INDEX

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
 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
1
2
 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
3
 through stoppages or any consequential damages.
Warranty for rubber parts like AVM’s, 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.
4
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.
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.

5
6
 2. Engine Description

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

7
8
 2.1 Model 2. Engine Description

2.1.1. Rating plate 2.1.2. Rating Plate Location.

For Genset For Industrial

ENGINE TYPE ENGINE TYPE

RATING kW/hp rpm RATING kW/hp rpm

RATING STD. RATING STD.

DATE OF MFG. GOVERNING CLASS

Sr No. ENGINE No.

KIRLOSKAR OIL ENGINES LTD

INDIA
KIRLOSKAR OIL ENGINES LTD. INDIA

The engine model and engine serial no. are stamped on nameplate along with engine The nameplate is fixed on engine
rating, rpm and referred standard. The nameplate details must be given while ordering crankcase as shown.
spares and asking for service.

9
 2. Engine Description 2.1 Model

2.1.3. Cylinder Numbering. 2.1.4. Direct Injection

1 2 3 4 5 6

Cylinder are numbered consecutively, Engines are with direct fuel injection to
beginning at the flywheel end. meet high performance and pollution
regulations

10
2.2 Engine Illustration 2. Engine Description

2.2.1. Service Side.

HA694 NA

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

11
 2. Engine Description 2.2 Engine Illustration

2.2.2. Exhaust Side.

HA694 NA
15. Charging Alternator
16. Starter
17. Crankcase
18. Crankcase Breather
19. Flywheel
20. Rocker Cover
21. Air Intake Manifold
22. Exhaust Manifold

12
2.2 Engine Illustration 2. Engine Description

2.2.3. Service Side.

HA694 TC

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

13
 2. Engine Description 2.2 Engine Illustration

2.2.4. Exhaust Side.

HA694 TC
15. Exhaust manifold
16. Charging Alternator
17. Starter
18. Crankcase
19. Crankcase Breather
20. Flywheel Housing
21. Flywheel
22. Turbocharger
23. Air Intake Manifold

14
2.3 Lube Oil System 2. Engine Description

2.3.1. HA694 NA

1 Lube Oil Sump

21 20 2 Suction Pipe
16 15
3 Lube Oil Pump
4 Pressure Relief Valve
17
6 5 Delivery Pipe
14
6 Lube Oil Cooler
7 Lube Oil Filter
13 8 Relief Valve (not shown)
18 9 Oil Gallery
10 Main Bearing
5
11 Large End Bearing
12 Camshaft Bearing
13 Tappet with groove for pulse fed
4 rocker arm lubrication.

3
19
7 9 1 12 2
8 11 10
22

15
 2. Engine Description 2.3 Lube Oil System

2.3.1. HA694 NA

14 Push Rod

21 20 15 Rocker Arm Bearing

16 15
16 Metering Plug
17 Push Rod Cover Tube
17
6 18 Restrictor ( for lubrication of gears)
14
19 Spray Nozzle for Piston Cooling
20 Connection for Pressure Gauge
13 21 Oil Pressure Gauge
18 22 Fuel Pump Connected to Lube Oil
Circuit

3
19
7 9 1 12 2
8 11 10
22

16
2.3 Lube Oil System 2. Engine Description

2.3.2. HA694 TC

1 Oil Sump
2 Suction Pipe
6 21 17 16
7 3 Oil Pump
18
4 Pressure Valve
15
5 Delivery Pipe
23 6 Pipe to Oil Cooler
7 Oil cooler plate type
8 Lube Oil Filter
22
9 Safety Valve
14
10 Oil Gallery
19
11 Main Bearing
5
8 12 Big-End Bearing

3 13 Camshaft Bearing
9

13

2
24 11
10 20 1 12

17
 2. Engine Description 2.3 Lube Oil System

2.3.2. HA694 TC

14 Tappet with groove for pulse fed

rocker arm lubrication
6 21 17 16 15 Push Rod
7
18
16 Rocker Arm Bearing
15 17 Metering Plug
18 Push Rod and Cover Tube
23
19 Restrictor Hole
20 Nozzle for Piston Cooling
22 21 Oil Pipe to Turbocharger
14 22 Oil return Pipe
19 23 Oil Pressure Gauge

