INDEX

1. Foreword 1- 6
2. Engine Description 7 - 24
3. Engine Operation 25 - 38
4. Routine Maintenance 39 - 44
5. Service & Maintenance 45 - 66
6. Faults, Causes & Remedies 67 - 70
7. Engine Specifications 71 - 76
8. Tightening Torque 77 - 88
 1. FOREWORD

Dear Customer, We maintain the facility for operators training for

We are happy to provide you with latest revision of maintenance of Kirloskar diesel engines. Please
R810/R1040 / R1080 series O & M manual. contact our authorized service dealer / distributors
nearest to you to avail this facility.
The R810/R1040 / R1080 series liquid cooled engines
are developed and supplied for wide range of Continuous improvements in the product design are
application meeting your requirements. incorporated from time to time which may not be
included in this manual.
We assure you that all necessary safety precautions
and regulations have been adhered to in the design, The manual is updated periodically to include such
material and manufacturing of R810/R1040 / R1080 changes in the latest editions.
Series engines. All the engines under go stipulated
Should you have any queries, fully equipped and
performance test before being delivered to customers.
trained team from Kirloskar Customer Support will
This manual provides specifications and operations be happy to provide the help.
guidelines for services maintenance procedure.The
performance of engine largely depends on its proper KIRLOSKAR OIL ENGINES LTD
maintenance and up keep. Hence, please maintain Customer Support
your R810/R1040 / R1080 engine properly as per the Laxmanrao Kirloskar Road, Khadki
guidelines and schedules given in this manual. Pune 411003 (INDIA)
We recommend that only trained manpower should Help Desk – 1800 2333344, 020-66084608
perform the operation and maintenance tasks on the Help Desk ID – koel.helpdesk@kirloskar.com
engine. Always use the genuine Kirloskar spare parts Visit us at: www.kirloskar.com
whenever required for periodic maintenance as well
Visit us at : www.koel.co.in
as for engine repairs.

1
2
 STANDARD WARRANTY FOR KOEL R810/R1040 / R1080 SERIES
ENGINE OPERATING IN INDIA

This warranty applies to the R810 / R1040 / R1080 Series approved by us, have been continuously used. The
KOEL Diesel Engine for off Highway application. repaired or (at its option) new parts will be delivered
free of cost, EX-works.
Duration of Warranty
At the termination of such period of 12 calendar months
Off Highway Engines
(or six calendar months as the case may be) all liability
Within 18 Calendar Months from Date of Dispatch from on our part ceases.
KOEL or 3600 operating hours or 12 Months of hours
In the case of goods not of our manufacture (e.g. Fuel
date of installation whichever occurs first if customer
Injection Equipments, Electrical Components like
source the filters, K-Oil Premium, K-Cool Super Plus
Starter, Alternator, Turbocharger), you are entitled to
and avail the services from KOEL Authorised Service the benefits of respective manufacturers warranty
dealer for off Highway application. given to us. In respect there of and our liability in
Scope of Warranty respect of such goods is limited to the warranty given
by the respective manufacturer. In no case shall we
After the Engine has been taken delivery by you, we be liable for the fitting charges of replacement parts
expressly guarantee, in lieu of any warranty implied of thereof.
by law, to make good any defective parts in machinery
of our own manufacture, which defect develops under The defective parts replaced by us shall become our
proper use and necessary maintenance practices as property. All goods are supplied on the Condition that
written in this manual and arises solely from faulty we shall not be liable for any loss incurred through
material or workmanship, provide always that such stoppages or any consequential damages. Warranty
defective parts are promptly returned carriage paid to for rubber parts like AVM’s, Belts, Hoses, O rings etc
our works and provided that Fuel and lubricants will be six months from date of installation.

3
 Limitations and Exclusions 4. The cost of maintenance or regular service of
the engine.
This warranty does not apply to
5. Any damage due to idle storage of engine beyond
1. To fair wear and tear or to damage due to
period of 6 months without treatment of long
negligence or improper handling or incorrect
storage.
application or incorrect installation by the
purchaser, or his employees or agents or in the 6. Any damage due to use of lubrication oil, coolant,
case of repairs or alterations carried out by the fuel quality and grade not recommended by
purchaser without our knowledge and written Kirloskar Oil Engines Ltd.
approval.
7. Any damage resulting from improper shutdown.
2. To reconditioned or second-hand combination
8. Any failure to meet its obligations hereunder
sets or Engines. The Engines will be deemed to
which are due to circumstances beyond its
have been taken over by the customer upon
reasonable control including but not limited to
dispatch from our works, in the case of direct
industrial disputes, fire, severe weather
deliveries EX-Factory and from the godowns of
conditions, government decisions, material
our authorized Dealers viz. Distributors and
shortage, power or machinery breakdown or
Dealers, in the case of supplies from their stock
failure or war.
and this warranty will come into effect from that
time. 9. Gradual reduction in operating performance
commensurate with the age, kilometers covered
3. Incorrect operational & maintenance practices,
or operating hours, including but not limited to,
lapse in scheduled maintenance or maintenance
gradual loss of engine compression or gradual
done by other than KOEL - Authorised dealership.
increase in oil consumption due to normal
operating functions.

4
10. We will not be responsible for loss or damage to * Consumables & spares required for free service
goods beyond the delivery stated in our tender checks will be on chargeable basis.
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 R810/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 Premium, K Cool
Super Plus Coolant & Kirloskar genuine filters to
be used in engine.
* KOEL will provide for 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

5
 General

Your engine needs : Maintenance and Repairs

* Clean high speed diesel. * Shut down the engine before carrying out
maintenance or repair work.
* Lubricating oil of specified quality and viscosity
grade. * When the work is complete, be sure to install safety
devices that may have been removed.
* KOEL recommends use of K Oil Premium.
* If you have to work on a running engine, ensure that
* Fresh air for combustion of fuel, for cooling of all clothing is tight fitting and cannot entrap the
genset / radiator. moving parts.
* Genuine spare parts for its maintenance. * Observe all industrial safety regulations when engine
* K - Cool Super Plus Coolant to avoid rust formation. are operating in enclosed spaces or underground.
* Please contact your Kirloskar Dealer for Spare parts
Service and Maintenance enquiry. Use only genuine spare parts.

* Sound service and maintenance practices will ensure Safety

that the engine continues to meet your requirements. * All Safety instructions (for both engine and operator)
Recommended preventive maintenance at regular in this manual are designed by the accompanying
intervals must be observed. The service and
maintenance work should be carried out symbol. Please follow them carefully.
conscientiously.
* The attention of operating personnel should be
* Special care should be taken under abnormally drawn to these instructions.
demanding operating conditions.
* General safety and accident prevention regulations
laid down by law must also be observed.

6
 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

7
 2. Engine Description

8
2.1 Engine numbering system 2. Engine Description

2.1.1. Engine name plate

ENGINE TYPE

RATING kW/hp rpm

RATING STD.

