You are on page 1of 89

1.

Foreword 1 - 6
2. Engine Description 7 - 22
3. Engine Operation 23 - 34
4. Operating Media 35 - 38
5. Routine Maintenance 39 - 44
6. Service & Maintenance 45 - 68
7. Faults, Causes & Remedies 69 - 72
8. Engine Preservation 73 - 76
9. Technical Specifications 77 - 86
INDEX
1
1. FOREWORD
Dear Customer,
We are happy to provide you with latest revision of HA
series O & M manual.
The HA series air cooled engines are developed and
supplied for wide range of application meeting your
requirements.
We assure you that all necessary safety precautions and
regulations have been adhered to in the design, material
and manufacturing of HA Series engines. All the engines
under go stipulated performance test before being
delivered to customers.
This manual provides specifications and operations
guidelines for of HA series engines, routine maintenance,
services maintenance procedure. The performance of
engine largely depends on its proper maintenance and up
keep. Hence, please maintain your HA engine properly as
per the guidelines and schedules given in this manual.
We recommend that only trained manpower should perform
the operation and maintenance tasks on the engine. Always
use the genuine Kirloskar spare parts whenever required
for periodic maintenance as well as for engine repairs.
We maintain the facility for operators training for
maintenance of Kirloskar diesel engines. Please contact
our authorized service dealer / distributors nearest to you
to avail this facility.
Continuous improvements in the product design are
incorporated from time to time which may not be included
in this manual
The manual is updated periodically to include such changes
in the latest editions.
Should you have any queries, fully equipped and trained
team from Kirloskar Customer Support will be happy to
provide the help.
In case of any difficulty please contact
KIRLOSKAR OIL ENGINES LTD
Customer Support
Laxmanrao Kirloskar Road, Khadki
Pune 411 003 (INDIA)
Help Desk 1800 2333344, 020-66084608
Help Desk ID helpdesk@koel.co.in
Visit us at : www.kirloskar.com
Visit us at : www.koel.co.in
2
3
STANDARD WARRANTY FOR KOEL HA SERIES
ENGINE OPERATING IN INDIA
This warranty applies to the HA Series KOEL Diesel
Engine.
Duration of Warranty
For Industrial Application (Engines working for Earth
moving equipment, material handling equipment and
liquid handling pumps, e.g. Backhoe Loader, Vibratory
Compactor, Concrete Pump, Transit Mixer,
Excavators, Pick and Carry Crane, Fork Lift Truck, Fire
Fighting Pumpsets etc.) - Within 18 Calendar Months
from Date of Dispatch from KOEL or 3600 operating
hours or 12 calendar months from date of installation
or within six calendar months where the machinery
has run continuously day and night, Whichever
occurs first.
Scope of Warranty
After the Engine has been taken delivery by you, we
expressly guarantee, in lieu of any warranty implied
by law, to make good any defective parts in machinery
of our own manufacture, which defect develops
under proper use and necessary maintenance
practices as written in this manual and arises solely
from faulty material or workmanship, provide always
that such defective parts are promptly returned
carriage paid to our works and provided that Fuel
and lubricants approved by us, have been
continuously used. The repaired or (at its option) new
parts will be delivered free of cost, EX-works.
At the termination of such period of 12 calendar
months (or six calendar months as the case may be)
all liability on our part ceases.
In the case of goods not of our manufacture (e.g.
Fuel Injection Equipments, Electrical Components like
Starter, Alternator, Turbocharger), you are entitled
to the benefits of respective manufacturers warranty
given to us. In respect there of and our liability in
respect of such goods is limited to the warranty given
by the respective manufacturer. In no case shall we
be liable for the fitting charges of replacement parts
of thereof.
The defective parts replaced by us shall become our
property. All goods are supplied on the Condition
that we shall not be liable for any loss incurred
4
through stoppages or any consequential damages.
Warranty for rubber parts like AVMs, Belts, Hoses, O
rings etc will be six months from date of installation.
Limitations and Exclusions
This warranty does not apply to
1. To fair wear and tear or to damage due to
negligence or improper handling or incorrect
application or incorrect installation by the
purchaser, or his employees or agents or in the
case of repairs or alterations carried out by the
purchaser without our knowledge and written
approval.
2. To reconditioned or second-hand combination sets
or Engines. The Engines will be deemed to have
been taken over by the customer upon dispatch
from our works, in the case of direct deliveries EX-
Factory and from the godowns of our authorized
Dealers viz. Distributors and Dealers, in the case
of supplies from their stock and this warranty will
come into effect from that time.
3. The cost of maintenance or regular service of the
engine.
4. Any damage due to idle storage of engine beyond
period of 6 months without treatment of long
storage.
5. Any damage due to use of lubrication oil, fuel
quality and grade not recommended by Kirloskar
Oil Engines Ltd.
6. Any damage resulting from improper shutdown.
7. Any failure to meet its obligations hereunder which
are due to circumstances beyond its reasonable
control including but not limited to industrial
disputes, fire, severe weather conditions,
government decisions, material shortage, power
or machinery breakdown or failure or war.
8. Gradual reduction in operating performance
commensurate with the age, kilometers covered
or operating hours, including but not limited to,
gradual loss of engine compression or gradual
increase in oil consumption due to normal
operating functions.
5
9. We will not be responsible for loss or damage to
goods beyond the delivery stated in our tender
and we will repair or replace free of charge goods
damaged in transit upto the point of delivery by
us, as specified above.
This warranty is the only document given by us
warranting the Kirloskar HA series engine. No other
document giving any warranty terms conflicting these
contents shall be considered and entertained.
6
7
2.1 Model
2.2 Engine Illustration
2.3 Lube Oil System
2.4 Fuel System
2.5 Engine Cooling System
2.6 Air Inlet System
2.7 Exhaust System
2. Engine Description
8
9
2.1 Model 2. Engine Description
The engine model and engine serial no. are stamped on nameplate along with engine
rating, rpm and referred standard. The nameplate details must be given while ordering
spares and asking for service.
2.1.1. Rating plate 2.1.2. Rating Plate Location.
For Genset For Industrial
ENGINE TYPE
Sr No.
RATING kW/hp rpm
RATING STD.
DATE OF MFG.
KIRLOSKAR OIL ENGINES LTD. INDIA
ENGINE TYPE
ENGINE No.
RATING kW/hp rpm
RATING STD.
GOVERNING CLASS
KIRLOSKAR OIL ENGINES LTD
INDIA
The nameplate is fixed on engine
crankcase as shown.
10
2. Engine Description 2.1 Model
2.1.3. Cylinder Numbering. 2.1.4. Direct Injection
Cylinder are numbered consecutively,
beginning at the flywheel end.
Engines are with direct fuel injection to
meet high performance and pollution
regulations
1 2 3 4 5 6
11
1. Cooling Blower
2. Lifting Hook
3. Fuel Injection Pump
4. Flywheel Housing
5. Crank Pulley
6. Belt Tension Unit
7. Oil Filler Neck / Cap
8. Lube Oil Sump
9. Lube Oil Filter
10. Fuel Filter
11. Air Cowling
12. V-Belt
13. Feed Pump
14. Lube Oil Drain Plug
2.2 Engine Illustration 2. Engine Description
2.2.1. Service Side.
HA694 NA
12
15. Charging Alternator
16. Starter
17. Crankcase
18. Crankcase Breather
19. Flywheel
20. Rocker Cover
21. Air Intake Manifold
22. Exhaust Manifold
2. Engine Description 2.2 Engine Illustration
2.2.2. Exhaust Side.
HA694 NA
13
1. Cooling Blower
2. Lifting Hook
3. Fuel Injection Pump
4. V-Belt
5. Crank Pulley
6. Belt Tension Unit
7. Oil Filler Neck
8. Lube Oil Sump
9. Lube Oil Filter
10. Fuel Filter
11. Air Cowling
12. Rocker Cover
13. Feed Pump
14. Lube Oil Drain Plug
2.2 Engine Illustration 2. Engine Description
2.2.3. Service Side.
HA694 TC
14
15. Exhaust manifold
16. Charging Alternator
17. Starter
18. Crankcase
19. Crankcase Breather
20. Flywheel Housing
21. Flywheel
22. Turbocharger
23. Air Intake Manifold
2. Engine Description 2.2 Engine Illustration
2.2.4. Exhaust Side.
HA694 TC
15
1 Lube Oil Sump
2 Suction Pipe
3 Lube Oil Pump
4 Pressure Relief Valve
5 Delivery Pipe
6 Lube Oil Cooler
7 Lube Oil Filter
8 Relief Valve (not shown)
9 Oil Gallery
10 Main Bearing
11 Large End Bearing
12 Camshaft Bearing
13 Tappet with groove for pulse fed
rocker arm lubrication.
2.3 Lube Oil System 2. Engine Description
2.3.1. HA694 NA
8
7 9
11
19
1
10
12
2
3
4
5
18
14
17
13
16
15
21
6
22
20
16
14 Push Rod
15 Rocker Arm Bearing
16 Metering Plug
17 Push Rod Cover Tube
18 Restrictor ( for lubrication of gears)
19 Spray Nozzle for Piston Cooling
20 Connection for Pressure Gauge
21 Oil Pressure Gauge
22 Fuel Pump Connected to Lube Oil
Circuit
2. Engine Description 2.3 Lube Oil System
2.3.1. HA694 NA
8
7 9
11
19
1
10
12
2
3
4
5
18
14
17
13
16
15
6
22
21
20
17
1 Oil Sump
2 Suction Pipe
3 Oil Pump
4 Pressure Valve
5 Delivery Pipe
6 Pipe to Oil Cooler
7 Oil cooler plate type
8 Lube Oil Filter
9 Safety Valve
10 Oil Gallery
11 Main Bearing
12 Big-End Bearing
13 Camshaft Bearing
2.3 Lube Oil System 2. Engine Description
2.3.2. HA694 TC
6
21 16 17
14
1
5
4
3
13
11
12
19
2
7
8
22
23
24
9
18
15
20 10
18
14 Tappet with groove for pulse fed
rocker arm lubrication
15 Push Rod
16 Rocker Arm Bearing
17 Metering Plug
18 Push Rod and Cover Tube
19 Restrictor Hole
20 Nozzle for Piston Cooling
21 Oil Pipe to Turbocharger
22 Oil return Pipe
23 Oil Pressure Gauge
2. Engine Description 2.3 Lube Oil System
2.3.2. HA694 TC
6
21 16 17
14
1
5
4
3
13
11
12
19
2
7
8
22
23
24
9
18
15
20 10
19
1. Fuel tank
2. Fuel pipe - tank to fuel pump
3. Fuel feed pump
4. Fuel filter
5. Injection pump
6. Fuel injection pipe
7. Fuel Injector
8. Leak-off pipe
9. Fuel overflow line
10. Overflow valve
11. Fuel return line to tank
A. Clearance; keep as far apart as
possible. (Min. 200mm)
2.4 Fuel System 2. Engine Description
2.4.1. Fuel System
7
6
5
3
4
2
11
1
10
8
9
20
Air cooling for the engine is achieved by
highly efficient,quite integral, axial blower
having sufficient reserve capacity to cope
up with high ambient temperatures. The
blower is driven by the engine crankshaft
pulley through V belts. The V belts
tension is maintained by belt tensioning
unit.
Air flow from the blower is directed on
the liners and cylinder heads by
detachable sheet metal lower & upper
cowlings.
2. Engine Description 2.5 Engine Cooling System
2.5.1. Cooling Air Flow
HOT AIR OUT
F
R
E
S
H