5
8
3
9

13

2
24 11
10 20 1 12

18
2.4 Fuel System 2. Engine Description

2.4.1. Fuel System

1. Fuel tank
2. Fuel pipe - tank to fuel pump
3. Fuel feed pump
8 7
4. Fuel filter
6 5. Injection pump
9
6. Fuel injection pipe
11
5 7. Fuel Injector
4 8. Leak-off pipe

2 9. Fuel overflow line

10. Overflow valve
1
11. Fuel return line to tank
A. Clearance; keep as far apart as
possible. (Min. 200mm)

10
3

19
 2. Engine Description 2.5 Engine Cooling System

2.5.1. Cooling Air Flow

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
FRESH AIR IN

unit.
Air flow from the blower is directed on
the liners and cylinder heads by
detachable sheet metal lower & upper
cowlings.

HOT AIR OUT

20
 2.6 Air Inlet System 2. Engine Description

2.6.1 Air Inlet System

Fresh air from

atmosphere Cleane air to
engine Wire clamps
Pre-cleaner
Insert for Air inlet
Housing
restiction Cover
indicator
mounting

Second
stage
Filtered
Dust air to
bowl engine

Dust First
stage PU
accumulated
element
in dust bowl Safety support Mounting
Strap Safety Vaccuator
tube
element Valve
Wire-mesh
Lube oil element

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. 21
 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” The figure above shows HA694 Engine The figure above shows HA394 Engine
after every 5 meter length of exhaust pipe. with exhaust outlet facing downwards. with exhaust manifold cum silencer.
Expansion bellows & flexible pipes should Exhaust silencer is mounted separately on
be installed between engine & exhaust the equipment & connected to exhaust
piping. manifold by flexible 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 450.
There shold be rain trap to avoid rain water
entry. If rain cap is used the distance
between exhaust pipe & rain cap should
22 be 2.5 times diameter of exhaust pipe.
 3. Engine Operation

3.1 Commissioning
3.2 Starting
3.3 Monitoring System
3.4 Stopping
3.5 Operating Conditions

23
24
3.1 Commissioning
3.1.1 Adding Engine Oil
Engines are delivered with first fill oil.
3. Engine Operation
3.1.2 Filling Oil Bath Air
Cleaner
Oil Level
Fill oil bowl of oil bath air cleaner with
engine oil up to the mark. For oil specs.
Refer 4.1
Do not fill oil into the dust
collector of the pre - cleaner, if
provided.
3.1.3 Adding Fuel
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.
25
 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 The following maintenance should be

Also check cable connection at the carried out after 50 operating hours;
starter and alternator end for tightness.
* Change lube oil see 6.1.2
* Remove engine lifting tackle.
* Change oil filter element /cartridge, see
* Trial run
6.1.3
After completing the engine
* Change fuel filter element / cartridge.
preparations run the engine for about
See 6.2.1
10-15 min. at no load. While engine is
running check lube oil pressure (3.5 to * Check V-belts and retension if
4.5 kg/cm 2 ), lube oil temperature. necessary, see 6.5
(Within green zone) * Check the engine for any leakages.
During and after trial run
- Check for any leakages.
* After trial run and engine stationary
* Loosen overflow valve 1 on the fuel - Check oil level, refer 6.1.2
pump. if required top up oil, refer 3.1.1
* Loosen hand pump 2 of the fuel feed Retension V-belts, refer 6.5
pump at the knurled grip by
* Running in
unscrewing it.
During running in period- about 50
* Operate the hand pump till fuel flow
running hours, check oil level twice a
without air bubble at overflow valve.
day After running in, checking oil level
* Tighten the overflow valve while fuel once a day will be sufficient.
is flowing simultaneously operating
the hand pump
* Tighten the hand pump at knurled grip

