for Turbocharger
Tips and recommendations for the proper operation and maintenance of turbochargers.
6.3 Periodical Inspection of Turbocharger for Generating set application
Schedule for periodical inspection and cleaning of turbochargers in generating set applications.
6.4 Recommendation for Turbocharger operation and maintenance
Recommendations for operating and maintaining turbochargers to ensure engine life.
7 Instruction Manual for Electronic Governor
System Troubleshooting
Troubleshooting steps for the electronic governor system if it becomes inoperative.
8 Engine preservation
8.1 Recommended Preservatives
List of recommended preservatives for engine lube oil, fuel system, cooling system, and metal parts.
8.2 Preservation Procedure
Step-by-step procedure for preserving the engine for prolonged idle periods.
8.3 Commissioning of Preserved Engine
Instructions for recommissioning an engine that has been preserved.
9 Tightening Torque, Settings
9.1 Tightening Torque
Information on tightening high tensile bolts, including stages, angles, and torque values.
9.2 Settings
General engine settings including tappet and bumping clearances, and fuel timing.
Fuel timing setting
Procedure for setting the engine's fuel timing using a locking pin and flywheel markings.
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