Index: R1040 Maintenance Manual

R1040 MAINTENANCE MANUAL
Index
Sr. Topic Page
No. 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
Page 1 of 48
1 General
Your engine needs
• Clean High Speed Diesel oil.
• Lubricating oil of specified quality and viscosity grade.
• Fresh air for combustion of fuel, for cooling of engine.
• Proper ventilation of engine compartment to avoid re-circulation of hot air.
• Genuine spare parts for its maintenance.
1.1 Service and Maintenance

Sound service and maintenance practices will ensure that the engine continues to
meet your requirements. Recommended service intervals must be observed. The
service and maintenance work should be carried out conscientiously.
Special care should be taken under abnormally demanding operating conditions.
1.2 Maintenance and Repairs

Shut down the engine before carrying out maintenance or repair work.
When the work is complete, be sure to install safety devices that may have been
removed.
If you have to work on a running engine, ensure that all clothing is tight fitting and
cannot catch the moving parts.
Never fill the fuel tank while the engine is running.
Observe all industrial safety regulations when engines are operating in enclosed
spaces or underground.
Please contact your Distributor for Spare parts enquiry. Use only genuine spare parts.
1.3 Safety
All Safety instructions (for both engine and operator) in this manual are designed by
the accompanying symbol. Please follow them carefully.
The attention of operating personnel should be drawn to these instructions.
General safety and accident prevention regulations laid down by law must also be
observed.
2 Engine details –
2.1 PCV / CCV Arrangement –
PCV / CCV Arrangement only for COM stage II engine.
2.2 Engine Name Plate
Fig 2.1.1
Page 2 of 48
Engine no is punched on the Name Plate which is fixed on the engine Crankcase.
Fig. No 2.1.1 show the engine nameplate
2.2.2 Engine Number System
4H 3002 / 06 00001
Engine serial No
Year of Manufacturing
Application code No. (i.e. build of the engine)
2H for 2R1040
3H for 3R1040
4H for 4R1040NA or 4R1040T or 4R1040TA
6H for 6R1080T or 6R1080TA
Please furnish the complete engine number so that matter concerning Customer Service and
Spare Parts can be more easily dealt with.
2.2.3 Model Designation
The engine model is punched on nameplate in column ‘TYPE’. The information about engine
series, No off cylinders, Piston displacement in liter per cylinder and Aspiration is
mentioned. The examples are stated below will clarify the matter.
3 R 1040
Indicates Piston displacement 1.04 Lit. /Cylinder as 1040
Indicates series of engine as R series
Indicates No.off Cylinders as 3
6 R 1080 TA
Indicates engine aspiration TA as ‘Turbocharged After cooled’
engine. (In case of Naturally aspirated engines this denomination is
not mentioned.)
Indicates Piston displacement 1.08 Lit. /Cylinder as 1080
Indicates series of engine as R series
Page 3 of 48
Indicates No. off Cylinders as 6

2.1 Engine illustrations
12 13 14 21
20
22
2
11
5 Fig. 2.2.1 Air Inlet side Fig. 2.2.2 Exhaust Manifold side 15
6 23
10 4 1 9 8 7 19 17 16 18
Inlet Manifold Side Exhaust Manifold Side
1 Air inlet manifold 13 Stop solenoid
2 Air cleaner 14 Breather (Positive crankcase ventilation)
3 Oil filling body 15 Alternator (for battery charging)
4 Fuel pump 16 Crankcase
5 Fuel Feed pump 17 Starter
6. Spin-on Lube oil filter 18. Engine mounting foot (Gear end side)
7. Spin-on Fuel Filter 19. Engine mounting foot (Flywheel end side)
8. Dipstick 20. Exhaust manifold
9. Lube oil sump with drain Plug 21. Rocker cover
10. Gear casing 22. Flywheel housing
11. Radiator 23. Flywheel
12. Balance Water Tank
2.3 Engine lifting device
2.3.3 For bare engine for ’R1040/R1080’

Before lifting the engine first fix the lifting hooks on the engine and then lift the engine
(see Fig. 2.3.1). The lifting hooks provided on the engine are meant for lifting bare engine
only. Use of engine lifting hooks for lifting of generating set must be avoided as it can
cause damage to engine or generating set in the event of breakage.
Page 4 of 48
Fig. 2.3.1
For Canopied generating set lifting is shown below. Use proper sling/tackle arrangement for
lifting the generating set.
2.4 Lube oil system
Lube oil circuit
Force feed lubrication is provided by a ‘G’ rotor type pump to main bearings, large end
bearings, camshaft journals and to the valve gear, fuel pump and turbocharger (incase of
turbocharged engines). Other components like connecting rod small end bushes, cylinder
liners and gear train are splash lubricated. Piston cooling nozzles are provided for piston
cooling for turbocharged engines only. Oil supply to valve gear is achieved through rocker
shaft core hole; the oil supply is controlled to the valves and rocker arm by oil metering screw,
which results into lower oil consumption and lower carbon deposition. The system includes
adequate filtering by replaceable ‘Spin-on’ filter cartridge. For 6R1080 series engines twin
filter cartridges are provided and a centrifuge Lube oil filter is also provided. The water-cooled
lube oil cooler is provided to maintain the oil temperature within limits. A relief valve controls
the maximum oil pressure, which is provided on delivery side of the lube oil pump.
Page 5 of 48
Page 6 of 48
2.4.2 Lube oil pump: -

Lube oil pump Delivery
Engine type 2R/3R/4R1040 4R1040T/TA 6R1080/T/TA

Engine rpm 1500 1500 1500
Lube oil pump rpm 1680 1680 1680
Delivery Liters/min. 20.5 30 32
at 4kg/cm2 pressure
Lube oil pressure: -
At low idling speed Minimum 1.5 Kg/cm2

In normal working condition when engine is warm 2.5 Kg/cm2
At loaded condition in operating range 2.5 to 5.5 Kg/cm2
If the pressure at any time drops, at engine idling rpm or below 1.5 kg/cm2 at operating
speed of 1500 rpm, under loaded condition, then replace the lube oil filter cartridge and
check the pressure. If the pressure is still low, then contact your Distributor.
2.4.3 Lube oil Temperature: -
The maximum lube oil temperature for ‘R1040/R1080’ series engines is ambient temperature
plus 700C. For example if ambient temperature is 400C, the maximum lube oil temperature
should be 1100 C
2.4.4 Lube oil consumption: -
Lube oil consumption for well run in 0.3 % of fuel

engine & under normal load condition. consumption
Note: -
1. During the running in period of first 50 hours, never exceed ‘full load’ even for a
short duration; this is applicable for stationary applications like power generation
application.
2. During the running in period the oil consumption is slightly more than the above
figure.
3 The lube oil consumption varies according to engine operating conditions. The value
mentioned above is for the normal engine operating condition.
2.4.5 Lube oil sump capacity and oil change period: -
The lube oil sump capacities and oil change period of ‘R1040/R1080’ series engines are as below: -
Page 7 of 48
These capacities are for the standard cast iron and standard sheet metal sumps.
Engine type 2R1040 3R1040 4R1040/T/TA 6R1080/T/TA
Oil sump type S.M. S.M. S.M. S.M.
Initial fill 5.5 9 11.5 15
(lit.)
Refill (lit.) 4.5 7.5 9.5 13.5
Oil Specifications Oil change period (Hours) To be used for
MIL-L-2104 C PLUS 400 Naturally aspirated as well

CF4, D4, D5 as Turbo charged engines
The oil must be changed at least once in a year. This is applicable to the engines, which are
running for standby duty application.
The above oil change period is subject to following conditions.