GOVERNING CLASS

ENGINE No.

KIRLOSKAR OIL ENGINES LTD

INDIA

Engine no is punched on the Name Plate which is fixed on the engine crankcase.

9
 2. Engine Description 2.1 Engine numbering system

2.1.2 Engine number system 2.1.3 Model designation

4H 3002 / 10 00001 3 R 1040

Indicates Piston displacement

Engine serial No 1.04 Lit. / Cylinder as 1040 cc
Year of Manufacturing Indicates series of engine
as R series
Application code No.
(i.e. build of the engine) Indicates No. of Cylinders as 3

2H for 2R1040 6 R 1080 TA

3H for 3R1040
Indicates engine aspiration TA as
4H for 4R1040
‘ Turbocharged Aftercooled’
6H for 6R1040
engine.(In case of Naturally
T3 1003 10 00001 aspirated engines this
denomination is not mentioned.)
Engine serial No Indicates Piston displacement
Year of Manufacturing 1.08 Lit. / Cylinder as 1080

Application code No. Indicates series of engine as

(i.e. build of the engine) R series
Indicates No. of Cylinders as 6
T3 for 3R810
T4 for 4R810 The engine model is punched on nameplate in column ‘TYPE’.
The information about engine series, No of cylinders, Piston
Please furnish the complete engine number, so that matter
displacement in liter per cylinder and Aspiration is mentioned.
concerning Customer Service and Spare Parts can be more easily
The examples are stated above will clarify the matter.
dealt with.

10
2.2 Engine illustration 2. Engine Description

2.2.1 Air inlet manifold side

1. Air cleaner

2. Aircleaner hose

3. Flywheel
2
17 4. Drain Plug

16 1 5. Crank case

6. Air inlet manifold

15
7. G. E. Mtg. foot
13
8. Spin-on lube oil filter
14 9. Fuel Pump
10
10. Oil Filling Body
11
12 11. Gear casing
9
12. Lifting Hook
7
13. Dipstick
6 3
14. H. P. Pipes
8
5 15. Fuel filter (Spin on)

4 16. Fuel filter - (Mud Filter)

17. Vacuator Valve

11
 2. Engine Description 2.2 Engine illustration

2.2.2 Exhaust manifold side

18. Thermostat / Thermostat Hsg.

31 19. Radiator cooling fan

20. Tension adjusting lever

21. V - Belt

22. Crankpulley

30 23. Lube oil sump

24. Breather tube

29 18
25. Starter
28
26. Flywheel housing
19
27. Charging alternator
26 20
28. Turbocharger
27
29. Exhaust manifold
25 30. Rocker cover
21
24 22 31. Lube Oil filling point

23

12
2.3 Engine lifting device 2. Engine Description

2.3.1 For bare engine – R810/R1040 / R1080

Fig. above shows the recommended lifting device

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.

13
 2. Engine Description 2.4 Lube oil system

2.4.1 Lube oil circuit 2.4.2 Lube oil pump

Force feed lubrication is provided by a ‘G’ rotor type pump to main Lube oil pump delivery
bearings, large end bearings, camshaft journals, valve gear etc.
Other components like connecting rod small end bushes, cylinder Engine type 4R1040T/TA
liners and gear train are splash lubricated. Oil supply to valve gear
is achieved through rocker shaft core hole; the oil supply is Engine rpm 2200
controlled to the valves and rocker arm by oil metering screw, which
results into lower oil consumption and lower carbon deposition. Lube oil pump rpm 2464
The system includes adequate filtering by replaceable
‘Spin-on’ filter cartridge. The water-cooled lube oil cooler is Delivery Liters/min. 44@4bar
provided to maintain the oil temperature within limits. A relief valve at 4kg/cm2 pressure
controls the maximum oil pressure, which is provided on delivery
side of the lube oil pump.
Engine type 6R1080T/TA

Engine rpm 2200

Lube oil pump rpm 2464

Delivery Liters/min. 47@4bar

at 4kg/cm2 pressure

Engine type R810 4R810T

Engine rpm 2200 2200

Lube oil pump rpm 1765 1765

Delivery Liters/min. 21@3bar 36@4bar

at 4kg/cm2 pressure

14
2.4 Lube oil system 2. Engine Description

2.4.3 Lubrication system for R810 / R1040 / R1080 Series engines

A schematic diagram, shown below, shows the lubricating oil circuit of a typical R810 / R1040 / R1080 series engines

1. Lube oil sump

18 2 Suction tube
3 Lube oil pump
4 Pressure relief valve
19
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
The above parts are arranged in typical lube oil flow, only.)
as observed in R810 / R1040 / R1080 series engine lube
oil circuit. 21 Fuel pump connected to lube oil
circuit 15
 2. Engine Description 2.4 Lube oil system

2.4.4 Lube oil pressure 2.4.5 Lube oil temperature

The maximum lube oil temperature for R810 / R1040 / R1080

At low idling speed Minimum 1.5 Kg/cm2
series engines is ambient temperature plus 750 C. For example if
At loaded condition 2.5 to 6.0 Kg/cm2 ambient temperature is 400 C, the maximum lube oil temperature
in operating range should be 1200 C

If the lube oil pressure at any time drops below 1.5 kg/cm2 at Note :- During the running in period of first 50 hours, never
operating speed of 1500 rpm, under loaded condition, then exceed ‘full load’ even for a short duration; this is applicable for
replace the lube oil filter cartridge and check the pressure. If the stationary applications like power generation application.
pressure is still low, then contact your Kirloskar Dealer.

16
2.4 Lube oil system 2. Engine Description

2.4.6 Lube oil sump capacity 2.4.7 Lube oil

The lube oil sump capacities of R810 / R1040 / R1080 series engines * Whenever Lube oil filter is drained off, add approximately
are as below 0.5 lit. / 1 lit. extra Lube oil (as per the size of the Spin-on filter
These capacities are for the standard sheet metal sumps. cartridge) in the sump to maintain the correct oil level.)
* The oil level in the sump should be checked at room
Engine type 3R810 4R810 temperature by using dipstick. Top up with fresh oil when the
level reaches the low level mark on dip stick, fill till it increases
Oil sump type C.I. C.I. to top level mark. Avoid over filling.
Initial fill (lit.) 7.0 9.0 The engine should be lubricated only with the specified oil. This
Refill (lit.) Max./Min. 5.0/6.0 7.0/8.0 specially blended engine oil designed for the best performance
of engine.
Engine type 4R1040T/TA 6R1080TA Using the specified oil has the following advantages:
* Extra protection against corrosion and rusting
Oil sump type S.M./C.I. S.M./Low Ht.
* Excellent performance at both high and low temperatures
Initial fill (lit.) 11.5 15.0 / 20.5
* Reduced fuel consumption
Refill (lit.) 9.5 13.0 / 18.0
Usage of improper lube oil could result in:
* Overheating of the engine
The oil must be changed at least once in a year. This is
applicable to the engines, which are running for standby * Sluggish performance
duty application. * Excessive fuel consumption
Note : * Increased wear of bearings and other parts
* Initial fill = Sump capacity + Gallery capacity + Lube oil filter The specified oil is available only through KOEL’s authorized
capacity service dealers in suitable packing.
* Fill the Lube oil filter with oil before fitting on the engine.

