KIRLOSKAR DV Series O & M Manual
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KIRLOSKAR DV Series O & M Manual

KIRLOSKAR DV Series O & M Manual

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  • Page 2 INDEX FOREWORD WARRANTY ENVIRONMENTAL POLICY SAFETY GUIDLINES AND ENVIRONMENTAL AWARENESS TECHNICAL INFORMATION COMMISSIONING AND OPERATION MAINTENANCE AND CARE CHECKING AND SETTING ROUNTINE MAINTENANCE CHART ENGINE PRESERVATION DIAGNOSIS AND REMEDY ENGINE FIRING ORDER...
  • Page 3 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.
  • Page 4 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.
  • Page 5 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.
  • Page 7 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.
  • Page 8 • 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.
  • Page 9 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. •...
  • Page 10 Production Year (2009) Application Code 4.2. Engine type The Engines DV series engines are 90 V 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.
  • Page 13 Engine Assembly 4.4.1 Engine Sectional View (Longitudinal)
  • Page 14 4.4.2 Engine Sectional View (Cross)
  • Page 15 4.4.3 Engine illustrations Starter 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 Alternator Side 9. Fuel Filter 12. Alternator 10.
  • Page 16 4.4.3 Engine illustrations Crank Pulley Side 14. Lube Oil Cooler 16. Crank Pulley 15. Water Pump 17. Vibration Damper Flywheel Side 18. Flywheel 19. Flywheel Housing...
  • Page 17 Gear Train Arrangment FUEL PUMP GEAR INTERMEDIATE GEAR (CAM AND FUEL PUMP GEAR) INTERMEDIATE DOUBLE GEAR (CRANK AND CAM GEAR) CAM GEAR GEAR TRAIN ASSEMBLY CRANK SHAFT GEAR Camshaft, lube oil pump and fuel injection pump are driven by a gear train arranged at Flywheel End. Water pump is belt driven.
  • Page 18 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.
  • Page 19 4.7.1 Oil Supply Through Oil Pump, Crankcase & Header 4.7.2 Oil Supply Through Cooler & Filter...
  • Page 20 4.7.3 Oil Supply In Crankcase 4.7.4 Rocker Lever Oil Supply...
  • Page 21 4.7.5 Crank & Cam Oil Supply 4.7.6 Piston Cooling Nozzle...
  • Page 22 4.7.7 Recommend of lubricating oil Initial factory fill is high quality break-in oil for API Service CF. During the break-in period (50 hours), frequently check the oil level. Somewhat higher oil consumption is normal until piston rings are seated. The oil level should be maintained in the safe range between the Min. and Max. marks on the dipstick. The safe range between the marks represents approximately 5 liters.
  • Page 23 4.7.8 Lube Oil cooler Lube oil cooler is provided between the oil pump and the lube oil filter. This cooler is a plate type heat exchanger. LUBE OIL COOLER LUBE OIL FILTER 4.7.9 Lube Oil filter Check for oil pressure and oil leaks, and repair or replace the oil filter if necessary. Change the oil filter cartridge simultaneously at every replacement of engine oil.
  • Page 24 Fuel System Fuel system consists of fuel pump, feed pump, fuel filter, high pressure pipes & leak off pipe etc. Fuel is supplied to fuel pump by feed pump (fuel lift pump) incorporated in the fuel pump itself. A dual type spin-on fuel filter consisting of efficient pre and micro filter cartridges ensure supply of clean fuel to the engine.
  • Page 26 4.8.3 ELECTRONIC GOVERNOR - ESD5500E SERIES SPEED CONTROL UNIT INTRODUCTION The ESD5500E Series speed control unit is an all electronic device designed to control engine speed with fast and precise response to transient load changes. This closed loop control, when connected to a proportional electric actuator and supplied with a magnetic speed sensor signal, will control a wide variety of engines in an isochronous or droop mode.
  • Page 27 power control. The output circuit can provide current of up to 10 amps continuous at 25°C for 12 and 24 VDC battery systems. The actuator responds to the average current to position the engine fuel control lever. In standard operation, the speed control unit performance is isochronous. Droop governing can be selected by connecting terminals K and L and the percent of droop governing can be varied with the droop adjustment control.
  • Page 28 Crank the engine with DC power applied to the governor system. The actuator will energize to the maximum fuel position until the engine starts. The governor system should control the engine at a low idle speed. If the engine is unstable after starting, turn the GAIN and STABILITY adjustments counterclockwise until the engine is stable.
