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KIRLOSKAR
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DV Series
KIRLOSKAR DV Series User Manual
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1
FOREWORD
3
1
W
ARRANTY
5
2
ENVIRONMENT
AL POLICY
7
3
SAFETY GUIDLINES
AND ENVIRONMENT
AL
A
W
ARENESS
9
4
TECHNICAL INFORMA
TION
1
2
5
COMMISSIONING AND OPERA
TION
6
1
6
MAINTENANCE AND CARE
6
3
7
CHECKING AND SETTING
8
2
8
ROUNTINE MAINTENANCE CHART
8
5
9
ENGINE PRESERV
A
TION
8
6
1
0
DIAGNOSIS AND REMEDY
8
8
1
1
ENGINE FIRING ORDER
1
00
INDEX
1
3
Table of Contents
Index
2
Warranty
4
Service Checks
5
Safety Guidelines and Environmental Awareness
7
Safety Guidelines
7
Commissioning and General Instructions
7
Starting the Engine
8
Engine Operation
8
Maintenance Operations
8
Storage
9
Environmental Aspects and Awareness
9
Health Precautions
9
Technical Information
10
Engine Model and Serial Number
10
Engine Type
10
Cylinder Block
10
Engine Assembly
13
Engine Sectional View (Longitudinal)
13
Engine Sectional View (Cross)
14
Engine Illustrations
15
Crank Pulley Side
16
Flywheel Side
16
Gear Train Arrangment
17
Valves
17
Fuel Pump Gear
17
Intermediate Gear
17
Gear Train Assembly
17
Crank Shaft Gear
17
Lubrication System
18
Lube Oil System Schematic
18
Oil Supply through Oil Pump, Crankcase & Header
19
Oil Supply through Cooler & Filter
19
Oil Supply in Crankcase
20
Rocker Lever Oil Supply
20
Crank & Cam Oil Supply
21
Piston Cooling Nozzle
21
Recommend of Lubricating Oil
22
Lube Oil Cooler
23
Lube Oil Filter
23
Fuel System
24
Injection Pump
24
Fuel Filter
24
Fuel System Schematic
24
Electronic Governor - Esd5500E Series Speed Control Unit
26
Description
26
Application and Installation Information
27
Warning
27
Wiring
27
Adjustments
27
Governor Speed Setting
28
Governor Performance
28
Starting Fuel Adjustment
28
System Troubleshooting
28
Idle Speed Setting
29
Speed Droop Operation
29
Accessory Input
29
Accessory Supply
29
ESD5500E Series Wiring Diagram and Outline
30
System Troubleshooting
31
System Inoperative
31
Unsatisfactory Performance
31
Insufficient Magnetic Speed Sensor Signal
32
Electromagnetic Compatibility (EMC)
32
Instability
33
Fuel Actuator
34
Specifications
34
Fuel Requirements
35
How to Select Fuel Oil
35
Fuel Oil Selection Chart
35
Air Inlet System - Air Cleaner
36
Cooling System
37
Coolant Pressure Cap
38
Water Passage for DV Series Engines
39
Water Passage from Waterpump to Lube Oil Cooler & then to Header
39
Water from Header to Crankcase & the to Liner - Right Side View
39
Water from Header to Crankcase & the to Liner - Left Side View
40
Water Passage from Crankcase to Header
41
Water Passage from Header to Thermostat
42
V-Belt Tension Check and Adjust
43
Alternate Method of Checking Belt Tesion
43
Turbocharger
43
Electrical Equipment
44
Part List
44
Alternator
44
Starter Motor
45
Recommended Battery Capacity
45
Engine Control Panel
46
Functions
46
Operation
47
Initial Power up
47
Standby
47
Mode Selection
48
Manual Operation
48
To Start Engine Manually
48
To Stop the Engine Manually
48
To Start the Engine Automatically
49
Autostart Engine Control
49
Display Operation
50
When the Engine Is Running
50
Load Transfer and Contactor Operation
50
Scheduler Operation
51
In Manual Mode
51
Alarms and Warnings
52
Speed Icon
52
Low Oil Pressure Icon
52
High Engine Temperature Icon
52
Speed Sensing
53
Low Water Level Icon
53
Low Fuel Level Icon
53
High Canopy Temperature Icon
53
Mpu
54
Battery Charging Alternator
54
Battery Charging Alternator Excitation
54
Battery Voltage Monitoring and Charging Detection
55
Trouble Shooting
55
Communications
57
Alarm Dial out
57
Maintenance
57
Specification
57
Commissioning and Operation
59
Your Engine Needs Preparations before Starting
59
Running-In
59
Operation of a New Engine (Break-In)
59
During Operation
60
Shutting down
60
Charging Alternator
60
Maintenance and Care
61
Periodical Inspection and Maintenance
61
Exchanging of Lubrication Oil
61
Oil Level
61
Replacement of Oil Filter Cartridge
62
Centrifuge Lube Oil Filter
63
Cleaning Frequency
63
Identification and Location
63
Servicing Instructions
64
Servicing Procedure
64
Don’ts about Centrifuge Cleaner
65
Points to Care about Centrifuge Cleaner
65
Troubleshooting
66
Coolant Draining
67
Drain Valve
67
Cleaning of the Cooling Inside System Circuit
67
Intercooler / Charge Air Cooler
68
K COOL Super Plus
68
Advantage of K COOL Super Plus against the Conventional Coolant
69
First Aid
69
Air Intake System
69
Maintenance of Air Cleaner
70
Cleaning of Filter Element
70
Fuel System Checks
72
Fuel Contamination and Water Trap
72
Priming Pump Strainer Cleaning
72
Bleeding the Fuel System
72
Injection Nozzle Maintenance (by Authorized Specialist Personnel)
73
Turbocharger Maintenance
75
Inspection of Parts for Re-Use
76
Bearing Housing
76
Compressor Wheel
76
Shaft and Wheel
76
Compressor Cover
77
Turbine Housing and Backplate
77
Flinger Sleeve
77
V Clamps
78
Checking and Setting
80
Adjustment of Valve Clearance
80
Adjusting Order of the Valve Clearance
80
Method of Adjusting the Valve Clearance
80
Adjustment of Injection Timing
82
Method of Adjusting Injection Timing
82
Tightening the Cylinder Head Bolts
82
Tightening Toruqes
82
Cylinder Compression Pressure
83
Rountine Maintenance Chart
84
Engine Preservation
85
Recommended Preservatives
85
Preservation Procedure
85
Engine Speed During above Running
85
Commissioning of Preserved Engine
86
Diagnosis and Remedy
87
Engine Starting Impossible
87
Engine Overheated
88
Output Insufficient
89
Oil Pressure Lowered
90
Fuel Consumption Excessive
91
Oil Consumption Excessive
92
Engine Knocking
93
Battery Discharge
94
Engine Noisy
96
Engine Firing Order
99
5
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KIRLOSKAR DV Series Specifications
General
Brand
KIRLOSKAR
Model
DV Series
Category
Engine
Language
English
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