Contents 1. Introduction 2. Product Specifications 3. Product Features 4. KG 545 Gen-set Controller 5. Technical Data Sheet 6.

The Cutting Edge

Emission Details Altitude / Temperature Capability Customer Entitlements

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1. INTRODUCTION
Kirloskar Engines - The driving force n The brand 'Kirloskar', a rich engineering heritage of over 120 years. n Kirloskar Oil Engines Ltd is a part of India's premier engineering Kirloskar group, founded in 1946. n India's largest & leading manufacturer of the widest range of Diesel Engines and applications (3 hp to 11000 hp). n Kirloskar engines are available in both air cooled & liquid cooled versions. n Annual engine volumes exceeding 2,30,000. n Active population of over two million engines worldwide n Sales exceeding Rs. 2100 cr. n Dominant market presence in power generation, construction, earthmoving & material handling equipments. n Our journey towards excellence : n ISO/TS 16949 since 2007 by ABS QE, Inc. n ISO 14001 certification for EMS systems, since 1999 by TUV NORD. n ISO 9001 certification for QMS since 1992 by ABS QE, Inc. n OHSAS 18001:2007 certification for Health, Safety & Environment since 2009 by PUV NORD n Awarded as 'best energy efficient unit ' by Govt of Maharashtra for Pune & Nashik plants. n CII Exim Business Excellence Award for Strong Commitment to Excel. Kirloskar Green Gensets n Kirloskar Green' Gensets are acknowledged market leaders in India with full range from 5 kVA to 625 kVA and 1.6 MW to 5.1 MW. n More than 60,000 Gen-sets across the country provide stable and reliable power for the Indian Telecom Network. n More than 15,000 Gen-sets deployed along the Indian Borders, supporting the Defence Organizations. n Large number of Satisfied Customers from Manufacturing, Software, Construction, Infrastructure & Service sectors in 320 kVA to 625 kVA range.

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2. PRODUCT SPECIFICATIONS
DV 12 powered Gen-set Technical specifications
GENSET PARAMETERS Genset Model KVA Rating KW Rating Voltage Frequency Phase Power factor Overall Dimensions of gen-set Length Width Height Height including silencer Approximate Dry Weight (with canopy) Genset static load (Max) Rated speed Method of Starting Overload capability (for 1hr in 12 hrs operation) Fuel consumption at 75% load Lube Oil Consumption % of fuel consumption Lube oil change period Alternator efficiency at 75% load DG set Noise level at 1Mtr (with canopy) Overall thermal effiency of engines/break thermal effiency of engines at 100%load Mechanical effiency 100% load Note : ** Considering Specific gravity of diesel as 0.845(+5% tolerance applicable as per ISO 3046) for well run Genset % Ltr/Hr % Hrs % dBA % % mm mm mm mm Kg Kg RPM 6670 2000 2750 3450 7500 8450 1500 Electric (24V) 10 91.9** 0.12^ 500 95.7 <=75dba as per CPCB norms 42.86 88 6670 2000 2750 3450 7500 8450 1500 Electric (24V) 10 96** 0.12^ 500 95.7 <=75dba as per CPCB norms 42.86 88 kVA kW V Hz KG600WS3 600 480 415 50 3 0.8 KG625WS3 625 500 415 50 3 0.8

In view of continuous product up-gradation, above specifications are subject to change without prior notice

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3. PRODUCT FEATURES
Engine Features n Four valve technology & Central injection system makes 'DV12 the most fuel efficient engine in its class. n Kirloskar 'DV12 engine is compliant to future emission norms of EU stage 2 level. n Kirloskar 'DV12 engine can operate on 100 % bio-diesel giving 100 % power & lower emissions. n Lower lub oil sump capacity as compared to others, lower maintenance cost. n Enhanced oil change period of 500 Hrs. n Coolant change after 4000 Hrs. n Light weight & strong crankshaft material, gives better strength and increases the power train peak cylinder capability by 20 %. n Gear cover & bell housing is a single piece design resulting in less leakage points & less torsional vibration. n 'Belly Mounted' engine design reduces the vibrations and thus improves the reliability of engine. n Most ideal for AMF application as well as for parallel operations. n Provision of 'Auto Idle run' during start & stop gives time reduces initial friction losses improving life of engine & Turbo charger. n Indigenously developed fuel injection system, designed in collaboration with 'Bosch', with two feed pump units. n 'Double feed pump' increases tolerance for low level of fuel in fuel tank, resulting in less chances of air locking. n Air to air CAC results in less exhaust temperature, hence less load on cooling system thereby improving the reliability of engine. n Heavy duty Turbo charger, fully matched for varying load conditions. n Rugged design to meet toughest operating conditions. Gen-set Features n Compact and aesthetically designed, CPCB approved canopy. n Excellent transient response for sudden loading. n State-of-art Engine and Gen-set monitoring system. n Safety control for low coolant level in radiator, as standard feature. n Engine health monitoring through internet and SMS to operator. (Optional)