• The minimum ambient temperature should not less than – 100C.
Please contact your distributor for change in the ambient temp condition.
Note:
First fill = Sump capacity + Gallery capacity + Lube oil filter capacity
Fill the oil Lube oil filter before fitting on the engine.
Do not forget to fill the Lube oil filter whenever you replace the filter.
Whenever Lube oil filter is drained off, add approximately 0.5 lit. /1 lit.extra Lube oil
(as per the size of the Spin-on filter cartridge) in the sump to maintain the correct oil
level.)
The oil level in the sump should be checked at room temperature by using dipstick.
Top up with fresh oil when the level reaches the low level mark on dip stick, fill till it
increases to top level mark. Avoid over filling.
2.4.6 Lube oil Specifications and recommendations
The chart below shows the nomenclature of lube oil in different standards. Lube oils of
correct viscosity and detergency grades should be used. For detergency, oil should comply
with the following specifications
US Military American CCMC

Specifications Petroleum Institute
classification (API)
MIL-2104C CD/SE -
MIL-2104C Plus CF4 D4
For viscosity, the recommended SAE number should be used. SAE J 30 specifies the viscosity of
Lube oils for each SAE No.
Always use oil brands of reputed oil companies. Too viscous oil causes starting difficulties. The
ambient temperature prevailing at the time of starting the engine should be governed the choice of the
viscosity grade, during winter operation.
Page 8 of 48
It is recommended to use ‘multi grade oil’ considering the maximum and minimum ambient
temperatures.
No guarantee claims will be entertained on the grounds of engine damages due to use of unsuitable
engine Lube oils.
Atmospheric Viscosity no
Temperature range in C
-200 to +200 SAE 10W30
-100 to +500 SAE 15W40
-50 to +450 SAE 20W40
Note:
The anticipated lowest temperature at the time of engine starting should be used as reference
in winter. While in summer the highest anticipated temperature of the day should be used as
reference.
2.5 Fuel supply system

2.5.1 Fuel Circuit
Fuel is supplied to the block type fuel pump by a fuel lift pump (feed pump) incorporated in the
fuel pump itself. A dual type spin-on fuel filter consisting of efficient pre and micro paper
filter cartridges ensures the supply of clean fuel to the fuel pump. The schematic diagram (Fig.
2.5.1) shows the fuel circuit of the engine.
Fig. 2.5.1
NOTE: It the fuel tank is to be installed below the fuel pump level, and then the bottom level
of the fuel tank should be less than 1 meter below the feed pump inlet
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 manufactured to very close tolerances and
slightest amount of dirt in fuel can cause wear on the injection equipment. Following
points are important in use of fuel on Kirloskar R1040/1080 series engines.
The following specifications are approved: -
• BS: 2869-A1&A2 (In case of A2, note sulphur content)
Page 9 of 48
• DIN 51 601
• ASTMD 975-81:1D&2D
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.
Fig.2.5.2
Proportion of Kerosene to be mixed in Diesel, depends on the ambient temperature

as shown in the graph (Fig.2.5.2). (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.
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.
Page 10 of 48
2.6 Cooling System
2.6.1 Radiator type cooling system
The Radiator type cooling system is used.
The Schematic diagram, of the typical water circuit with Radiator type cooling system, is
Shown in the Fig. 2.6.1 below.
Fig. 2.6.1
IMPORTANT
• In order to have the efficient cooling and optimum performance of the engine, we
recommend using the radiator supplied by KOEL.
• It is also necessary to ensure proper ventilation to avoid hot air re-circulation into the
cooling system. Please refer KOEL Genset Manual for details.
2.6.2 Coolant
In summer, use fresh water with anticorrosion additive for engine cooling to avoid rust
formation.
Water should be clear and free of any corrosive chemicals such as chloride, sulphates and
acids.
We recommend to use, coolant blend of soft water and one of the following rust preventive
compound as mentioned below
Nalco-2000 35 cc per liter.
In winter, use Ethylene glycol antifreeze diluted with coolant blend as mentioned above in
the proportion in the cooling system as mentioned below
Ambient Ratio by volume of antifreeze
temperature 0 C to cooling winter blend
+5 to –5 20:80
-6 to -15 33:67
-16 to -25 40:60
Below -25 50:50(Max. permissible ratio)
Page 11 of 48
Commercially available ready mixed coolants can also be used, with Antifreeze
and anticorrosion additives after ascertaining suitability for low ambient
temperature.
Storage of engine with only fresh water in engine cooling system should be
avoided at ambient temperature below 5° C. This may cause cracks in the engine
components.
• If the engine is to be transported from normal ambient areas to Low ambient areas
ambient below +5°C the complete cooling system should be drained and
refilled with Antifreeze + water mixture as mentioned above.
2.7 Electrical System
2.7.1 Electrical Equipment
Standard engines are equipped with 12V, negative earth electrical starting system
without battery and leads.
12 V Electrical system
Alternator
Make Specification Remarks
MICO 12V Common for 2 to 6
Cylinder engines
Starter
Make Specification Remarks
MICO 12V Common for 2 to 6
Cylinder engines
2.7.2 Battery
Battery Capacity Ratings

• C.I.M (Compression ignition Motor) Rating - Minimum current at 27° C
with full charged battery should sustain for 5 min. 30 sec with cell voltage of
1.33 V/cell
• Cranking Performance Rating- It is a minimum current in amperes which
fully charged battery at 27°C will sustain for a period of 2 minutes and
maintain cell voltage of 1.2V/cell or higher.
• 20 hours capacity rating-it is the capacity in ampere- hour, which the fully
charged battery will deliver when it is discharged at 27°C at a constant current
for 20 hour before reaching a final voltage over all of 1.75 V/cell.
Recommended Battery Capacity
Ambient temperature Battery Capacity in Amp-hr 20 hr rate

in 0 C 12 V 24V
Above + 10 135 Two Batteries of 12V, 88 Amp-hr. in series
Below +10 up to- 20 180 Two Batteries of 12V,120 Amp-hr. in series
Page 12 of 48
For battery capacity at extreme low temperature i.e. below -20°C, contact your
distributor.
Battery Cables setting Parameter
Cable drop should not exceed than 1.2 V at 600 A.
Normal starting current is 600A
Based on above two parameters, battery cables are recommended as below
Length in meter Core size in mm2 Wire Specification

Up to 2.5 70 19/2.14 or 440/0.4
Up to 1.5 35 7/2.5 or 276/0.4
Up to 0.75 25 7/2.14 or 196/0.4
All above cable sizes are for copper cables and use of copper cables is
recommended.
The battery leads and terminals should be lead coated to avoid corrosion.
2.7.3 Engine wiring
Battery + ve and –ve connection, charging alternator +ve and –ve connections, starter
coil and pull coil connection should be wired/connected with 4 mm2 wires. Since
current through these wire is 30 A. All other wires should be of 1.5 mm2 minimum
due to mechanical strength consideration and not by electrical current capacity.
3 Engine operation
3.1 Commissioning
Before you start a new or overhauled engine, attend following points
3.1.1 Oil
Fill the engine with Lube oil through oil filling neck as shown in fig. 3.1.1 below. For
oil quantity, grade and viscosity refer point no. 2.4.5 & 2.4.6 respectively.
Fig 3.1.1
Page 13 of 48
3.1.2 Diesel
Fill the fuel tank after making sure that it is properly clean. Use High Speed Diesel fuel
as recommended in section 2.5.2. According to the ambient temperatures, summer or
winter grade diesel fuel should be used. Connect the fuel pump to fuel supply tank as
shown in fuel circuit diagram fig. 2.5.1.
• Never fill the fuel tank while the engine is running. Strictly observe cleanliness.
Do not spill any fuel.
• The recommended minimum fuel pipe inside diameter for fuel inlet pipes & fuel
return pipe (leak off) between tank and engine are as below.
Fuel pipe Min. inside diameter mm

