R1040 SERIES WELL THOUGHT - OUT ENGINES Enriching LivesKirloskar engines: Prime movers to the Indian nation. Kiiloskar Oil Engines Limited founded in 1946 end populatly known as KOELis India’s leading manufacturer of the finestand widest range of diesel engines -ftom 3 hpto 800 hp, and from 2400 hp to 11,000 hp. The engines are branded as ‘Kirloskar’. With annual manufacturing volumes exceeding 225,000, Kiiloskar engines are available in both air-cooled end liquid-cooled versions. The main engine manufacturing plant is at Pune, anc ‘other manufacturing locations are Nashik, Anmecinagar, Rajkot, Indore. With an investment outlay of over USS 200 Mnwe are setting up world class engine manufacturing facilty at Kagal near Kolhapur (200 Kms south of Pune). This will enhance our manufacturing capacty by 1C0,000 engines per year staring 2008. Kirioskar engines are aveilable in Industial, Agicuture, Power Generation as well as Marine Application. The engine ‘manufacturing facities are cortinualy upgraded and improved to ensure the requisite qualty at competitive cost. Critical components lke crankcases, crankshafts, camshaits, goarcasing, cyinderheads and connecting rods are manufectured in-house. KOEL also manufactures forts exclusive use, special purpose machines to achieve ciitical degrees of precision that international specifications demand. The prestigious ISO 9001 cetification for Qualty Management Systems in 1992 and ISO 14001 certiication for Environmental Management Systems in 1999 & TS 16949 in 2004 are the proof of Kirloskar’s commitment to qualty and environment. KOEL is the first engine manufacturing company in India to be awarded the ISO 14001 certification. At Kirtoskat, we beleve thatthe industry and the environment can, end must coexist in a mutually beneficial vay. Bringing this thought into practice, is what has driven us to manufacture the engines that ‘re not only eco-tiendly, but ere also manulactured in an ‘ervironment-‘riencly way. Product Support Kisdoskar has one of the most extensive service networks in India, Almost 90% of Kirloskar medium engines are within 100 Kilometre periphery of a Kitloskar Service Desler. 230 Service Dealership locations provide relentless service to the customers. The location of the dealerships and their infrastructure is continually assessed based on the Kirloskar engine population build-up in each terrtory, and the emerging service needs of the cusiomers. Out of these, 96 Service Dealership locations provide 24-hour service, The numbor of ‘Service Dealerships that provide 24-hour service are growing day by day, Additionally over 85 Kiloskar Territory Managers. Service Engineers and Technicians are stationad at 15 Kiloskar Area Offices. A well spread out service network manned by ‘about 2,200 Kirioskar trained engineers and technicians censures promptsonice and easy availablity of gonuino spare pars, thus ensuring highest up time for Koskar engines. Allpervasive IT in operations Having foreseen the power of IT to transform businesses, way back in 1998, KOEL instaled the world's leading Enterprise-wide Solution (ERP) Oracle. This instaletion is noted to be one of the most comprehensive Instalations of Oracle in the manufacturing industry. The instalation of ERP in 1998 was followed up with web-enabled business processes in 2000; comprising 26 specific moduies, connecting over 2.500 stake-holders who together commit over 50,000 transactions every day. With this iniiatve, Kifoskar Service Dealers. OEMs, Area Sales Offices, Supplies and Logistic Providers form a cigtal commuritythatis everready torespond to each customer need oficently. The Service Dealerships are able to respond to customer needs uichly and effcierty by accessing atest senice information and parts availabilty over the internet, 24 hours 2 day 365 days year.includingaleap year. We are in the