KIRLOSKAR DV8 - Page 101

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Index2
Warranty4
Service Checks5
Safety Guidelines and Environmental Awareness7
Safety Guidelines7
Commissioning and General Instructions7
Starting the Engine8
Engine Operation8
Maintenance Operations8
Storage9
Environmental Aspects and Awareness9
Health Precautions9
Technical Information10
Engine Model and Serial Number10
Engine Type10
Cylinder Block10
Engine Assembly13
Engine Sectional View (Longitudinal)13
Engine Sectional View (Cross)14
Engine Illustrations15
Crank Pulley Side16
Flywheel Side16
Gear Train Arrangment17
Valves17
Fuel Pump Gear17
Intermediate Gear17
Gear Train Assembly17
Crank Shaft Gear17
Lubrication System18
Lube Oil System Schematic18
Oil Supply through Oil Pump, Crankcase & Header19
Oil Supply through Cooler & Filter19
Oil Supply in Crankcase20
Rocker Lever Oil Supply20
Crank & Cam Oil Supply21
Piston Cooling Nozzle21
Recommend of Lubricating Oil22
Lube Oil Cooler23
Lube Oil Filter23
Fuel System24
Injection Pump24
Fuel Filter24
Fuel System Schematic24
Electronic Governor - Esd5500E Series Speed Control Unit26
Description26
Application and Installation Information27
Warning27
Wiring27
Adjustments27
Governor Speed Setting28
Governor Performance28
Starting Fuel Adjustment28
System Troubleshooting28
Idle Speed Setting29
Speed Droop Operation29
Accessory Input29
Accessory Supply29
ESD5500E Series Wiring Diagram and Outline30
System Troubleshooting31
System Inoperative31
Unsatisfactory Performance31
Insufficient Magnetic Speed Sensor Signal32
Electromagnetic Compatibility (EMC)32
Instability33
Fuel Actuator34
Specifications34
Fuel Requirements35
How to Select Fuel Oil35
Fuel Oil Selection Chart35
Air Inlet System - Air Cleaner36
Cooling System37
Coolant Pressure Cap38
Water Passage for DV Series Engines39
Water Passage from Waterpump to Lube Oil Cooler & then to Header39
Water from Header to Crankcase & the to Liner - Right Side View39
Water from Header to Crankcase & the to Liner - Left Side View40
Water Passage from Crankcase to Header41
Water Passage from Header to Thermostat42
V-Belt Tension Check and Adjust43
Alternate Method of Checking Belt Tesion43
Turbocharger43
Electrical Equipment44
Part List44
Alternator44
Starter Motor45
Recommended Battery Capacity45
Engine Control Panel46
Functions46
Operation47
Initial Power up47
Standby47
Mode Selection48
Manual Operation48
To Start Engine Manually48
To Stop the Engine Manually48
To Start the Engine Automatically49
Autostart Engine Control49
Display Operation50
When the Engine Is Running50
Load Transfer and Contactor Operation50
Scheduler Operation51
In Manual Mode51
Alarms and Warnings52
Speed Icon52
Low Oil Pressure Icon52
High Engine Temperature Icon52
Speed Sensing53
Low Water Level Icon53
Low Fuel Level Icon53
High Canopy Temperature Icon53
Mpu54
Battery Charging Alternator54
Battery Charging Alternator Excitation54
Battery Voltage Monitoring and Charging Detection55
Trouble Shooting55
Communications57
Alarm Dial out57
Maintenance57
Specification57
Commissioning and Operation59
Your Engine Needs Preparations before Starting59
Running-In59
Operation of a New Engine (Break-In)59
During Operation60
Shutting down60
Charging Alternator60
Maintenance and Care61
Periodical Inspection and Maintenance61
Exchanging of Lubrication Oil61
Oil Level61
Replacement of Oil Filter Cartridge62
Centrifuge Lube Oil Filter63
Cleaning Frequency63
Identification and Location63
Servicing Instructions64
Servicing Procedure64
Don’ts about Centrifuge Cleaner65
Points to Care about Centrifuge Cleaner65
Troubleshooting66
Coolant Draining67
Drain Valve67
Cleaning of the Cooling Inside System Circuit67
Intercooler / Charge Air Cooler68
K COOL Super Plus68
Advantage of K COOL Super Plus against the Conventional Coolant69
First Aid69
Air Intake System69
Maintenance of Air Cleaner70
Cleaning of Filter Element70
Fuel System Checks72
Fuel Contamination and Water Trap72
Priming Pump Strainer Cleaning72
Bleeding the Fuel System72
Injection Nozzle Maintenance (by Authorized Specialist Personnel)73
Turbocharger Maintenance75
Inspection of Parts for Re-Use76
Bearing Housing76
Compressor Wheel76
Shaft and Wheel76
Compressor Cover77
Turbine Housing and Backplate77
Flinger Sleeve77
V Clamps78
Checking and Setting80
Adjustment of Valve Clearance80
Adjusting Order of the Valve Clearance80
Method of Adjusting the Valve Clearance80
Adjustment of Injection Timing82
Method of Adjusting Injection Timing82
Tightening the Cylinder Head Bolts82
Tightening Toruqes82
Cylinder Compression Pressure83
Rountine Maintenance Chart84
Engine Preservation85
Recommended Preservatives85
Preservation Procedure85
Engine Speed During above Running85
Commissioning of Preserved Engine86
Diagnosis and Remedy87
Engine Starting Impossible87
Engine Overheated88
Output Insufficient89
Oil Pressure Lowered90
Fuel Consumption Excessive91
Oil Consumption Excessive92
Engine Knocking93
Battery Discharge94
Engine Noisy96
Engine Firing Order99

KIRLOSKAR DV8 - Page 101

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