17
 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 Multi-grade oil should be used.
used It is recommended to use ‘K Oil Premium’ (SAE15W40) As the viscosity of lube oil is dependent on temperature. the
K-OIL PREMIUM Genuine Oil for Kirloskar BS-III engines - Next choice of SAE grade should be governed by the ambient
generation lubricant. temperature prevailing at the engine operating site..
K-Oil PREMIUM is formulated using superior quality Group 11+ Optimum operating behavior will be attained if you take the
base oils and highly developed additive technology, specially accompanying oil viscosity diagram as a guide Should be
developed to meet the stringent demands of modern low temperature fall temporarily below the limits of the SAE grade
emission BS-III engines manufactured by Kirloskar Oil Engines. selected, cold starting may be affected but the engine will not be
• Suitable for engines fitted with EGR technology. • Excellent damaged.
soot dispersing capability ensures lower pressure drops across In order to keep wear to a minimum, do not exceed application
filters and enhances filter life. • Superior protection of engine limits for extended period of time.
components from wear & corrosion even under severe working
conditions. • Enhanced oxidation stability reduces sludge varnish
& deposit formation and extends oil service life. • Backward
compatible with all previous API Service categories. • Extensively
evaluated and tested under severe conditions to establish the
performance”.

Warranty is applicable on use of ‘K Oil Premium’ engine

oil only.

18
2.4 Lube oil system 2. Engine Description

2.4.9 Viscosity

Only with preheating

19
 2. Engine Description 2.5 Fuel system

2.5.1 Fuel system

Mud Filter Feed Pump

Injector FIP Fuel Filter

Fuel is supplied to the Rotary fuel pump by a fuel lift pump (feed The fuel tank is to be installed below the fuel pump level, and
pump) a spin-on fuel filter ensures the supply of clean fuel to the then the bottom level of the fuel tank should be less than 1 meter
rotary fuel pump. The schematic diagram shows the fuel circuit below the feed pump inlet. Fuel pipe from fuel tank to feed pump
of the engine. should be of 9mm I.D.

The indicated figure is typical fuel circuit diagram,

where as the scope & routine of fuel system can be
changed according type & application.
20
2.5 Fuel system 2. Engine Description

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 WINTER GRADE
manufactured to very close tolerances and slightest amount of HIGH SPEED DIESEL
dirt in fuel can cause wear on the injection equipment. Following
points are important in use of fuel on Kirloskar
R810 / R1040 / R1080 series engines.
The following specifications are approved: -
* IS:1460 - 2005
* ASTM D975-88:1-D & 2-D
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.
* Proportion of Kerosene to be mixed in Diesel, depends on the
ambient temperature as shown in the graph.
(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. 0 10 20 30 40 50
% OF KEROSENE

21
 2. Engine Description 2.5 Fuel system

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.

22
2.6 Cooling system 2. Engine Description

2.6.1 Radiator type cooling system 2.6.2 Coolant

The engine uses a specially formulated coolant “K-Cool Super

Plus” with deminteralised water & glycol. Use only “K-Cool Super
Plus” coolant and do not use ordinary water. “K-Cool Super Plus”
is available only through KOEL’s authorized dealer in suitable
packings.
Coolant Recommendation – It is recommended to use K-Cool
Super Plus coolant in the cooling system.

The radiator type cooling system is used in R810 / R1040 / R1080

series engines.
The schematic diagram, of the typical coolant circuit with radiator
type cooling system, is shown in the figure above.

23
 2. Engine Description 2.7 Electrical system

2.7.1 Electrical equipment 2.7.2 Battery & battery cables

Engines are equipped as per customer requirement with 12V & Recommended Battery Cable (Copper) – 35mm2 - up to 1mtr.
24V negative earth electrical starting system. 50mm2 - up to 2mtr.
Electrical system 12 V 24 V 70mm2 - up to 3mtr.
Alternator – 12V DC, 35Amp 24V DC, 30Amp
12V DC, 55Amp 24V DC, 55Amp
12V DC, 65Amp 24V DC, 45Amp
Starter – 12V DC, 2.7 KW 24V DC, 4.5 KW
12V DC, 3.0 KW
Recommended Battery Capacity –
R810 / R1040 DC, 120 AH above 100 C
R1080 DC, 150 AH above 100 C

24
 3. Engine Operation

3.1 Commissioning
3.2 Operating conditions
3.3 Starting & stopping
3.4 Running in period
3.5 Engine cleaning & preservation

25
 3. Engine Operation

26
3.1 Commissioning 3. Engine Operation

3.1.1 Oil

Before you start a new or overhauled engine, attend following

points

Oil filling
Fill the engine with Lube oil through oil filling neck as shown in
figure above. For oil quantity, grade and viscosity refer point
no. 2.4.8 & 2.4.9 respectively.

27
 3. Engine Operation 3.1 Commissioning

3.1.2 Cooling system 3.1.3 Belts

Check that belts are in position and the belt tension is proper. If the
belt tension is not proper adjust the same as described in
section 5.4

* Fill the cooling system with recommended K-Cool Super Plus.

Fill the coolant through neck of radiator till it flows through the
radiator over flow pipe and then connect the pipe to balance
water tank. Coolant filling through radiator neck is recommended
only for initial fill. For regular coolant top up, coolant is to be
added in balance water tank.
* Do not open the radiator cap while engine is running or hot.
The cooling system is under pressure hence danger of burning
body skin.
* Add coolant when the coolant system is cold. The temperature
difference between the coolant in the engine and the coolant
being added must not exceed 500C. Coolant is to be added in
balance water tank, do not open the radiator cap for coolant
filling.
28
3.1 Commissioning 3. Engine Operation

3.1.4 Valve clearance 3.1.5 Other preparations

It is not necessary to check / adjust the valve clearance on a new * Check battery and lead connections. Also check the cable
engine as it is already adjusted at its required value in factory. connections at the starter & alternator. Loose connections lead
However after overhauling the engine, it is necessary to recheck to improper contact and damage to the terminals.
and adjust the valve clearance before starting the engine. Refer * Remove lifting hooks after engine installation.
section 5.6 for adjustments.
* After completing the preparations, run the engine for a short
period of 10 minutes without load.
- Check the engine for oil and water leakages. If the leakages
are noticed, remove them.
* After stopping the engine check following.
- With engine stationary, check the oil level. Top up the oil if
necessary
- Retighten the V belts

29
 3. Engine Operation 3.2 Operating conditions

3.2.1 Deration charts

* The declared power ratings of the engine are obtained at The engine power mentioned on name plate is at NTP conditions.
standard reference conditions as per ISO 3046 / BS 5514 / DIN Based on altitude, ambient tempature & relative humidity engine
6271 / IS 10000. requires to be derated accordingly.
* Where engines are operated at greater altitudes and / or higher Deration chart for Naturally Aspirated engines
ambient temperatures, they must be derated in accordance The chart is prepared on the basis of standard ambient
with respective standards. conditions mentioned in ISO 3046/DIN 6271/BS 5514, with 30%
* In case of doubt concerning such engine application, contact relative humidity. For higher relative humidity the deration
your engine equipment supplier. increases by 2% for 20% rise in relative humidity above 30%
relative humidity.
The deration chart applicable for R810 / R1040 / R1080 engines
is illustrated below.