  • Page 29 Idle Speed Setting If the IDLE speed setting was not adjusted as detailed in “Starting Fuel Adjustment” section, then place the optional external selector switch in the IDLE position. The idle speed set point is increased by clockwise rotation of the IDLE adjustment control. When the engine is at idle speed, the speed control unit applies droop to the governor system to insure stable operation.
  • Page 30 ESD5500E Series Wiring Diagram and Outline...
  • Page 31 4.8.4 SYSTEM TROUBLESHOOTING SYSTEM INOPERATIVE If the engine governing system does not function, the fault may be determined by performing the voltage tests described in Steps 1,2,3, and 4. (+) and (-) refer to meter polarity. Should normal values be indicated as a result of following the trouble shooting steps, the fault may be with the actuator or the wiring to the actuator.
  • Page 32 SYMPTOM TEST PROBABLE FAULT Actuator does not 1. Measure the voltage at the battery 1. If the voltage is less than 7V for a 12V energize fully. while cranking. system, or 14V for a 24V system, replace the battery if it is weak or undersized.
  • Page 33 As an aid to help reduce the levels of EMI of a conductive nature, a battery line filter and shielded cables are conveniently supplied by GAC in KT130. To reduce the levels of EMI of a radiated nature, a shielded container P/N CA114 can be sourced from GAC and its distributors.
  • Page 34 4.8.5 FUEL ACTUATOR The 175 SERIES electric actuator is designed io mount directly on a Bosch “P” size fuel injection pump, with a right hand rack, in place of the mechanical governor. When the 175 actuator is installed on the fuel pump, an optimum performance, long life fuel control system results.
  • Page 35 4.8.6 Fuel requirements KOEL Diesel engines was designed to use Number 2-D diesel fuel or equivalent that meets specification DIN 51601-DK. For maximum fuel economy, Number 2-D fuel whenever possible. When temperatures are below -7’C(20°F), use Number 1-D fuel. If Number 1-D fuel is not available, the mixture of one kerosene to two gallons of Number 2-D fuel can be used.
  • Page 36 Air Inlet System - Air cleaner Air cleaner supplied with the engine is Dry Type aircleaner. It consists if two filter elements - Outer & Inner element. Outer element is the main filter element with in built cyclone separater which gives swirling effect to incoming air, to separate out heavy dust particles.The dust is collected in evacuator valve at the bottom of air cleaner housing.
  • Page 37 4.10 Cooling system A properly designed and installed cooling system is vital to satisfactory engine life. Engines using a liquid for cooling have jackets or passage around each cylinder and throughout the cylinder head. The coolant enters the jacket under pressure and on its way to the outlet absorbs heat from the engine.
  • Page 38 4.10.1 Coolant pressure cap Check the pressure valve opening pressure using a Radiator Cap expansion tank cap tester. Replace the filler cap assembly if the measured valve does not reach the specified limit, (pressure valve opening pressure : 0.9 kg/cm Radiator Note : Because it is dangerous to open the pressure cap quickly when coolant is hot, after lowering the inside...
  • Page 39 4.10.3 Water Passage For DV Series Engines Water Passage From Waterpump To Lube Oil Cooler & Then To Header 4.10.4 Water From Header To Crankcase & The To Liner - Right Side View...
  • Page 40 4.10.5 Water From Header To Crankcase & The To Liner - Left Side View LINER 4.10.6 Water Passage From Crankcase To Liner, Liner To Cylinder Head & Then To Crankcase...
  • Page 41 4.10.7 Water Passage From Crankcase To Header...
  • Page 42 4.10.8 Water Passage From Header To Thermostat...
  • Page 43 4.11 V-belt tension check and adjust Check the V - belt tension pressing with thumb midway between the pulleys to see whether the belt deflects. The deflection should more than 10mm ~ 15mm, if necessary re-adjust the belt tension. For the adjustment of the tension, loosen the adjusting nuts which support the alternator, adjust the tension and tighten the nuts again.
  • Page 44 Part List Compressor cover Journal bearing Compressor locknut Bearing hosing O ring (optional) Compressor wheel Bearing Housing Circlip Clamp plate Insert Screw and washer assembly Insert O ring Piston ring (Turbine) Piston ring (Compressor) Turbine backplate Flinger sleeve Shaft and Turbine wheel Oil deflector Setscrew 10.