26
3.2 Starting 3. Engine Operation

3.2.1 Electric Starting Starting Without Cold-Start

Aid

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)
Stopping
Lever
Accelerating
Lever
* 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.
OFF ON
SRART
Charge Lamp
* 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)

27
 3. Engine Operation 3.2 Starting

With Cold-Start Aid/Flame With Cold-Start Aid/Flame

Glow Plug - 12V Glow Plug - 24V

Push button for Push button for

cold starting ON cold starting ON
OFF OFF
P.B. START P.B. START

Charge Lamp Charge Lamp

* Insert key. * 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.
28 - Charge Lamp goes out.
- 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.
3.3 Monitoring System
3.3.1 Engine Lube Oil Pressure
Lube Oil Pressure Gauge
The pointer indicates the lube oil pressure
of engine. It must be above minimum lube
oil pressure. Refer 9.1
3. Engine Operation
3.3.2 Engine Oil Temperature
Lube Oil Temp. Indicator
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.
3.3.3 Belt Failure Switch For
HA394/494/694 &
HA494TC/694TC
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.
29
 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 If the V - Belt fails, lever (1) of automatic
point 175 ± 50 C) protects the engine in belt tension operates the lever (2), which
case of belt failure. in turn operates stopping lever of the fuel
pump. Thus the engine is stopped.

30
3.4 Stopping System 3. Engine Operation

3.4.1 Manual Shutdown 3.4.2 Electrical Shutdown

Ignition Key

Push button for

cold starting ON
OFF
P.B. START

Stop
Solenoid
Stopping
Lever Charge Lamp

* 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.

31
 3. Engine Operation 3.5 Operating Conditions

3.5.1 Winter Operation

* Lube Oil Viscosity * Cold- Start Aid

- Select the oil viscosity (SAE grade) - At temperatures near or below
according to the ambient freezing point use flame glow plugs
temperature when the engine is if necessary, see 3.2.1
started, see 4.1.2
- Increase oil change frequency when
operating below -10°C, see 6.1.1
* Diesel Fuel
- Use winter- grade diesel fuel
operation below 0°C, see 4.2.2
* Additional Maintenance Work
- Drain the sludge from the fuel tank
once a week. (Unscrew the drain
plug.)
* Battery.
- If necessary, allow the oil in the oil
bath air cleaner and the engine oil to - Efficient cold starting requires a
settle at the ambient temperature healthy battery, see 6.7.1
while checking oil level. - The starting limit temperatures can
- Below -20°C after removing the starter be lowered by 4-5°C by heating the
if necessary, smear the ring gear on battery up to about +20°C (to do so,
the flywheel via the pinion bore from remove the battery and store in a
time to time with cold resistant grease. warm place.)

32
3.5 Operating Conditions 3. Engine Operation

3.5.2 High Ambient Tempera-

tures, High Altitude

* 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.

* 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.

33
34
 4. Operating Media

4.1 Lube Oil

4.2 Fuel

35
with
nt

36
4.1 Lube Oil 4. Operating Media
4.1.1 Quality Grade 4.1.2 Viscosity

Lube oil of correct viscosity and Multi-grade oil should be used.

detergency grades should be used It is As the viscosity of lube oil is dependent
recommended to use ‘K Oil Super’ on temperature. the choice of SAE grade
( SAE15W40 ). For detergency it should should be governed by the ambient
comply with following specifications:- temperature prevailing at the engine
operating site..
Is 13656:2002 API Optimum operating behavior will be
E - DL2 CF attained if you take the accompanying oil
viscosity diagram as a guide Should be
CF+ temperature fall temporarily below the
E - DL3 MACK limits of the SAE grade selected, cold
T - 7 / T - 8A starting may be affected but the engine
E - DL4 CF4 will not be damaged.
In order to keep wear to a minimum, do
KOEL approved Lube Oils :- not exceed application limits for extended
period of time.
Manufacturing Co. Trade Name
Bharat Petroleum Bharat Ultra
Supreme 15W40
Hindustan Petroleum Hylube LL15W40
Indian Oil Corporation Servo Premium
XHP15W40 Only with preheating

Warranty is applicable on use

of ‘K Oil Super’ engine oil only.

