KIRLOSKAR DV Series User manual

1
FOREWORD 3
1 WARRANTY 5
2 ENVIRONMENTAL POLICY 7
3 SAFETY GUIDLINES AND ENVIRONMENTAL
AWARENESS 9
4 TECHNICAL INFORMATION 12
5 COMMISSIONING AND OPERATION 61
6 MAINTENANCE AND CARE 63
7 CHECKING AND SETTING 82
8 ROUNTINE MAINTENANCE CHART 85
9 ENGINE PRESERVATION 86
10 DIAGNOSIS AND REMEDY 88
11 ENGINE FIRING ORDER 100
INDEX

3
Dear Customer.
We are glad to welcome you to the family of KIRLOSKAR GENSET OWNERS.
As you are aware, Kirloskar products are based on the strong foundation of long experience in Research
& Manufacturing of Diesel Genset for power generation. Kirloskar products have been accepted by customers
the world over for their reliability, low running costs and simplicity in maintenance. Prompt after sales service
through countrywide network of Dealers and Distributors is one of the plus in buying Kirloskar products.
This manual has been prepared to help you use and operate the DV Series diesel engine in a safe and correct
manner.
The maximum performance of the engine largely depends on its proper maintenance and upkeep. We strongly
urge you to thoroughly read this manual and to acquaint yourself fully with all the information contained in this
manual.
We recommend that only trained staff should be permitted to perform the operating and maintenance task.
Always use genuine KIRLOSKAR SPARE PARTS.
In addition to the publication of this manual, we maintain facilities for training operators and owners in the
maintenance of KIRLOSKAR GENSET. You can avail yourself of these facilities by contacting our nearest
authorised Distributor / Dealer.
Thanking you, and congratulating you for choosing this model, we wish you to be proud owner of
KIRLOSKAR ENGINES for many years to come.
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 – [email protected]
Visit us at : www.kirloskar.com
FOREWORD

5
1. WARRANTY
This warranty is applicable to KOEL DV - Series Engines for 36 months from date of despatch from our Pune
factory or from 24 months from the date of commissioning or 5000 hrs of operation whichever is earlier subject
to use of K-Oil Super, K Cool Super Plus Coolant and Kirloskar filters sourced through KOEL authorised
service dealer.
Kirloskar Oil Engines Ltd. hereby warrants that this engine manufactured by us is free from defects in
material, design, and workmanship.
This warranty shall be limited for repair and replacement under normal use, regular check up and maintenance
of the engine as per our maintenance schedule and purchase and servicing of the engine through our
authorised dealer.
This warranty is the only document given by us warranting the engine. No other document giving any warranty
terms conflicting these contents shall be considered and entertained.
Kirloskar Oil Engines Ltd. is not liable to service, or repair of engine free of costs during the warranty period,
for the engines purchased from person other than an authorised person of Kirloskar Oil Engines Ltd.
This warranty does not include the engine removal and reinstallation charges.
Kirloskar Oil Engines Ltd. is not liable for any loss or damage, direct or consequential, labour charges or the
effect or any accident resulting from defective material, faulty workmanship or otherwise. In any case the
liability of Kirloskar Oil Engines Ltd. will not exceed the engine price or the market value of the Engine
whichever is lower, and shall be without interest.
Warranty Coverage on Engine Accessories:
Where problems of warranty nature are experienced with engine accessories, they are rectified by the
Company / by the KOEL Distributor or by KOEL Dealer on behalf of the manufacturer. However, the warranty
coverage will be the same as offered by the individual accessory manufacturer.
KOEL will not be responsible for warranty replacement of electrical Components, hoses, belts, instruments
and gauges beyond 1000 hours or 6 months of engine operation, whichever is earlier.
This warranty does not apply for the following:
1. The engine’s failure due to misuse, including improper shutdown, improper handing and adjustments,
negligence, over speeding, alteration of specification, and due to accident or Act. of God.
2. Engine if not maintained as per the maintenance schedule given by Kirloskar Oil Engines Ltd.
3. Damage due to improper installment of the parts, components and accessories.
4. For the parts supplied under warranty or voluntarily or at special rates or free of charge, the warranty
will be applicable only to the unexpired portion of machines warranty.
5. Damage due to use of improper lubricant or the lubricant used other than suggested by
Kirloskar Oil Engines Ltd.
6. Normal wear and tear of engine.
7. For resale of engine or the engine purchased is second hand. Any claim or obligation in connection
with the sale or performance of Engine shall be subject to Pune Jurisdiction