  • Page 45 2 x 180 Amp-hr Below +10 2 X 200 Amp-hr For exterme low temp. i.e. below – 20 C, refer to Kirloskar Dealer. Battery Cable : 35 sq.mm copper cable upto 1.5 meter 70 sq.mm. copper cable above 1.5 meter...
  • Page 46 4.14 Engine Control Panel 4.14.1 Introduction The KG907V1 is an engine controller that incorporates automatic start and stop sequencing, engine operating parameter measurement and display and engine protection, in a single integrated package. An LCD display is used to show current operating mode, engine temperature, oil pressure, battery volts, fuel level, engine speed, and engine hours.
  • Page 47 4.14.3 Operation Initial Power Up On initial power up, the unit displays “Kirloskar Green Power Ideas” as a company logo. Then it displays Serial number, Application code and Software version. If configured to maintain its mode during power down, it powers up in the same mode as last powered down.
  • Page 48 4.11.4 Mode Selection The unit may be operated in Auto, Manual or Test modes. In the Auto mode, the unit responds to the autostart input, Scheduler or Remote Starts and controls A and B contactors. In Manual mode the unit responds only to the manual push button and may control A and B contactors if this option has been enabled.
  • Page 49 The fuel output is controlled until the engine stops rotating and oil pressure decays (Oil Pressure systems). If the Oil Pressure has not decayed by the end of the Max Fuel Time, the fuel output is deactivated and the controller waits until the oil pressure has decayed, or for the remainder of the Stop Time.
  • Page 50 • “Run On” follows “Running” and is a provided as an adjustable delay to reduce nuisance stopping. The Contactor A & B Outputs remain activated and the Display shows “Run On” with a countdown value.value. If the autostart input is re-activated during “Run On” the unit returns to normal “Running” until the Autostart input is deactivated.
  • Page 51 In Manual Mode Contactor A may be controlled asynchronously from the running of the engine, in response to activity of the auto start input. If “Man Mde Con” is set to Yes, then Contactor A will be unloaded when the autostart is active, and loaded when the autostart restores.
  • Page 52 4.11.8 Alarms and Warnings In the event of abnormal operating conditions the unit will issue a warning or an alarm and shut the engine down as required. The LCD shows an appropriate message indicating the nature of the condition. To draw operator attention to the condition the flashing general alarm LED is used.
  • Page 53 Low Water Level Icon The low water level icon flashes red as a warning if the water level in the radiator is low. The engine remains running. The icon is supplemented with an LCD message. If the water level is very low the icon is lit and alarm LEDs flash. The engine is shutdown.
  • Page 54 The magnetic pickup unit usually counts teeth on the flywheel and is mounted in the bell housing. It is important to ensure the gap between the MPU face and the teeth is 1mm to 2mm, as this distance greatly affects the output of the MPU. The unit requires a minimum of 1.2V RMS at low speed to ensure proper crank disconnect.
  • Page 55 Alternator excitation may also be used as a secondary crank disconnect signal for the case where the speed signal has failed immediately the engine starts to run. This feature can be disabled if not required by setting “Excite Dis” to No. For systems where a battery-charging alternator is not fitted turning off the excitation warning can disable the excitation system.
  • Page 56 Oil Pressure Flt The unit has detected that the Oil Pressure sender has become open circuit. Normally this indicates a faulty sender or broken wiring. The Oil Pressure icon flashes. This will only shut down when the Oil System is set to Sender.
  • Page 57 AutoStart On The unit has detected an Autostart signal when not in auto mode,indicating the engine needs to be started in Auto mode. Scheduler On The unit has detected that a scheduled run is due when not in auto mode,indicating the engine needs to be started in Auto mode. Low Oil Pressure The Oil Pressure has dropped below the Oil Pressure Warning set point while the engine is running.
  • Page 58 Speed Input Sensitivity 0.5 - 350 Volts Pk Input reference 0 volts common Speed Frequency Range 10Hz – 20KHz Displayed speed range 0 – 9999 RPM Engine Hours 0 – 99999.9 Hours Oil pressure sensor type Switch: close on fault, open on fault Resistive 10 to 180 Ohms (VDO/Datcon) Resistive 0 to 90 Ohms (Pricol/Datcon) User Curve...