Fuel supply pipe between tank, engine & 10 mm
filters
Leak off return pipe from engine to tank 6 mm
3.1.3 Bleeding of fuel system
Loosen the vent screw on primary fuel filter as shown in fig.3.1.3.1 below
Fig.3.1.3.1 Primary element Fig. 3.1.3.2 Micro element
Operate the fuel lift pump (feed pump) until oil flows without air bubbles as
shown in fig. 3.1.3.3 below.
Fig. 3.1.3.3
Page 14 of 48
Tighten the vent screw on primary fuel filter while the diesel fuel id flowing
without air bubbles.
Similarly bleed the micro filter element by loosening the vent screw on it as
shown in fig. 3.1.3.2 above and tighten the vent screw after the removing the air
lock.
Loosen the banjo bolt on fuel pump gallery as shown in fig. 3.1.3.4 below.
Operate the fuel lift pump till the fuel flows free of air bubbles.
Fig. 3.1.3.4
3.1.4 Cooling system
Fill the cooling water system with recommended coolant blend (See section 2.6.2)
Fill the coolant through neck of radiator till it flows through the radiator over flow
pipe. (See fig. 3.1.4)
Fig. 3.1.4
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.
3.1.5 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 5.5
Page 15 of 48
3.1.6 Valve Clearance
It is not necessary to check adjust the valve clearance on a new engine as it is already
adjusted at its required value. However after overhauling the engine, it is necessary to
recheck and adjust the valve clearance before starting the engine. See section 5.6.1
3.1.7 Other preparations
Check battery and lead connections. Also check the cable connections at the starter &
alternator. Loose connections lead to improper contact and damage to the terminals.
Remove lifting eyebolts after engine installation.

For trial run starting instructions, see section 3.2
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 after the trial run check following.
- With engine stationary, check the oil level. Top up the oil if necessary see section
5.1.2
- Retighten the V belts, see section 5.5.1
3.2 Starting
3.2.1 Electric Starting

Before starting, make sure that no one is standing in the close vicinity of the engine
driven machine.
Open the ‘Shut off’ cock under fuel tank (if provided).
After repairs:
Make sure that all safety guards have been put back into their original position.
All tools are removed from the engine and the driven machine.
.
3.3 Engine stopping
Never stop the engine suddenly when running on load. First allow the engine to run on “NO”
load for 5 minutes and then stop the engine.
To stop the engine, follow the instructions as below.
Press the stop push button till the engine is completely stopped.
Charging current lamp lights up when engine has come to rest.
Turn the key counter clockwise to ‘OFF’ position and withdraw the key. The pilot
lamp will be goes off.
After stopping the engine, close the ‘Shut off’ cock under fuel tank (if provided)
Page 16 of 48
3.4 Operating conditions
3.4.1 Operation in winter
Lube oil viscosity
Select specified viscosity grade to meet the performance level for the ambient
temperature prevailing at the time of starting the engine. Refer section 2.4.6
Note shorter periods between oil changes when operating below –100C. See section 5.1.1
Diesel fuel
Use winter grade fuel for operation below +100C. See section 2.5.2.
Cold starting aids
Cold starting of a diesel engine depends upon the capacity of starter motor and that of the
battery. Since the starting equipment of the engine may differ according to its application,
please consult your dealer about the use of cold starting aid. However the general
guidelines are given below.
Temperature range Starting aid

Up to 00C No cold starting aid is required.
00 to –200C Use flame heater or start pilot
Below –200C Consult your distributor
Battery
Cold starting requires a good state of charge of battery. Lowering the starting limit
temperature by 40 to 50C is possible by increasing the battery temperature to about +200C.
Removing the battery and storing it in a warm room or by using battery-preheating pads
could achieve this.
Engine coolant
Use coolant blend with antifreeze ‘Ethylene Glycol’ for operations below +50C. The
percentage of mixing the antifreeze into water as per ambient temperatures is given in
section 2.6.2
High ambient temperature and/or High altitude
With increasing altitude or ambient temperature, the air density decreases, which affects,
1) Maximum power output of the engine.
2) The exhaust gas temperature.
3) In extreme cases the starting behavior.
Page 17 of 48
Note: - The declared power ratings of the engine are obtained at standard reference
conditions as per ISO 3046/ BS 5514/ DIN 6271/ IS 10000.
Where engines are operated at greater altitudes and or higher ambient temperatures, they
must be derated in accordance with respective standards.
Deration Charts
Deration chart for Naturally aspirated engines
The deration chart applicable for naturally aspirated engines is illustrated below.
The chart is prepared on the basis of standard ambient conditions mentioned in ISO
3046/DIN 6271/BS 5514, with 60% relative humidity. For higher relative humidity the
deration increases by 2% for 20% rise in relative humidity above 60% relative humidity.
Deration chart for 4R1040T/6R1080T engines

The deration chart applicable for R1040T/6R1080T engines is illustrated below.
Page 18 of 48
Deration chart for 4R1040TA/6R1080TA engines

The deration chart applicable for 4R1040TA/6R1080TA engines is illustrated below
In case of doubt concerning such engine applications, contact your distributor.
3.5 Running in period
3.5.1 After first 100 hours running

• Change engine oil and see 5.1.3
• Change the Lube oil filter Cartridge/element see 5.1.4.
• Check and retighten fasteners for Lube oil sump if necessary.
• Clean the fuel strainer (button filter or sediment bowl at feed pump inlet) see 5.2.1
• Clean and drain fuel filter bowl and change pre filter element/cartridge see 5.2.4
• Check V belt tension and retighten if necessary see 5.5.1
• Check engine for leakages of Lube oil, fuel, water.
• Check the engine mounting bolts, retighten if necessary. See 5.8.3.
• Retighten intake and exhaust manifold fastening at cylinder heads.
Page 19 of 48
4 Routine Maintenance
4.1 Maintenance Schedule

Every In running hours1) Check See
10th Secti-
Hour/ 1st Clean on
Daly 50 100 250 400 500 800 1200 2400 3600 Renew
Job
Engine oil level2 5.1.2
Fuel level in the tank2 -
Coolant level in Radiator2 5.3.1
Dry type air cleaner3 4 5.4.1
Rubber hose & clips of dry type air -
cleaner
Check the restriction indicator 5.4.1
Engine oil5 5.1.1
&5.1.
3
5
Lube oil filter cartridge 5.1.4
Battery and lead connections
‘V’ Belt condition and tension 5.5
(adjust/replace if required)
4, 13
Fuel Filter Cartridge (Pre) 5.2.2
Radiator fins (depends on site 5.3.2
condition)12
Radiator tubes (depends on type of 5.3.2
cooling water)
4, 13
Fuel Filter Cartridge (micro) 5.2.2
Thermostat element (change if 5.3.3
necessary)
Valve clearance (adjust if 5.6.1
necessary)10
Starter/Alternator5 5.7
10
Fasteners 5.8
10
Injector -
10
Fuel tank -
3
Exhaust silencer -
11
Fuel Pump -
10
Turbocharger 6.2
1) Maximum permissible 7) Depends on rate of deposition 11) FIP should be calibrated
guide Intervals of scale. after 3600 hours of engine
2) Top-up if required 8) 400 hours or at engine oil run.
3) Clean if necessary change. 12) Blow out dust
9) Whenever restriction 13) Refer point no 5.2.2 foot
4) Renew element/
indicator indicates note.
Cartridge
10) Every six months or 1200
5) Depends on engine use
hours which is earlier.
6) Depends on engine oil
change
Page 20 of 48
4.2 Top Overhaul and Major Overhaul Periods
The duration of the operating period before overhaul depend entirely on the maintenance and
service given to engine and also the type of environment and engine load cycle. However
after about 3000 running hours engine may need top overhaul (servicing of combustion
system) and after about 9000 running hours engine may need major overhaul. These periods
are based upon the assumption that the engine is maintained properly as per the instructions
given in this manual. Hence, the above estimated overhaul periods are to be referred to as
general guideline. Please refer the workshop manual for further details.
5 Service and Maintenance

