Kohler KD1500 Operating instructions

Category
Engine
Type
Operating instructions

This manual is also suitable for

Operation and Maintenance Manual
Translation of the original instructions
Diesel engine
KD45V20
From serial number 2016 18 0001
EN
33521030001_4_1
08-2018
Preface Operation and Maintenance Manual
Preface
Only for the United States of America:
WARNING:
This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth
defects or other reproductive harm.
For more information go to www.p65warnings.ca.gov/.
WARNING:
Breathing diesel engine exhaust exposes you to chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area.
- If in an enclosed area, vent the exhaust to the outside.
- Do not modify or tamper with the exhaust system.
- Do not idle the engine except as necessary.
For more information go to www.p65warnings.ca.gov/diesel.
This Operating and Maintenance Manual has been written for the operator and
maintenance personnel of the Diesel engine.
It contains descriptions of the:
Technical data
Safety regulations
Handling and operation
Maintenance
Anyone involved in working with or on the Diesel engine must read and follow the
instructions in the Operating and Maintenance Manual carefully both before the
first commissioning and at regular intervals.
Work with the diesel engine includes:
Handling
Servicing, including maintenance, inspection.
The Operating Manual facilitates the operator's familiarization with the diesel
engine and prevents faults through incorrect operation.
Kohler Co. will not allow any warranty claims that arise due to incorrect operation,
insufficient maintenance, use of unapproved operating fluids or non-compliance
with safety regulations.
Kohler Co. will annul any obligations entered into by Kohler Co. and/or their
dealers such as warranty assurances, service agreements etc. without prior notice
if spare parts other than original Kohler parts or parts purchased from Kohler Co.
are used for maintenance and repairs.
2
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Operation and Maintenance Manual Preface
In extreme conditions, more frequent maintenance than scheduled in the
inspection plan can be required.
Changes, conditions, copyright
This document is protected by copyright. The copyright is held by:
Kohler Co.
Subject to changes in the interests of technical progress.
Proprietary notice ISO 16016: “The reproduction, distribution and utilization of this
document as well as the communication of its contents to others without express
authorization is prohibited. Offenders will be held liable for the payment of
damages. All rights reserved in the event of the grant of a patent, utility model or
design.”
List of changes
Version from serial number Comments Date
33521030001_1_1 2016 16 0001 First version December 2016
33521030001_2_1 2016 16 0001 Various changes April 2017
33521030001_3_1 2016 16 0001 Change of maintenance
schedule
August 2017
33521030001_4_1 2016 16 0001 Various changes August 2018
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
3
Preface Operation and Maintenance Manual
4
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Contents
Service Assistance
9
1 Product description
11
1.1 Technical description
11
1.1.1 Design overview
11
1.1.2 Overview of sensors
13
1.1.3 Explanation of the type designation
14
1.2 Technical data
17
1.2.1 Diesel engine
17
1.2.2 Cylinder head
17
1.2.3 Coolant thermostat
18
1.2.4 Battery charging alternator
18
1.2.5 Starter
18
1.2.6 Flywheel housing
18
2 Safety
19
2.1 Identification of the warnings
19
2.2 Target audience
20
2.2.1 International standard classification of occupations
20
2.2.2 Occupational references
20
2.2.3 Unauthorized personnel
21
2.3 Intended use
22
2.4 Foreseeable misuse
22
2.5 General safety instructions
23
2.6 Preventing personal injuries
23
2.6.1 Bruises
23
2.6.2 Burns and scalding
24
2.6.3 Fires and explosions
24
2.6.4 Poisoning
24
2.6.5 High-pressure injection (liquids at high pressure can squirt out)
24
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Contents Operation and Maintenance Manual
2.6.6 Electrical energy
25
2.6.7 Danger due to noise
25
2.7 Personal protective equipment
25
2.8 Operating areas and maintenance areas
26
2.8.1 Safety instructions
26
2.8.2 Operating areas
27
2.8.3 Maintenance areas
27
2.8.4 Secure and release the diesel engine against accidental starting
28
2.8.5 Emergency stop
29
2.8.6 Signage
29
2.9 Prevent material damages
30