30
3.2 Operating conditions 3. Engine Operation

3.2.1 Deration charts 3.2.1 Deration charts

Deration chart for Turbocharged engines Deration chart for Turbocharged Aftercooled engines
The deration chart applicable for R810T / R1040T / 6R1080T The deration chart applicable for 4R1040TA/6R1080TA engines
engines is illustrated below. is illustrated below

31
 3. Engine Operation 3.3 Starting & stopping

3.3.1 Lubrication - Precautions to be observed.

* Fill recommended grade of fresh oil in the sump up to the high

mark of the dipstick.
* Add an additional 1/2 liter or 1 liter oil to compensate for the
extra volume of the lube oil filter.
* Lube oil level in the oil sump should be checked and topped
up after initial starting and stopping the engine.

32
3.3 Starting & stopping 3. Engine Operation

3.3.3 Cooling: Liquid cooled engines 3.3.4 Electrical

* Fill the radiator with “K-Cool Super Plus” coolant only. * Check the battery for correct voltage and current capacity.
* After starting the engine recheck the coolant level in the radiator * Check that the battery cables are correctly connected and
and top up if required. secure.
* The Compensation tank on the radiator should also be filled as * Ensure correct polarity.
per the specified marking. * Apply petroleum jelly on battery terminals.

33
 3. Engine Operation 3.3 Starting & stopping

3.3.5 Mechanical 3.3.6 Procedure of starting & stopping

* Ensure that all electrical wiring of the alternator is intact. Before starting
* Ensure that all the fasteners in the foundation, couplings etc * Check the oil and coolant levels - top up if required.
are properly secured. * Ensure that there is sufficient fuel in fuel tank.
* Check the restriction indicator of air cleaner.
* Clean the engine with a dry cloth.
* Crank the engine. Release the starter switch as soon as engine
fires. Keep the ignition switch in the ‘ON’ position. Do not
crank the engine for more than 10 seconds at a time.
* If engine fails to start, wait for a minute before trying again.
After starting
* Check for leakages of fuel, oil and coolant.
* Allow the engine to run idle for about 3 minutes and then start
loading the engine.
* While the engine is operating, check the oil pressure, coolant
temperature and battery charging rate regularly.

34
3.3 Starting & stopping 3. Engine Operation

3.3.6 Procedure of starting & stopping

Stopping
Before stopping
* Unload the engine and let it run at idling speed for about 5
minutes.
* Check if lube oil pressure and coolant temperature have
stabilized.
* Shut the engine from the ‘Stop’ push button on the Engine
Controller.
After stopping
* Check for any fuel, oil and coolant leakages.
* Check the oil level 30 minutes after stopping and top up if
required.

35
 3. Engine Operation 3.4 Running in period

3.4.1 After first 50 hours running

* Change engine oil see 5.1.2

* Change the lube oil filter cartridge / element see 5.1.3
* Check and retighten fasteners for lube oil sump if necessary
* Check V belt tension and retighten if necessary see 5.4
* Check engine for leakages of lube oil, fuel, water.
* Check the engine mounting bolts, retighten if necessary.
See 5.7.2
* Retighten intake and exhaust manifold fasteners at cylinder
heads.
* Check battery electrolyte level, top up if required.

36
3.5 Engine cleaning & preservation 3. Engine Operation

Remove the dust deposit from the engine and radiator fins with
compressed air. Cleaning with diesel fuel or kerosene or water
may cause dust to deposit again on the cleaned parts.
* Cleaning should be done from the side opposite to the normal
air flow.
* When deposits are hard, scrape and clean with a water jet. Run
the engine after such cleaning till all the water has evaporated.
* When the engine is not used for some time, it should be
protected from atmospheric moisture and condensates that
could damage the engine parts such as bearings, piston
crankshaft, etc.

37
 4. Routine Maintenance

4.1 Maintenance Schedule

4.2 Maintenance Work Completed

39
 4. Routine Maintenance

40
4.1 Maintenance Schedule 4. Routine Maintenance

Every In Running Hours

10th
Hour/ 1st Job Refer
Daily 50 250 500 750 1000 2500 5000 section

Engine oil level 5.1.1

Coolant level in radiator and compensatory tank 5.3.1

Restriction indicator of dry type air cleaner 5.4.2

Rubber hose & clips of dry type air cleaner / radiator —
     Engine oil ( Every 500 Hrs.) 5.1.2
     Lube oil filter cartridge ( Every 500 Hrs.) 5.1.3

Battery and lead connections ( Every 50 Hrs.) 5.7.2




‘V’ Belt condition and tension (adjust / replace if required) 5.4




Radiator fins (depends on site condition) externally 5.3.1

Radiator tubes internally 5.3.2
     Replace fuel filter cartridge after every 500 Hrs. 5.2.2


Injector —






Fuel strainer (Button filter)

Thermostat element (change if necessary) 5.3.3


Valve clearance (adjust if necessary) 5.6.1


Starter / Alternator —


Fasteners —

Exhaust silencer —

Check / Adjust  Change
Clean 41

 4. Routine Maintenance 4.2 Maintenance Work Completed

Hours Date Remark Signature / Stamp

50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000

42
4.2 Maintenance Work Completed 4. Routine Maintenance

Hours Date Remark Signature / Stamp

4250
4500
4750
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000

43
 4. Routine Maintenance 4.2 Maintenance Work Completed

Hours Date Remark Signature / Stamp

8250
8500
8750
9000

Top Overhual and Major Overhaul

periods
The duration of the operating period
before overhaul is dependant entirely on
the quality of maintenance and service
given to the engine and also type of
environment and engine load cycle.
However, after about 5000 running hours
engine will need top overhaul (servicing
of combustions system) and after about
9000 running hours engine will need major
overhaul. These periods are based on
assumption that engine is maintained
properly as per the instructions given in
this manual. Hence the above estimated
overhaul periods are to be referred as
general guide lines. Get the engine top
overhauled or major overhauled from
KOEL authorised service dealer. Use
genuine spare parts for top & major
overhaul of the engine.