process of expanding the IT applications in the area of Customer Relationship Management [CRM]. Tho CRM Module wil enable us to actively address the needs of its existing, as well as prospective customer base. By being always online and in real ime, What started as an ERP initiative in 1998 has today become one ofthe largest eBusiness suites operating outsidethe United States.Maximum economy and refiailty are the features of Kisloskar diesel engines. The power units are produced to meet the high precision and quality standards symbolised by the name Kirloskar. A strictly modular design ensures component standardisation which resolves many spare parts supply problems. The R1040 engine series conform to Euro | & ICOM Stage I & land US Tier 8 norms orolt roaduse. Salient features Designed for heavy duty Industial applications tke Tactor, Mining, Earth Moving, Corsttuction, Material handing, Automotive market segments = The Piston is designed to have centraised cavity. High ar to fuel ratio, injectors with smaller spray holes and large number of holes ensure proper combustion of ue! |= Piston continuously cooled by bult.in olljct spray or minimum liner piston wear. © Infine gear driven MICO fuel pump with EP-RSV governor for ease of fuel setting andfield servicing © Lomertuetconsumption as compared wit otherengines inthis lass © Fullflowplatetype lube oer formaintcining optimum lube ciltemperature © Noextemal teal piping orenginelubrication © Labo ilcoclorsis ofmadem plato type design, whichis compact and officio. © Rigid Load bearing crank case, acts as load bearing member for application liketractor,forklitete, © The rigid structure also ensures minimum cylinder bore distorion, low lube oil consumption, extended if of lube olland reduced partculateemission, © The rigid and integral cyinder head Is equipped with replaceable valve ‘seals and valve guides. The heads are provided with six bolts per cylinder to ensure uniform clamping. Stocl backbone cyindor hozd gasket ensures proper seating, © Crankshaftis of forged alley steel with hardened joumals.and pins. © Rogld engine structure and crowned gears in gear tain substantially reduce theenginencise, | Ability otake drive from both engine ends to meet specific application requirement © Highbackuptorque © Provision for engine-mounted, belt or gear-driven compensatory, gear driven hydraulic pump to meet specific application requirements for compactinstallation. |= Al maintenance points like fuel pump, fuel lit pump, lube oil filing, cipstick, fuel and lube oil fiters on one side for easy ‘maintenance, Injectors are housed outside rocker cover i enable easy maintenance. | Wot liners ensure low cost of maintenance as compared to engines with dry liners. Also wet liners are easy to replace at ste ‘withoutany special tooling, © Mocting prevailing omission norms and capableto moo! ikely future omission norms. "© MTBO of minimum 8000 hours Low operating cost as compared to other engines in its class (lube of change petiod of 400 hours, lowfuetandlube oil consumption) © Turbochargedand Turbo After cooled versions availablefor 4 and 6cyinderengines,User advantages Optional equipment Benefits ofte same engine family covering the output range 38 to 188 BHP and variety of equipment. Lowest possible parts stocking to meet any fleld service need. 85% components are common throughout the R1040 engine fami. ‘As the R1040 engine family also has a very wide operating speed range upto 2500 rpm, the need for training of maintenance personnelis minimized. Better logistics support is possible due to lower woight and volume of equipment and individual engine parts, lower frequency ‘ofworkshop attendance, extended MTOBs, faster maintenance, extended diesel and ube ciltop-upintervals. ‘Agency Geriifcation by institutions ke R&D Dighi, Pune, ARAI Pune for engines used in