5.1 Maintenance of Lubrication system
5.1.1 Oil change intervals
• The oil change intervals depend on engine application and on quality of lube oil. Refer table
below: -
• Should, within ONE YEAR, the engine run less than the hours stated in the table, the oil
must be changed at least ONCE A YEAR.
• The table is subject to the following condition: - Prevailing ambient temperature
down to -10°C.
Standard Oil Grade Oil change (Running hours)

U.S.Military MIL-L-2104C/ 2104 C plus, 400
API CD/CD plus, CE, CF-4 400
CCMC D4,D5 400
5.1.2 Checking oil level
• Stop the engine and wait for a while till oil level in the sump is settled. Ensure that
engine is in horizontal position.
• Pull out dipstick, wipe it with a non-fraying rag and push it in as far as it will go
and then withdraw again (Fig. 5.1.2).
Fig 5.1.2
• The film of oil left on the dipstick should extend to the upper (max) mark. If the
level only reaches to the lower mark, the oil should be topped-up without delay.
Page 21 of 48
IMPORTANT Failure to attend to this may result in serious damage to

the engine (piston & bearing seizure)
5.1.3 Changing Engine Oil
• Change engine oil at recommended intervals, See 5.1.1

• Run engine until warm.(lube oil temp. approx. 80°C)
• Stop the engine (Fig. 5.1.3.1)
Fig 5.1.3.1
• Place oil tray under drain pipe
• Unscrew oil drain plug on the end of drain pipe and drain oil completely
(Fig, 5.1.3.2)
Fig 5.1.3.2
• Collect used oil in suitable receptacle ready for proper disposal to prevent
environmental pollution.
• Refit oil drain plug with new joint washer and tighten firmly.
• Fill in fresh lube oil.
- Lube oil specifications, refer 2.4.6
- Lube oil sump capacity, refer 2.4.4
IMPORTANT Take care when draining off hot oil: Danger of scalding!
Page 22 of 48
5.1.4 Lube oil filter
Replace ‘Spin-on’ lube oil filter cartridge for every oil change.
• Release lube oil filter cartridge with special tool and spin off as shown in fig. 5.1.4.1
Fig 5.1.4.1
• Clean sealing surface of filter carrier (Fig.5.1.4.2).
Fig 5.1.4.2
• Fill the new cartridge with Lube oil before assembly
• Apply light film of oil to rubber seal of new cartridge.
• Screw cartridge into place by hand until seal is evenly seated.
• Tighten lube oil filter cartridge firmly by giving a final half turn. (Fig-5.1.4.3)
Fig 5.1.4.3
Page 23 of 48
• Check oil level and lube oil pressure.

• Check seal of lube oil filter cartridge for leaks
5.1.5 Centrifuge Lube oil filter (Applicable for 6R1080T/TA engines)

Instruction Manual
• Introduction
The Centrifuge Cleaner cleans your engine oil continuously when your engine is
running. It separates dirt above 1 micron approximately from engine oil thus lowers
wear rate of engine components drastically. It avoids harmful oil degradation and
arrests depletion of oil additives increasing the oil life. The Centrifuge Cleaner does not
require any spare parts to be replaced and gives consistent performance throughout engine
oil.
• Cleaning frequency
For consistent performance, the centrifuge rotor needs to be cleaned periodically as
mentioned in this manual. It is recommended that you service the centrifuge every 250
hours of working or at every oil change period.
The volume of dirt collected depends upon engine application, loading and environment in
which engine is working. Exact period of servicing the centrifuge can thus vary between
200 hours of working to your oil change period. Please follow the instructions given
below for cleaning of centrifuge cleaner.
• Identification and location
The centrifuge Cleaner is located on the same manifold on which full flow oil filter
is mounted. The centrifuge can be easily identified with a dome shaped cover bearing
instruction sticker. The exact location is as shown in this photograph 5.1.5.1. The internal
components of the centrifuge is shown in Fig 5.1.5.2
Fig 5.1.5.1
Centrifuge Lube oil filter
Page 24 of 48
Fig 5.1.5.2
• Servicing Instructions
- It is a precision assembly, handle with care.
- Carry out servicing preferably when the engine oil is still warm
- All threaded parts of the centrifuge require following gadgets: a 13 mm spanner, a
blint knife, a small adjustable pliers and waste cotton for cleaning.
Servicing procedure
Fig 5.1.5.3
Unscrew top nut with a 13 mm spanner and remove centrifuge cover. See Fig 5.1.5.3 above.
The centrifuge cover nut has a puller arrangement so that the cover will be lifted as you
unscrew the top nut.
Page 25 of 48
Fig 5.1.5.4
Hold the rotor in hand and lift rotor to remove it completely from central shaft. See Fig
5.1.5.4 above.The rotor will contain about 200 ml of oil. Drain oil from the rotor. The
rotor has two bushes at its ends. Take care while removing rotor from central shaft. The
rotor should not fall; otherwise it will damage the bushes.
Unscrew rotor nut by holding rotor assembly in hand. The rotor nut can be opened by hand. if it
is tight, unscrew it with light pliers. Never grip the rotor nut tightly in clamping device
like a bench vice. It may damage the rotor body permanently. Remove rotor cover and
deflector inside. For removing rotor cover, remove the rotor nut completely, hold the
rotor cover in hand and give a light blow to the rotor body at the rotor nut end by hand.
The rotor body and deflector will come out from the opposite end.
After you open the rotor, you will see cake formed sticky dirt mass all around the rotor
cover from inside. Remove the dirt by a blunt knife as shown. Clean the rotor cover and all
rotors thoroughly by compressed air. See Fig 5.1.5.5 below. Clean the centrifuge central
shaft also.
Fig 5.1.5.5
Assemble rotor in correct sequence of parts. Match arrow marks on rotor cover and rotor.
Tighten rotor nut firmly by hand. Install rotor on shaft and assemble cleaner cover.
Fig 5.1.5.6
Arrow mark
Now your centrifuge is ready to collect more dirt from oil.
Points to care about centrifuge cleaner

1. Replace rubber rings if deformation or cuts are observed. Using damaged rubber
rings will result in oil leakage and improper functioning of centrifuge cleaner.
Page 26 of 48
2. While assembling the rotor, ensure that the rubber ring has taken proper seat in its
place. This is necessary for proper sealing of rotor assembly.
3. Take care with the centrifuge housing and rotor body. They are made of aluminium, hence
are susceptible to damage due to accident.
4. Always ensure that the arrow marks on rotor cover and rotor are matched after
assembling the rotor. See Fig 5.1.5.6 above. The rotor body is dynamically balanced.
Mismatch of arrow marks on rotor cover and rotor will result in excessive vibrations of
the cleaner and part breakage.
5. The rubber ring is made of Viton rubber. Use genuine spare rubber ring only. Rubber
ring of any other material will not give desired performance.
Don’ts about centrifuge cleaner
Fig 5.1.5.7
Do not over tighten the top nut. Tighten just enough to prevent leakage of oil from
centrifuge cover and housing. Over tightening top nut will damage the threading in
centrifuge housing and damage the centrifuge permanently.
Use 1.2 kg-m torque for tightening of centrifuge cover.
Fig 5.1.5.8
Do not hold the rotor nut in clamping device like bench vice as shown. Extra
clamping pressure on rotor nut may result in damaging the circularity of upper bush
and will result in permanent damage to rotor assembly. See Fig 5.1.5.7 above
Do not open or tamper with the valve assembly. The valve assembly is preset for
opening oil pressure in engine’s oil gallery. If the setting is lost or the valve
assembly is damaged, there is risk that your engine will not get enough oil or the
centrifuge will not function properly. See Fig 5.1.5.8 above
Page 27 of 48
Consult your Distributor in case of any doubt.
Troubleshooting
Sr. Problem Probable cause Action
No
1 Leakage through cleaner Rectangular rubber ring Change rubber ring.
damage
2 Rotor does not rotate Nozzles blocked Open rotor and clean nozzles
Thoroughly.
Re-assemble the cleaner.
3 Rotor does not rotate even Entry valve blocked Do not open entry valve
after cleaning nozzles assembly. It requires special
tools Contact your Distributor.
4 Rotor rotates but at low Leakage of oil through rotor Open rotor and ensure that the
Speed assembly. rubber ring has taken proper
seat on rotor body. Then
re-assemble the rotor.
Rotor filled with dirt Time for cleaning the rotor
completely
5 Rotor speed very low Bushes damaged Ensure that the rotor is free on
or even rotor does not permanently Shaft. Else replace entire rotor
rotate Assembly.
6 Abnormal vibrations of Mismatch between arrow Open rotor and reassemble it
centrifuge cleaner marks on rotor cover and properly.
rotor
7 Cleaner does not collect Rotor not rotating at desired See point 2 & 3.
any dirt speed Consult your Distributor.
5.2 Maintenance of Fuel System