  • Page 59 Commissioning and Operation Your engine needs preparations before starting At the time of initial commissioning of a new or overhauled engine and before daily starting of the engine, • Check the fuel, coolant and oil level, replenish if necessary. The notches in the dipstick indicate the highest and lowest permissible oil levels. The technical specifications for fuel, oil and coolant are specified in the “Technical Information”...
  • Page 60 Note: Oil pressure will rise as RPM increases, and fall as RPM decreases. In addition, cold oil will generally show higher oil pressure for any specific RPM than hot oil. Both of these conditions reflect normal engine operation. • Check the coolant level on indicator located on balance water tank. If level is low then top up to the “High”...
  • Page 61 Maintenance and care Periodical inspection and maintenance In order to Insure maximum, trouble-free engine performance at all times, regular inspection, adjustment and maintenance are vital. • Daily inspections in below figure should be checked every day. • The maintenance should be executed thoroughly at regular internals, (refer to appendix “General Engine Inspection Cycle”.) Lubrication system 6.2.1...
  • Page 62 • Lightly oil the O-ring and turn the oil filter until sealing face is fitted against the O-ring. Turn 1-1/4 turns further with the filter wrench. Note : Use Kirloskar make genuine lube oil filter.
  • Page 63 6.2.5 Centrifuge Lube oil filter Instruction Manual • Introduction The Centrifuge Cleaner cleans your engine oil continuously when your engine is running. It separates dirt above 1 micron approximately from engine oil thus lowers wear rate of engine components drastically. It avoids harmful oil degradation and arrests depletion of oil additives increasing the oil life.
  • Page 64 • Servicing Instructions It is a precision assembly, handle with care. Carry out servicing preferably when the engine oil is still warm All threaded parts of the centrifuge require following gadgets : a 13 mm spanner, a blint knife, a small adjustable pliers and waste cotton for cleaning. Servicing Procedure Unscrew top nut with a 13 mm spanner and remove centrifuge cover.
  • Page 65 Assemble rotor in correct sequence of parts. Match arrow marks on rotor cover and rotor. Tighten rotor nut firmly by hand. Install rotor on shaft and assemble cleaner cover. Now your centrifuge is ready to collect more dirt from oil. Points to care about centrifuge cleaner Replace rubber rings if deformation or cuts are observed.
  • Page 66 Troubleshooting Problem Probable cause Action Leakage through cleaner Rectangular rubber ring damage Change rubber ring. Rotor does not rotate Nozzles blocked Open rotor and clean nozzles Thoroughly. Re-assemble the cleaner. Rotor does not rotate even Entry valve blocked Do not open entry valve assembly. after cleaning nozzles It requires special tools Contact your Distributor.
  • Page 67 Cooling system The coolant must be changed at intervals of 3000 hours operation or three years whichever comes first. 6.3.1 Coolant draining Drain Valve Remove the pressure cap. Open the drain valve at the radiator lower part to drain the coolant as the right figure. Loosen the coolant drain plug.
  • Page 68 Recooled charge air to intake pipe (max. 50 6.3.4 K COOL Super Plus Pre-mixed 50/50 Extended Life Coolant. Specially developed for Kirloskar Oil Engines Ltd. For all water cooled engines. How to use: Arrest all leakage from the cooling system before cleaning •...
  • Page 69 After cleaning Fill up the system completely with K COOL Super Plus • Do not add any water. Use K KOOL Super Plus only for top up. K COOL Super Plus available only at authorized Kirloskar service dealer outlets. Air intake system Pre - Cleaner...
  • Page 70 Maintenance of air cleaner • The pre-cleaner (if provided) should be cleaned to remove the accumulated dust, after each day’s work, when the engine is stopped. • The restriction indicator, mounted on air cleaner near the hose, indicates the condition of the air cleaner element, when the air element is in good condition, a red signal will be seen through the transparent window on the indicator when the engine is running and will disappear when engine is stopped.
  • Page 71 Use a damp cloth to wipe out all dust in the air cleaner. Thorough cleaning of the fitter element with compressed air is recommended. Clean the element from inside to outside using the pressurised air pipe. IMPORTANT - Too much air pressure can break the filter paper and destroy the element. (Max. Air Pressure 3.0 kg/cm2) Replace the main element after two cleaning intervals.