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4. KG 545 GEN-SET CONTROLLER

Gen-set Metering Parameters Phase/Line voltage Line current Frequency Average Voltage Average Current Phase kW & Total kW Kwh & PF kVA / kVAr Earth fault current

Engine Metering Parameters Oil Pressure Engine coolant Temperature Fuel Status Engine speed Oil Temperature (optional) Canopy Temperature Engine run Hours Total starts Battery condition monitoring

Electrical Safeties (Along with Metering) Genset Under/Over voltage Battery Under/Over voltage Under/Over frequency Phase Failure Phase sequence reverse Over Current Over kW High Earth Current Mains monitoring

Mechanical Safeties (Along with Metering) Under/Over speed Low Lube oil pressure High Lube oil Temperature (optional) High engine coolant temperature Charging Alternator fail Low coolant level Low fuel level High canopy temperature Start/Stop fail

Unique features of KG 545 Gen-set Controller

measurement values) for ease of maintenance/service & preventive maintenance annunciation. n Remote monitoring of entire gen-set (optional). n Remote start/stop provision (optional). n Capability of withstanding wide range of operating temperatures (-20 to 70 Deg. Cel.). n Canopy temperature monitoring. n Individual touch buttons for Manual, Auto and Test mode. n LED indications for gen-set status and alarms. n Battery condition monitoring. n Statistical cumulative counters like No. of starts, Engine run Hrs, kWH. n Setting provision for different parameters and access to set parameters on front panel. n Common controller for AMF and manual operation. n Additional provision for three spare digital inputs & two spare digital outputs. n Manual control for Mains & DG set contactor.

KG 400 WS
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n State of the art Compact Microprocessor based fully configurable technology. n Integration of all engine and alternator parameters. n For ease of viewing, high performance graphical LCD and prominent display. n Event logging history (stores last 100 events with date time stamp and complete

5. TECHNICAL DATA SHEET

ENGINE DATA Engine model Rated output (prime power rating as per ISO 3046) No. of cylinders Engine configuration (Inline / V type) Operating cycle Displacement Bore x Stroke Aspiration Compression Ratio Piston speed Brake Mean Effective Pressure (BMEP) Firing order (Starting from gear end) Overall dimension (L (HSG to Fan pulley) x W x H) Block loading capacity (as per ISO 3046-Part4) Engine weight (Dry weight of bare engine) FUEL SYSTEM Type Static Injection timing Injectors hole Nos. x Size Fuel oil Fuel Filter type Filtration capacity Fuel transfer line restriction (maximum allowable) Fuel transfer pump pressure Max lift of fuel transfer pump Nozzle opening pressure Specific Fuel Consumption at 50% load 75% load 100% load mm DV 12 kW ( hp ) No. 532.13(723) 12 V type 4 Stroke DI 23.88 130 150 TA 16.5:1 7.5 18.73 1-12-5-8-3-10-6-7-211-4-9 1827 1125 1410 45% Kg 2100 DV 12 SR1 552(750) 12 V type 4 Stroke DI 23.88 130 150 TA 16.5:1 7.5 18.73 1-12-5-8-3-10-6-7-211-4-9 1827 1125 1410 On request 2100

Ltrs mm

m/s Kg/cm2

Deg BTDC mm

Micron KPa Kpa m Kg/cm2 (g/Hp-hr) (g/Hp-hr) (g/Hp-hr)

Inline 16 1 7 0.248 HSD IS 1460 Spin on 5 100 250 1 260 150* 144* 143*

Inline 16 1 7 0.268 HSD IS 1460 Spin on 5 100 250 1 260 150* 144* 143*

* Declared sfc for well run engine tested at standard conditions(+5% tolerance applicable as per ISO 3046)

(Contd)