37
 4. Operating Media
4.2.1 Quality Grade
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
38
4.1 Lube Oil
4.2.2 Winter Grade Fuel
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
Diesel fuels must never be Mix in tank only. Fill with the
mixed with petrol appropriate amount of
kerosene first, then the diesel
fuel.
 5. Routine Maintenance

5.1 Maintenance Schedule

5.2 Maintenance Work Completed

39
40
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
S Cooling system 6.3
Engine lube oil 6.1.2

Major Overhaul
Lube oil filter element / cartridge 6.1.3

Top Overhaul
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

Checking Recommended Change SClean 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.
41
 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

42
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

43
 5. Routine Maintenance 5.2 Maintenance Work Completed

Hours Date Remark Signature / Stamp

8250
8500
8750
9000

44
 6. Service & Maintenance

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

45
46
6.1 Lubrication System 6. Service & Maintenance

6.1.1. Oil Change Intervals

* The oil change intervals are Engine Operating Conditions

dependent on engine application and - Normal Duty
operating environment. Refer
subsequent table. Naturally
Aspirated & 500 hrs.
* If the engine runs fewer hours than Turbocharged
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.

Recommended lube oil For use of any recommended

change period is applicable in lube oil other than K Oil Super,
case of use of K Oil Super in the lube oil change period will be
engine, sourced from Kirloskar 250 hours. 47
Service Dealer only.
 6. Service & Maintenance
6.1.2. Checking Oil Level /
Changing Engine Oil
6.1.2.1 Checking Oil Level
OIL
MAX.
MIN.
* 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.
Oil level should never be below
Min. mark.
48 Oil level should not exceed
Maximum mark.
6.1 Lubrication System
6.1.2. Checking Oil Level /
Changing Engine Oil
6.1.2.2 Engine Oil Change
+ 800C
+ 1760F
OIL
* 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.
6.1 Lubrication System
6.1.3 Changing Oil Filter
Element - Spin On Type
* Remove the filter cartridge by rotating
it anticlockwise with commercial tool.
* Collect dripping oil in a tray.
* Destroy the removed cartridge.
Beware of burns from hot oil.
6. Service & Maintenance
* 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.
49
 6. Service & Maintenance 6.1 Lubrication System

6.1.4 Changing Oil Filter

Element - Paper Element
Type
* Assemble the bowl and tighten centre
bolt firmly.
* Check oil level.
* Check oil pressure.

* 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.

50
6.2 Fuel System 6. Service & Maintenance

6.2.1. Changing Fuel Filter -

Spin On Type

* 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

Keep naked flames away when

working on they fuel system. Do
not smoke.
51
 6. Service & Maintenance 6.2 Fuel System

6.2.2. Changing Fuel Filter - 6.2.3. Fuel Strainer

Element Type

* 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.

* Close fuel valve * Remove banjo bolt at inlet of feed

* Unscrew the plug at bottom of bowls pump.
and collect the fuel in tray. * Unscrew the strainer fitted inside the
banjo bolt.
* Unscrew the center bolt of bowls and
remove bowls & fuel inserts. * Clean the fuel strainer in fuel & blow it
with compressed air. Replace if
* Clean the bowl with diesel.
necessary.
* Change Pre-filter insert only. Do not * Refit the fuel strainer in banjo bolt.
change Pre-filter insert & Micro filter
* Refit the banjo bolt to feed pump with
insert at a time.
new copper washer.
* Bleed the fuel system.

Do not clean fuel filter inserts. No naked flames when working

Always replace the insert with on the fuel system.
52 new one at recommended No smoking!
intervals.
6.2 Fuel System 6. Service & Maintenance

6.2.4 Lube Oil Filter & Fuel

Filter With Common
Filter Header

Fuel Filter

Lube Oil Filter

Lube oil filter & fuel filter (Spin On type)

with common filter header can be
supplied as an optional feature.