5.2.1 Cleaning Fuel Strainer
• Close fuel stop cock.
• Remove special banjo bolt situated at the bottom at the Inlet of feed pump.
• Takeout screw with strainer fitted inside banjo bolt (Fig.5.2.1).
Fig 5.2.1
• Clean the strainer with clean diesel.
Page 28 of 48
• Refit the strainer inside the banjo bolt and screw in the banjo bolt using new copper
washers
• Bleed the fuel system (see 3.1.5) check for leaks
5.2.2 Fuel Filter
• Close fuel stopcock.

• Change pre-filter cartridge only. Do not change Pre-filter cartridge and Micro filter
cartridge at a time. * (see Notes below)
Fig 5.2.1
• Complete the filter assembly and bleed the fuel system before starting the engine,
see 3.1.5
• Change over period for pre-filter insert and micro filter insert is given in ‘Routine
Maintenance Schedule 4.1.
• For changing micro-filter insert follow the same procedure explained above.
NOTE:
1) Always replace the cartridge with new one at recommended intervals.
2) Since a filter attains the maximum efficiency only after a film of dirt is deposited on the
surface of the filter insert, avoid replacing pre-filter cartridge and micro-filter
cartridge at the same time. First change pre-filter cartridge and then after 250
running hours change micro-filter cartridge.
3) The Routine Maintenance schedule is meant to serve as a guide only for normal fuel storage
and engine operating conditions. Replacement of cartridges may have to be made earlier
than the recommended period.
IMPORTANT when working on the fuel system, keep naked lights away! Do
not smoke!
5.3 Maintenance of Cooling System
Engine cooling system contains radiator, fan, water pump and temperature controller i e.
thermostat. The engine control panel consists of water temperature gauge. High water
temperature trip for engine safety could be provided as an optional.
The chemical treatment of cooling water for rust prevention and antifreeze solution in
winter is given in section 2.6.2
Page 29 of 48
Check coolant level in the radiator every day before starting the engine Remove the
radiator cap and fill coolant through radiator neck until it spills out of overflow pipe
fitted on radiator (Fig.5.3.1). Refit radiator cap firmly.
5.3.1 Radiator
IMPORTANT Do not open radiator cap while the engine is running or hot. The cooling
system is under pressure. Danger of burning body skin!
• 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.
• Cleaning the radiator fins
• Clean the radiator fins after every 1000 hours.
(Under very dusty conditions, this is to be done if coolant overheating is observed)
Fig 5.3.1
• For cleaning, blow the pressurized air through radiator fins in the reverse direction of the
flow of radiator fan (Fig.5.3.2). Do not spill water on radiator fins.
Fig 5.3.2
Flushing the radiator
Flush the radiator inside after every 1000 hours or once in a year whichever is earlier. This
period is applicable for clean soft water. If the water is hard and saline, the flushing is to be
done after every 500 hours or even earlier depending upon the type of water. In order to
Page 30 of 48
prevent the rust formation use rust preventive compound.

To flush, top up the radiator with clean fresh water and run the engine on no load till it
reaches working temperature.
• While the engine is still running, open the drain cock of radiator and allow the water to
flow out. This will wash away any impurities embedded in water passages. With engine
still running, keep on adding fresh coolant for at-least 5 minutes. Stop the engine and
discontinue adding fresh water. Then drain the radiator completely.
• Check the radiator hoses and connections. Replace the damaged hoses and tighten the
connections.
5.3.3 Thermostat
A thermostat having single element is used in the water 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 i.e. whether or not
close tightly. See Fig 5.3.3.1 below.
Fig 5.3.3.1
5.4 Maintenance of Dry type air cleaner
Construction of typical Dry type Plastic Air Cleaner, supplied, is shown below in fig,
5.4.1 and construction of typical Dry type air cleaner with sheet metal
housing is shown below in Fig 5.4.2
Page 31 of 48
Dry type air cleaner with Plastic housing Dry type air cleaner with sheet metal housing
Fig 5.4.1 Fig 5.4.2
Inlet cap or pre - cleaner is supplied for the air intake inlet cap prevents ingress of
rain/heavy particles.
Two filter elements are co - axially fitted in the air cleaner housing. 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 bottom of cover
helps in expelling the accumulated dust. This is achieved by opening / closing of vacuator
valve outlet due to the airflow fluctuations inside the air cleaner.
Inner element is a ‘Safety Element’ to prevent ingress of dust into the engine, when the
outer (main) element is removed for cleaning / replacement. (For genset application, air
cleaners with only single main element are used.)
Maintenance
Regular check up and maintenance of the air cleaner is essential to ensure maximum protection
to the engine from the dust.
• Daily check the connection of rubber hose and the hose clips between the manifold and the
air cleaner before starting the engine. Damaged hose/ clips must be replaced
immediately. Any bypassing of unfiltered air through cracks in the hose / loose hose will
quickly lead to serious damage to the engine.
IMPORTANT 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.
• 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.
NOTES: -
1. If engine performance is poor, but restriction is still within limits, do not change the
element. The air cleaner is probably not at fault.
2. To get those extra service hours out of air cleaner element, make sure the air inlet is
Page 32 of 48
away from any heavy dust clouds caused by operation. Also, make sure that exhaust
carbon cannot enter the air cleaner.
3 Discharge the dust vaccuator valve by pressing apart the lips of the ejection slot,
applying pressure as indicated by the arrows. See Fig 5.4.2 below.
Fig 5.4.2
• Clean the vacuation slot time to time.
• Remove any cakes of dust by pressing together the upper part of the valve.
• Make sure that vacuator valve is not damaged, if required change it
Cleaning of Filter Element
Cleaning of filter element is to be done only when a restriction indicator shows a red signal
even after the engine is stopped. For cleaning proceed as follows -
1) Loosen the mounting band of the dust cup, take out the outer element for checking and
cleaning. See Fig 5.4.3 below
.
Fig 5.4.3
2) Use a damp cloth to wipe out all excess dust in the air cleaner.
3) Thorough cleaning of the fitter element with compressed air is recommended.

Clean the element from inside to outside using the pressurised air pipe. See Fig
5.4.4 below
Fig 5.4.4
Page 33 of 48
IMPORTANT Too much air pressure can break the filter paper and destroy
the element. (Max. Air Pressure 3.0 kg/cm2)
4) Replace the main element after two cleaning intervals.