6
Conditions precedent to Engine Warranty
1. The engine warranty given by the company is subject to the below condition which are to be observed
by every purchaser/user of engine, without which the warranty claims if any will be rejected.
2. Proper installation of the engine is the sole responsibility of the owner of the engine/purchaser of the
engine.
3. Carrying Free Service Checks as per the scheduled Service Checks.
4. Preventive Maintenance as recommended by the company (Ref Maintenance Manual / Chart)
5. Any defective part claimed, to be returned to the company if such part is replaced by the company
under warranty, the returned part becomes the property of the company. The transportation charges
to be paid by the customer.
6. In case of interchange of part between engines shall void the warranty.
SERVICE CHECKS :
Kirloskar Oil Engines Limited offers Nine Free Service checks to DV series Genset.
K1 - Joint commissioning check
K2 - Service check at first 50 hrs or three months whichever is earlier
K3 to K9 - Service check at every 500 hrs or three months whichever is earlier.
Engine Type :
Engine serial no. :
Date of commissioning. :

7

9
3 Safety Guidelines and Environmental Awareness
Improper engine operation, maintenance or repair can be injurious to both engine / genset and operators.
Reading of information makes you only aware of possible safety hazards. It does not necessarily give the
competence to execute these operations.
Execution must be entrusted to trained operators
and service dealers.
Do not undertake any operation unless you have read and
understood the information in this manual.
The guidelines given are not exhaustive and considering all possibilities. Do not attempt to use any
procedure, tool and procedure which are not recommended in this manual.
Kirloskar Oil Engines Ltd. is committed to reduce the damage to the environment through our products.
KOEL’s environmental policy is enclosed for reference.
In following paragraphs, major safety precautions for the safety of both operators and the engine, and
responsibility for environment during operations of our diesel engines are highlighted. As an esteemed
customer of Kirloskar Engines, you are also part of Kirloskar family and we hope that you will join us in our
efforts to protect the environment to the best of our capabilities.
In this note, we have given guidelines for identification of hazardous waste and their disposal. In case you
require any specific information, kindly contact ‘Management Representative -EMS - KOEL.
Safety Guidelines :
Commissioning and General Instructions.
Before putting the engine into operation for the first time, read the operating instructions carefully and
familiarize yourself with the “critical” points. If you are unsure, ask your KIRLOSKAR representative.
• Prohibit access of unauthorized persons to engine room.
• Make engine operating persons responsible for the safety of persons who enter the engine room.
• Do not wear loose clothing or jewelry that can get caught in the engine parts
• Wear hard hat, protective glasses as required.
• Make certain that all protective guards and covers are in place and properly clamped.
• Use cleaning solutions with care.
• Do not use glass containers for maintenance fluids, They can break.
• Keep engine room clean, free of oil and grease spillage, to avoid slippage.
• During engine lifting, no one should be allowed to stand underneath or pass underneath. Keep lifting
gear in good condition.
• Engine must be started and operated by authorized personnel.
• Do not touch running engine with bare hands. There is a risk of burns.
• Keep away from running engine. Do not go too near to the rotating parts.
• Fuel is inflammable. Do not smoke in the engine room, or in the vicinity of fuel storage. Do not use
naked lights in the vicinity of fuel. The fuel tank must be filled only when the engine is switched off.
• Exhaust gases are toxic. Ensure adequate ventilation and air circulation.