Defence, Mining and Govemment sectors, Residential type exhaust silencer Heat exchanger cooling arrangement, Holset type flexible coupling with folloning unfrished bore flanges Engine Model Unfinished bore / Coupling Type 3R1040 25 mm (0.12 RB) 4R1040 25mm (012RB) AR1040T 30mm(020RB) SRIOROIT/TA 30mm (0.24R8) Provision for gear criven hydraulic pump Bet /geardriven compressor Right angle or straighttacho-chive unit ‘Automatic engine shut down arrangementin case of low lube oil pressure, high cyinder head temperature, Vbet-faiire and, engine over sped (ceteils onrequest) Industrial Power Take-Offs (Twin Disctype)* 3R1040__ FWHSAE3, Flywhoolto suit GPSP111 PTO 41040 FWHSAE3, Flywheeltosut GP SP111 PTO 4R1040T _ FWHSAES. Flywheelto suk GP SP 111 PTO 4RIO40TA_FWH SAE1. Flywheelto suit GP SP211 PTO. 6R1080/ TTA FWH SAE1. Flywheelto suit GP'SP211 PTO ‘Standard il fling andreised dipstick arrangement Special ube oil sumpsto sui highinclinations (details on request) Flywheel housing (SAE4,3,2 and 1) 24V electrical staring system Cold staring aid for engine starting below minus $°C downto minus 20° (detail on request) Mud flterand water separator “Nese! Selection depends on application, rpm and torque to be transmitted. Consul KOEL R&E for proper selection,Horse power ratings as per IS 10002/BS: Engne Rem Continuous ating |CXN Enriching Lives 514/DIN 6271/ISO 3046 Max Torque kom @ 1300-1400 rpm R040 1500 sr1040 1800 R040 1500 ARIAOT 1500 AR I040TA 1500 eR1060T 1500 6RI060TA 1500 cr + BESRLRNNSBIINISSHSHHRSSSRBN ae 129 B 8 54+@ 1600 RM 67 @ 160 RM uaz SRSSREBRS aes BResssrareKs 3! aaas8s a3 SBS 138 143 75@ 1600 RPM Notes Continous rating © For NA engines as per ISO 3046 ICXN (NA - Naturally aspirated, TC - Turbocharged. TA Turbo Alter Cooled) = The power available lor heavy continuous load. An over load of 10% is reemissible for 1 hour for every 12 hours of ‘consecutive cunring, Fusl stop power rating, © Rs per paver avaiable or arable loadivanable speed appsieations where the ayeragp load factor as high 98 TO% (Approval fiom KOEL Engnocring Oops. is ossenta for applying max povr tng toa paricular application).Overall dimensions and installation drawings ( 2R1040/3R860/3R1040/4R 1040/4R 1040T/4R 1040TA/6R1040T A/6R1040TA Engi 099 805, 65 on 650 900. 909, 8 ‘All imensions are in mm ° For 3, 4R, 4RT, ARTA there are 4 holes, 46 dil twough for engine foot For BR, 6RT, RTA there are 12 holes, 16 dll rough for engine foot For 4RTA. 6R, 6RT. 6RTA there are 4 slots for mounting radiator on base plate ‘These dimensions may vary trom alternations depending on applications.ae — Enriching Lives Brief specifications Modde aio | sReo | aria | aRtow aRtotoT | 4RIO4OTA EngneDesviption | Vertied Liaic-oooed, corpresion lrtion four sroke onediesd encnes Agpration Naud | Naa | Naud | Naud | Turbo | TuboAftc| Turbo | Turbo After Cooled Cooled Bore X Stroke(mm) | 105X120 100 X 110) 105 X 120 Disgiaarent ma | so | a | ai | ae) | 60 CCameresion Ratio 181 aA Cirecion of Rotation Counter dodevise (lckingad fiywhed end) ‘Speed Maximuan Operation (ru) 2600 ‘Minimum cperating (RM) 4600 Dry weight of engine, with radiator without bai housing | 350 8 338 494 521 = 00 0 Dry weight of engine with flywhoo & SAE3 flywhed Housings Ratio | 391 aan aan 536 584 1 ma Weight of sendad flyhed in kg a a a a a a a a Approximate shipping specifications with standard equipment [Nas Naesti re a Peking ae = es a soo = * a es = 5 faeces oe a a = ee gi = re aoa on Pa soca | ces = se erste aan z = sacs |Horse power ratings as per IS 10002/BS:5514/DIN 6271/ISO 3046 Continuous Power Curve Fuel Stop Power Curve a6 —— BRIO8oT eo BRIOBOTA KIRLOSKAR ENGINES SOUTH AFRICA (PTY)LTD HEAD OFFICE: Address: 36 Rawbone Street Ophirton Johannesburg South Africa Tel: +27 (0) 11 493 3330 Fax: +27 (0) 11 493 3336, Email: kirloskarsa@tiscali.co.za www.kirloskarsa.co.za Enriching Lives