  • Page 72 Fuel system checks Fill the tank with the recommended fuel. Keeping tanks full reduces water condensation and helps keep fuel cool, which is important to engine performance. Make sure fuel supply valves (if used) are open. To insure prompt starting and even running, the fuel system must be primed with the fuel feed pump manually before starting the engine the first time, or after a fuel filter change.
  • Page 73 6.5.4 Injection pump • Check the fuel injection pump housing for cracks or breaks, and replace if damaged. • Check and see if the lead seal for idling control and speed control levers have not been removed. • No alterations must be made to the injection pump. If the lead seal is damaged the warranty on the engine will become null and void.
  • Page 74 6.5.7 KOEL Recommends use of K Add (D) for diesel. • This hepls in easier starting. • Improves fuel economy & power. • Enhances fuel stability. • Reduces exhaust emissions. • Provides detergency action to keep nozels / injectors cleane. •...
  • Page 75 Turbocharger Maintenance IMPORTANT: Disassembly nullifies Schwitzer warranty responsibility so it is important to check that the turbocharger is no longer under warranty before dismantling. Mark the relative positions of the turbine housing and compressor cover to the bearing housing. Check the motion of the shaft for excessive radial or axial play. Refer to the ‘Service Limits and Torque Values’...
  • Page 76 15. Remove inner circlips. Cleaning is generally done by soaking the components in commercially available non-caustic solvent, wiping, brushing or scraping any residue off and then blow drying with clean compressed air. However, vapour blasting is a good alternative if available, providing the vapour blasting equipment manufacturers instructions are carefully followed and critical surfaces are appropriately protected (see details below).
  • Page 77 Bearing Housing Inspect visually for evidence of cracks and fractures, pitting of gasket and other machined surfaces, or distortion of the turbine end flange. Reject and replace if any of the above conditions are severe. Closely inspect the bearing bore visually for signs of damage or wear. The condition of the removed bearings will be a good indicator of the bore condition.
  • Page 78 V Clamps Inspect visually for evidence of cracks or distortion of the clamp and T-bolt threads. Reject and replace if damage is excessive. When reassembling the turbocharger a Schwitzer Overhaul Kit should always be used (see Parts List on the S300 Exploded View). Re-use only parts complying with the “Inspection of Parts for re-use”...
  • Page 79 11. Fit the new ‘O ring onto the insert and a new piston ring into the flinger sleeve. ’ 12. Fit the flinger sleeve assembly into the insert. TAKE CARE NOT TO DAMAGE. THE PISTON RING. 13. Lubricate the insert ‘O ring and press the insert into the bearing housing.
  • Page 80 Checking and setting Adjustment of valve clearance 7.1.1 General information The valve clearances are to be adjusted at the times of the following situations. • After initial 50 hour’s operation. • When the engine is overhauled and the cylinder heads are disassembled. •...
  • Page 81 Checking and setting Adjustment of valve clearance 7.1.1 General information The valve clearances are to be adjusted at the times of the following situations. • After initial 50 hour’s operation. • When the engine is overhauled and the cylinder heads are disassembled. •...
  • Page 82 Adjustment of Injection Timing Injection timing is required to be adjusted when fuel pump has been removed from the engine during major overhaul or fuel pump calibration. 7.2.1 Method of Adjusting Injection Timing • Turn the flywheel until TDC mark on flywheel (Cylinder No.1) matches with the mark on flywheel housing (Ensure that it is compression TDC).
  • Page 83 Cylinder compression pressure Stop the engine after warming it up, then remove the nozzle assemblies. Install a special tool (gauge adapter) in nozzle holder hole and connect the compression pressure gauge to the adapter. Cut off fuel circulation, rotate the starter, then measure compression pressure of each cylinder. Standard 24-28 kg/cm Limit...
  • Page 84 ROUNTINE MAINTENANCE CHART Inspection Remarks Check for leakage (hoses, clamp) Check the coolant level Change the coolant Every 5000 hrs Cooling Check & Adjust the V-belt tension system Replace V-Belts 3000 Hours Check Radiator Cooling fins Check the radiator hoses Check for leakage Lubrication Check the oil level...
  • Page 85 Engine preservation Preservatives and Preservation procedure is recommended for engine when it is to be kept idle (out of use) for prolonged period (more than 12 months). Recommended Preservatives MANUFACTURER Engine Lube oil and Engine Cooling Unpainted Ferrous Fuel system System metal Parts Bharat...