10
Starting the Engine.
• Make sure all guards and covers are in place and secure.
• Engine room is properly cleaned of all spillage of oil and fuel.
• Automatic shut off circuits are in place and are not bypassed.
• Inspect engine for possible potential hazards.
Engine Operation
• Never demand more from the engine. The injection pump must not be adjusted.
• If faults occur, find the cause immediately and have it eliminate in order to prevent more serious of
damage.
• Use only genuine KIRLOSKAR spare parts.
• Never let the engine run when dry, i.e. without lube oil or coolant. Use only KIRLOSKAR approved
service products (engine oil, anti-freeze and anticorrosion agent).
• Pay attention to cleanliness. The Diesel fuel must be free of water.
• Have the engine maintained at the specified intervals.
• Do not switch off the engine immediately when it is warm, but let it run without load for about 5
minutes so that temperature equalization can take place.
• Never put cold coolant into an overheated engine.
• Do not add so much engine oil that the oil level rises above the max. marking on the dipstick.
• Always ensure that the testing and monitoring equipment (for battery charge, oil pressure, and
coolant temperature) function satisfactorily.
• Comply with instructions for operation of the alternator.
• Do not let the water pump run dry. If there is a risk of frost, drain the water when the engine switched off.
Maintenance operations
• Stop the engine. Allow engine to cool before any repair work is commenced.
• Ensure that protective locks and controls are in place.
• Disconnect batteries.
• Do not attempt any repairs, which you do not understand.
• Use only recommended tools which are in satisfactory condition.
• During cleaning, do not use pressurized air. It can cause personal injury. Wear protective face shield,
protective clothes and footwear during such cleaning.
• Do not tighten or loosen pipes, hoses during operation. The fluid inside will be under pressure and
can cause severe injury.
• Do not bend or strike high pressure pipes. Do not install bent or damaged lines, tubes.
• Inspect all lines for leakage. Leaks can cause fire.
• When checking injectors, do not put your hands under the jet. Do not inhale atomized fuel.
• Do not attempt to open cooling system when the coolant is hot.
• While handling coolants, battery fluids, avoid contact with skin and eyes.

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Storage
• All fuels, most lubricants and coolant additives are inflammable. Store them in a separately marked
area, in properly marked containers, away from unauthorized access.
• Store all oily rags and cleaning cloths in a safe place.
• Do not smoke in the storage area.
• Have a fire extinguisher available. Train operators for how to use it. Keep is periodically checked and
serviced.
Environmental Aspects and Awareness
A variety of waste products are generated through engine operations, exhaust gases, used and replaced
oil, changed filter elements, replaced components, batteries and the oil filled cleaning cloths. Many of
them are of hazardous nature. Careful disposal of these products is important.
Exhaust gases should be properly ventilated out of the engine room. The exhaust stack should be of
sufficient height to conform to the requirements of local pollution control board. The engine operations
should be carried out in accordance with the instructions given in the maintenance manual. This will avoid
generation of excessive smoke or uncontrolled pollution through exhaust.
Waste / used oils are classified as hazardous material. It may appear to have only hazards associated
with flammability and combustibility, they can carry health hazards. Used oil must be properly managed.
It should not be mixed with other wastes, as the other ordinary waste will also get classified as hazardous
waste. The cleaning cloths, used for wiping of spilled oil or for cleaning of components also falls into this
category. These wastes should be either sent to parties to collect used oil for regeneration and who have
proper waste disposal system for the residue generated, or should be disposed of in a properly located
and constructed landfill.
Used and replaced fuel and lubricating oil filters are equally hazardous as the used oil. These should be
disposed of in a properly located and constructed landfill.
Batteries contain acid, lead which are hazardous. To reduce wastage, recharge batteries at proper interval.
For best results, recharge at the first sign of weakness. Batteries last upto four times longer when charged
after only a 50 % discharge. Find -out from the service stations or battery charging outfits and return the
used batteries to these stations for disposal.
Dispose off the used components in accordance with the type of material.
Health precautions
• Wear protective gloves and head gear.
• Do not put oily rags into your pockets.
• Avoid prolonged or repeated skin contact with used engine oil.
• Change oil-soaked clothing and shoes
• Clean skin which has been in contact with engine oil.
o Wash thoroughly with soap and water.
o Certain products make it easier to clean your hands.
o Do not use petrol, Diesel, thinners or solvents as washing agents.
• After washing apply a fatty skin cream to the skin.