A
I
R

I
N
21
2.6 Air Inlet System 2. Engine Description
2.6.1 Air Inlet System
Engine requires fresh, clean, cool, and
sufficient quantity of air to burn the fuel
and satisfactory performance.
Clean air is required to avoid unnecessary
wear & tear of engine componant.
Air Intake System consist of Pre-cleaner,
Air cleaner, Hose & Air Inlet Manifold.
Pre-cleaner - Air enters pre-cleaner
through angled fins which causes air swirl.
Thus heavier dust particles are collected
in plastic dust bowl.
Figure above shows the construction of
oil bath air cleaner used on HA series
engines.
Oil bath air cleaner are generally used for
light duty application.
The filtration efficiency of oil bath air
cleaner is 96 - 98%.
Figure above shows the construction of
dry type air cleaner used on HA series
engines. Dry type air cleaners are generally
used for earth moving, construction
equipments.
The filtration efficiency of Dry type air
cleaner is 98.9 - 99.9%.
Generally two elements are used in this
type of air cleaner - Main element & Safety
element.
Restriction indicator is provided for all
dry type air cleaners.
Cleaning of filter element is required when
restiction indicator shows red signal even
after engine has stopped.
Second
stage
Cleane air to
engine
First
stage
Lube oil
Dust
accumulated
in dust bowl
Dust
bowl
Pre-cleaner
Fresh air from
atmosphere
Wire-mesh
element
Vaccuator
Valve
Safety
element
Air inlet
Housing
Wire clamps
Cover
PU
element Mounting
Strap
Safety support
tube
Filtered
air to
engine
Insert for
restiction
indicator
mounting
22
2. Engine Description 2.7 Exhaust System
2.7.1 Exhaust System
The Exhaust System is necessary to direct
exhaust gases to non confined areas &
reduce the noise level to tolerable level.
Exhaust system should exhert minimum
back pressure on engine. Exhaust back
pressure should be restricted to less than
50 mm of Hg.
Exhaust system consist of exhaust
manifold, adaptor & exhaust silencer.
Exhaust piping should be lagged to avoid
injury to operating personnel.
Total length of exhaust pipe should not
exceed 15 meters and should have
maximum of four right angle bends. Avoid
using elbows. Increase pipe I.D. by 1.5
after every 5 meter length of exhaust pipe.
Expansion bellows & flexible pipes should
be installed between engine & exhaust
piping.
The exhaust pipe outlet should be bent so
that outgoing exhaust gases are not
recirculated. The exhaust pipe outlet
should be bent in the direction of wind &
the end should be cut at an angle of 45
0
.
There shold be rain trap to avoid rain water
entry. If rain cap is used the distance
between exhaust pipe & rain cap should
be 2.5 times diameter of exhaust pipe.
The figure above shows HA694 Engine
with exhaust outlet facing downwards.
Exhaust silencer is mounted separately on
the equipment & connected to exhaust
manifold by flexible piping.
The figure above shows HA394 Engine
with exhaust manifold cum silencer.
23
3.1 Commissioning
3.2 Starting
3.3 Monitoring System
3.4 Stopping
3.5 Operating Conditions
3. Engine Operation
24
25
3.1.1 Adding Engine Oil 3.1.2 Filling Oil Bath Air 3.1.3 Adding Fuel
Cleaner
Fill oil bowl of oil bath air cleaner with
engine oil up to the mark. For oil specs.
Refer 4.1
Engines are delivered with first fill oil.
Use only High speed diesel fuel. For fuel
specs refer 4.2
Never fill the tank while the
engine is running. Observe
cleanliness and do not spill any
fuel.
3.1 Commissioning 3. Engine Operation
Do not fill oil into the dust
collector of the pre - cleaner, if
provided.
Oil Level
26
* Loosen overflow valve 1 on the fuel
pump.
* Loosen hand pump 2 of the fuel feed
pump at the knurled grip by
unscrewing it.
* Operate the hand pump till fuel flow
without air bubble at overflow valve.
* Tighten the overflow valve while fuel
is flowing simultaneously operating
the hand pump
* Tighten the hand pump at knurled grip
The following maintenance should be
carried out after 50 operating hours;
* Change lube oil see 6.1.2
* Change oil filter element /cartridge, see
6.1.3
* Change fuel filter element / cartridge.
See 6.2.1
* Check V-belts and retension if
necessary, see 6.5
* Check the engine for any leakages.
3. Engine Operation 3.1 Commissioning
3.1.4 Fuel System Ventilation 3.1.5 Other Preparations 3.1.6 Additional Maintenance
Work
* Check battery and lead connections
Also check cable connection at the
starter and alternator end for tightness.
* Remove engine lifting tackle.
* Trial run
After completing the engine
preparations run the engine for about
10-15 min. at no load. While engine is
running check lube oil pressure (3.5 to
4.5 kg/cm
2
), lube oil temperature.
(Within green zone)
During and after trial run
- Check for any leakages.
* After trial run and engine stationary
- Check oil level, refer 6.1.2
if required top up oil, refer 3.1.1
Retension V-belts, refer 6.5
* Running in
During running in period- about 50
running hours, check oil level twice a
day After running in, checking oil level
once a day will be sufficient.
27
3.2.1 Electric Starting Starting Without Cold-Start
Aid
3.2 Starting 3. Engine Operation
Before starting, make sure that
nobody is standing in the
immediate vicinity of the
engine or driven machine.
After repair work;
Check that all guards have been replaced
and all tools have been removed from
the engine.
When starting with flame glow system,
do not use any other starter substance
(e. g. injection with start pilot).
Caution: If the speed regulator has been
removed for any reason, the engine must
not be started under any circumstances.
Disconnect the battery.
Do not actuate the starter for more than
10 seconds. If the engine does not start
wait a minute then try again.
If the engine does not start after two
attempts, refer to the Diagnosis Chart
(see 7.1)
* Where possible, disengage the
Caution: If the speed regulator has
been clutch to separate the engine
removed for any reason, the engine
from any driven equipment. must not
be started under any
* Move speed control lever 1 to
circumstances. idle position.
* Insert key.
- Position OFF = no operating voltage.
* Turn key clockwise
- Position ON = operating voltage
- Charge Lamp comes on.
(If applicable)
* Turn key further clockwise against
spring pressure.
- Position 2 = start
* Release key as soon as engine fires
- Charge Lamp goes out. (If applicable)
OFF
ON
SRART
Charge Lamp
Stopping
Lever
Accelerating
Lever
28
* Insert key.
- Position OFF = no operating voltage.
* Turn key clockwise
- Position ON = operating voltage
- Charge Lamp comes on.
* Press push button Glow plug indicator
come on Hold the push button for
60 sec & release.
Glow plug indicator goes out
* Immediately turn key further clockwise
against spring pressure.
Position START = Engine cranking
* Release key as soon as engine fires.
- Charge Lamp goes out.
3. Engine Operation 3.2 Starting
With Cold-Start Aid/Flame With Cold-Start Aid/Flame
Glow Plug - 12V Glow Plug - 24V
* Insert key.
- Position OFF = no operating voltage.
* Turn key clockwise
- Position ON = operating voltage
- Charge Lamp comes on.
* Press push button Glow plug indicator
come on Hold the push button for 30
sec & release.
Glow plug indicator goes out
* Immediately turn key further clockwise
against spring pressure.
Position START = Engine cranking
* Release key as soon as engine fires.