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6. TECHNICAL DATA SHEET

LUBE OIL SYSTEM Recommended lube oil Lube oil pump Lube oil sump capacity(Max) Lube oil sump capacity(Min) Lube oil system capacity Angularity Limit of oil sump (along or across crankshaft axis) Lube oil Pressure range at rated load Lube oil filter type Filtration capacity Lube oil pump flow rate (At 2935 rpm with 3.5bar pressure) Lube oil change period COOLING SYSTEM Type of cooling Engine coolant flow rate Coolant pressure Radiator Cooled: Total qty of coolant (including pipings) K-Cool super(Water: Cooling/Ventilation Air flow through canopy Combustion Air inlet flow Total Fresh Air required Heat Exchanger cooled: Qty of coolant (HE + CAC + pipings) Raw water Flow rate across Heat exchanger Raw water Flow rate across CAC Raw water pressure Ventilation Air Flow required to carry out radiated heat in case of Acoustic enclosure installations Operating Temperature range of the Thermostat Maximum Coolant temp allowed * First oil change at 50 hrs. K-Oil Super Gear Pump 50 40 57 15 4-4.5 Spin on 12 130 500* Liquid cooled 700 1 144 10 % 50:50 596 49 645 On request On request On request On request On request K-Oil Super Gear Pump 50 40 57 15 4-4.5 Spin on 12 130 500* Liquid cooled 700 1 144 10 % 50:50 600.6 53 653.1 On request On request On request On request On request

Ltr Ltr Ltr Deg bar Micron LPM Hrs

LPM Kg/cm2 Ltr

m3/min m3/min m3/min Ltr LPM LPM Kg/cm2 m3/min

Deg C Deg C

74-88 104

74-88 104
(Contd)

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7. TECHNICAL DATA SHEET

HEAT REJECTION DETAILS Heat Rejection to coolant Heat Rejection to CAC Heat Rejection to exhaust Heat Rejection from engine surface AIR INTAKE SYSTEM Intake filter type Dirty element restriction Intake manifold pressure Maximum Intake manifold temperature (at Altitude 1000m & at temp 45 deg) EXHAUST SYSTEM Exhaust silencer type Max. Permissible exhaust back pressure Exhaust gas flow Exhaust gas temperature (Max ) Exhaust Smoke level at 100% load (at NTP condition) Min exhaust gas pipe size (per bank)(diameter) GOVERNER DATA Type Whether adjustable droop provided Transient speed increase for sudden 100% decrease of load Transient speed decrease for permissible sudden increase of load Recovery time Speed raise / lower from panel provided VALVE MECHANISM Type Valve clearance at cold: Inlet / Exhaust Valve Timing: Inlet open / Inlet close Exhaust open / exhaust close OTHER INFORMATION Maximum time to start from cold & attain rated Speed & ready to take load Overload capacity kW kW kW kW 213.1 108.6 358.0 117.5 Dry 635* 310 75 Residential grade 1175 (11.5) 3026 600 2 127 Electronic :Integral with Fip & Isochronous capability Yes <10 <10 <5 Optional OHV 0.35 1 27 min BTDC/ 11 27 min ABDC 24 43 min BBDC/ 7 18 min BTDC 30 10% for 1 hr in 12 hrs of Operation 221.6 112.9 372.3 122.2 Dry 635* 310 75 Residential grade 1175 (11.5) 3147.04 600 2 127 Electronic :Integral with Fip & Isochronous capability Yes <10 <10 <5 Optional OHV 0.35 1 27 min BTDC/ 11 27 min ABDC 24 43 min BBDC/ 7 18 min BTDC 30 10% for 1 hr in 12 hrs of Operation

mm of H2O Kpa Deg C

mm of H2O (kpa) kg/hr Deg C BSU mm

% % sec

mm Deg Deg

Sec %

* Do the maintenance of air cleaner element depends on Restriction indicator showing red band or 635 mm of wg pressure whichever will be earlier

(Contd)

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8. TECHNICAL DATA SHEET

In view of continuous product up-gradation, specifications given in Technical data sheet are subject to change without prior notice

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9. THE CUTTING EDGE

Emission Details
DV .12 Engine is ready to meet future emission norms having emission values well below the prescribed CPCB limits.

Parameter Nox (g/kW Hr) CO (g/kW Hr) HC (g/kW Hr) PM (g/kW Hr) Smoke (in m-1) Average Sound level at 1m with canopy (dBA)

CPCB Limits 9.2 3.5 1.3 0.3 0.7 75

KOEL: DV12 6.1 0.38 0.13 0.06 0.05 75

Altitude / Temperature Capability

Ambient Temp Deg C Altitude in meters
n Full rated

20 2400

30 1500

38 1200

45 900

output is available at above corresponding ambient temperatures and altitudes. n For site conditions other than stated above, please contact KOEL for available power output.