5) Rapping, Tapping or Pounding dust out of them is dangerous. Severe damage to the filter
will result!
6) Carefully check new or properly cleaned element for damage before installing.
Conduct a light test by passing the light through element as shown in Fig 5.4.5. If there is
any crack in the element, the light will pass through it. In that case replace the element.
Fig 5.4.5
7) Inspect the rubber-sealing ring at the end cover of the element. In case the seal is
damaged, replace the filter element. (Fig 5.4.6)
Fig 5.4.6
7) Replace the cleaned or new element in the air cleaner body and reinstall the end cover,
making sure it seals 360° around the air cleaner body. Reset the restriction indicator by
pressing the button at the top.
Page 34 of 48
5.5 Belt drives
A single V belt of NPA/XPA section is used to drive engine water pump, radiator fan and
battery charging alternator for R1040/3R1040/4R1040/4R1040T engines.
• Inspect V-belts over whole length for damage or cracks. Renew damaged or cracked v-
belts.
• Check by pressing with the thumb midway between the pulleys to see whether the belt
deflects inwards by not more than 10 to 15 mm. (Fig 5.5.1)
Fig 5.5.1
• If necessary re-tension V-belt by loosening and re-tightening the battery charging

alternator.
On 6R1080T/TA engines a separate fan drive is provided with two belts in addition to
single belt drive for engine water pump, radiator fan and battery charging alternator.
Refer Fig 5.5.2
Fig 5.5.2
Check the belt tension for fan drive in the similar fashion. If necessary adjust the fan belt
Page 35 of 48
tension with the help of tension adjusting screw provided on the fan driving arrangement.
5.6 Adjustments
5.6.1 Checking and adjusting valve clearance
The valve clearance is the requisite gap between the rocker arm toe and valve stem end. See
Fig 5.6.1 below. Engine performance and power output depend on its correct setting, which
can be done by a skilled mechanic according to the instructions below -
Fig 5.6.1
Checking Valve Clearance
• Check clearance when engine is cold. (At room temperature)
• Remove the rocker cover.
• Turn crankshaft until the valves of the cylinder (on which the clearance is being
checked) are “overlapping” (exhaust valve about to close, inlet valve about to
open).
• Then continue turning the crankshaft through 360° (one complete revolution).At this
position both valves are closed.
• Insert a feeler gauge of 0.25 mm in the gap between rocker arm toe and valve for both
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 follows –
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 0.25 mm can be
inserted and with drawn with slight drag. (Fig 5.6.2).
Page 36 of 48
Fig 5.6.2
• 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 and readjust, if necessary.
• Do not change the setting of oil metering screw unless required. With hot engine
running at idling, an oil flow to pad at rocker arm must be just noticeable. An
excess oil flow can lead to higher oil consumption.
5.7 Maintenance of Electrical Equipment
5.7.1 Starter Motor
• Ensure that the mounting bolts are securely fastened and all electrical connections are clean
and tight. Cables should be examined for fractures, particularly where the strands enter the
terminal lugs.
• Check the brushes. They must be renewed if worn to approximately 10 mm (for 2 &
3 cylinder engines, and 13mm (for 4 & 6 cylinder engines, which is half of the original
or to a point where springs no longer provide effective pressure.
• Brushes must always be replaced in sets and with the correct grade.
• Check the brush spring balance as shown in F ig.5.7.1. The spring pressure
should be as follows-
Fig 5.7.1
0.965 to 1 -080kg (for 2 & 3 cylinder engines)
1.220 to 1.580 kg (for 4 & 6 cylinder engines)
If the pressure is not within the above limits, renew the springs in set and not
individually.
Page 37 of 48
• Check the commutator surface. It should be clean and entirely free from oil, any trace of
which should be removed by pressing a dry fluff less cloth against the commutator while the
armature is hand rotated. It the surface is dirty or badly discolored, clean it with a strip of
fine emery. Remove all traces of dust and abrasive using compressed air.
• The starter does not require lubrication from outside, since it is equipped with sealed type
bearings.
• Check the drive assembly for free movement over the shaft splines. If necessary, smear
grease over the shaft splines to enable the drive assembly to move freely.
(frequency once in 3 months.)
• Any work involving repairs/replacement of components of starter contact your
distributor.
5.7.2 Battery charging Alternator
• Check the brushes. Renew the brush and spring assemblies, if the overall lengths of the
brushes are worn to less than 10 mm. If brushes are satisfactory but require cleaning, use
petrol moistened cloth.
• The slip ring surfaces should be clean and smooth. If slip rings are burnt and require
refinishing, the surfaces may be cleaned with a piece of very fine emery paper.
• Check bearings and renew if worn.
• Check belt tension, readjust if necessary (see 5.5.1 & 5.5.4)
• 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.
IMPORTANT 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.
• Any work involving repairs/replacement of components of alternator contact your

distributor.
5.8 Checking of Fasteners
• Check & Tighten-up the fasteners for following -

Air intake and exhaust manifolds, exhaust piping
Radiator hose connections
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
6 Troubleshooting and Remedial measures
• Operating troubles are often due to improper operation or maintenance of the engine.
Page 38 of 48
• In the event of trouble, always check whether the operating and maintenance
instructions have been strictly followed.
• An appropriate diagnosis chart is given on the next page.
• If you are unable to identify the cause of the trouble or to put it right yourself, contact
your Distributor.
6.1 Troubleshooting
Trouble Cause Redress
Engine does not No fuel in tank Fill in fuel, vent fuel system.
start. Air in fuel system. Vent fuel system
In sufficient speed of starter Charge batteries.
Engine does not start See above or the ready to start Of above or change lamp
at temperatures signal lamp does not light.
below 0°C. Defect of series resister solenoid Consult your Distributor
valve or flame heater plug.
Heat up fuel piping. Change

Paraffin precipitation of fuel filter.
Engine starts but Fuel tank cock closed Open cock
stop after brief time. Dirt in primery fuel strainer or in Clean the strainer or change the
fuel filter filer cartridge.
No fuel in tank, no conveyance of Fill in fuel, vent fuel system,
fuel inspect correct operation of fuel
pump, repair if necessary and
check safe venting of tank.
Clean fuel tank, fill in clean fuel,
Water or dirt in fuel system replace filter and vent fuel system
No power and Interruption of air supply or heavy Inspect, clean or replace air filter
misfiring of engine jamming of air cleaner element
Air in fuel Vent fuel system
Fuel filter cartridge jammed Replace fuel filter cartridge
Starts of fuel supply mjssed Reset start of fuel supply
Defect of exhaust brake Inspect and repair
Engine emits white Retorted and start of fuel supply Set correct start of fuel supply
or bluish fumes Engine is still cold Permit engine to heat up in
operation
Miss setting of fuel injection system Check start of fuel supply.

Inspect injectors.
Engine emits black Engine is overloaded Reset fuel injection system,
fumes contact your Distributor
Air filter jammed Clean or change filter element
Fuel injection piping loose or broken Tighten fuel injection piping or

replace it respectively
Heavy knocking of Starts of fuel supply too early Set correct start of fuel supply
Page 39 of 48
engine Mis setting of valve air gaps Adjust correct valve air gaps
Mechanical defects of engine Consult your Distributor
Engine grows Slipping of V-belts Tighten or replace V-belts
excessively hot V-belts broken Replace V-belts
Defect of temperature governor Emergency operation; forced
opening of valve plate
Defect of temperature Controller Perform electrical check of

temperature controller
Fill in coolant
Lack of coolant
Clean radiator
Radiator is dirty
Set correct engine in fuel supply
Mis setting of fuel supply
Redress cause of trouble
Intake or exhaust system jammed
Heavy dirt accumilation on cylinder
elements Consult your Distributor
Irregular speed of Defect of speed governor Inspect fuel pump and governor
engine
Excessively high fuel Mis-setting of fuel injection system Check fuel injection system
consumption Lealage in fuel system Check and repair
Injection of excessively high fuel Have fuel injection pump
quantity, engine emits black fumes adjusted by specialized workshop
Leakage of solenoid valve of cold Replace solenoid valve
starting device
Jammed air filter Clean or change filter element
Engine is worn Consult your Distributor
Defective exhaust brake Consult your Distributor
Very low oil Jammed paper filter cartridge Replace paper filter cartridge
pressure Deficient oil level Check and add oil
Pressure gauge or pressure gauge Inspect and replace or tighten
tube loose or defective
Leakage in oil system Check and repair
Improper lube oil (viscosity) Check oil brand
Defect in control valve for cooling Replace valve
pistons
Heavy wears of bearings
Consult your Distributor
Increase in lube oil Leakage in lube oil system Inspect pipings, filter and ducts
consumption for tightness
Excessively high oil level Adjust oil level
Defect of air filter system and