- Charge Lamp goes out.
ON
START
OFF
P.B.
Push button for
cold starting
Charge Lamp
ON
START
OFF
P.B.
Push button for
cold starting
Charge Lamp
29
3.3.1 Engine Lube Oil Pressure 3.3.2 Engine Oil Temperature 3.3.3 Belt Failure Switch For
HA394/494/694 &
HA494TC/694TC
3.3 Monitoring System 3. Engine Operation
Lube Oil Pressure Gauge Lube Oil Temp. Indicator
The pointer indicates the lube oil pressure
of engine. It must be above minimum lube
oil pressure. Refer 9.1
The lube oil temperature gauge pointer
should be in green sector while engine is
running. If the pointer enters the red sector
then oil temperature is beyond acceptable
limits. Shut Down engine and refer
diagnosis chart (Refer 7.1 ) for the cause
of high oil temp.
If the V - Belt fails, lever of automatic belt
tension actuates thePressure pin of
electrical switch. An audible/visual alarm
is initiated.
Shut down the engine immediately to
prevent engine overheating.
30
3. Engine Operation 3.2 Starting
3.3.4 High cylinder Head 3.3.5 Belt Failure System
Temperature Switch Mechanical Shutdown
For HA294 Engine
Cylinder head temperature switch (Set
point 175 5
0
C) protects the engine in
case of belt failure.
If the V - Belt fails, lever (1) of automatic
belt tension operates the lever (2), which
in turn operates stopping lever of the fuel
pump. Thus the engine is stopped.
1
2
31
3.4.1 Manual Shutdown 3.4.2 Electrical Shutdown
Ignition Key
3.4 Stopping System 3. Engine Operation
* Move the accelerating lever to idle
position (if possible)
* Allow the engine to run for 5 Minutes.
(If Possible) without load.
* Pull the stop lever / stopping cable till
the engine comes to halt.
Charge Lamp comes on when engine
stops.
* Turn the key anticlockwise and remove
the key.
Charge lamp goes out.
* If possible, do not suddenly switch off
the engine when under full load. Allow
it to run for 5 Minutes without load.
* Turn key anticlockwise (to position OFF)
and remove.
The Charge Lamp goes out.
* Stop solenoid is connected to fuel
pump stopping lever through a lever.
Stop solenoid used is Energised To
Stop type.
* Turning the key anticlockwise (to
position OFF) battery voltage is
supplied to stop solenoid.
* Coil of the stop solenoid is energised
& pulls the plunger, with in turn operates
the stopping lever of the fuel pump
there by stopping the engine.
Stopping
Lever
ON
START
OFF
P.B.
Push button for
cold starting
Charge Lamp
Stop
Solenoid
32
3. Engine Operation 3.5 Operating Conditions
3.5.1 Winter Operation
* Lube Oil Viscosity
- Select the oil viscosity (SAE grade)
according to the ambient
temperature when the engine is
started, see 4.1.2
- Increase oil change frequency when
operating below -10C, see 6.1.1
* Diesel Fuel
- Use winter- grade diesel fuel
operation below 0C, see 4.2.2
* Additional Maintenance Work
- Drain the sludge from the fuel tank
once a week. (Unscrew the drain
plug.)
- If necessary, allow the oil in the oil
bath air cleaner and the engine oil to
settle at the ambient temperature
while checking oil level.
- Below -20C after removing the starter
if necessary, smear the ring gear on
the flywheel via the pinion bore from
time to time with cold resistant grease.
* Cold- Start Aid
- At temperatures near or below
freezing point use flame glow plugs
if necessary, see 3.2.1
* Battery.
- Efficient cold starting requires a
healthy battery, see 6.7.1
- The starting limit temperatures can
be lowered by 4-5C by heating the
battery up to about +20C (to do so,
remove the battery and store in a
warm place.)
33
3.5.2 High Ambient Tempera-
tures, High Altitude
3.5 Operating Conditions 3. Engine Operation
* As the altitude and ambient
temperature rise, the density of air
tends to decrease, which affects the
maximum power output of the engine,
the exhaust gas quality and in extreme
cases the starting behavior.,
The engine can be used for operating
conditions other than NTP conditions
(Temp. - 27deg.C, R.H. 60% & 100m
above sea level ) however power
output will have to be derated
accordingly.
* In case of doubts about engine
operation under severe conditions,
refer to your dealer / equipment
supplier whether engine has been
derated for power to enhance service
life, reliability and exhaust gas quality.
Otherwise contact KIRLOSKAR
SERVICE.
34
35
4.1 Lube Oil
4.2 Fuel
4. Operating Media
36
with
nt
37
4.1.1 Quality Grade 4.1.2 Viscosity
4.1 Lube Oil 4. Operating Media
Lube oil of correct viscosity and
detergency grades should be used It is
recommended to use K Oil Super
( SAE15W40 ). For detergency it should
comply with following specifications:-
Multi-grade oil should be used.
As the viscosity of lube oil is dependent
on temperature. the choice of SAE grade
should be governed by the ambient
temperature prevailing at the engine
operating site..
Optimum operating behavior will be
attained if you take the accompanying oil
viscosity diagram as a guide Should be
temperature fall temporarily below the
limits of the SAE grade selected, cold
starting may be affected but the engine
will not be damaged.
In order to keep wear to a minimum, do
not exceed application limits for extended
period of time.
E - DL2 CF
CF+
E - DL3 MACK
T - 7 / T - 8A
E - DL4 CF4
Is 13656:2002 API
KOEL approved Lube Oils :-
Bharat Petroleum Bharat Ultra
Supreme 15W40
Hindustan Petroleum Hylube LL15W40
Indian Oil Corporation Servo Premium
XHP15W40
Manufacturing Co. Trade Name
Warranty is applicable on use
of K Oil Super engine oil only.
Only with preheating
38
4.2.1 Quality Grade 4.2.2 Winter Grade Fuel
4. Operating Media 4.1 Lube Oil
The commercially available diesel fuel
with sulphur content less than 0.05% be
used. If sulphur content is higher, then oil
change period should be halved. The
following specifications / standards are
approved
* IS 1460 : 2005
* ASTM D975 - 88 :1-D & 2-D
Waxing may occur at low temperatures
clogging the fuel system and reducing
engine efficiency. If the ambient
temperature is less than 0 deg. C Winter
grade fuel ( suitable down to -20deg.cel. )
should be used. This fuel is usually
available from filling stations well in
advance of the cold months.
* At temperatures below -20deg C.
kerosene should be added to the diesel
fuel. The relevant percentages are given
in the diagram at the right.
If summer grade diesel fuel must be used
at temperatures below 0 deg.C, up to 60%
kerosene can be added ( see diagram )
Legend :
I Summer diesel fuel
II Winter diesel fuel
A Outside temprature
B Percentage of kerosene to be
added
Mix in tank only. Fill with the
appropriate amount of
kerosene first, then the diesel
fuel.
Diesel fuels must never be
mixed with petrol
39
5.1 Maintenance Schedule
5.2 Maintenance Work Completed
5. Routine Maintenance
40
41
5.1 Maintenance Schedule 5. Routine Maintenance
Operating Hours Job Refer section
Daily 250 500 750 1000 5000 9000
Oil level in engine 6.1.2
Air Cleaner - oil bath 6.4
Air Cleaner - dry type 6.4
Battery & lead connections 6.7.1
Cooling system 6.3
Engine lube oil 6.1.2
Lube oil filter element / cartridge 6.1.3
Fuel strainer 6.2
V - Belt tension 6.5.3
V - Belt 6.5.2 / 6.5.4
Fuel filter insert - pre-filter element / cartridge 6.2
Fuel filter insert - micro filter element / cartridge 6.2
Fasteners 9.2
Starter & Alternator
Valve clearance 6.6
Injector
Safety system 6.5.5
Flame heater 6.9.2
T
o
p