3 Handling, operation
31
3.1 Start-up procedure
31
3.1.1 Filling the operating fluids
31
3.1.2 Starting the engine
31
4 Operating faults
33
4.1 Errors – Cause – Remedy
33
5 Operating fluids and maintenance
39
5.1 Fill quantities
39
5.1.1 Lubricants and operating materials
39
5.2 Lubricants and operating materials
40
5.2.1 Diesel fuels
40
5.2.2 Engine oils
41
5.2.3 Coolant
43
5.3 Maintenance
45
5.3.1 Maintenance schedule
45
5.3.2 Daily, weekly and monthly maintenance work - Version: 2018/06-1
46
5.4 Maintenance schedule — ESP Fuel optimized
47
5.4.1 ESP Fuel optimized — Service level 1 - Version: 2018/06-1
47
5.4.2 ESP Fuel optimized — Service level 2 - Version: 2018/06-1
48
5.5 Maintenance schedule — ESP Emission optimized
49
5.5.1 ESP Emission optimized — Service level 1 - Version: 2018/06-1
49
6
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Operation and Maintenance Manual Contents
5.5.2 ESP Emission optimized — Service level 2 - Version: 2018/06-1
50
5.6 Maintenance schedule — ESP 50Hz emission optimized top power
51
5.6.1 ESP 50Hz emission optimized top power — Service level 1 - Version:
2018/06-1 51
5.6.2 ESP 50Hz emission optimized top power — Service level 2 - Version:
2018/06-1 52
5.7 Maintenance schedule — PRP Fuel optimized
53
5.7.1 PRP Fuel optimized — Service level 1 - Version: 2018/06-1
53
5.7.2 PRP Fuel optimized — Service level 2 - Version: 2018/06-1
54
5.8 Maintenance schedule — PRP Emission optimized
55
5.8.1 PRP Emission optimized — Service level 1 - Version: 2018/06-1
55
5.8.2 PRP Emission optimized — Service level 2 - Version: 2018/06-1
56
5.9 Maintenance schedule — COP Fuel optimized
57
5.9.1 COP Fuel optimized — Service level 1 - Version: 2018/06-1
57
5.9.2 COP Fuel optimized — Service level 2 - Version: 2018/06-1
58
5.10 Maintenance schedule — COP Emission optimized
59
5.10.1 COP Emission optimized — Service level 1 - Version: 2018/06-1
59
5.10.2 COP Emission optimized — Service level 2 - Version: 2018/06-1
60
5.11 Special tools for maintenance activities
61
5.12 Preparatory maintenance activities
62
5.13 Daily, weekly and monthly maintenance work
63
5.13.1 Perform visual inspection (leaks, damage, loose components) — SL000
63
5.13.2 Checking the engine oil level — SL001
65
5.13.3 Check coolant level — SL001
67
5.13.4 Check the ventilation holes on the water pump — SL003
68
5.13.5 Check/drain water trap on the primary fuel filter — SL004
68
5.14 Maintenance activities
70
5.14.1 Take oil sample and perform oil analysis — SL100
70
5.14.2 Replace diesel engine oil and oil filter — SL121
70
5.14.3 Replace the oil separator filter insert of the crankcase breather —
SL107 73
5.14.4 Replace main fuel filter — SL105
76
5.14.5 Replace the primary fuel filter — SL106
78
5.14.6 Take coolant sample and perform coolant analysis — SL120
78
5.14.7 Change air filter main element — SL108
79
5.14.8 Check state of fan drive belt drive and replace if necessary — SL118
79
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
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Contents Operation and Maintenance Manual
5.14.9 Check and change the V-ribbed belt for the battery charging alternator
— SL109 82
6 Transport and storage
85
6.1 Fastening during transport
86
6.2 Wooden transport stand
88
6.3 Steel transport stand
89
6.4 Suspension device
90
6.5 Storage
92
6.6.1 Storage for up to 6 months
92
6.7.1 Storage for over 6 and up to 24 months
92
7.1 Standard torques
93
7.1.1 Standard torques for screw connections
93
7.1.2 Standard torques for screw plugs and hollow screws
94
7.1.3 Standard torques for flange joints
95
7.1.5 Metric flange joints, series L (light) for aluminum
98
7.1.6 Standard torques for cutting ring flange joints
99
7.1.7 Standard torques for Triple Lok® flange joints
99
7.1.8 Standard torques for VSTI screw plugs
100
7.2 Special tool
101
7.3 Terms used (glossary)
102
Index
103
8
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Service Assistance
Please contact your nearest Kohler Power Systems distributor or dealer for
professional advice on the generator set power requirements and conscientious
service.
For Kohler generating sets:
Visit the web site of Kohler CO. at KOHLERPower.com.
Pay attention to the labels and decals on your Kohler product or review the
appropriate literature or documents included with the product.
In the USA and Canada, call toll-free 1-800-544-2444.
Outside the USA and Canada, call the nearest regional office.