cooling of pistons Consult your Distributor
No dirt deposits in Rotor jam Inspect rotor bearings, Inspect oil
centrifugal filter supply to rotor
Page 40 of 48
Heavy blowing from Excessively high lube oil level, Adjust oil level. Consult your
venting hose of damages of cylinder elements Distributor
engine
No air supply from Defect of cylinder element or of Consult your Distributor
piston or compressor valve plate
Battery charging Defective insulation in fanned cable Consult your Distributor
signal lamp alight
while ignition is
switched off
Battery charging Defect of signal lamp Replace signal lamp
signal lamp does not Interruption of D governor and Plug in connector
light when ignition is generator
switched on
Battery discharged Charge battery
Battery charging Broken V-belt Replace V-belt
signal lamp alight Defective alternator Inspect or Consult your
during normal Distributor
operation
Heavy boiling of Defective governor, excessive Consult your Distributor
battery contact resistance of negetive
polarity across brush holder and end
shield bearing of generator
Starter does not run Battery discharged Charge battery
Deficient speed of Starter terminal voltage too low Check battery cells, recharge
starter battery
Oxidised or loose terminal

connection Clean and fasten terminals
Carbon brushes jam or are worn Clean or replace brushes
6.2 Useful tips for Turbocharger
Tampering of fuel pump and ignition system is prohibited as it may result in
engine as well as turbocharger damage.
Changes in boost pressure control of the turbocharger (where applicable)
may result in reduced engine life.
Use only the air filter recommended by the engine manufacturer.
Use only the oil filter recommended by the engine manufacturer.
Use only the charges air cooler (where applicable) recommended by
the engine manufacturer.
Changes in the exhaust system are not recommended.
Use original gaskets and connecting pipes.
6.3 Periodical Inspection of Turbocharger for Generating set application

Check rotor freeness every 1200 Hours.
Clean Turbocharger if dirt or carbon deposited on compressor & turbine
wheel every 1200 hours & 2400 hours.
Renew overhaul kit every 3000 hours.
Page 41 of 48
6.4 Recommendation for Turbocharger operation and maintenance

Operation Recommendations
Engine should not be put under full load immediately after start. We recommend the
engine to be run at idling speed for a short time (60 seconds). Warm up the engine
under medium load.
After the engine has been operating at full toad for a longer period of time,
we recommend a short idling time (60 seconds) before switching off.
Maintenance Recommendations
Turbochargers and boost pressure control valves do not require any maintenance.
Engine oil has to be changed regularly.
Maintenance work has to be carried out regularly on the oil filter and air filter
systems.
Checks have to be made on the oil, air and exhaust piping, as well as, on all other
connections and seals, to ensure that they are still tight and no damage has
occurred.
When carrying out maintenance work on the engine (e.g. adjusting valves), in
most cases the piping leading from or to the turbocharger must be removed.
Close the piping opening on the turbocharger. Before fitting, clean the piping
carefully.
When fitting the turbocharger to the engine, fill the central housing with clean
oil and before fitting make absolutely sure that all piping connected to the
turbocharger is cleaned carefully.
From our experiences, if this advice is followed, a turbocharged engine has the same
life span as a naturally aspirated engine.
DO’S and DON’TS for satisfactory functioning of Turbocharger

DO’S
Regular change of engine oil/oil filters.
Regular change/cleaning of air filter element.
Check for oil pressure at engine idling condition Minimum oil pressure to be
as per engine manufactures recommendation during idling.
Idle the engine for 60 seconds after starting the Engine.
Idle the engine for 60 seconds before switching off the engine.
Periodic cleaning of crankcase breather is necessary to allow free flow
o f oil from turbocharger outlet.
Regularly check all air, oil and exhaust connections for leaks and abnormal
dust/oil/carbon build up.
DON’TS
Don’t run the engine with low oil pressure.
Don’t put the engine under full load immediately after starting.
Don’t switch off the engine under full load.
Don’t run the engine with damaged oil feed & drain pipes, pipes between air filter and
turbocharger and as well as exhaust pipes.
Don’t open the Turbocharger yourself. Please contact the Distributors for
any turbocharger problems.
7 Instruction Manual for Electronic Governor
Page 42 of 48
Electronic Governor
The Electronic Governor consists of three components.
Electric Actuator - Connected to engine fuel pump & controls the fuel quantity
delivered to the engine.
Electronic Speed Control Unit - Compares the existing engine speed with desired speed &
sends corrective signals to the electric actuator.
Magnetic Speed Sensor - Measures the engine speed by sending a proportional frequency signal
to the speed control unit.
The system does maintain any desired speed very accurately, independent of engine load. The
system offered is highly reliable with consistent accuracy & simplicity of adjustment.
The speed control unit is factory set. It is recommended that not to disturb the
settings.
System Troubleshooting
System inoperative
If the engine governing system does not function, the fault may be determined by performing the
voltage tests described in steps 1 through 6. Positive (+) and negative (-) refer to meter polarity.
Page 43 of 48
Should normal values be indicated during troubleshooting steps, then the fault may be with the actuator
or the wiring to the actuator. Tests are performed with the battery power on, engine off except
where noted. See actuator publication for testing details.
Step Terminals Normal Reading Probable Cause of Abnormal

Reading
1 E(+) & F(-) Battery Supply Voltage 12 1.DC battery power not
or 24 VDC) connected. Check for blown fuse.
2 Low battery voltage.
3. Wiring error.
2 A(+) & B (- 0-3.9 with speed trim 1.Speed trim shorted or miswired
) 7.1-7.9without speed trim 2. Defective unit.
3 C(+) & D(-) 1.0 VAC RMS min., 1.Gap between speed sensor and
while cranking gear teeth too great. Check gap.
2. Improper of defective wiring
to the speed sensor. Resistance
between C and D should be 300
to 1200 ohms.
3. Defective speed sensor
4 E(+) & H(-) 0.8-1.5 V while cranking 1. Wiring error to actuator.
2. Defective speed control unit.
3.Defective actuator.
8 Engine preservation
Preservatives and Preservation procedure is recommended for engine when it is to be

kept idle (out of use) for prolonged period (more than 12 months).
8.1 Recommended Preservatives
Manufacturer Engine Lube oil and Engine cooling Unpainted ferrous

fuel system system metal parts
Castrol India - - Rustilo DW 904 or DW 901
Veedol tied water Veedol 30/40 Veedol Amulkut 4 Veedol Rustop IT
oil co. Emulsion with water
ratio 1:15
8.2 Preservation Procedure