53
 6. Service & Maintenance 6.3 Cooling System

6.3.1. Cleaning Intervals

* The amount of contamination in the

cooling system depends on the Inspection and
engine application. Clearing Intervals Engine application
Recommended
* Oil or fuel leakages on the engine
increase the risk of contamination. Be Operating Hours
careful and avoid leakage when engine 2000 Ships, Gensets in enclosed areas, pumps
is used in dusty envornment. 1000 Vehicles on reinforced highways
* Serious contamination can occur, for 500 Tractors, fork-lift trucks, mobile electrical units.
example :
250 Vehicles on construction sites and on roads with loose
- on construction sites where there is surfaces, construction machinery, compressors, mining
a high level of air - borne dust. equipments.
- in harvesting application where there 125 Agricultural machinery, tractor used for harvesting purpose.
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.

54
6.4 Combustion Air Filter 6. Service & Maintenance

6.4.1. Cleaning Intervals 6.4.2 Cleaning Cyclone

Type Precleaner

* 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.

* The soiling of air cleaner depends on * Remove the clamps of dust collector
the dust in air, operating environment bowl.
and size of air cleaner used. Cyclone * Remove collector bowl & empty it.
type pre-cleaner is recommended in
dusty environment * Clean cyclone type prefilter.

* Cleaning intervals will have to be * Reposition collector bowl on air

determined from case to case. cleaner & refitt the clamps.

* If dry-type air cleaners are used,it * Replace collector bowl if damaged.

should be cleaned only in accordance
with the service indicator.

55
 6. Service & Maintenance 6.4 Combustion Air Filter

6.4.3 Cleaning Oil Bath Air Cleaner

* Stop the engine and wait for about 15 * Lift the filter element and remove it.
mins. for oil to drain from filter
housing.
* Remove the clamp and remove oil
bowl.

Never clean air cleaner with gasoline. Dispose off oil in accordance with
envornmental regulations!
56
6.4 Combustion Air Filter
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.
6. Service & Maintenance
* 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
57
 6. Service & Maintenance
6.4.4 Dry Type Air Cleaner
Dust Ejector valve.
* 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.
58
6.4 Combustion Air Filter
Filter Element
* 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.
Cleaning Filter Element
* Clean the element by dry compressed
air (air pressure 3 kg/cm2 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.
Never clean air cleaner with
gasoline.
6.4 Combustion Air Filter 6. Service & Maintenance

6.4.4 Dry Type Air Cleaner

Checking Element - Light Test Checking Sealing Ring Inner / Safety Element

* Inner / safety element should be

replaced after every two changes of
outer element.
* Repeat same procedure as outer
element while replacing inner
element.

* Check cleaned/new element for * Check rubber sealing ring for

damage before installing. damage. Replace if necessary.
* 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.

Never clean the inner element,

always replace it.

59
 6. Service & Maintenance
6.5.1 Checking V-Belts
* 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.
60
6.5. Belt Drives
6.5.2 Checking Fan V- Belt
v
- Push slowly on the black pad 4 at * To replace V-belts, press in tension
right angles to belt 2 until the spring unit using a commercial tool and
is heard or felt to trigger. remove the V-belts.
- Carefully remove the gauge without * Fit new V-belts.
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.
Check tension and change belts When new V-belts are fitted, check the
only when engine is at belt tension after 15 minutes running
standstill. Refit belt guard, if
provided.
time.
6.4 Combustion Air Filter
6.5.3 Tensioning Alternator
Belts
* 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.
Check/ tension/ replace V-belts
only when the engine is at a
standstill. If necessary replace
V-belt cover
6. Service & Maintenance
6.5.4 Changing Alternator
Belts
* 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.
Retighten new V-belts after 15 minutes
running time.
6.5.5 Checking Warning
System.
* 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.
Carry out a check only when
the engine is at a standstill.
61
 6. Service & Maintenance
6.6.1 Checking Valve
Clearance
VALVE
PUSH
ROD
* 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.
62
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
6.6 Adjustments
6.6.2 Adjusting Valve
Clearance
* 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).
6.7 Accessories
6.7.1.1 Checking Battery
& Cable Connectors
* 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
6. Service & Maintenance
6.7.1.2 Checking Electrolyte
Level
* 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.
6.7.1.3 Checking Electrolyte
Density
* 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.
63
 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
64 protective goggles.
Do not rest tools on the battery.
6.7 Accessories 6. Service & Maintenance

