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KD83V16
Kohler KD83V16 User Manual
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Maintenance
Operation and Maintenance Manual
Daily or monthly maintenance activities
Fig. 46: Visual inspection of engine (1)
1
Crankshaft flange — Shaft seal
4
Injection system
2
Crankcase ventilation
5
Oil centrifuge
3
T
urbochargers
92
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
2018-07
91
93
Table of Contents
Default Chapter
9
Table of Contents
9
Product Description
17
Technical Description
17
Design Overview
17
Cylinder Designation, Direction of Rotation
23
Nameplates
23
Diesel Engine Accessory Equipment
26
Technical Data
30
Diesel Engine
30
Cylinder Head
30
Coolant Thermostat
30
Battery Charging Alternator
31
Starter
31
Flywheel Housing
31
Safety
33
Identification of the Warnings
33
Warnings
33
Additional Identifications
33
Additional Rules and Directives
34
Target Audience
34
Responsibility of Machinery Owner
34
International Standard Classification of Occupations
34
Occupational References
34
For the SL1 Maintenance of Power Generation Engines: Maintenance Technician
34
For the SL2 Maintenance of Power Generation Engines: Technician
35
For the SL3 Maintenance of Power Generation Engines: Mechanical Technician
35
For the Operation of Power Generation Engines: Operator
35
Unauthorized Personnel - Servicing
36
Intended Use
36
Limitation of Liability
37
Safety Instructions
38
General Safety Instructions
38
Safety While Commissioning
38
Safety When Starting
39
Preventing Injuries
40
Preventing Bruising
40
Preventing Burns
41
Preventing Fires and Explosion Hazards
41
Preventing Intoxication and Poisoning Hazards
42
Preventing Electrical Hazards
42
Preventing Noise Hazards
42
Preventing Vibrations Hazards
43
Preventing Electro-Magnetic Hazards
43
Preventing Falling Risks
43
Personal Protective Equipment (PPE)
43
Operating and Maintenance Areas
45
Engine Ready for Use or in Operation
45
Engine in Commissioning - Test-Run
46
Emergency Stop
46
Signage Recommendations
47
Prevent Property Damages
48
Safety Instructions for Engine Control Unit (ECU)
48
Alarm Conditions
48
Safety Instructions for the Fuel System
49
Cleanliness Standards and Safety
50
Disposal and Environment Protection
51
Transportation - Storage
53
Safe Handling
53
Dimensions and Weight
54
Transport
56
Safe Transportation
56
Transport Fastening
56
Transport Devices
58
Transport Conditions
58
Storage
60
Storage Conditions
60
Storage Site Foundation Requirements
60
Storage up to 12 Months
60
Storage over 12 Months
60
Unpacking/Depreservation
61
Unpacking
61
Depreservation
62
Suspension of Activity
63
Preservation, Packaging
64
Preservation
64
Control and Operation
65
Filling Lubricants and Operating Fluids
65
Engine Oil
65
Coolant
65
Fuel
65
Starting the Engine
66
Final Check
66
Starting in Cold Temperatures
67
Monitoring the Running Engine
67
Exhaust
68
Drainage
68
Air Filter
68
Engine and Coolant Pumps - Charge Air Cooler
68
Stopping the Diesel Engine
69
Initial Starting/Test Run/After out of Service Period
69
Dismantling
70
Components Disposal
71
Packaging Material Disposal
72
Maintenance
73
Inspection and Maintenance Schedule
73
Maintenance Plan Use
74
Generator Set Ratings
75
Continuous Operating Power (COP)
75
Prime Power (PRP)
75
Emergency Standby Power (ESP)
75
Time between Overhaul (TBO)
75
Service Level Definition
76
Daily or Monthly Maintenance Activities (Level 1) - Version: 2018/07-2
76
Service Level 1 - Engine Service, TBO 4000 Hrs for ESP - Engine Operation - Version: 2018/07-2
78
Service Level 2- Engine Service, TBO 4000 Hrs for ESP - Advanced Maintenance - Version: 2018/07-2
80
Service Level 1 - Engine Service, TBO 15000 Hrs for PRP - Engine Operation - Version: 2018/07-2
82
Service Level 2- Engine Service, TBO 15000 Hrs for PRP - Advanced Maintenance - Version: 2018/07-2
84
Service Level 1 - Engine Service, TBO 24000 Hrs for COP - Engine Operation - Version: 2018/07-2
86
Service Level 2- Engine Service, TBO 24000 Hrs for COP - Advanced Maintenance - Version: 2018/07-2
88
Preparatory Maintenance Activities
90
Daily or Monthly Maintenance Activities
91
Visual Inspection - SL000
91
Observation of the Engine While Running - SL007
94
Removal of the Battery Charging Alternator Cover
95
Checking Drive Belt - SL109
96
Replacing V-Ribbed Belt - SL
97
Replacing Tensioning Device - SL110
98
Test Run - SL008
99
Lubricating System
100
Oil Sampling and Analyze - SL100
100
Checking Prelubricating Pump (Optional) - SL103
101
Checking the Engine Oil Level - SL001
101
Changing Oil Filters - SL101
102
Replacing Centrifuge Paper Filter - SL102
103
Changing Diesel Engine Oil - SL101/SL121
107
Cooling System
111
Coolant Sampling - SL120
111
Checking Coolant Level - SL001
111
Inspecting Low Temperature Circuit (Charge Air Cooler) - SL002
112
Checking Relieve Bores - Water/Coolant Pump - SL003
113
Coolant Drain Points - SL116
114
Fuel System
117
Draining off Water from Fuel Prefilter - SL004
117
Replacing Main Filter - SL105
117
Bleeding the Fuel System
118
Checking Differential Pressure - Fuel Prefilter - SL005
118
Air System
119
Check Service Indicator on Air Filter - SL006
119
Lubricants and Operating Fluids
120
Handling Lubricants and Operating Fluids
120
Filling Volume
121
Diesel Fuels
121
Diesel Engine Lubricants
125
Diesel Engine Coolant
129
Operating Faults
135
Diagnosis Principles
135
Faults - Cause - Remedy
136
Tools and Devices
141
Tools
141
Special Tools
141
Appendix
145
Technical Design Documents
145
Error Code
146
Cleaning Agents, Thread-Locking Adhesives and Greases
158
Cleaning Agents and Thread-Locking Adhesives
158
Standard Tightening Torques
159
Screws Pre-Tightening, Reuse and Marking
159
Standard Torques for Hexagonal / Cylinder / External Hexalobular Heads
161
Standard Torques for Locking Screws and Banjo Bolts
163
Standard Torques for Metric Flange Joints
164
11603 Psi)
165
7252 Psi)
166
Standard Torques for Imperial Thread Unions S Series
167
11603 Psi)
167
Standard Torques for Metric Thread Unions L Series (up to 500 Bar/7252 Psi) for Aluminum
167
Standard Torques for Cutting Ring Flange Joints
168
Standard Torques for Triple Lock Flange Joints
169
Standard Torques for VSTI Screw Plugs
170
Abbreviations - Acronyms
172
Unit Conversion Tables
174
Length Conversion Factors
174
Mass Conversion Factors
174
Pressure Conversion Factors
174
Volume Conversion Factors
174
Power Conversion Factors
175
Moment of Inertia and Torque Conversion Factors
175
Fuel Consumption Conversion Factors
175
Flow Conversion Factors
175
Temperature Conversion Factors
175
Density Conversion Factors
175
Prefix
177
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Kohler KD83V16 Specifications
General
Brand
Kohler
Model
KD83V16
Category
Engine
Language
English
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