Headquarters in Europe, the Middle East and Africa (“EMEA”) India, Bangladesh, Sri Lanka
Kohler Power Systems Netherlands B.V. India Regional Office
Kristallaan 1 Bangalore, India
4761 ZC Zevenbergen Phone: (91) 80 3366208
Netherlands (91) 80 3366231
Phone: (31) 168 331630 Fax: (91) 80 3315972
Fax: (31) 168 331631
Japan, Korea
Asia Pacific North Asia Regional Office
Kohler Asia Pacific Headquaters Tokyo, Japan
Singapore, Republic of Singapore Phone: (813) 3440-4515
Phone: (65) 6264-6422 Fax: (813) 3440-2727
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
Tab. 1
To order special tools, please refer to the cross reference list in the annex.
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
9
Operation and Maintenance Manual
For KOHLER-SDMO power generating units:
Visit the web site of KOHLER-SDMO at www.kohlersdmo.com.
Pay attention to the labels and stickers on your KOHLER-SDMO product or
check the corresponding literature or documents included with the product's
scope of delivery.
Call the nearest regional office.
SALES OFFICE FRANCE SOUTHWEST BRANCH OFFICES
WEST SDMO TOULOUSE SOUTH AFRICA
SDMO BREST TEL.: +33 (0) 5 61 24 75 75 SDMO SOUTH AFRICA
TEL.: +33 (0) 2 98 41 13 48 FAX: +33 (0) 5 61 24 75 79 TEL.: +27 (0) 8 32 33 55 61
FAX: +33 (0) 2 98 41 13 57
SUBSIDIARIES
FAX: +33 (0) 1 72 27 61 51
MID-WEST GERMANY ALGERIA
SDMO CHOLET SDMO GMBH SDMO ALGIERS
TEL.: +33 (0) 2 41 75 96 70 TEL.: +49 (0) 63 32 97 15 00 TEL.: +213 (0) 21 68 12 12
FAX: +33 (0) 2 41 75 96 71 FAX: +49 (0) 63 32 97 15 11 FAX: +213 (0) 21 68 14 14
PARIS/NORTH & NORMANDY LATIN AMERICA & CARRIBEAN DUBAI
SDMO ARRAS TEL.: +1 (305) 863 0012 SDMO MIDDLE EAST
TEL.: +33 (0) 3 21 73 38 26 FAX: +1 (954) 432 8330 TEL.: +971 4 458 70 20
FAX: +33 (0) 3 21 73 14 59
BELGIUM
FAX: +971 4 458 69 85
SDMO GENNEVILLIERS
TEL.: +33 (0) 1 41 88 38 00 SDMO NV/SA EGYPT
FAX: +33 (0) 1 41 88 38 37 TEL.: +32 36 46 04 15 SDMO KAIRO
EAST
FAX: +32 36 46 06 25 TEL./FAX: +20 (2) 22 67 12 78
BRAZIL KENYASDMO METZ
TEL.: +33 (0) 3 87 37 88 50 KOHLER MAQUIGERAL SDMO NAIROBI
FAX: +33 (0) 3 87 37 88 59 TEL.: +55 (11) 37 89 60 00 TEL./FAX: +25 (47) 07 60 54 00
SOUTHEAST SPAIN RUSSIA
SDMO AIX-EN-PROVENCE SDMO INDUSTRIES IBERICA SDMO MOSCOW
TEL.: +33 (0) 4 42 52 51 60 TEL.: +34 (9) 35 86 34 00 TEL.:/FAX: +7 495 665 16 98
FAX: +33 (0) 4 42 52 51 61 FAX: +34 (9) 35 80 31 36
TOGOSDMO VALENCE
UNITED KINGDOMTEL.: +33 (0) 4 75 81 31 00 SDMO WEST AFRICA
FAX: +33 (0) 4 75 81 31 10 SDMO ENERGY LTD. TEL.: +228 22 22 65 65
TEL.: +44 (0) 16 06 83 81 20
TURKEYFAX: +44 (0) 16 06 83 78 63
To order special tools, please refer to the cross reference list SDMO ISTANBUL
in the annex. TEL.: +90 53 07 35 09 10
Tab. 2
10
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
1 Product description
1.1 Technical description
1.1.1 Design overview
This section contains an overview of the diesel engine with the names of the parts
shown.