6.7.2 Lifting Tackle

* 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

65
 6. Service & Maintenance
6.8.1 Cleaning the engine
With Compressed Air
* 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.
66
With Cold Cleaning Agent
* 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.
6.8 Engine Cleaning
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 .
* Clean the engine with steam jet.
(Steam pressure - 60 bar and
temperature 90 deg.C)
6.9 Additional Maintenance 6. Service & Maintenance

6.9.1 Checking the 6.9.2 Checking the function

mountings of Flame Heater

Push button for

cold starting ON
OFF
P.B. START

4 2 1

3 Charge Lamp

Check following components for * When functioning correctly, inlet * Move speed adjustment lever and
fasteners tightness. manifold heats up in the vicinity of shut- off lever to “stop” position.
* Rocker cover flame heater when starting with * Insert key
preheating.
* Air-inlet manifold - Position OFF = no operating voltage
* Coupling * Turn key clockwise.
* Exhaust manifold - Position ON = operating voltage
* Engine mountings - 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.

67
 6. Service & Maintenance
6.9.2 Checking the function
of Flame Heater
4 2 1 4
3 3
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.
68
6.9 Additional Maintenance
* Use heat resistant sealant when fitting
flame glow plug 2.
* Refit flame glow plug 2 on fuel line.
Keep away from rotating parts.
2 1
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.
Collect any leaked fuel and
dispose off in an envornmentlly
friendly fashion
 7. Faults, Causes & Remedies

7.1 Diagnosis Chart

69
70
Diesel knock
Bearing wear
Engine overheat

Mechanical knock
Excessive vibration
Engine will not start

Engine lacks power

Engine fails to rotate

Low lube oil pressure

Breaking of valve springs

Excessive oil consumption
Excessive fuel consumption
Excessive smoke at no load
Engine has starting difficulty

Excessive smoke at full load

Battery runs down frequently

Engine gives out blue smoke

Mixing of diesel with lube oil

Engine gives out white smoke
Engine misfires during operation

Excessive liner & piston ring wear

Excessive valve & valve guide wear
Engine starts but stops after some time

Engine does not reach governed speed

Engine speed does not remain constant

Excessive fuel injection equipment wear

Engine rotates very slowly during starting
7.1 Diagnosis Chart

         Dust entry in air inlet system

            Dirty / clogged air cleaner
     High exhaust back pressure
System

  Derating due to altitude

Air / Exhaust

  Derating due to temperature

  No fuel
        Poor quality of fuel
    Air in fuel line
     Choked fuel line
    External / Internal fuel leakage
       Choked fuel injector holes
      Damaged or dribbling nozzle
Loose HP. pipe connections
Fuel System

 
      Dirty / Choked fuel filter
    Control lever settings wrong
           Faulty fuel pump
     Water mixed with fuel
        Wrong grade of lube oil used
   Dirty / Choked suction tube strainer
  Oil cooler choked
  Lube oil dilution
     Dirty / Clogged lube oil filter
   Clogged oil passage
  Excessive oil in the sump
Lubricating System

 External / Internal leakages

   Faulty oil pump
   Dirty air cooling fins
   Loose fan belt
 Air leakages through cowling
      Engine overloading
      Engine used after a long time
          Wrongly adjusted valve clearances
System Operation

Prolonged oil change period

Cooling Maintenance

     
      Blown cylinder head gasket
      Valve leakages
    T.C. compressor seal leaking
    T.C. turbine side seal leaking
           Broken / worn out piston rings
   Excessive end play in crankshaft
           Worn out cylinder liner & piston
      Incorrect bearing clearances
        Damaged main & connecting rod brgs.
     Worn out valves & valve guides
         Incorrect valve & fuel timing
        Injector needs adjustment
      Engine seized
Mechanical System