44
 5. Service & Maintenance

5.1 Maintenance of lube system

5.2 Maintenance of fuel system
5.3 Maintenance of cooling system
5.4 Maintenance of dry type air cleaner
5.5 Belt drives
5.6 Adjustments
5.7 Maintenance of electrical equipment
5.8 Additional jobs

45
 5. Service & Maintenance

46
5.1 Maintenance of lube system 5. Service & Maintenance

5.1.1 Checking oil level 5.1.2 Changing engine oil

Removing engine oil

* Stop the engine and wait for a while (Approximately 30 to 45 * Run engine until it gets warm. (lube oil temp. approx. 80°C)
mins.) till oil level in the sump is settled. Ensure that engine is * Stop the engine, remove battery connections.
in horizontal position.
* Place oil tray under the engine.
* Pull out dipstick, wipe it with a non-fraying cloth and push it in
* Unscrew oil drain plug on the end of drain pipe & drain oil
as far as it will go and then withdraw again
completely. Wait until last drop of oil.
* The film of oil left on the dipstick should extend to the upper
* Collect used oil in suitable receptacle ready for proper
(max.) mark. If the level approaches near to the lower mark,
disposal to prevent environmental pollution.
the oil should be topped-up without delay.
* Refit oil drain plug with new joint washer and tighten firmly.

Failure to attend to this may result in serious damage to

the engine (piston & bearing seizure)

47
 5. Service & Maintenance 5.1 Maintenance of lube system

5.1.2 Changing engine oil 5.1.3 Changing lube oil filter

Removing engine oil Removing lub oil filter

* Fill in fresh lube oil. Replace ‘Spin-on’ lube oil filter cartridge for every oil change.
– Lube oil specifications – Use K Oil Premium * Release lube oil filter cartridge with special tool and spin off
as shown in figure above.
– Lube oil sump capacity, refer 2.4.5
* Do not flush the lube oil system with diesel or kerosene.

Take care when draining off hot oil : Danger of scalding!

48
5.1 Maintenance of lube system 5. Service & Maintenance

5.1.3 Changing lube oil filter

Assembling lub oil filter

* Clean sealing surface of filter carrier. * Tighten lube oil filter cartridge firmly by giving a final half turn
* Fit the filter cartridge in dry condition. Do not fill oil in the filter as shown in figure above.
before assembly. * Check oil level and lube oil pressure.
* Apply light film of oil to rubber seal of new cartridge. * Check seal of lube oil filter cartridge for leaks
* Screw cartridge into place by hand until seal is evenly seated.
* Use genuine KOEL lube oil filter.

49
 5. Service & Maintenance 5.2 Maintenance of fuel system

5.2.1. Changing Fuel Filter - Spin On Type

* Remove the cartridge by rotating in anticlockwise by hand. * Clean the sealing surface of filter.
* Collect driping fuel in a tray. * Apply light film of oil or diesel fuel to the rubber gasket of the
* Destroy the removed cartridge. new fuel filter cartridge.
* Use genuine KOEL fuel filter. * Screw in the new cartridge finger tight against the gasket.

Keep naked flames away when working on they fuel

system. Do not smoke.

50
5.2 Maintenance of fuel system 5. Service & Maintenance

5.2.1. Changing Fuel Filter - Spin On Type

* Tighten the fuel filter cartridge with a final half turn using
commercial tool.
* Open fuel stopcock.
* Check for leaks.

51
 5. Service & Maintenance 5.3 Maintenance of cooling
system
5.3.1 Radiator

Engine cooling system consists of radiator, fan, water pump and

temperature controller i e. thermostat. High coolant temperature
trip for engine safety has been provided.
Check coolant level in the balance water tank every day before
starting the engine. If required add the coolant in balance water
tank, never top up the coolant level above the Max. mark on the
tank.

Coolant filling

* Add coolant only when the cooling system is cold. The

temperature difference between the coolant in the engine and
the coolant being added must not exceed 50 °C.

Do not open radiator cap while the engine is running

or hot. The cooling system is under pressure. Danger
of burning body skin!
52
5.3 Maintenance of cooling 5. Service & Maintenance
system
5.3.1 Radiator 5.3.2 How to clean the cooling systems with
the help of K clean cleaner.

* K Clean is designed to remove the contaminants like scale, oil,

grease, rust, loose material present in the engine cooling
systems.
* Add K Clean in the ratio of 375 ml for every 16 lit capacity of
radiator and balance clean water (mineral or similar water) in
the radiator.
* Run the engine for minimun 20-30 minutes.
* Allow the water to cool down and drain it completaly.
* Refill it with plain clean water and run the engine for another
15-20 minutes for flushing the system.
* Allow the water to cool down and drain it entirely.
* Observe the drained water, if it still contents rust, scale and
Cleaning the radiator fins dirt, repeat the above procedure for one more time.
* Fill the system with K Cool Super Plus.
* Cleaning the radiator fins * This will provide maximum life and benefits of K Cool Super
* Clean the radiator fins after every 400 hours. Plus for better engine performance.
(Under very dusty conditions, fins cleaning frequency will have
to be increased.)
* For cleaning, blow the pressurized air through radiator fins in
the reverse direction of the flow of radiator fan as shown in
figure above. Do not spill water on radiator fins.
* After every 5000 hours while replacing the coolant, the cooling
system should be clean.

53
 5. Service & Maintenance 5.3 Maintenance of Cooling
System
5.3.3 Thermostat

Thermostat inspection

A thermostat having single element is used in the cooling circuit.

Thermostat is provided to attain working temperature quickly
during warm-up period and maintains desired temperature of
coolant during running of the engine.
Normally thermostat does not require regular maintenance. Its
operation shall be checked if sudden deviations from the specified
coolant temperature occurs. Visual inspection will reveal whether
or not the element rests in its seat properly. See figure above.
* It is necessary to replace defective element.

54
5.4 Maintenance of dry type 5. Service & Maintenance
air cleaner
5.4.1
Dry type air cleaner with plastic housing Dry type air cleaner with sheet metal housing

Construction of typical dry type plastic air cleaner, supplied, is bottom of cover helps in expelling the accumulated dust. This is
shown above in figure and construction of typical dry type air achieved by opening / closing of vacuator valve outlet due to the
cleaner with sheet metal housing is shown above in figure. airflow fluctuations inside the air cleaner.
Inlet cap or pre - cleaner is supplied for the air intake inlet cap Inner element is a ‘Safety Element’ to prevent ingress of dust into
prevents ingress of rain / heavy particles. the engine, when the outer (main) element is removed for cleaning
Two filter elements are co - axially fitted in the air cleaner housing. / replacement.
The outer element is the main filter element, with a built in cyclone
separator which gives a swirling effect to incoming air, to separate
out heavy dust particles by centrifugal action. This dust is collected
in the end cover (which is removable). The vacuator valve at the

55
 5. Service & Maintenance 5.4 Maintenance of dry type
air cleaner
5.4.2 Maintenance

