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R1040 MAINTENANCE MANUAL

Page 41 of 48

Heavy blowing from
venting hose of
engine

Excessively high lube oil level,
damages of cylinder elements

Adjust oil level. Consult your
Distributor

No air supply from
piston or compressor

Defect of cylinder element or of
valve plate

Consult your Distributor

Battery charging
signal lamp alight
while ignition is
switched off

Defective insulation in fanned cable

Consult your Distributor

Battery charging
signal lamp does not
light when ignition is
switched on

Defect of signal lamp

Interruption of D governor and
generator

Battery discharged

Replace signal lamp

Plug in connector

Charge battery

Battery charging
signal lamp alight
during normal
operation

Broken V-belt

Defective alternator

Replace V-belt

Inspect or Consult your
Distributor

Heavy boiling of
battery

Defective governor, excessive
contact resistance of negetive
polarity across brush holder and end
shield bearing of generator

Consult your Distributor

Starter does not run

Battery discharged

Charge battery

Deficient speed of
starter

Starter terminal voltage too low

Oxidised or loose terminal
connection

Carbon brushes jam or are worn

Check battery cells, recharge
battery

Clean and fasten terminals

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.

se 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.

Содержание 2R1040

Страница 1: ...ntenance 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 A...

Страница 2: ...g 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 fittin...

Страница 3: ...ts 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 c...

Страница 4: ...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 Wa...

Страница 5: ...icated 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 valv...

Страница 6: ...R1040 MAINTENANCE MANUAL Page 6 of 48...

Страница 7: ...ature 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 2...

Страница 8: ...never 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 s...

Страница 9: ...ump 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 s...

Страница 10: ...imited to 50 For cold starting aid see 3 4 1 PREPARETHEBLENDINTHETANKITSELF FILL IN THE NECESSARY AMOUNT OF KEROSENEFIRST THENADDDIESELFUEL 2 5 3 Storing Fuel Oil The storage of fuel oil is of utmost...

Страница 11: ...em 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 corr...

Страница 12: ...r 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 Com...

Страница 13: ...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...

Страница 14: ...nning 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...

Страница 15: ...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...

Страница 16: ...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 Startin...

Страница 17: ...l guidelines are given below Temperature range Starting aid Up to 00 C No cold starting aid is required 00 to 200 C Use flame heater or start pilot Below 200 C Consult your distributor Battery Cold st...

Страница 18: ...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 ambien...

Страница 19: ...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...

Страница 20: ...tor fins depends on site condition 12 5 3 2 Radiator tubes depends on type of cooling water 5 3 2 Fuel Filter Cartridge micro 4 13 5 2 2 Thermostat element change if necessary 5 3 3 Valve clearance ad...

Страница 21: ...Maintenance of Lubrication system 5 1 1 Oil change intervals Theoilchangeintervalsdependonengineapplication and on quality of lube oil Refer table below Should within ONE YEAR the enginerun less than...

Страница 22: ...gine 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 re...

Страница 23: ...altooland 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 Applylightfilm of oiltorubbe...

Страница 24: ...tent 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 everyoilchangeperi...

Страница 25: ...warm Allthreadedpartsofthecentrifugerequirefollowing gadgets a 13 mm spanner a blint knife a small adjustable pliers and waste cotton for cleaning Servicingprocedure Fig 5 1 5 3 Unscrew top nut with...

Страница 26: ...ld 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 c...

Страница 27: ...will not give desired performance Don tsaboutcentrifugecleaner Fig 5 1 5 7 Donotover tightenthe topnut Tightenjustenough to prevent leakage of oil from centrifuge cover and housing Over tightening top...

Страница 28: ...arrow marks on rotor cover and rotor Rotor notrotating at desired speed Changerubberring Openrotor andcleannozzles Thoroughly Re assemblethecleaner Do notopenentryvalve assembly It requires special t...

Страница 29: ...um 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 cartri...

Страница 30: ...tin 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 over...

Страница 31: ...d tightenthe connections 5 3 3 Thermostat A thermostathaving singleelement is used inthe water circuit Thermostat is provided to attain working temperature quickly during warm up period and maintainsd...

Страница 32: ...aircleaner is essential to ensure maximum protection to the engine from the dust Daily check the connection of rubber hose and the hose clips betweenthe manifoldandthe aircleaner before starting the e...

Страница 33: ...Make sure thatvacuator valve is notdamaged 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 th...

Страница 34: ...damage before installing Conduct a light test by passingthe light throughelement 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 ele...

Страница 35: ...ngwiththethumbmidwaybetween the pulleys tosee whether the belt deflectsinwards 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 batter...

Страница 36: ...ver Turn crankshaft until the valves of the cylinder on which the clearance is being checked are overlapping exhaust valve about to close inlet valve aboutto open Thencontinueturningthecrankshaftthrou...

Страница 37: ...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 Checkthe brushes They must...

Страница 38: ...loth 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 wor...

Страница 39: ...in fuel system Open cock Clean the strainer or change the filer cartridge Fill in fuel vent fuel system inspect correct operation of fuel pump repair if necessary and check safe venting of tank Clean...

Страница 40: ...high fuel quantity engine emits black fumes Leakage of solenoid valve of cold starting device Jammed air filter Engine is worn Defective exhaust brake Check fuel injection system Check and repair Hav...

Страница 41: ...f generator Consult your Distributor Starter does not run Battery discharged Charge battery Deficient speed of starter Starter terminal voltage too low Oxidised or loose terminal connection Carbon bru...

Страница 42: ...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 tur...

Страница 43: ...the engine speedby sending aproportionalfrequency signal to the speed control unit The system does maintain any desired speed veryaccurately independentofengineload The system offered is highly reliab...

Страница 44: ...e is recommendedforengine whenitistobe keptidle out of use for prolonged period more than 12 months 8 1 Recommended Preservatives Manufacturer Engine Lube oil and fuel system Engine cooling system Unp...

Страница 45: ...k Loosen Vbeltstension l Battery for engine starting if provided should be disconnected and stored ina cool dry place after ensuring the electrolyte level refill with distilled water if necessary It i...

Страница 46: ...e 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 seatin...

Страница 47: ...10x1 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 tightening torque refer Fig 9 2 3 6kgm 0kgm 12kg...

Страница 48: ...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 meth...

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