Kohler KD103V20 Manuals

Manuals and User Guides for Kohler KD103V20. We have 1 Kohler KD103V20 manual available for free PDF download: Operation And Maintenance Manual

Kohler KD103V20 Operation And Maintenance Manual (204 pages)

Brand: Kohler | Category: Engine | Size: 9.23 MB

Table of Contents
11
Product Description
17
Technical Description
17
Design Overview
17
Conventions
22
Engine or Component Identification
23
Diesel Engine Accessory Equipment
26
Technical Data
30
Diesel Engine
30
Cylinder Head
30
Coolant Thermostat
30
Battery Charging Alternator
31
Starter
31
Safety
32
Identification of the Warnings
32
Warnings
32
Additional Identifications
32
Additional Rules and Directives
33
Target Audience
34
Responsibility of Machinery Owner
34
Recommended Occupations According to International Standards
34
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
41
Preventing Bruising
41
Preventing Burns
41
Preventing Fires and Explosion Hazards
42
Preventing Intoxication and Poisoning Hazards
43
Preventing Electrical Hazards
43
Preventing Noise Hazards
43
Preventing Vibrations Hazards
44
Preventing Electro-Magnetic Hazards
44
Preventing Falling Risks
44
Personal Protective Equipment (PPE)
44
Accessible Areas
46
Engine Ready for Use or in Operation
46
Engine in Commissioning - Test Run
47
Lockout/Tagout
47
Emergency Stop
48
Signage Recommendations
48
Prevent Property Damage
50
Safety Instructions for Engine Control Unit (ECU)
50
Alarm Conditions
50
Safety Instructions for the Fuel System
51
Cleanliness Standards and Safety
52
Disposal and Environment Protection
53
Transportation - Storage
54
Safe Handling
54
Dimensions and Weight
55
Transport
58
Safe Transportation
58
Transport Fastening
58
Transport Devices
60
Transport Conditions
60
Storage
62
Storage Conditions
62
Storage Site Foundation Requirements
62
Storage up to 12 Months
62
Storage over 12 Months
63
Unpacking and Depreservation
64
Unpacking
64
Depreservation
65
Suspension of Activity
67
Preservation, Packaging
68
Preservation
68
Control and Operation
70
Filling Lubricants and Operating Fluids
70
Lubricating Oil
70
Coolant
70
Diesel Fuel
70
Starting the Engine
71
Final Check
71
Starting in Cold Temperatures
72
Monitoring the Running Engine
73
Stopping the Engine
74
Shutting down the Engine
74
Emergency Stop
74
Initial Starting after out of Service Period
75
Preparation of Initial Starting
75
Dismantling
76
Components Disposal
77
Packaging Material Disposal
78
Maintenance
80
Maintenance Information
80
General Information
80
Maintenance Intervals
80
Time between Overhaul (TBO)
80
Generator Set Ratings
81
Continuous Operating Power (COP)
81
Prime Power (PRP)
81
Emergency Standby Power (ESP)
81
Service Level Definition
82
Inspection and Maintenance Schedules
83
Daily or Monthly Maintenance Activities (Level 1) - Version: 2018-07
83
Service Level 1 - Engine Service, TBO 4000 Hours for ESP - Engine Operation - Version: 2018-07
84
Service Level 2- Engine Service, TBO 4000 Hours for ESP - Advanced Maintenance - Version: 2018-07
87
Service Level 1 - Engine Service, TBO 15000 Hours for PRP - Engine Operation - Version: 2018-07
89
Service Level 2- Engine Service, TBO 15000 Hours for PRP - Advanced Maintenance - Version: 2018-07
91
Service Level 1 - Engine Service, TBO 24000 Hours for COP - Engine Operation - Version: 2018-07
93
Service Level 2- Engine Service, TBO 24000 Hours for COP - Advanced Maintenance - Version: 2018-07
95
Preparatory Maintenance Activities
97
Post Maintenance Activities
98
Spray Painting
98
Daily or Monthly Maintenance Activities
100
Inspecting Engine Overall Condition - SL000
100
Inspecting Engine Running at Idle Speed - SL0-007
104
Testing Engine in Operation (ESP Application Only) - SL008
104
Generic Maintenance Activities
106
Removing the Battery Charging Alternator Cover
106
Checking Drive Belt - SL109
107
Replacing Drive Belt - SL
109
Replacing Tensioning Device - SL110
109
Lubricating System
111
Collecting and Analyzing Oil Sample - SL100
111
Checking Prelubricating Pump (Optional) - SL103
112
Checking the Engine Oil Level - SL001
112
Changing Oil Filters - SL101
113
Replacing Centrifuge Paper Filter - SL102
114
Changing Diesel Engine Oil - SL101, SL121
118
Cooling System
122
Collecting Coolant Sample - SL120
122
Replacing Coolant - SL116
122
Inspecting Low Temperature Circuit (Charge Air Cooler) - SL002
125
Checking Relief Bores - Coolant Pump - SL003
126
Bleeding the HT/LT Coolant System
127
Fuel System
131
Draining off Water from Fuel Pre-Filter - SL004
131
Draining off Water and Sediment of Fuel Tank
131
Replacing Main Filter - SL105
131
Bleeding the Fuel System
132
Checking Differential Pressure - Fuel Pre-Filter - SL005
132
Air System
133
Checking Service Indicator on Air Filter - SL006
133
Replacing Crankcase Breather - SL107
133
Lubricants and Operating Fluids
134
Handling Lubricants and Operating Fluids
134
Approved Diesel Fuels, Diesel Exhaust Fluids (DEF), and Fuel Additives
135
Approved Lubricating Oils and Lubricating Oil Additives
140
Approved Coolants
146
Filling Volume
150
Operating Faults
152
Diagnosis Principles
152
Faults - Cause - Remedy
153
Tools and Devices
158
Tools
158
Special Tools
158
Turning Device
161
Appendix
164
Technical Design Documents
164
Error Code
165
Cleaning Agents, Thread-Locking Adhesives and Greases
177
Cleaning Agents and Thread-Locking Adhesives
177
Standard Tightening Torques
178
Lubricant and Threadlocker Application Rules
178
Screws Pre-Tightening, Reuse, and Marking
178
Standard Torques for Hexagonal / Socket / Flange Screws and Hexagonal / Flange Nuts
181
Standard Torques for Internal Drive Pipe Plug with Conical Thread
182
Standard Torques for Screws According to DIN 7643, DIN 910, DIN
182
Standard Torques for Flange Joints
184
Assembling Pipes with Cutting Rings
190
Standard Torques for Triple Lock Flange Joints
191
Standard Torques for VSTI Screw Plugs for Steel and Iron Cast Part
192
Standard Torques for VSTI Screw Plugs for Aluminium
193
Assembling Pipes with DKO Connectors (EL, ET, EW, GZ, GZR, RED)
195
Standard Torques for Collar Clamps
196
Standard Torques for Pipe Clamps According to DIN 3015
197
Abbreviations - Acronyms
198
Unit Conversion Tables
200
Length Conversion Factors
200
Mass Conversion Factors
200
Pressure Conversion Factors
200
Volume Conversion Factors
200
Power Conversion Factors
201
Moment of Inertia and Torque Conversion Factors
201
Factors of Fuel Consumption Conversion
201
Flow Conversion Factors
201
Temperature Conversion Factors
201
Density Conversion Factors
201
Prefix
203

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Kohler KD103V20 Operation And Maintenance Manual (204 pages)

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