O
v
e
r
h
a
u
l
M
a
j
o
r

O
v
e
r
h
a
u
l
Checking Recommended Change Clean Fuel Filter Insert Change For HA2/HA3 Engines Only
Note - i) For use of any recommended lube oil other than K Oil Super, lube oil change period will be 250 hours.
ii) Above maintenance schedule is applicable for Standard Operating Conditions.
42
5. Routine Maintenance 5.2 Maintenance Work Completed
Hours Date Remark Signature / Stamp
50
250
500
750
1000
1250
1500
1750
2000
2250
2500
2750
3000
3250
3500
3750
4000
43
5.2 Maintenance Work Completed 5. Routine Maintenance
Hours Date Remark Signature / Stamp
4250
4500
4750
5000
5250
5500
5750
6000
6250
6500
6750
7000
7250
7500
7750
8000
44
Hours Date Remark Signature / Stamp
8250
8500
8750
9000
5. Routine Maintenance 5.2 Maintenance Work Completed
45
6.1 Lubrication system
6.2 Fuel System
6.3 Cooling System
6.4 Combustion Air System
6.5 Belt Drive
6.6 Adjustments
6.7 Accessories
6.8 Engine Cleaning
6.9 Additional Maintenance
6. Service & Maintenance
46
47
6.1 Lubrication System 6. Service & Maintenance
* The oil change intervals are
dependent on engine application and
operating environment. Refer
subsequent table.
* If the engine runs fewer hours than
stated in the table, oil should be
changed atleast once in a year.
* The oil change period in table refer
to following operating conditions:
Ambient temperature down to -
10deg.C. sulphur content less than
0.05%
* If the sulphur content is above 0.05%
to 1% or operating temperature is
below -10deg.C. then oil change
intervals should be halved.
* If case fuel containing more than 1%
sulphur.
Contact KIRLOSKAR DEALER.
6.1.1. Oil Change Intervals
Engine Operating Conditions
- Normal Duty
Naturally
Aspirated & 500 hrs.
Turbocharged
Recommended lube oil
change period is applicable in
case of use of K Oil Super in the
engine, sourced from Kirloskar
Service Dealer only.
For use of any recommended
lube oil other than K Oil Super,
lube oil change period will be
250 hours.
48
6.1.2. Checking Oil Level / 6.1.2. Checking Oil Level /
Changing Engine Oil Changing Engine Oil
6.1.2.1 Checking Oil Level 6.1.2.2 Engine Oil Change
* Ensure engine is horizontal.
* Stop the engine if running, wait for 30
minutes
* Remove the oil dipstick.
* Wipe the dipstick with clean,
nonfibrous cloth.
* Insert the dipstick to the stop and
remove again.
* Check oil level, it should be between
Max.and Min. mark. If required top
up to Max. mark.
* Ensure that the engine or vehicle is on
a level surface.
* Start the engine if idle.
* Allow the engine warm up
- Lube oil temperature approx. 80
deg.C.
* Switch off the engine
* Place oil tray under the engine.
Unscrew drain plug.
* Drain oil.
* Fit oil drain plug, with the new gasket
and tighten firmly.
* Fill with lube oil.
- For grade / viscosity.Refer 4.1
- For quantity, Refer 4.1
* Check oil level.
Be careful when draining hot oil
-danger of scalds!
Do not let used oil run into the
soil but catch it in a container
ready for proper disposal.
6. Service & Maintenance 6.1 Lubrication System
Oil level should never be below
Min. mark.
Oil level should not exceed
Maximum mark.
+ 80
0
C
+ 176
0
F
OIL
OIL
MAX.
MIN.
49
6.1.3 Changing Oil Filter
Element - Spin On Type
6.1 Lubrication System 6. Service & Maintenance
* Remove the filter cartridge by rotating
it anticlockwise with commercial tool.
* Collect dripping oil in a tray.
* Destroy the removed cartridge.
* Clean sealing surface of filter carrier
rim.
* Apply light film of oil to rubber seal of
new cartridge.
* Assemble the new cartridge by
rotating it clockwise.
* Sealing gasket of cartridge be hand
tight.
* Tighten the oil filter cartridge with
another half - turn using commercial
tool.
* Check oil level, see 6.1.2
* Check oil pressure, see 3.3.1
* Check cartridge seal for leaks.
Beware of burns from hot oil.
50
6. Service & Maintenance 6.1 Lubrication System
6.1.4 Changing Oil Filter
Element - Paper Element
Type
* Unscrew the center bolt of bowl and
collect the oil in tray.
* Discard the removed element and
sealing ring.
* Clean the bowl with diesel.
* Lightly oil the new sealing ring.
* Assemble new filter element.
Assembly sequence - centre bolt,
copper washer, bowl, spring,
machined washer & element.
Machined face of washer
should be on upward side.
* Assemble the bowl and tighten centre
bolt firmly.
* Check oil level.
* Check oil pressure.
51
6.2 Fuel System 6. Service & Maintenance
6.2.1. Changing Fuel Filter -
Spin On Type
Keep naked flames away when
working on they fuel system. Do
not smoke.
* Remove the cartridge by rotating in
anticlockwise using commercial tool.
* Collect driping fuel in a tray.
* Destroy the removed cartridge.
* Clean the sealing surface of filter.
* Apply light film of oil or diesel fuel to
the rubber gasket of the new fuel filter
cartridge.
* Screw in the new cartridge finger tight
against the gasket.
* Tighten the fuel filter cartridge with a
final half turn using commercial tool.
* Open fuel stopcock.
* Check for leaks.
* Fuel system bleeding is not required
52
* Remove banjo bolt at inlet of feed
pump.
* Unscrew the strainer fitted inside the
banjo bolt.
* Clean the fuel strainer in fuel & blow it
with compressed air. Replace if
necessary.
* Refit the fuel strainer in banjo bolt.
* Refit the banjo bolt to feed pump with
new copper washer.
* Bleed the fuel system.
6. Service & Maintenance 6.2 Fuel System
6.2.2. Changing Fuel Filter - 6.2.3. Fuel Strainer
Element Type
* Close fuel valve
* Unscrew the plug at bottom of bowls
and collect the fuel in tray.
* Unscrew the center bolt of bowls and
remove bowls & fuel inserts.
* Clean the bowl with diesel.
* Change Pre-filter insert only. Do not
change Pre-filter insert & Micro filter
insert at a time.
* Discard the removed insert.
* Check the condition of sealing ring,
change if required.
* Assemble the bowls and tighten centre
bolts firmly.
* Bleed the fuel system before starting
engine.
* For changing Micro filter insert follow
the same procedure.
No naked flames when working
on the fuel system.
No smoking!
Do not clean fuel filter inserts.
Always replace the insert with
new one at recommended
intervals.
53
6.2.4 Lube Oil Filter & Fuel
Filter With Common
Filter Header
Lube oil filter & fuel filter (Spin On type)
with common filter header can be
supplied as an optional feature.
6.2 Fuel System 6. Service & Maintenance
Fuel Filter
Lube Oil Filter
54
6. Service & Maintenance 6.3 Cooling System
6.3.1. Cleaning Intervals
* The amount of contamination in the
cooling system depends on the
engine application.
* Oil or fuel leakages on the engine
increase the risk of contamination. Be
careful and avoid leakage when engine
is used in dusty envornment.
* Serious contamination can occur, for
example :
- on construction sites where there is
a high level of air - borne dust.
- in harvesting application where there
are high concentrations of chaff and
chopped straw in the vicinity of the
machine.
* Because applications vary, cleaning
intervals have to be determined from
case to case.
The cleaning intervals given in the
table on the right can be used as a
guide.
Inspection and
Clearing Intervals Engine application
Recommended
Operating Hours
2000 Ships, Gensets in enclosed areas, pumps
1000 Vehicles on reinforced highways
500 Tractors, fork-lift trucks, mobile electrical units.
250 Vehicles on construction sites and on roads with loose
surfaces, construction machinery, compressors, mining
equipments.
125 Agricultural machinery, tractor used for harvesting purpose.
55
6.4 Combustion Air Filter 6. Service & Maintenance
6.4.1. Cleaning Intervals 6.4.2 Cleaning Cyclone
Type Precleaner
* The soiling of air cleaner depends on
the dust in air, operating environment
and size of air cleaner used. Cyclone
type pre-cleaner is recommended in
dusty environment
* Cleaning intervals will have to be
determined from case to case.
* If dry-type air cleaners are used,it
should be cleaned only in accordance
with the service indicator.
* Air cleaner servicing is needed
when :The red signal is visible and
coincides with level indicated on the
service indicator.
* After completing the service work,
reset the signal by pressing the button
on the indicator.
* Remove the clamps of dust collector
bowl.
* Remove collector bowl & empty it.
* Clean cyclone type prefilter.
* Reposition collector bowl on air
cleaner & refitt the clamps.
* Replace collector bowl if damaged.
56
6. Service & Maintenance 6.4 Combustion Air Filter
6.4.3 Cleaning Oil Bath Air Cleaner
Never clean air cleaner with gasoline. Dispose off oil in accordance with
envornmental regulations!
* Stop the engine and wait for about 15
mins. for oil to drain from filter
housing.
* Remove the clamp and remove oil
bowl.
* Lift the filter element and remove it.
57
* If necessary clean the element by
compressed air, blowing air in
opposite direction of air flow.
* Clean the filter housing.
* Inspect the rubber gasket and replace
if necessary.
* Fill oil bowl with engine oil up to mark.
* Assemble filter element.
* Refit oil bowl and reassemble clamp
6.4 Combustion Air Filter 6. Service & Maintenance
6.4.3 Cleaning Oil Bath Air Cleaner
* Remove dirty oil and sludge from oil
bowl. Clean the bowl.
* Clean filter element in diesel fuel and
allow it to dip dry.
58