Customer Entitlements
Assistance n
n Assistance

for DG set sizing. for DG set installation and clearances from local administrative authorities. by Service & Sales dealer.

n Joint commissioning n 2 years

/5000 hrs. warranty on use of K-oil & K-filters. covers entire Genset subjects to our standard warranty terms.

n Warranty n 9 free

periodic service checks during warranty period. of lubrication oil along with DG Set. on maintenance & operations of DG set. super plus coolant, filled in Radiator

n First fill n K-Cool

n Training

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After Sales Service Support

Customer Care : Round the clock, at your service, whenever & wherever you need. After sales service is the key to the long-term viability of any business. We are committed to provide adequate after sales service support & believe in creating enduring relationship with every individual customer we serve. Kirloskar believes in the wise saying think global & act local with full dedication, which have helped us, successfully achieve 100 years of great service. Service Offerings
Jammu & Kashmir

Service Network across the Nation Where your business operations are far reaching across the country & moreover when they are located in absolute remote places, your business counts on reliability & availability ensuring minimum downtime. Key to the quality of our after sales service is our strong service force, which are always ready to attend your calls anywhere anytime.

: North Zone
Leh

n Free service checks. n Authorized Kirloskar Service Dealers in your neighborhood to promptly respond to your service calls, provide extensive after sales support including operational, maintenance & repair contract. n Single window service for Genset & Customised AMC. n 24/7 help line service for all our customers, offering timely customer support to deal with inquiries. n Fully implemented CRM module to provide proactive & quick service response. n Trained & experienced service team to provide value-added support to the highest standards ensuring customer satisfaction at all times. n Support systems like Mean Time to Restore, Engine Down Order, First Pick Availability for maximum uptime of Gensets. n K-oil / K-cool super plus for product life extension. n Excellent product support through easy availability of spare parts, product training, Re-conditioning and warranty administration. n Easy and Quick delivery anywhere anytime.

: Factory, Training & Service Centre

A : Area Office - 13

Srinagar Rajouri
Jammu

: East Zone : West Zone

: Service Dealer - 100 : Service Dealer Branch - 290

Kathua
Himachal Pradesh

Gujarat
Bhuj

Jharkhand
Pakur

Ahmedabad Rajkot Ankleshwar Gandhinagar

Madhya Pradesh
Bhopal Indore
A

Ranchi

Asansol Burdwan

Tripu ra

Damtal Kulu Mandi Una Punjab Amritsar Baddi Jalandhar Ferozpur Shimla Ludhiana Uttaranchal A Chandigarh Dehradun Sangrur Yamuna Bhatinda Haridwar nagar Patiala Karnal Saharanpur Sri Ganganagar Panipat Haldwani Sirsa Rohtak Bijnor Hissar Haryana DELHI Rewari Moradabad A Nepal Ghaziabad Uttar Jhunjunu Prad Bikaner Noida esh Gurgaon Meerut Jaipur Karauli F'bad Sitapur Rajasthan Aligarh Bareilly A Bhiwadi Gonda Jaisalmer Hardoi Agra Alwar Ajmer Shahjahanpur Lucknow Muzaffarpur Faizabad Jodhpur Hardoi A Madhubani Gorakhpur Balotra Kanpur Sultanpur Mau Patna Hajipur Gwalior Rajsamand Bhilwara Allahabad Katihar A Barmer Bihar Varanasi Udaipur Jhansi Kota Bhagalpur Badohi Gaya Dungarpur Satna Mehesana Dhanbad

: South Zone

hal n ac Aru desh Pra

Guwahati

Itanagar

Siliguri Barpeta

Assam

Nagaland
Johrat

Meghalaya

Manipur
Imphal

Aizwal

Jabalpur Khandwa Jamshedpur

Mizoram

West Bengal
A

Jamnagar Bhavnagar Silvassa

Baroda Surat Nashik Akola Amravati Nagpur Yavatmal Chandrpur Aurangabad A'Nagar Latur Pandharpur PCMC Z A Pune

Chattisgarh
Raipur
Orissa

Rourkela Sambalpur Barbil Raygada

A

KOLKATTA
Bhubaneshwar Angul Balasore

Maharashtra
Bhiwandi

Jharsuguda Jajpur Road

MUMBAI Thane
Panvel Raigad Ratnagiri Chiplun Kankavli

Andhra Pradesh
A

Solapur Satara Kolhapur Gulbarga Kagal Belgaum

Warangal Secundrabad Hyderabad Vijaywada

Vishakhapattanam Rajamundri

Karnataka
Goa
Dharwad Ananthapur Kurnool Hasan Udupi Mangalore
A

Hubli

Cuddapah

Nellore

Tirupati Chittor
A

Bangalore Mysore Salem Dindigul Erode Tirupur Coimbatore Pallakad Kottayam Trivandrum Trichy Tirunelveli Sivakashi Madurai Tuticorin Nagarcoil Karur

