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-ENGINE OPERATION. . abstract. engine - ENGINE description -ENGINE operatiON -routine Maintenance - ENGINE service &maintaince -Faults , Causes & Remedies - -engine specification.

Engine Description. . abstract. . ENGINE descriptiON.

Commissioning Operating conditions starting & stopping Running in period Engine cleaning & preservation.

Routine- Maintenance. . . Maintenance Schedule Maintenance Work Completed.

. . Maintenance Schedule Maintenance Work Completed.

abstract. Service & Maintenance. . - Maintenance of lube system -Maintenance of fuel system -Maintenance of cooling system -Maintenance of dry type air cleaner -Belt drives Adjustments -Maintenance of electrical equipment -Additional jobs.

abstract. . Routine maintanace Maintenance Schedule Maintenance Work Completed.

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Routine Maintenance 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..

Engine cleaning & preservation 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. Engine Operation.

abstract. - Maintenance of lube system -Maintenance of fuel system -Maintenance of cooling system -Maintenance of dry type air cleaner -Belt drives Adjustments -Maintenance of electrical equipment -Additional jobs.

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Maintenance of cooling system 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 . * 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..

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. Fuel Filter Lube Oil Filter. abstract.

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..

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eesesezzszs:tsz. Construction of typical dry type plastic air cleaner, supplied, is shown above in figure and construction of typical dry type air cleaner with sheet metal housing is shown above in figure. 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.

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abstract. 5. Service & Maintenance. Maintenance Of dry type air cleaner.

* Carefully check new or properly cleaned element for damage before installing. Conduct a light test by passing the light 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 the element. Inspection of air cleaner element - Light test.

abstract. * 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..

. Service & Maintenance 5.4 Belt drives.

abstract. 5. Service & Maintenance. Adjustment. 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..

0.3 mm. Adjusting valve clearance. Service & Maintenance Adjustments.

abstract. 5.7 Maintenance of electrical equipment.

1 Exhaust silencer 5.8.2 Checking of fasteners * Knock out soot from exhaust silencer and clean the exhaust piping after every 1200 hours. * The time span of exhaust silencer chocking is entirely dependant on the working conditions and maintenance & operating practices, so the time span will be vary accordingly. * 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.

ENGINE DESCRIPTION 22 23 ErörziYgE,iE 27.

Engine nameplate ENGINE TYPE RATING kW/ hp rpm RATING STD. GOVERNING CLASS ENGINE No. KIRLOSKAR OIL ENGINES LTD INDIA.

till. Engine description. Engine numbering system.

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.4.1 Lube oil circuit 2.4.2 Lube oil pump Force feed lubrication is provided by a ‘G’ rotor type pump to main bearings, large end bearings, camshaft journals, valve gear etc. Other components like connecting rod small end bushes, cylinder liners and gear train are splash lubricated. 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. 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..

Engine description. . Engine Description 2.4 Lube oil system 2.4.4 Lube oil pressure 2.4.5 Lube oil temperature At low idling speed Minimum 1.5 Kg/cm2 At loaded condition in operating range 2.5 to 5.5 Kg/cm2 If the lube oil pressure at any time drops 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 Kirloskar Dealer. The maximum lube oil temperature for R1040 / R1080 series engines is ambient temperature plus 700 C. For example if ambient temperature is 400 C, the maximum lube oil temperature should be 1100 C Note :- 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.

Lube oil system 2. Engine Description. 2.4.6 Lube oil sump capacity 2.4.7 Lube oil The lube oil sump capacities of R1040 / R1080 series engines are as below These capacities are for the standard sheet metal sumps. The oil must be changed at least once in a year. This is applicable to the engines, which are running for standby duty application. Note : Initial fill = Sump capacity + Gallery capacity + Lube oil filter capacity Fill the Lube oil filter with oil before fitting on the engine. 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. The engine should be lubricated only with the specified oil. This specially blended engine oil designed for the best performance of your genset . Using the specified oil has the following advantages: Extra protection against corrosion and rusting Excellent performance at both high and low temperatures Reduced fuel consumption Usage of improper lube oil could result in: Overheating of the engine Sluggish performance Excessive fuel consumption Increased wear of bearings and other parts The specified oil is available only through KOEL’s authorized service dealers in suitable packing..

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Only with preheating. abstract. viscosity.

abstract. 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 above shows the fuel circuit of the engine..