6. Service & Maintenance 6.4 Combustion Air Filter
6.4.4 Dry Type Air Cleaner
Dust Ejector valve. Filter Element Cleaning Filter Element
Never clean air cleaner with
gasoline.
* Loosen the mounting clamp of dust
cup / top cover assembly.
* Take out the element for cleaning.
* Use damp cloth to wipe out dust in
the air cleaner.
* Empty dust ejector valve by pressing
apart lips of discharge slot as
indicated.
* Clean discharge slot from time to time.
* Remove any caked dirt by pressing
together the upper section of the
valve.
* Inspect the dust ejector valve, replace
if necessary.
* Clean the element by dry compressed
air (air pressure 3 kg/cm
2
Max.) Blow
the air from inside to outside for
cleaning the element.
* Replace main element after two
cleaning intervals.
* Replace outer element atleast once in
a year.
59
6.4 Combustion Air Filter 6. Service & Maintenance
* Check cleaned/new element for
damage before installing.
* Conduct a light test by passing the
light through element as shown.
* If there is any crack in the element the
light will pass through it. In that case
replace the element.
* Check rubber sealing ring for
damage. Replace if necessary.
* Inner / safety element should be
replaced after every two changes of
outer element.
* Repeat same procedure as outer
element while replacing inner
element.
Never clean the inner element,
always replace it.
6.4.4 Dry Type Air Cleaner
Checking Element - Light Test Checking Sealing Ring Inner / Safety Element
60
6. Service & Maintenance 6.5. Belt Drives
6.5.1 Checking V-Belts 6.5.2 Checking Fan V- Belt
* To replace V-belts, press in tension
unit using a commercial tool and
remove the V-belts.
* Fit new V-belts.
Check tension and change belts
only when engine is at
standstill. Refit belt guard, if
provided.
When new V-belts are fitted, check the
belt tension after 15 minutes running
time.
- Push slowly on the black pad 4 at
right angles to belt 2 until the spring
is heard or felt to trigger.
- Carefully remove the gauge without
altering the position of the indicator
arm 1.
Read off the valve where the black
indicator arm 1 intersects scale 5
(arrow). For settings, see 9.1
- If necessary, retension belt and
measure again.
* Inspect entireV-belt for damage
* Replace damaged V-belts.
* After installing new, belts, run engine
for 15 minutes, then check belt tension.
* To check the tension of the V-belts,
use a tension gauge (see 9.3)
- Place indicator arm 1 into gauge
- Position gauge on V-belt 2, midway
between the pulleys, with flange 3
on bottom of gauge against the edge
of belt.
v
61
6.4 Combustion Air Filter 6. Service & Maintenance
6.5.3 Tensioning Alternator 6.5.4 Changing Alternator 6.5.5 Checking Warning
Belts Belts System.
* Loosen bolts which fix alternator on
mounting bracket. Also loosen bolts
of tension adjusting lever.
* Press alternator outwards until correct
belt tension is achieved.
* Retighten all bolts firmly.
* Remove fan V-belts as described in
6.5.2
* Loosen alternator mtg. bolts.
* Push alternator inwards
* Remove V-belt and place on new belt.
* Push alternator outwards until desired
belt tension is achieved.
* Retighten alternator mtg. bolts.
* Fit fan V-belts.
* If the V-belts fails, pressure pin of the
electrical switch is actuated by the
belt tension unit and an acoustic /
visible signal is initiated.
* Functional check, press pressure pin
to initiate visual / acoustic alarm.
Check/ tension/ replace V-belts
only when the engine is at a
standstill. If necessary replace
V-belt cover
Retighten new V-belts after 15 minutes
running time.
Carry out a check only when
the engine is at a standstill.
62
6. Service & Maintenance 6.6 Adjustments
6.6.1 Checking Valve 6.6.2 Adjusting Valve
Clearance Clearance
* Check valve clearance when engine is
at ambient temperature.
* Remove the rocker cover.
* Turn crankshaft until the valves of
cylinder (on wich clearance is being
checked) are overlapping
* Then turn the engine by 360 degree
* Check valve clearance between rocker
arm toe and valve stem with feeler
gauge.
Feeler gauge of 0.15mm should pass
with slight resistance. Failing this,
adjust valve clearance. Refer 6.6.2
For permissible valve clearance, see
9.1
* Loosen lock nut of adjusting screw.
* Use screw driver to loosen setscrew
so that feeler gauge of 0.15mm can
be inserted and removed with slight
resistance Tighten the lock nut.
* Check and adjust valve clearance on
all remaining cylinders.
* Reassemble rocker cover. (use new
gasket if needed).
VALVE
PUSH
ROD
63
6.7 Accessories 6. Service & Maintenance
6.7.1.1 Checking Battery 6.7.1.2 Checking Electrolyte 6.7.1.3 Checking Electrolyte
& Cable Connectors Level Density
* Keep the battery clean and dry.
* Ensure the cable terminals tightly fitted
on the battery posts.
* Secure the battery firmly on the cradle.
Ensure battery earth. Use rubber or
wooden strip between battery & cradle.
* Clean the terminals (+ve and -ve) and
clamps with ammonia solution Ratio
115 gms of ammonia for 1 litre of
water.
* Apply petroleum jelly / vaseline on
terminals & posts. Never apply grease.
* Ensure good contacts of terminals
* Remove cell caps 1.
* Top up only with distilled water &
maintained the level corresponding
to the maximum level, never add
Acid.
* Keep vent plugs tightly closed.
* Ensure battery vent holes are open.
Choked vent holes could lead to
bursting of the battery.
* Check the specific gravity of
individual cell with hydrometer. If
battery has been topped up with
distilled water, check specific gravity
after 5 minutes of top up.
* The measured values indicate state
of charge of battery.
* Charge the battery if necessary.
* Avoid measuring specific gravity
when battery is warm.
64
6. Service & Maintenance 6.7 Accessories
Specific Gravity (kg/1) State of Charge
Normal Tropics
1.28 1.23 Fully charged
1.20 1.12 Half charged, Recharge
1.12 1.08 Discharged, Charge up immediately.
The gases emitted by the battery are explosive!
Keep spark and naked flames away from the battery.
Do not allow battery acid to come into contact with skin or clothing. Wear
protective goggles.
Do not rest tools on the battery.
65
6.7.2 Lifting Tackle
6.7 Accessories 6. Service & Maintenance
* Always use proper lifting tackle when
transporting and lifting the engine.
* After transportation / lifting engine,
remove lifting tackle before starting
the engine.
Use only the correct lifting
tackle
66
6. Service & Maintenance 6.8 Engine Cleaning
6.8.1 Cleaning the engine
With Compressed Air With Cold Cleaning Agent With High Pressure Steam Jet
* Stop the engine.
* Release the cowling clamps and
remove cowling. Remove baffle on
exhaust side.
* Cover electrical / electronic
components. ( Starter, alternator, stop
solenoid etc.)
* Cover inlet & exhaust ports.
* Spray the engine with cold cleaning
agent and allow it to soak for 10 mins.
* Clean the engine with pressurized
water jet. Repeat the process if
necessary
* Blow the engine with compressed air
to remove water.
* Stop the engine.
* Release the cowling clamps and
remove cowling. Remove baffle on
exhaust side.
* Cover electrical / electronic
components. ( Starter, alternator, stop
solenoid etc.)
* Cover inlet & exhaust ports .
* Clean the engine with steam jet.
(Steam pressure - 60 bar and
temperature 90 deg.C)
* Stop the engine.
* Release the cowling clamps and
remove cowling. Remove baffle on
exhaust side.
* Cover electrical / electronic
components. ( Starter, alternator, stop
solenoid etc.)
* Blow the compressed air through the
engine starting from exhaust side. Be
careful with cooling fins and cooler.
* Remove dirt blown inside engine
compartment.
* Reassemble the cowling.
67
6.9 Additional Maintenance 6. Service & Maintenance
6.9.1 Checking the 6.9.2 Checking the function
mountings of Flame Heater
Check following components for
fasteners tightness.
* Rocker cover
* Air-inlet manifold
* Coupling
* Exhaust manifold
* Engine mountings
* When functioning correctly, inlet
manifold heats up in the vicinity of
flame heater when starting with
preheating.
* Move speed adjustment lever and
shut- off lever to stop position.
* Insert key
- Position OFF = no operating voltage
* Turn key clockwise.
- Position ON = operating voltage
- Charge lamp comes on.
* Press push button and hold for approx.
60 sec. Glow plug indicator comes
on
* Otherwise flame glow plug defective
or power interrupted.
4 2 1
3
ON
START
OFF
P.B.
Push button for
cold starting
Charge Lamp
68
6. Service & Maintenance 6.9 Additional Maintenance
Test stage 2:
* Loosen pipe connection 1.
* Rotate engine with starter, key switch
in START position.
* Fuel must be emitted at loosened pipe
connection. Otherwise have the
system, solenoid 3, checked by a
specialist.
Test stage 3:
* Loosen pipe connection 1.
* Remove flame glow plug 2 and
reconnect pipe.
* Rotate engine with starter, key switch
in START position.
* Fuel must be emitted at flame glow
plug 2, replace plug 2 if necessary.
6.9.2 Checking the function
of Flame Heater
* Use heat resistant sealant when fitting
flame glow plug 2.
* Refit flame glow plug 2 on fuel line.
Keep away from rotating parts.
4 2 1
3
4 2 1
3
Collect any leaked fuel and
dispose off in an envornmentlly
friendly fashion
69
7.1 Diagnosis Chart
7. Faults, Causes & Remedies
70