CHENNAI

Andaman Islands

Port Blair

Kerala
Calicut Trichur Ernakulam Kochi

Pondicherry

Help Desk : Call 1800 233 3344 (Toll-free from BSNL / MTNL) 020-6608 4608 (Other than BSNL / MTNL) Email : koel.helpdesk@kirloskar.com
Customer assistance is available from our help desk (24 hrs. x 7 days a week) for all after sales & service assistance.

Karaikkal Thanjavur

Lakshadweep

Idukki

Tamilnadu

Nicobar Islands

KOEL Sales Offices l Ahmedabad : Ground Floor, D Block, Pruthvi Tower, Jodhpur Char Rasta, Ahmedabad - 380015. Phone : +91 (79) 2692 9687, 2692 9689. l Bangalore : 3rd Floor, Shri Lakshmi Complex, 15, St. Marks Road, Bangalore - 560 001. Phone : +91 (80) 2558 7562, 30578164, 30578165. Fax : +91 (80) 2558 7559. l Bhubaneswar : 178 A, Zone-B, Mancheswar Industrial Estate, Bhubaneswar-751010, Orissa. Phone :+91 (674) 2585064, 2586059, 2588047. Telefax : +91 (674) 2588021. l Chennai : Nelson Tower, 1st Floor, 2nd Wing, 51, Nelson Manickam Road, Chennai - 600 029. Phone : + 91 (44) 23744661, 23744624. l Cochin : No. 39/2694 A1, Anugraha, Panthiyil Lane, Warriam Road, Cochin - 682016. Phone : +91 (484) 2385757, 2385758. Fax: +91 (484) 2385756. l Guwahati : 29,G & B Road, Pan Bazzar, Guwahati - 781 001. Phone : +91 (361) 2736016, 2736017. Telefax : +91 (361) 2736015. l Indore : 203, Goldstar Complex, Opp Treasure lsland, 576, MG Road, Indore - 452001. Phone : +91 (731) 3913108, 3913109, 3913110, 3913111 Telefax : +91 (731) 3913112. l Jaipur : 21, Sudarshan Pura, Industrial Area, Bais Godwn, Jaipur - 302006. Phone : +91 (141) 2210405, 2214149, 2214150. Fax : +91 (141) 2214149. l Kolkata : 8th Floor, Poonam Building, Flat Nos. 8A & 8B, 5/2, Russel Street, Kolkata - 700 071. Phone : +91 (33) 2217 0858, 2217 0860, 2217 0861. Fax : +91 (33) 2217 0859. l Lucknow : 498 / 143 KA, Faizabad Road, Near IT Collage Chauraha, Upper Floor of State Bank of Indore, Lucknow - 226 007. Phone : +91 (522) 2741440/42/43. Fax : +91 (522) 2741441. l Ludhiana : Plot No. 12, NPC Tempo Union Street, Near Arjun Gas Godown Sherpur Chowk Ludhiana - 141003. Phone : +91 (161) 254 6667, 2546669. Fax : +91 (161) 2546753. l New Delhi : 404, 4th Floor, Surya Kiran Building, 19, Kasturba Gandhi Marg, New Delhi-110001. Phone : +91 (11) 23711786, 47195200, 47195202, 47195217, 47195205. Fax : +91 (11) 23710159. l Secunderabad : 5-2-220 to 222, 2nd Floor, Padmavathi Tower, Hyder Basti, Opp. Andhra Bank, Ranigunj, Secunderabad- 500003. Phone : +91 (40) 27534197, 27534176. Telefax : +91 (40) 27534170.

Laxmanrao Kirloskar Road, Khadki, Pune 411 003 INDIA. Tel. : +91(20) 2581 0341 Fax : +91(20) 2581 3208, 25810209 www.kirloskar.com

Stamp of Authorised Representative

This Catalog is copyrighted and may not be reproduced in any form not even parts of it, without previous written permission by copyright owners, Kirloskar Oil Engines Ltd.

Dv12 / 26 Jan.2010 /01

KIRLOSKAR OIL ENGINES LIMITED