Regular check up and maintenance of the air cleaner is essential NOTES: -

to ensure maximum protection to the engine from the dust. * If engine performance is poor, but restriction is still within
* Damaged hose / clips must be replaced immediately. Any limits, do not change the element. The air cleaner is probably
bypassing of unfiltered air through cracks in the hose / loose not at fault.
hose will quickly lead to serious damage to the engine. * To get those extra service hours out of air cleaner element,
* The pre-cleaner (if provided) should be cleaned, to remove make sure the air inlet is away from any heavy dust clouds
the accumulated dust, after each day’s work, when the engine caused by operation. Also, make sure that exhaust carbon
is stopped. This cleaning can be done by removing the top cannot enter the air cleaner.
cover of pre-cleaner.
* The restriction indicator, mounted on air cleaner near the hose,
indicates the condition of the air cleaner element, when the air
element is in good condition, a red signal will be seen through
the transparent window on the indicator when the engine is
running and will disappear when engine is stopped. However,
if the element is choked, then the red signal will remain ‘ON’
even after engine is stopped. This is an indication that the main
filter element must be removed & cleaned or replaced.
* Do not clean the air cleaner element if restriction indicator
does not show red band.

Since this is a dry type air cleaner, do not fill a single

drop of oil in it. Also, protect the air cleaner form ingress
of rain / moisture.

56
5.4 Maintenance of dry type 5. Service & Maintenance
air cleaner
5.4.2 Maintenance 5.4.3 Cleaning of filter element

Discharging vaccuator valve Removing air cleaner housing

* Discharge the dust vaccuator valve by pressing apart the lips Cleaning of filter element is to be done only when a restriction
of the ejection slot, applying pressure as shown above. indicator shows a red signal even after the engine is stopped. For
* Clean the vacuation slot time to time. cleaning proceed as follows -
* Remove any cakes of dust by pressing together the upper part * Loosen the mounting band of the dust cup, take out the outer
of the valve. element for checking and cleaning. See figure above. Do not
remove inner element (Safety element)
* Make sure that vacuator valve is not damaged, if required
change it * Use a damp cloth to wipe out all excess dust in the air cleaner.
* Thorough cleaning of the fitter element with compressed air is
recommended.

57
 5. Service & Maintenance 5.4 Maintenance of dry type
air cleaner
5.4.3 Cleaning of filter element

Cleaning air filter element with compressed air Inspection of air cleaner element - Light test

Clean the element from inside to outside using compressed air as * Carefully check new or properly cleaned element for damage
shown in figure. before installing. Conduct a light test by passing the light
* Replace the main element after two cleaning intervals. through element as shown in figure above. If there is any crack
in the element, the light will pass through it. In that case replace
* Rapping, Tapping or Pounding dust out of element is the element.
dangerous. It will result in severe damage to the filter element.

Too much air pressure can tear the filter paper and
destroy the element. (Max. Air Pressure 3.0 kg/cm2)

58
5.4 Maintenance of dry type 5. Service & Maintenance
air cleaner
5.4.3 Cleaning of filter element

* The inner element (Safety element) is not to be removed, when

the main element is removed for cleaning / replacement. It
should be replaced by a new safety element at every change
of the main element.
* Assemble the cleaned or new element in the air cleaner body
and reinstall the end cover, making sure it seals all around the
air cleaner body. Reset the restriction indicator by pressing
the button at the top.
* For certain application involving extremely dusty
environment, we recommend use of series air cleaner systems,
i.e. dry type air cleaner in series with oil bath air cleaner.

Assembling rubber sealing ring

* Inspect the rubber-sealing ring at the end cover of the element.

In case the seal is damaged, replace the sealing ring.

59
 5. Service & Maintenance 5.5 Belt drives

5.5.1 Checking belt tension

* Never check / retension / renew V- belt while engine is running.

Refit V-belt guard, if provided.

A single V belt of NPA/XPA section or Poly V belt is used to drive

engine water pump, radiator fan and battery charging alternator
for R810/R1040/R1080 engines.
* Inspect V-belts over whole length for damage or cracks. Renew
damaged or cracked v-belt.
* Check by pressing midway between the pulleys to see whether
the belt deflects inwards by not more than 10 to 15 mm as
shown above.
* If necessary re-tension V-belt by loosening and re-tightening
the battery charging alternator.

60
5.6 Adjustments 5. Service & Maintenance

5.6.1 Checking and adjusting valve clearance 5.6.2 Checking valve clearance

ADJUSTING * Check clearance when engine is cold. (At room temperature)

SCREW TOE * Remove the rocker cover.
* Turn crankshaft until the valves of the cylinder (on which the

Valve Clearance
clearance is being checked) are “overlapping” (exhaust valve
about to close, inlet valve about to open).
ROCKER
ARM * Then continue turning the crankshaft through 360° (one
complete revolution). At this position both valves are closed.
PUSH ROD VALVE
* Insert a feeler gauge of 0.25 mm in the gap between rocker
arm toe and valve for inlet. The valve clearance is correct
when the filler gauge can be inserted with a slight drag. Failing
this, the valve clearance must be readjusted as mentioned in
5.6.3.

The valve clearance is the requisite gap between the rocker arm
toe and valve stem end. See figure above. Engine performance
and power output depend on its correct setting, which can be done
by a skilled mechanic according to the instructions in 5.6.3.

61
 5. Service & Maintenance 5.6 Adjustments

5.6.3 Adjusting valve clearance

* Loosen lock nut of adjusting screw through one or two turns

and adjust the screw with screwdriver so that, when locknut is
retightened, the feeler gauge of 0.3 mm can be inserted and
withdrawn with slight drag.
* Similarly, check the valve clearance of exhaust valve with
0.3mm feeler gauge. Readjust if necessary.
* Check the valve clearances of each of the remaining cylinders
at their respective TDC and readjust, if necessary.

Adjusting valve clearance

Tappet clearance (in cold condition only)

Inlet Exhaust

0.25 mm 0.30 mm

62
5.7 Maintenance of 5. Service & Maintenance
electrical equipment
5.7.1 Battery charging alternator 5.7.2 Battery

* Check belt tension, readjust if necessary

* Check the battery condition
* Keep the alternator reasonably clean and ensure that ventilation
slots or air spaces are clear and unobstructed. Check mounting
bolts for tightness.
* Any work involving repairs / replacement of components of
alternator contact Kirloskar authorised service dealer.

Checking battery and lead connections

* Clean the battery. Use damp cloth for cleaning.

A slack belt will rapidly wear and because of slip may

not drive the alternator at the required speed. Too tight a
belt will impose severe side thrust on the bearings and
seriously shorten their life.
63
 5. Service & Maintenance 5.7 Maintenance of
electrical equipment
5.7.2 Battery

* Check battery lead & terminal connections are tight.

* Apply petroleum jelly to terminals.
* When reconnecting, ensure good contact of the terminals.
Tighten clamping bolts firmly.
* Ensure correct polarity before connecting.
For technical details, specification & maintenance of battery please
refer battery manufacturers recommendations.