D
u
s
t

e
n
t
r
y

i
n

a
i
r

i
n
l
e
t

s
y
s
t
e
m

D
i
r
t
y

/

c
l
o
g
g
e
d

a
i
r

c
l
e
a
n
e
r

H
i
g
h

e
x
h
a
u
s
t

b
a
c
k

p
r
e
s
s
u
r
e

D
e
r
a
t
i
n
g

d
u
e

t
o

a
l
t
i
t
u
d
e

D
e
r
a
t
i
n
g

d
u
e

t
o

t
e
m
p
e
r
a
t
u
r
e

N
o

f
u
e
l

P
o
o
r

q
u
a
l
i
t
y

o
f

f
u
e
l

A
i
r

i
n

f
u
e
l

l
i
n
e

C
h
o
k
e
d

f
u
e
l

l
i
n
e

E
x
t
e
r
n
a
l

/

I
n
t
e
r
n
a
l

f
u
e
l

l
e
a
k
a
g
e

C
h
o
k
e
d

f
u
e
l

i
n
j
e
c
t
o
r

h
o
l
e
s

D
a
m
a
g
e
d

o
r

d
r
i
b
b
l
i
n
g

n
o
z
z
l
e

L
o
o
s
e

H
P
.

p
i
p
e

c
o
n
n
e
c
t
i
o
n
s

D
i
r
t
y

/

C
h
o
k
e
d

f
u
e
l

f
i
l
t
e
r

C
o
n
t
r
o
l

l
e
v
e
r

s
e
t
t
i
n
g
s

w
r
o
n
g

F
a
u
l
t
y

f
u
e
l

p
u
m
p

W
a
t
e
r

m
i
x
e
d

w
i
t
h

f
u
e
l

W
r
o
n
g

g
r
a
d
e

o
f

l
u
b
e

o
i
l

u
s
e
d

D
i
r
t
y

/

C
h
o
k
e
d

s
u
c
t
i
o
n

t
u
b
e

s
t
r
a
i
n
e
r

O
i
l

c
o
o
l
e
r

c
h
o
k
e
d

L
u
b
e

o
i
l

d
i
l
u
t
i
o
n

D
i
r
t
y

/

C
l
o
g
g
e
d

l
u
b
e

o
i
l

f
i
l
t
e
r

C
l
o
g
g
e
d

o
i
l

p
a
s
s
a
g
e

E
x
c
e
s
s
i
v
e

o
i
l

i
n

t
h
e

s
u
m
p

E
x
t
e
r
n
a
l

/

I
n
t
e
r
n
a
l

l
e
a
k
a
g
e
s

F
a
u
l
t
y

o
i
l

p
u
m
p

D
i
r
t
y

a
i
r

c
o
o
l
i
n
g

f
i
n
s

L
o
o
s
e

f
a
n

b
e
l
t

A
i
r

l
e
a
k
a
g
e
s

t
h
r
o
u
g
h

c
o
w
l
i
n
g

E
n
g
i
n
e

o
v
e
r
l
o
a
d
i
n
g

E
n
g
i
n
e

u
s
e
d

a
f
t
e
r

a

l
o
n
g

t
i
m
e

W
r
o
n
g
l
y

a
d
j
u
s
t
e
d

v
a
l
v
e

c
l
e
a
r
a
n
c
e
s

P
r
o
l
o
n
g
e
d

o
i
l

c
h
a
n
g
e

p
e
r
i
o
d

B
l
o
w
n

c
y
l
i
n
d
e
r

h
e
a
d

g
a
s
k
e
t

V
a
l
v
e

l
e
a
k
a
g
e
s

T
.
C
.

c
o
m
p
r
e
s
s
o
r

s
e
a
l

l
e
a
k
i
n
g

T
.
C
.

t
u
r
b
i
n
e

s
i
d
e

s
e
a
l

l
e
a
k
i
n
g

B
r
o
k
e
n

/

w
o
r
n

o
u
t

p
i
s
t
o
n

r
i
n
g
s

E
x
c
e
s
s
i
v
e

e
n
d

p
l
a
y

i
n

c
r
a
n
k
s
h
a
f
t

W
o
r
n

o
u
t

c
y
l
i
n
d
e
r

l
i
n
e
r

&

p
i
s
t
o
n

I
n
c
o
r
r
e
c
t

b
e
a
r
i
n
g

c
l
e
a
r
a
n
c
e
s

D
a
m
a
g
e
d

m
a
i
n

&

c
o
n
n
e
c
t
i
n
g

r
o
d

b
r
g
s
.