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4. Technical information
4.1. Engine model and serial number
The engine model and serial number is located on the engine
as illustrated. These numbers are required when requesting
warranty and ordering parts. They are also referred to as engine
model and serial number because of their location.
4.2. Engine type
The Engines DV series engines are 900V series water-cooled four-stroke diesel engines with direct
injection. It is turbocharged and After-cooled engine.
4.2.1. Cylinder block
The cylinder block is a single piece of alloy cast iron. To increase its stiffness, it is extended to a level
below the crankshaft center line. The engine has wet cylinder liners and individual cylinder heads with
struck-in valve seat rings and replaceable valve guides,
4.2.2. Piston con-rod / crankshaft
The forged crankshaft has detachable counterweights (Balance Weights). Radial oil seal is on crankshaft
at crank pulley and at flywheel end oil seal is on crank gear. Flywheel end and crank gear end is same for
the engine.
The con-rods (connecting rods) are die-forged, diagonally split and can be removed through the top of the
cylinders together with the pistons. Crankshaft and connecting rods run in steel-backed lead bronze
ready-to fit type bearings.
• Engine serial No. (eg. 2) : DV8
DV8.1002/0900001
Engine Serial No.
Production Year (2009)
Application Code
• Engine serial No. (eg. 1) : DV10
DV0.1002/0900001
Engine Serial No.
Production Year (2009)
Application Code
rpm
Year of Mfg.
Year of Mfg.
PUNE,INDIA.
PUNE,INDIA.
OIL ENGINES LTD.
OIL ENGINES LTD.
KIRLOSKAR
THIS ENGINE CONFIRMS TO ENVIRONMENT
THIS ENGINE CONFIRMS TO ENVIRONMENT
(PROTECTION)RULES 1986
(PROTECTION)RULES 1986
Sr. No.
Sr. No.
Engine Type
Rating Std.
Rating Std.
Rating Kw/hp
Rating Kw/hp
ISO 3046
ISO 3046

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4.3 ENGINE SPECIFICATIONS FOR DV SERIES ENGINES
Sr. No. Model Unit DV8 DV10 DV12
1 Bore x Stroke mm 130x150 130x150 130x150 2 Firing Order 1-5-7-2-6-3-4-8 1-6-5-10-2-7-3-8-4-9 1-12-5-8-3-10-6-7-2-11-4-9 3 Displacement lit. 15.93 19.91 23.89 4 Number of Cylinder 8 10 12 5 Direction of Rotation Viewed from F.W.E. Anti-clockwise 6 Aspiration Turbocharged Aftercooled 7 Compression Ratio 16.5 : 1 8 Starting Arrangement Electric Start - 24V ( 2x12V ) 9 Governer Electronic Type
10 Class of Governing A0
11 Specific Fuel Consumption
Under Std. Test Conditions gm/kw-hr. 198.64 198.64 200
12 Fuel Timing deg. BTDC 16±116±116±1 13 Injector Opening Pressure bar 250 250 250 14 Valve Clearance - Inlet mm 0.35 0.35 0.35
Valve Clearance -Exhaust mm 0.35 0.35 0.35
15 Bumping Clearance mm 1.4 to 1.55 1.4 to 1.55 1.4 to 1.55 16 Lube Oil Consumption (max) gm/hr. 0.2 % of Fuel Consumption 17 Recommended Lube Oil K Oil Super 18 Lube Oil Pump Flow at 3.5 bar pressure lpm 130 130 145 19 Lube Oil Sump Capacity lit. 38 42 48