64
5.8 Additional Jobs 5. Service & Maintenance

5.8.1 Exhaust silencer 5.8.2 Checking of fasteners

* Knock out soot from exhaust silencer and clean the exhaust * Check & tighten-up the fasteners for following -
piping after every 1200 hours.
– Air intake and exhaust manifolds, exhaust piping
* The time span of exhaust silencer chocking is entirely
– Radiator hose connections
dependant on the working conditions and maintenance &
operating practices, so the time span will be vary accordingly. – Engine and radiator mountings
– Lube oil sump
– Front cover
– Hose clip for air cleaner
– Lube oil filter mounting
– Engine mountings
– Fuel connections
– All external nuts and bolts

Do not overtighten the fasteners.

65
 6. Faults, Causes & Remedies

6.1 Diagnosis Chart

67
 6. Faults, Causes & Remedies

68
Diesel knock
Bearing wear
Engine overheat

Mechanical knock
Excessive vibration
Engine lacks power
Engine fails to rotate
Engine does not start

Low lube oil pressure

Breaking of valve springs

Excessive oil consumption
Excessive fuel consumption
Excessive smoke at no load
Engine has starting difficulty

Excessive smoke at full load

Battery runs down frequently

Complaints

Engine gives out blue smoke

Mixing of diesel with lube oil

Engine gives out white smoke
Engine misfires during operation

Excessive liner & piston ring wear

Excessive valve & valve guide wear
Engine starts but stops after some time

Engine does not reach governed speed

Engine speed does not remain constant

Excessive fuel injection equipment wear

Engine rotates very slowly during starting
6.1 Diagnosis Chart

Dust entry in air inlet system

Dirty / clogged air cleaner





High exhaust back pressure
System

Derating due to altitude

Air / Exhaust

Derating due to temperature

No fuel








Poor quality of fuel




Air in fuel line





Choked fuel line




External / Internal fuel leakage







Choked fuel injector holes






Damaged or dribbling nozzle
Fuel System

Loose HP. pipe connections

Dirty / Choked fuel filter




Control lever settings wrong











Faulty fuel pump





Water mixed with fuel








Wrong grade of lube oil used



Dirty / Choked suction tube strainer


Lube oil dilution





Dirty / Clogged lube oil filter



Clogged oil passage


Excessive oil in the sump
External / Internal leakages
Lubricating System

Faulty oil pump



Radiator fins choked



Loose V - Belt

Air leakages through radiator & shroud
System
Cooling

No coolant in radiator / Coolant level low

Engine overloading






Engine used after a long time
Maint.

Wrongly adjusted valve clearances

Operation

Prolonged oil change period

Blown cylinder head gasket






Valve leakages











Broken / worn out piston rings



Excessive end play in crankshaft











Worn out cylinder liner & piston






Incorrect bearing clearances








Damaged main & connecting rod brgs.





Worn out valves & valve guides









Incorrect valve & fuel timing








Injector needs adjustment






Engine seized
Mechanical System

Faulty governor setting

One or more cylinders not working


Loose mounting bolts


Loose flywheel / wrong alignment










Engine needs overhauling

Fuel pump rack stuck in stop position
6. Faults, Causes & Remedies

Battery run down / under rated battery

Faulty starter




Battery of wrong capacity
System
Electrical

Loose or dislodged wiring

 7. Engine Specifications

7.1 ENGINE SPECIFICATIONS FOR R810 SERIES ENGINES

7.2 ENGINE SPECIFICATIONS FOR 4R1040TC / TA SERIES ENGINES
7.3 ENGINE SPECIFICATIONS FOR 6R1080TA SERIES ENGINES

71
 7. Engine Specifications

72
 7. Engine Specifications

7.1 ENGINE SPECIFICATIONS FOR R810 SERIES ENGINES

Sr. No. Model Unit 3R810 4R810NA 4R810T

1 Bore x Strock mm 96 x 112 96 x 112 96 x 112
2 Firing order — 1-2-3 1-3-4-2 1-3-4-2
3 Displacement cc 2430 3240 3240
4 Direction of Rotation — ACWR ACWR ACWR
5 Aspiration — Naturally Aspirated Turbocharged
6 Compression Ratio — 18 : 1 18 : 1 17 : 1
7 Starting Arrangement — Electric Start
8 Governer Type — Mechanical
9 Class of Governing — M2 As Per ISO 3046
10 Lube Oil Consumption — <0.3% of Fuel Consumpation
11 Lube Oil Sump Capacity lit. 5 7 7
12 Rated Output as per
ISO 3046 hp 45 49.5 49.5 56 58 60 62
13 Rated Speed rpm 2600 2000 2200 2000 2200 2400 2600
14 Rating Standard — ISO 3046
16 B. M. E. P at Rated Output : kg/cm 2 6.54 7 6.37 7.93 7.46 7.08 6.75
17 Maximum Torque (+/- 100 rpm) Nm 141@1400 rpm 210@1400 rpm 203@1400 rpm 215@1400 rpm
18 Dry Engine Weight
- With Flywheel & Flywheel Hsg. kg 350 400 415
19 Noise Lever at 1m dBA <97

73
 7. Engine Specifications

7.2 ENGINE SPECIFICATIONS FOR 4R1040TC / TA SERIES ENGINES

Sr. No. Model Unit 4R1040TC 4R1040TA

1 Engine Model 4R1040TC 4R1040TA1 4R1040TA2 4R1040TA3 4R1040TA4
2 Bore x Strock mm 105 X 120
3 Firing order — 1-3-4-2
4 Displacement cc 4160
5 Direction of Rotation — ACWR
6 Aspiration — Turbocharged Turbocharged After Cooled
7 Compression Ratio — 17 : 1
8 Starting Arrangement — Electric Start
9 Governer Type — Mechanical
10 Class of Governing — M2 As Per ISO 3046
11 Lube Oil Consumption — <0.3% of Fuel Consumpation
12 Lube Oil Sump Capacity lit. 9.5
13 Rated Output as per
ISO 3046 hp 76 90 96 105 110
14 Rated Speed rpm 2200 2200 2200 2200 2500
15 Rating Standard — ISO 3046
16 B. M. E. P at Rated Output : kg/cm 2 7.6 9.0 9.6 10.5 9.7
17 Maximum Torque (+/- 100 rpm) Nm 300@1500 rpm 350@1400 rpm 377@1400 rpm 375@1300 rpm 380@1300 rpm
18 Dry Engine Weight
- With Flywheel & Flywheel Hsg. kg 490 510
19 Noise Lever at 1m dBA <100