    Faulty governor setting

        One or more cylinders not working
  Loose mounting bolts
  Loose flywheel / wrong alignment
          Engine needs overhauling
 Fuel pump rack stuck in stop position
    Battery run down / under rated battery
7. Faults, Causes & Remedies

    Faulty starter
    Battery of wrong capacity
System
Electrical
 8. Engine Preservation

8.1 Preservation

73
74
8.1 Preservation 8. Engine Preservation

8.1 Preservation 8.1.1 Preserving Engine

If the engine is to remain idle for an * Clean the engine preferably using * External unpainted surfaces to be
extended period of time, it is necessary thinner and compresed air. treated with rust preventive oil .
to take protective measures to prevent rust * Run the engine until warm and stop. * Plug all the openings, vents of the
formation. The preservative measures engine.
described here will protect the engine * Drain the lube oil.
upto 12 months.. * Fill the engine with preservative oil. * Disconnect the battery & store it in a
safe place.
Recommended Preservatives For : * Clean the oil bath air cleaner, fill oil
bowl with preservative oil. * Cover the engine with polythene bag
Lube and Fuel system if possible.
* Drain the fuel tank.
Indian Oil Corp. Servo Preserve 30 * Procedure to be repeated if engine is
* Prepare mixture of Diesel + to be stored for more than 12 months.
Bharat Petroleum Bharat Preserve Preservative, ratio 5 :1. Refill the fuel
Oil 30 tank with mixture.
Hindustan Petroleum Autoprun T120 * Run the engine for 5 mins. at low
Veedol Tide Oil Co. Veedol 30/40 speed / fix speed engine at No Load.
* Stop the engine.
External Surfaces * Turn the engine manually several times
Indian Oil Corp. Servo RP 125 to preserve the cylinders and
Bharat Petroleum Bharat Rustrol 152 combustion chamber. While rotating
with starter, stop lever of fuel pump to
Hindustan Petroleum Rustop 274
be in stop condition.
Veedol Tide Oil Co. Veedol Ruspro IT
* Drain the preservative oil from engine
Castrol India Rustilo DW-904
* Drain the Diesel + Preservative oil
or DW-901
from fuel tank.
Recommanded cleansing agent to * Remove the V-belts
remove preservatives when
recommissioning engine : - NC Thinner

75
 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

76
 9. Technical Specifications

9.1 Engine Specifications

9.2 Power Output
9.3 Torque Wrench Setting

77
78
9.1 Engine Specifications 9.Technical Specifications

9.1.1 CPCB / 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/cm2 1.5
- At rated speed kg/cm2 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/cm2 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
79
* These engines are not CMVR compliant
 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/cm2 0.5 to 1.0
- At rated speed kg/cm2 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/cm2 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
80 24 Dry Weight of engine kg 326 370 421 450 477 440 495
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

81
 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 ----- ----- ----- -----
2150 19.5 26.5 0.086 8.85 ----- ----- ----- -----
HA294
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 ----- ----- ----- -----
2150 32.4 44.0 0.143 14.6 ----- ----- ----- -----
HA394
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
82
* Compliant for CMVR, other ratings as per torque curve of family engines.
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
2000 18.4 25.0 0.087 8.95 26.5 9.50 28.0 10.00
HA294
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
2000 30.2 41.0 0.144 14.70 44.0 15.75 46.0 16.50
HA394
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
2000 41.2 56.0 0.196 20.0 60.0 21.50 63.0 22.50
HA494
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

83
 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
2000 62.6 85.0 0.298 30.4 90.0 32.2 95.0 34.0
HA694
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
2000 76.0 103.0 0.365 37.2 108.0 39.0 114.0 41.6
HA694TC
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

84
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)

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.
85
86
KIRLOSKAR OIL ENGINES LIMITED
A Kirloskar Group Company
13,LAXMANRAO KIRLOSKAR ROAD KHADKI, PUNE - 411 003, INDIA.
HELPDESK - 1800 233 3344, 020-66084608
HELPDESK ID - koel_helpdesk@kirloskar.com PART NO. 03.066.01.0.02
Visit us at : www.koel.co.in DECEMBER 2008