a) Using H.S.D. fuel, run the engine at approximately 70% of maximum rated speed with
‘No’ load for 5 minutes to warm up the engine (in case of fixed speed engines like engine
for Genset, it can be run at rated speed).
b) After stopping the engine, drain lube oil from sump and refill with suitable preservative oil
as mentioned above.
c) Run the engine on ‘No’ load for 3 minutes. During this time the preservative will be
circulated throughout the lube oil system of engine. Stop the engine and disconnect
diesel fuel supply to fuel pump inlet. For engine speed refer point 8.2 (a).
d) Prepare a solution Diesel + Preservative Oil (5:1 ratio) in a separate tank and connect fuel
line from this tank, directly to fuel pump inlet ensuring gravity feed (by-pass fuel
filter).
e) Electrically crank the engine tilt it fires ( in case of purely hand start engine, hand - crank
Page 44 of 48
the engine using decompressor lever, till it fires) and let it run for 30 seconds. During
this time the diesel in fuel pump gallery and high pressure pipes will be displaced by
Diesel + Preservative Oil mixture. Stop the engine.
Engine speed during above running -
• In case of variable speed engine - 800 to 1000 rpm
• In case of fixed speed engine - Rated speed at ‘No’ load. (Genset, Pumpset etc.)
f) Close the air inlet manifold (for the air cleaner inlet) and crank the engine by starter for 5 to
10 seconds. (In case of purely hand start engine, it should be hand cranked using the de-
compressor lever). This will ensure coating of Diesel + Preservative oil on the combustion
chamber surfaces.
g) Drain preservative oil from oil sump, reinstall drain plugs and reconnect fuel filter into
the fuel pipe line.
h) Treat all unpainted external ferrous metal parts with two coats of suitable rust
preventer as recommended in 8.1, allowing sufficient time for the first coat to
thoroughly dry before applying second coat.
i) All vents i.e. engine inlet pipe, exhaust pipe, air cleaner inlet, crankcase breather
etc. to be carefully sealed with water proof paper and water proof adhesive tape.
j) Dipstick on engine to be sealed in place, with water proof adhesive tape.
NOTE: - DO NOT ROTATE CRANKSHAFT AFTER ABOVE MENTIONED
OPERATIONS.
k) Loosen ‘V belts tension.
l) Battery for engine starting, if provided, should be disconnected and stored in a cool, dry
place after ensuring the electrolyte level, refill with distilled water, if necessary.
It is recommended to recharge the battery every 30 days.
m) Tag engine to indicate that it has been treated with preservatives, and should not
be turned over until ready to run, due to possible reduction of protective film. The
tag should show the date of treatment and validity date.
n) It is preferable to warp the engine in polyethylene bag and store in dry shade.
Periodically inspect the engine for rust or corrosion and take corrective action
if any.
o) If the engine is to be stored unused for more than 12 months, repeat the above procedure
completely, after every 12 months.
8.3 Commissioning of Preserved Engine
a) Remove all the sealing tapes / papers from various openings.
b) Remove the Rust Preventive coating from those unpainted machined surfaces,
which are interfacing surfaces for the driven equipment. This can be done using
NC Thinner.
c) Fill recommended grade of lube oil in the oil sump upto the ‘Top’ mark of the
dipstick. For oil filling quantity see 2.4.4.
d) Readjust the V-belt tension after checking the condition of V-belt (s), replace, if
necessary (see 5.5).
e) Reconnect a fully charged battery to recommended voltage and Amp-hr capacity
ensuring correct polarity connection (where applicable).
The engine is now ready for reuse. Follow the instructions given in section 3
before starting the engine.
Page 45 of 48
9 Tightening Torque, Settings

9.1 Tightening Torque
To prevent faulty assembly, following information on tightening of high tensile

bolts is important. The bolts are to be tightened in stages as specified in the table
below. For connecting rod bolt and main bearing cap bolt use angle torque method
with the help of goniometer. The tightening angles for these two bolts are
particularly important, hence Fig. 9 . 1 indicates the various angles can be readily
obtained by comparison with a clock face.
Fig 9.1
Tommy bar is to be clamped in the tool slot and specified angle is to be turned with reference
to the initial graduation on outer dial of the tool or a relation of hex head of bolt can be
referred.
NOTE:
1. Lubricate threads and seating face of bolt with engine oil before 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 and connecting rod cap.
1 Nm = 0.102 kgm = 0.74 Ib.ft.
Tightening Torque 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
Page 46 of 48
(M12x1.75x60mm long 10.9) 3 300 300 - 600

2 Bolt for main bearing cap
(M14x2x128 mm long 10.9) 3 600 450 - 1050
3 Bolt for Connecting rod
(M12x1.5x55mm long 10.9) 3 300 600 - 900
4 Bolt for Crank pulley
(M24x2x100 mm long 10.9) 5 250 480 - 480
without power take off
5 Bolt for flywheel
(M10x1x45mm long 10.9) 3 300 600 - 900
6 Bolt for flywheel housing
(M10x1.5x40mm long 10.9) 5 - - - 5 kgm
7 Nut for injector stud M10 3 - - - 3 kgm
8 Nut for fuel pump hub M14
8 - - - 8 kgm
9 Bolt for cylinder head
(M12x1.75) for sequence of 3 6kgm 0kgm 12kgm 12 kgm
tightening torque refer Fig 9.2
10 All M8x1.25 screws & bolts 8.8
2.5 - - - 2.5 kgm
11 All M10x1.5 screws & bolts 8.8
3.5 - - - 3.5 kgm
Fig 9.1.1
Tightening torque sequence for cylinder head bolts for 4R1040 engines is shown above. See
Fig 9.1.1
9.2 Settings
9.2.1 Tappet clearance( in cold condition only
Inlet Exhaust
0.25 mm 0.30 mm
9.2.2 Bumping clearance: - 0.9 mm to 1.1 mm
Others – Fuel timing
Fuel timing setting:
Page 47 of 48
A provision for locking the engine at fuel timing is provided with the help of locking pin and
corresponding hole on the flywheel.
• Bring the engine near firing TDC position and Lock the engine at fuel timing by
using the locking pin as shown.
• Assemble the fuel pump and set the fuel timing, using standard spill cut off method.
• Remove the locking pin before cranking the engine.
Engine Name Static Injection Timing

2R1040,3R1040,4R1040 13 Deg BTDC
4R1040TC, 4R1040TA, 6R1080TA 11 Deg BTDC
Page 48 of 48

Index: R1040 Maintenance Manual

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R1040 MAINTENANCE MANUAL

1.2 Maintenance and Repairs 2

1.1 Service and Maintenance

1.2 Maintenance and Repairs

2.2 Engine Name Plate

2.2.2 Engine Number System

Application code No. (i.e. build of the engine)

2.2.3 Model Designation

Indicates Piston displacement 1.04 Lit. /Cylinder as 1040

Indicates series of engine as R series

Indicates No.off Cylinders as 3

Indicates Piston displacement 1.08 Lit. /Cylinder as 1080

Indicates series of engine as R series

Indicates No. off Cylinders as 6

2.3 Engine lifting device

2.3.3 For bare engine for ’R1040/R1080’

2.4 Lube oil system

Lube oil circuit

2.4.2 Lube oil pump: -

Engine type 2R/3R/4R1040 4R1040T/TA 6R1080/T/TA

Lube oil pressure: -

At low idling speed Minimum 1.5 Kg/cm2

2.4.3 Lube oil Temperature: -

2.4.4 Lube oil consumption: -

Lube oil consumption for well run in 0.3 % of fuel

2.4.5 Lube oil sump capacity and oil change period: -

MIL-L-2104 C PLUS 400 Naturally aspirated as well

The above oil change period is subject to following conditions.

2.4.6 Lube oil Specifications and recommendations

US Military American CCMC

2.5 Fuel supply system

Proportion of Kerosene to be mixed in Diesel, depends on the ambient temperature

2.5.3 Storing Fuel Oil

2.6 Cooling System

2.6.1 Radiator type cooling system

The Radiator type cooling system is used.

Nalco-2000 35 cc per liter.

2.7 Electrical System

2.7.1 Electrical Equipment

Battery Capacity Ratings

Ambient temperature Battery Capacity in Amp-hr 20 hr rate

Length in meter Core size in mm2 Wire Specification

Fuel pipe Min. inside diameter mm

3.1.3 Bleeding of fuel system

Fig.3.1.3.1 Primary element Fig. 3.1.3.2 Micro element

3.1.4 Cooling system

3.1.6 Valve Clearance

3.1.7 Other preparations

Remove lifting eyebolts after engine installation.

3.2.1 Electric Starting

To stop the engine, follow the instructions as below.

3.4 Operating conditions

3.4.1 Operation in winter

Lube oil viscosity

Cold starting aids

Temperature range Starting aid

High ambient temperature and/or High altitude

Deration chart for 4R1040T/6R1080T engines

Deration chart for 4R1040TA/6R1080TA engines

In case of doubt concerning such engine applications, contact your distributor.

3.5 Running in period

3.5.1 After first 100 hours running