KIRLOSKAR 4R1040T 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

KIRLOSKAR 4R1040T Specifications

General

Engine Model	4R1040T
Number of Cylinders	4
Compression Ratio	17.5:1
Fuel Type	Diesel
Cooling System	Water cooled
Rated RPM	2200 RPM
Lubrication System	Forced lubrication
Starting System	Electric start
Governor Type	Mechanical
Dry Weight	380 kg
Displacement	4.04 liters
Engine Type	4-Stroke, Direct Injection Diesel Engine

Summary

General Information

Safety Precautions

Essential safety instructions and precautions for engine operation and maintenance.

Lubrication System

Lube Oil Specs, Capacity, and Changes

Fuel Supply System

Fuel Strainer and Filter Maintenance

Engine Operation: Initial Setup

Commissioning and Preparations

Steps before starting, including fueling, bleeding, cooling, belts, and valve clearance.

Starting and Stopping Procedures

Correct procedures for starting and stopping the engine safely.

Operating Conditions

Winter Operation and Cold Starting

Engine Deration and Running-in

Deration charts and procedures for the initial 100-hour running-in period.

Routine Maintenance

Maintenance Schedule

Comprehensive schedule of maintenance tasks and intervals.

Service and Maintenance: Lubrication

Lubrication System Service

Detailed procedures for oil level checks, oil changes, and filter replacement.

Air Cleaner Maintenance

Dry Type Air Cleaner Service

Belt Drives

Belt Inspection and Tensioning

Adjustments

Valve Clearance Adjustment

Detailed procedure for setting valve clearances using feeler gauges.

Troubleshooting and Turbocharger

Engine Troubleshooting Guide

A chart detailing common engine problems, causes, and solutions.

Turbocharger Tips and Maintenance

Electronic Governor

Governor Components and Troubleshooting

Engine Preservation

Preservation Procedures and Commissioning

Tightening Torque and Settings

Tightening Torque Procedures

Information on tightening high tensile bolts using torque and angle methods.