W
o
r
n

o
u
t

v
a
l
v
e
s

&

v
a
l
v
e

g
u
i
d
e
s

I
n
c
o
r
r
e
c
t

v
a
l
v
e

&

f
u
e
l

t
i
m
i
n
g

I
n
j
e
c
t
o
r

n
e
e
d
s

a
d
j
u
s
t
m
e
n
t

E
n
g
i
n
e

s
e
i
z
e
d

F
a
u
l
t
y

g
o
v
e
r
n
o
r

s
e
t
t
i
n
g

O
n
e

o
r

m
o
r
e

c
y
l
i
n
d
e
r
s

n
o
t

w
o
r
k
i
n
g

L
o
o
s
e

m
o
u
n
t
i
n
g

b
o
l
t
s

L
o
o
s
e

f
l
y
w
h
e
e
l

/

w
r
o
n
g

a
l
i
g
n
m
e
n
t

E
n
g
i
n
e

n
e
e
d
s

o
v
e
r
h
a
u
l
i
n
g

F
u
e
l

p
u
m
p

r
a
c
k

s
t
u
c
k

i
n

s
t
o
p

p
o
s
i
t
i
o
n

B
a
t
t
e
r
y

r
u
n

d
o
w
n

/

u
n
d
e
r

r
a
t
e
d

b
a
t
t
e
r
y

F
a
u
l
t
y

s
t
a
r
t
e
r

B
a
t
t
e
r
y

o
f

w
r
o
n
g

c
a
p
a
c
i
t
y
7.1 Diagnosis Chart 7. Faults, Causes & Remedies
Air / Exhaust Fuel System Lubricating System Cooling Maintenance Mechanical System Electrical
System System Operation System
Engine will not start
Engine fails to rotate
Engine has starting difficulty
Engine starts but stops after some time
Engine lacks power
Engine misfires during operation
Engine speed does not remain constant
Engine does not reach governed speed
Excessive smoke at no load
Excessive smoke at full load
Engine overheat
Engine gives out blue smoke
Engine gives out white smoke
Excessive fuel consumption
Mixing of diesel with lube oil
Excessive oil consumption
Low lube oil pressure
Bearing wear
Excessive liner & piston ring wear
Excessive valve & valve guide wear
Breaking of valve springs
Diesel knock
Mechanical knock
Excessive vibration
Engine rotates very slowly during starting
Battery runs down frequently
Excessive fuel injection equipment wear
73
8.1 Preservation
8. Engine Preservation
74
75
8.1 Preservation 8. Engine Preservation
8.1 Preservation 8.1.1 Preserving Engine
If the engine is to remain idle for an
extended period of time, it is necessary
to take protective measures to prevent rust
formation. The preservative measures
described here will protect the engine
upto 12 months..
Recommended Preservatives For :
Lube and Fuel system
Indian Oil Corp. Servo Preserve 30
Bharat Petroleum Bharat Preserve
Oil 30
Hindustan Petroleum Autoprun T120
Veedol Tide Oil Co. Veedol 30/40
* Clean the engine preferably using
thinner and compresed air.
* Run the engine until warm and stop.
* Drain the lube oil.
* Fill the engine with preservative oil.
* Clean the oil bath air cleaner, fill oil
bowl with preservative oil.
* Drain the fuel tank.
* Prepare mixture of Diesel +
Preservative, ratio 5 :1. Refill the fuel
tank with mixture.
* Run the engine for 5 mins. at low
speed / fix speed engine at No Load.
* Stop the engine.
* Turn the engine manually several times
to preserve the cylinders and
combustion chamber. While rotating
with starter, stop lever of fuel pump to
be in stop condition.
* Drain the preservative oil from engine
* Drain the Diesel + Preservative oil
from fuel tank.
* Remove the V-belts
* External unpainted surfaces to be
treated with rust preventive oil .
* Plug all the openings, vents of the
engine.
* Disconnect the battery & store it in a
safe place.
* Cover the engine with polythene bag
if possible.
* Procedure to be repeated if engine is
to be stored for more than 12 months.
External Surfaces
Indian Oil Corp. Servo RP 125
Bharat Petroleum Bharat Rustrol 152
Hindustan Petroleum Rustop 274
Veedol Tide Oil Co. Veedol Ruspro IT
Castrol India Rustilo DW-904
or DW-901
Recommanded cleansing agent to
remove preservatives when
recommissioning engine : - NC Thinner
76
8. Engine Preservation 8.1 Preservation
8.1.2 Commissioning
Preserved Engine
* Remove plugs, tapes from inlet port,
exhaust port and vent
* Remove the rust preventive coating
from all external surfaces.
* Install V- belts.Retension belts after brief
operation if required.
* Set the engine in operation. Refer 3.1
77
9.1 Engine Specifications
9.2 Power Output
9.3 Torque Wrench Setting
9. Technical Specifications
78
79
9.1.1 CPCB / CMVR Compliant
9.1 Engine Specifications 9.Technical Specifications
* These engines are not CMVR compliant
Sr No. Specification Unit HA294 HA394 HA494 HA694 *HA494TC *HA694TC
1 Number of cylinders 2 3 4 6 4 6
2 Cylinder arrangement Vertical in line
3 Bore mm 100 100 100 100 100 100
4 Stroke mm 120 120 120 120 120 120
5 Total displacement cc 1885 2827 3770 5655 3770 5655
6 Compression ratio 18:1 18:1 18:1 18:1 17:1 17:1
7 Working cycle 4 - Stroke diesel engine
8 Combustion system Direct Injection
9 Direction of rotation Counter Clockwise looking from FWE
10 Starting arrangement Electric Start
11 Firing order 1-2 1-3-2 1-3-4-2 1-5-3-6-2-4 1-3-4-2 1-5-3-6-2-4
12 Power Refer 9.2.1 / 9.2.2
13 Speed Refer 9.2.1 / 9.2.2
14 Lubrication Force feed G rotor pump
15 SAE oil K - Oil Super (SAE 15W40)
16 Lube oil temperature deg. C 90-125 90-125 90-125 90-125 90-125 90-125
17 Min. oil pressure - At idle kg/cm
2
1.5
- At rated speed kg/cm
2
3.0 to 4.5
18 Sump capacity - w/o Lube filter Litre 4.5 8 11 13.5 11 13.5
19 Sump + Lube filter Litre 5.5 9 12.5 15.5 12.5 15.5
20 Valve clearance in cold condition mm 0.15
21 Injector opening pressure kg/cm
2
260 10
22 Fuel Timing : 1500 - 1800 rpm deg. 9 9 9 9 10 10
2300 - 2500 rpm deg. 14 14 14 16 ---- ----
23 Bumping clearance mm 0.9 to 1.1
24 Dry Weight of engine kg 326 370 421 477 440 495
80
9. Technical Specifications 9.1 Engine Specifications
9.1.2 Non Emission
Sr No. Specification Unit HA294 HA394 HA494 HA594 HA694 HA494TC HA694TC
1 Number of cylinders 2 3 4 5 6 4 6
2 Cylinder arrangement Vertical in line
3 Bore mm 100 100 100 100 100 100 100
4 Stroke mm 120 120 120 120 120 120 120
5 Total displacement cc 1885 2827 3770 4712 5655 3770 5655
6 Compression ratio 17:1 17:1 17:1 17:1 17:1 15.5:1 15.5:1
7 Working cycle 4 - Stroke diesel engine