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Sr. No. Model Unit DV8 DV10 DV12
4.3 ENGINE SPECIFICATIONS FOR DV SERIES ENGINES
20 Lube Oil System Capacity lit. 44 47 57 21 Maximum Engine Inclination deg. 15 15 15 22 Rated Output Continuous - ISO 3046 kw. 360 448 559 23 Rated Output Standby - ISO 3046 kw. 394 495 613 24 Rated Speed rpm 1500 1500 1500 25 B. M. E. P at Rated Output bar 18.1 18.0 18.7 26 Overall Diamensions - L x W x H mm 1603 x 1125 x 1410 1793 x 1125 x 1410 1983 x 1125 x 1410 27 Dry Engine Weight
- With Flywheel & SAE1 Flywheel Hsg. kg. 1508 1885 2262
28 Noise Level (dBA) at 1m dBA < 75 < 75 < 75 29 Exhaust Back Pressure - Max mm of Hg 50 50 50 30 Recommended Battery Capacity Ah 180 180 180

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4.4 Engine Assembly
4.4.1 Engine Sectional View (Longitudinal)

16
4.4.2 Engine Sectional View (Cross)

17
4.4.3 Engine illustrations
Starter Side
Alternator Side
1. Air Intake Pipe To Intercooler 5. Lube Oil Sump
2. Air Intake Pipe From Intercooler 6. Lube Oil Filter
3. Turbocharger 7. Centrifuge
4. Starter 8. W.I.Manifold
9. Fuel Filter 12. Alternator
10. Thermostat 13. Exhaust Manifold
11. Fan Adaptor
1
2
3
4
5
6
7
8
9
10
11
12
13

18
Crank Pulley Side
Flywheel Side
4.4.3 Engine illustrations
14. Lube Oil Cooler 16. Crank Pulley
15. Water Pump 17. Vibration Damper
18. Flywheel 19. Flywheel Housing
15
16
17
14
19
18

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FUEL PUMP
GEAR
INTERMEDIATE GEAR
(CAM AND FUEL
PUMP GEAR)
INTERMEDIATE
DOUBLE GEAR
CAM GEAR)
(CRANK AND
CAM GEAR
GEAR TRAIN
ASSEMBLY
CRANK SHAFT GEAR
4.5 Gear Train Arrangment
Camshaft, lube oil pump and fuel injection pump are driven by a gear train arranged at Flywheel End.
Water pump is belt driven.
4.6 Valves
The overhead valves are actuated via chilled cast iron tappets, push rods and rocker arms from the camshaft.

20
TURBOCHARGER
OIL STRAINER
V
Lube Oil System Schematic
4.7 Lubrication system
The engine is provided with force-feed lubrication by Gear type pump.
The pressure is produced by a gear pump whose drive gear is in mesh with the crankshaft gear at the
flywheel end of engine.
The oil pump draws the oil from the oil sump and delivers it through the oil cooler and oil filter to the main
distributor gallery and from there to the main bearings, big-end bearings and camshaft bearings as well as
to the small-end bearings and the rocker arms.
The injection pump and the turbocharger are also connected to the engine lubricating system.
The cylinder walls and timing gears are splash-lubricated. Each cylinder has an oil jet provided for cooling
the underside of the pistons.
The system includes adequate lube oil filtering by replacable ‘Spin - on’ filter cartridge. Two separate lube
oil filter cartridges are provided for each side. Centrifuge lube oil filter is also provided for greater oil life.
The water cooled lube oil cooler is provided to maintain the lube oil temperature within limits.The relief valve
controls the engine lube oil pressure. Relief valve is provided on delivery side of the lube oil pump. A
secondary pressure relief valve is also provided in the engine crankcase.

21
4.7.1 Oil Supply Through Oil Pump, Crankcase & Header
4.7.2 Oil Supply Through Cooler & Filter

22
4.7.3 Oil Supply In Crankcase
4.7.4 Rocker Lever Oil Supply