74
 7. Engine Specifications

7.3 ENGINE SPECIFICATIONS FOR 6R1080TA SERIES ENGINES

Sr. No. Model Unit 6R1080TA

1 Engine Model 6R1080TA1 6R1080TA2 6R1080TA3
2 Bore x Strock mm 105 X 125
3 Firing order — 1-5-3-6-2-4
4 Displacement cc 6495
5 Direction of Rotation — ACWR
6 Aspiration — Turbocharged After Cooled
7 Compression Ratio — 17 : 1
8 Starting Arrangement — Electric Start
9 Governer Type — Mechanical
10 Class of Governing — M2 As Per ISO 3046
11 Lube Oil Consumption — <0.3% of Fuel Consumpation
12 Lube Oil Sump Capacity lit. 18 13
13 Rated Output as per
ISO 3046 hp 125 130 169
14 Rated Speed rpm 2300 2500 2300
15 Rating Standard — ISO 3046
16 B. M. E. P at Rated Output : kg/cm 2 7.7 7.3 10.4
17 Maximum Torque (+/- 100 rpm) Nm 420@1600 rpm 420@1600 rpm 585@1500 rpm
18 Dry Engine Weight
- With Flywheel & Flywheel Hsg. kg 750
19 Noise Lever at 1m dBA <100

75
 8. Tightening Torque

8.1 Tightening torque table for fasteners

8.2 Tightening torque sequence for R1040 / R1080 engine

77
 8. Tightening Torque

78
 8. Tightening Torque

To prevent faulty assembly, following information on tightening Tommy bar is to be clamped in the tool slot and specified angle
of high tensile bolts is important. The bolts are to be tightened in is to be turned with reference to the initial graduation on outer
stages as specified in the table below. For connecting rod bolt and dial of the tool or a relation of hex head of bolt can be referred.
main bearing cap bolt use angle torque method with the help of NOTE:
goniometer. The tightening angles for these two bolts are
particularly important, hence figure below indicates the various 1. Lubricate threads and seating face of bolt with engine oil before
angles can be readily obtained by comparison with a clock face. it is assembled.
2. Screw the bolt by hand till it is engaged up to the seating face.
3. Apply initial torque and tighten the bolts according to the angles/
torques in stages as specified in the “Tightening table”.
4. In case of replacing main and big end bearings/overhaul/piston
seizures, fit new bolts for main bearing cap, connecting rod
cap, balance weight & cylinder head.
1 Nm = 0.102 kgm = 0.74 Ib.ft.

Tightening torque angles

79
 8. Tightening Torque 8.1.1 Tightening Torque
R810 Table for fasteners

Sr. Description Initial Tightening Method Total

No. Torque Angle/kgm Angle
kgm Torque

Stage1 Stage2 Stage 3

1 Bolt for balance weight 3 300 300 - 600

(M12x1.75x60mm long, 10.9 grade)

2 Bolt for main bearing cap 3 600 450 - 1050

(M14x2x128 mm long, 10.9 grade)

3 Bolt for Connecting rod 3 3 kgm 6 kgm 10 kgm -

(M12x1.5x110mm long, 10.9 grade)

4 Bolt for Crank pulley 5 25 kgm 48 kgm - 48 kgm

(M24x2x110mm long, 10.9 grade)
without power take off

5 Bolt for flywheel 3 6 kgm - - 15 kgm

(M10x1x45mm long, 10.9 grade)

6 Bolt for flywheel housing 3 5 - - 8 kgm

(M12x1.75x45mm long, 10.9 grade)

80
8.1.1 Tightening Torque 8. Tightening Torque
R810 Table for fasteners

Sr. Description Initial Tightening Method Total

No. Torque Angle/kgm Angle
kgm Torque

Stage1 Stage2 Stage 3

7 Nut for injector 3 - - - 3 kgm

8 Nut for fuel pump hub M14 8 - - - 8 kgm

9 Bolt for cylinder head

(M12x1.5) for sequence of 3 3 kgm 5 kgm 8 kgm 8 kgm
tightening torque refer Fig 8.2

10 All H.P. pipe nut 2.3 - - - 2.3 Kgm

11 All M8x1.25 screws & bolts 8.8 2.5 - - - 2.5 kgm

12 All M10x1.5 screws & bolts 8.8 3.5 - - - 3.5 kgm

13 All M12x1.75 screws & bolts 8.8 7 - - - 7 kgm

81
 8. Tightening Torque 8.1.2 Tightening Torque
R1040 Table for fasteners

Sr. Description Initial Tightening Method Total

No. Torque Angle/kgm Angle
kgm Torque

Stage1 Stage2 Stage3

1 Bolt for balance weight 3 300 300 - 600

(M12x1.75x60mm long, 10.9 grade)

2 Bolt for main bearing cap 3 600 450 - 1050

(M14x2x128 mm long, 10.9 grade)

3 Bolt for Connecting rod 3 3 kgm 6 kgm - 9 kgm

(M13x1.25x55mm long, 10.9 grade)

4 Bolt for Crank pulley 5 25 kgm 48 kgm - 48 kgm

(M24x2x110 mm long, 10.9 grade)
without power take off

5 Bolt for flywheel 3 300 600 - 900

(M10x1x45mm long, 10.9 grade)

6 Bolt for flywheel housing 5 - - - 5 kgm

(M10x1.5x40mm long, 10.9 grade)

82
8.1.2 Tightening Torque 8. Tightening Torque
R1040 Table for fasteners

Sr. Description Initial Tightening Method Total

No. Torque Angle/kgm Angle
kgm Torque

Stage1 Stage2 Stage 3

7 Nut for injector 3 - - - 3 kgm

8 Nut for fuel pump hub M14 8 - - - 8 kgm

9 Bolt for cylinder head

(M12x1.5-12.9grade) for sequence of 3 900 620 - -
tightening torque refer Fig 8.2

10 All H.P. pipe nut 2.3 - - - 2.3 Kgm

11 All M8x1.25 screws & bolts 8.8 2.5 - - - 2.5 kgm

12 All M10x1.5 screws & bolts 8.8 3.5 - - - 3.5 kgm

13 All M12x1.75 screws & bolts 8.8 7 - - - 7 kgm

83
 8. Tightening Torque 8.2 Tightening torque sequence

Tightening torque sequence for cylinder head bolts for R810 / R1040 / R1080 Engines
is shown below
EXHAUST SIDE

INLET SIDE

84
8.2 Tightening torque sequence 8. Tightening Torque

Tightening torque sequence for cylinder head bolts for R810 / R1040 / R1080 Engines
is shown below
EXHAUST SIDE

14 10 6 1 4 8 12

11 7 3 2 5 9 13

INLET SIDE

85
 8. Tightening Torque

Tightening torque sequence for cylinder head bolts for R810 / R1040 / R1080 Engines
is shown below
EXHAUST SIDE

18 14 12 16

15 11 13 17

INLET SIDE

86
 8. Tightening Torque

Tightening torque sequence for cylinder head bolts for R810 / R1040 / R1080 Engines
is shown below
EXHAUST SIDE

26 22 18 14 12 16 20 24

23 19 15 11 13 17 21 25

INLET SIDE

87