8 Combustion system Direct Injection
9 Direction of rotation Counter Clockwise looking from FWE
10 Starting arrangement Electric Start
11 Firing order 1-2 1-3-2 1-3-4-2 1-2-4-5-3 1-5-3-6-2-4 1-3-4-2 1-5-3-6-2-4
12 Power Refer 9.2.3
13 Speed Refer 9.2.3
14 Lubrication Force feed G rotor pump
15 SAE oil K - Oil Super (SAE 15W40)
16 Lube oil temperature deg. C 90-125 90-125 90-125 90-125 90-125 90-125 90-125
17 Min. oil pressure- At idle kg/cm
2
0.5 to 1.0
- At rated speed kg/cm
2
3.0 to 4.5
18 Sump capacity - w/o Lube filter Litre 4.5 8 11 12.5 13.5 11 13.5
19 Sump + Lube filter Litre 5.5 9 12.5 14 15.5 12.5 15.5
20 Valve clearance in cold condition mm 0.15
21 Injector opening pressure kg/cm
2
180 175 + 5
22 Fuel Timing : 1500 rpm deg. 29 26 26 26 29 28 24
1800 rpm deg. 29 26 26 26 29 32 30
1801 - 2300 rpm deg. 32 30 30 30 32 34
2301 - 2500 rpm deg. 32 32 32 32 35 35
23 Bumping clearance mm 1.0 to 1.2
24 Dry Weight of engine kg 326 370 421 450 477 440 495
81
9.2 Power Output 9.Technical Specifications
9.2.1 CPCB Compliant
ENGINE SPEED Continuous Power as per
MODEL rpm ISO 3046
RATING
kw bhp
HA294
1500 14.0 19.0
1500 15.0 20.5
HA394 1500 23.5 32.0
HA494 1500 31.6 43.0
HA694 1500 47.5 65.0
HA494TC 1500 41.0 56.0
HA694TC 1500 61.0 83.0
82
9. Technical Specifications 9.2 Power Output
9.2.2 CMVR Compliant
ENGINE SPED AS PER IS : 10002 / ISO 3046 / SEA J 1995
MODEL rpm
ISO STD POWER ISO NET BREAK FUEL STOP
(CONTINUOUS) POWER (MAX. RATING)
HEAVY DUTY LIGHT DUTY
RATING TORQUE RATING TORQUE RATING TORQUE
kw bhp kNm kgm bhp kgm bhp kgm
*2300 20.2 27.5 0.084 8.55 ----- ----- ----- -----
HA294
2150 19.5 26.5 0.086 8.85 ----- ----- ----- -----
2000 18.4 25.0 0.087 8.95 ----- ----- ----- -----
1800 16.9 23.0 0.09 9.15 ----- ----- ----- -----
*2300 34.6 47.0 0.143 14.6 ----- ----- ----- -----
HA394
2150 32.4 44.0 0.143 14.6 ----- ----- ----- -----
2000 30.2 41.0 0.144 14.7 ----- ----- ----- -----
1800 28.0 38.0 0.148 15.10 ----- ----- ----- -----
*2500 ----- ----- 70.0 20.1 ----- -----
2300 ----- ----- 66.0 20.56 ----- -----
HA494 2150 ----- ----- 63.0 21.0 ----- -----
2000 ----- ----- 60.0 21.5 ----- -----
1500 ----- ----- 54.0 21.5 ----- -----
*2500 ----- ----- ---- ----- 110.0 32.1
*2300 ----- ----- ---- ----- 106.0 33.0
HA694 2150 ----- ----- ---- ----- 100.0 33.3
2000 ----- ----- ---- ----- 95.0 34.0
1800 ----- ----- ---- ----- 87.0 34.6
* Compliant for CMVR, other ratings as per torque curve of family engines.
83
9.2 Power Output 9.Technical Specifications
9.2.3 Non Emmission
ENGINE SPED AS PER IS : 10002 / ISO 3046 / SEA J 1995
MODEL rpm
ISO STD POWER ISO NET BREAK FUEL STOP
(CONTINUOUS) POWER (MAX. RATING)
HEAVY DUTY LIGHT DUTY
RATING TORQUE RATING TORQUE RATING TORQUE
kw bhp kNm kgm bhp kgm bhp kgm
1500 14.0 19.0 0.089 9.10 20.0 9.55 21.0 10.00
1800 16.9 23.0 0.090 9.15 24.5 9.75 25.5 10.15
HA294
2000 18.4 25.0 0.087 8.95 26.5 9.50 28.0 10.00
2150 19.5 26.5 0.086 8.85 28.0 9.35 29.5 9.85
2300 20.2 27.5 0.084 8.55 29.0 9.00 30.5 9.50
2500 - - - - 30.5 8.70 32.0 9.20
1500 23.6 32.0 0.150 15.30 34.0 16.25 36.0 17.20
1800 28.0 38.0 0.148 15.10 40.0 15.90 42.0 16.70
HA394
2000 30.2 41.0 0.144 14.70 44.0 15.75 46.0 16.50
2150 32.4 44.0 0.143 14.60 47.0 15.65 49.0 16.30
2300 34.6 47.0 0.143 14.60 49.0 15.25 51.0 15.90
2500 - - - - 52.0 14.90 54.0 15.50
1500 31.5 43.0 0.201 20.5 46.0 22.00 48.0 22.90
1800 38.2 52.0 0.203 20.7 54.0 21.50 58.0 23.00
HA494
2000 41.2 56.0 0.196 20.0 60.0 21.50 63.0 22.50
2150 44.2 60.0 0.196 20.0 63.0 21.00 67.0 22.30
2300 46.4 63.0 0.192 19.6 66.0 20.56 70.0 21.80
2500 51.5 70.0 - - 70.0 20.10 74.0 21.20
84
9. Technical Specifications 9.2 Power Output
9.2.3 Non Emmission (Continued)
ENGINE SPED AS PER IS : 10002 / ISO 3046 / SEA J 1995
MODEL rpm
ISO STD POWER ISO NET BREAK FUEL STOP
(CONTINUOUS) POWER (MAX. RATING)
HEAVY DUTY LIGHT DUTY
RATING TORQUE RATING TORQUE RATING TORQUE
kw bhp kNm kgm bhp kgm bhp kgm
HA594 2300 57.4 78.0 - - - - - -
1500 47.8 65.0 0.304 31.0 69.0 32.9 73.0 34.8
1800 57.4 78.0 0.304 31.0 82.0 32.6 87.0 34.6
HA694
2000 62.6 85.0 0.298 30.4 90.0 32.2 95.0 34.0
2150 66.2 90.0 0.294 30.0 95.0 31.6 100.0 33.3
2300 69.9 95.0 0.290 29.6 100.0 31.15 106.0 33.0
2500 - - - - 106.0 30.4 110.0 32.1
1500 41.0 56.0 - - - - - -
HA494TC 1800 48.0 65.0 - - - - - -
2000 51.5 70.0 - - - - - -
1500 61.0 83.0 0.387 39.5 88.0 41.9 93.0 44.3
1800 72.0 98.0 0.380 38.8 103.0 40.8 109.0 43.2
HA694TC
2000 76.0 103.0 0.365 37.2 108.0 39.0 114.0 41.6
2150 78.0 106.0 0.352 35.9 112.0 37.7 119.0 40.0
2300 81.0 110.0 0.340 34.7 116.0 36.3 123.0 38.6
2500 84.5 115.0 0.324 33.0 121.0 34.7 128.0 36.7
85
1. Total angle torque 165 degree for cylinder head with steel gasket.
2. During replacement of piston, piston rings & bearings it is recommended to change
main bearing cap bolts, connecting rod cap bolts & cylinder head bolts.
9.3 Torque Wrench Setting 9. Technical Specifications
DECRIPTION SIZE INITIAL TIGHTENING ANGLE IN DEGREE TOTAL REMARK
TORQUE 1st 2nd 3rd 4th ANGLE
Nm (kgm) STAGE STAGE STAGE STAGE
Cylinder Head Bolt M12x1.75x211 30 (3.1) 45 45 45 30 165 See foot Note 1
Connecting Rod Bolt M12x1.5x55 30 (3.1) 60 30 ---- ---- 90
Bearing Cap Bolt M14x110 30 (3.1) 60 45 ---- ---- 105 See foot Note 2
Intermediate Gear Bolt M10x60 30 (3.1) 60 ---- ---- ---- 60
Balance Weight Bolt M12x60 30 (3.1) 30 30 ---- ---- 60
Crank Pulley M24x2x110 50 (5.1) 210 ---- ---- ---- 210 Left Hand Theads
Cooling Blower Bolt M12x140 30 (3.1) ---- ---- ---- ---- 90
(HA294/394/494)
Cooling Blower Bolt M12x180 30 (3.1) ---- ---- ---- ---- 90
(HA694)
Flywheel Bolt M10x1x35/ 30 (3.1) 30 60 ---- ---- 90
40/45/50
Fuel Injector Nut M10x1.5 ---- ---- ---- ---- ---- ---- ---- 25-30Nm
(2.5-3.1kgm)
86