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KIRLOSKAR 3R1040 - User Manual

KIRLOSKAR 3R1040
48 pages
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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

Table of Contents

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Summary

General

1.2 Maintenance and Repairs

Details procedures for shutting down, safety devices, and working on running engines.

1.3 Safety

Highlights safety instructions and general accident prevention regulations.

Lube Oil System

Lube Oil Specifications

Recommends specific oil grades and standards for viscosity and detergency.

Fuel Supply System

Cooling System

Coolant

Details recommendations for coolant types, mixtures, and winter additives.

Engine Operation

3.1 Commissioning

Details essential steps before starting a new or overhauled engine, including oil and fuel.

3.2 Starting

Covers electric starting procedures and safety checks before operation.

3.3 Engine Stopping

Explains the correct procedure for stopping the engine, avoiding sudden load removal.

Operating Conditions

3.4.1 Operation in Winter

Addresses lube oil viscosity, diesel fuel, cold starting aids, battery, and coolant for winter.

Deration Charts

Provides correction factors for engine power based on altitude and ambient temperature.

Running-In Period

3.5.1 After First 100 Hours Running

Lists essential maintenance tasks to be performed after the initial 100 operating hours.

Routine Maintenance

4.1 Maintenance Schedule

Presents a schedule of checks, cleaning, and renewal tasks based on running hours.

Service and Maintenance

5.1 Maintenance of Lubrication System

Covers oil change intervals, checking oil level, and changing engine oil.

5.1.4 Lube Oil Filter

Details the procedure for replacing the spin-on lube oil filter cartridge.

Centrifuge Lube Oil Filter

Maintenance of Fuel System

Maintenance of Cooling System

Maintenance of Dry Type Air Cleaner

Adjustments

5.6.1 Checking and Adjusting Valve Clearance

Provides detailed steps for checking and adjusting valve clearances using feeler gauges.

Troubleshooting and Remedial Measures

6.1 Troubleshooting

Presents a table of common engine problems, their causes, and recommended actions.

Recommendations for Turbocharger Operation and Maintenance

Tightening Torque, Settings

9.1 Tightening Torque

Provides information on tightening high tensile bolts using stages and angle methods.

Fuel Timing Setting

Summary

General

1.2 Maintenance and Repairs

Details procedures for shutting down, safety devices, and working on running engines.

1.3 Safety

Highlights safety instructions and general accident prevention regulations.

Lube Oil System

Lube Oil Specifications

Recommends specific oil grades and standards for viscosity and detergency.

Fuel Supply System

Cooling System

Coolant

Details recommendations for coolant types, mixtures, and winter additives.

Engine Operation

3.1 Commissioning

Details essential steps before starting a new or overhauled engine, including oil and fuel.

3.2 Starting

Covers electric starting procedures and safety checks before operation.

3.3 Engine Stopping

Explains the correct procedure for stopping the engine, avoiding sudden load removal.

Operating Conditions

3.4.1 Operation in Winter

Addresses lube oil viscosity, diesel fuel, cold starting aids, battery, and coolant for winter.

Deration Charts

Provides correction factors for engine power based on altitude and ambient temperature.

Running-In Period

3.5.1 After First 100 Hours Running

Lists essential maintenance tasks to be performed after the initial 100 operating hours.

Routine Maintenance

4.1 Maintenance Schedule

Presents a schedule of checks, cleaning, and renewal tasks based on running hours.

Service and Maintenance

5.1 Maintenance of Lubrication System

Covers oil change intervals, checking oil level, and changing engine oil.

5.1.4 Lube Oil Filter

Details the procedure for replacing the spin-on lube oil filter cartridge.

Centrifuge Lube Oil Filter

Maintenance of Fuel System

Maintenance of Cooling System

Maintenance of Dry Type Air Cleaner

Adjustments

5.6.1 Checking and Adjusting Valve Clearance

Provides detailed steps for checking and adjusting valve clearances using feeler gauges.

Troubleshooting and Remedial Measures

6.1 Troubleshooting

Presents a table of common engine problems, their causes, and recommended actions.

Recommendations for Turbocharger Operation and Maintenance

Tightening Torque, Settings

9.1 Tightening Torque

Provides information on tightening high tensile bolts using stages and angle methods.

Fuel Timing Setting

KIRLOSKAR 3R1040 Specifications

General IconGeneral
Engine Model3R1040
Number of Cylinders3
Bore104 mm
Rated Engine Speed1500 RPM
Rated RPM1500
AspirationNaturally Aspirated
Cooling SystemWater Cooled
Starting SystemElectric Start
Fuel Injection SystemDirect Injection
Compression Ratio17.5:1
Weight380 kg
Engine TypeDiesel
Engine Power45 hp

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