  • Page 86 All vents i.e. engine inlet pipe, exhaust pipe, air cleaner inlet, crankcase breather etc. to be carefully sealed with water proof paper and water proof adhesive tape. Dipstick on engine to be sealed in place, with water proof adhesive tape. NOTE: - DO NOT ROTATE CRANKSHAFT AFTER ABOVE MENTIONED OPERATIONS.
  • Page 87 Diagnosis and Remedy 1. Engine Starting Impossible Starting motor operation poor Starting motor revolution Engine Inspection of battery electrolytic Fuel liquid amount & gravity Inspect air cleaner Inspect amount of fuel Normal Too low Normal Polluted Normal None Replace or Replenish Adjustments clean element...
  • Page 88 2. Engine Overheated Operating state 1. Overload 2. Radiator core clogged 3. Continuous over-run Cooling unit Fuel unit Inspect fuel quality Fuel excessive supply Check coolant Normal Too low Poor Check fan belt Check injection nozzle Clean and replace Repair tension wear with specified fuel Replace...
  • Page 89 3. Output Insufficient Engine Installation improper Check for coupling Fuel Unit Other alignment Adjust or replace Check for air mixing in fuel Inspect air cleaner coupling Inspect fuel supply pump Clean - Replace Normal Inspect air leakage of air piping line Clean - Replace Normal Inspect engine control...
  • Page 90 4. Oil pressure lowered Check if oil pressure gauge indicates wrongly Check oil amount Normal Too low Use recommended oil Check cooling (replenish) temperature Too high Normal Refer to engine overheating Inspect oil quality Normal Improper Check oil relief Water & fuel mixed valve in oil Disassemble engine...
  • Page 91 5. Fuel Consumption Excessive Causes according to Use Conditions 1. Overload 2. Governor's Arbitrary Adjustment 3. Full Speed Operation for Long time Inspect fuel leakage 4. Sudden Speed change from Low to High Speed Normal Oil leakage Inspect injection nozzle (injection pressure Adjust - Replace atomizing state etc.)
  • Page 92 6. Oil Consumption Excessive Cause according to use conditions 1. Excessive oil infusing 2. Continuous operation in low or extremely cold state Inspect oil leakage Inspect oil cleaner Clean Replace Oil leakage Normal Internal Check oil quality External Retighten Check compressed Replace with Replace pressure...
  • Page 93 7. Engine Knocking Inspect combustion of fuel & oil (carbon residue exhaust gas) Unconfirmed confirm Inspect compressed Disassemble Too low pressure engine Check valve clearance and Normal cylinderhead gasket for damage Inspect injection pump Replace Normal Adjust Adjust Normal Disassemble engine Check fuel quality Use specified fuel...
  • Page 94 8. Battery Discharge Battery Wiring Switch Generator Inspect cut wire Check fan belt Check electrolytic shorts and loose liquid amount tension & damage connections Repair Replace Normal Battery room Battery over Battery self Electrolytic damage discharge charging liquid's standard Inspect generator Replace Charging Voltage regulator...
  • Page 95 9. Oil Consumption Excessive Oil level elevated Oil level lowered Clearance between Looseness of valve Replace Replace in set cylinder liner & piston stem & guide Wear of piston ring, Replace piston, Replace seal Wear of valve stem seal ring groove piston ring Piston ring's damage, Cylinder head gasket's...
  • Page 96 10. Engine noisy For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. 1. Crankshaft As the wear of bearing Replace bearing & or crankshaft progress, grind crankshaft the oil clearances increase. Lopsided wear of crankshaft Grind or replace Oil supply insufficient due to...
  • Page 97 10. Engine noisy For noises arise compositely such as rotating parts, lapping parts etc., there is necessity to search the cause of noises accurately. 3. Piston, piston pin & piston ring Piston clearance increase Replace piston & as the wear of piston and piston ring piston ring progresses.
  • Page 98 11. Fuel Consumption Excessive Injection timing Fuel injection Adjust Adjust injection pump incorrect amount excessive...
  • Page 99 Engine Firing Order 8 Cylinder V : Firing Order 10 Cylinder V – Firing Order 1 - 5 - 7 - 2 - 6 - 3 - 4 - 8 1 - 6 - 5 - 10 - 2 - 7 - 3 - 8 - 4 - 9 12 Cylinder V –...

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