Fig. 1: Overview of flywheel side
1 Combustion air intake 5 Oil module 9 Fastening point for turning
device
2 Charge air line 6 Battery charging alternator 10 Flywheel
3 Pressure line rail 7 Oil drain shut-off valve 11 Flywheel housing
4 Engine control unit 8 High pressure pump
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
11
Product description Operation and Maintenance Manual
Technical description
Fig. 2: Overview of power unit support side
1 Coolant connection to coolant
cooling
5 Combustion air intake 9 V-ribbed fan belt
2 Charge air connecting line
from charge air cooler
6 Charge air line 10 Oil filter
3 Crankcase breather 7 Main fuel filter
4 Exhaust gas turbocharger 8 Coolant connection from
coolant cooling
12
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Operation and Maintenance Manual Product description
Technical description
1.1.2 Overview of sensors
Fig. 3: Overview of sensors
1 Rotational speed sensor 4 Rotational speed sensor 7 Rotational speed sensor
2 Service switch 5 Temperature sensor
3 Temperature sensor 6 Pressure sensor
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
13
Product description Operation and Maintenance Manual
Technical description
1.1.3 Explanation of the type designation
Type description
K D 45 V 20 - 5 A F C Engine type designation
K Manufacturer
D Diesel engine
45 Total displacement: 45 l
V V-engine
20 No. of cylinders
6 Frequency: 5=50 Hz; 6=60 Hz
A Power level: A where A = the lowest power and E =
the highest power
F Optimization: F = Fuel Optimized; E = Emissions
Optimized
C Application: C = COP; P = Prime; S = Stand by; D =
Data center
Tab. 3
Diesel engine company nameplate
The Diesel engine company nameplate is mounted on the oil sump. A second
company nameplate is attached to the device.
Fig. 4: Company nameplate
Engine serial number
The engine serial number is stamped into the engine company nameplate and the
crankcase.
14
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Operation and Maintenance Manual Product description
Technical description
Fig. 5: Engine serial number
2016 18 0001 Engine serial number
2016 Year of manufacture
18 Engine type code: 18 = KD45V20
0001 Consecutive production number
Tab. 4
Engine control unit nameplate
Fig. 6: Position of the engine control unit nameplate
1 Software nameplate
2 Hardware nameplate
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
15
Product description Operation and Maintenance Manual
Technical description
Fig. 7: Example of an engine control unit nameplate
1 Delivery date 5 Engine serial number
2 2D code bar 6 Control unit ID number
3 Engine type 7 ID number certification
4 Control unit description 8 ID number parameter set
Note The information on the engine control unit
nameplate corresponds to the delivery status.
Depending on software updates in the field, this
information may no longer be up-to-date. The real
information can be viewed in the device display or
read out using the KODIA diagnosis and service
tool.
Tab. 5
16
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
Operation and Maintenance Manual Product description
Technical data
1.2 Technical data
1.2.1 Diesel engine
Description Unit Value
Design V-Diesel engine
No. of cylinders 20
Firing order according to DIN 73021 1–15–4–20–8–17–
2–13–6–19–10–16–
7–11–3–14–9–18–
5–12
Firing order according to ISO 1204 B10–A6–B7–A1–
B3–A4–B9–A8–B5–
A2–B1–A5–B4–
A10–B8–A7–B2–
A3–B6–A9
Bore mm
in
135
5.31
Stroke mm
in
157
6.18
Displacement l
gal
44,946
11.8735
Compression ratio 15 :1
Direction of rotation of the Diesel engine (seen
from flywheel)
Counterclockwise
Power specification as per ISO 3046–1
Rated power See emission control
information label
Rated speed See emission control
information label
Emission limit stage See engine
emissions
nameplate
1.2.2 Cylinder head
Description Unit Value
Inlet valve clearance, cold mm
in
0.5
0.019
Outlet valve clearance, cold mm
in
0.6
0.023
KD45V20 33521030001_4_1 en 2018-08-01
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17
Product description Operation and Maintenance Manual
Technical data
1.2.3 Coolant thermostat
Description Unit Value
Opening start °C
°F
82
179
Completely open °C
°F
92
197
1.2.4 Battery charging alternator
Description Unit Value
Voltage V 28
Current A 140
1.2.5 Starter
Description Unit Value
Voltage V 24
Output per start system kW 7.8
1.2.6 Flywheel housing
Description Unit Value
Connection SAE 0
18
© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01
2 Safety
2.1 Identification of the warnings
This is a warning sign. It warns you of the risk of possible injury.
Follow all of the instructions that accompany this warning sign to
avoid any injuries or death.
Tab. 6
This warning sign only appears in conjunction with the signal words:
DANGER
WARNING
CAUTION
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE indicates a hazardous situation which, if not
avoided, could result in material damages.
Tab. 7
Additional markings
Information indicates useful information and tips.
Tab. 8
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 by Kohler Co. All rights reserved.
19
Safety Operation and Maintenance Manual
Target audience
2.2 Target audience
Level 1 — Basic Maintenance Level 2 — Advanced Maintenance
Daily checks, inspection and maintenance tasks which
can be carried out in intervals between operation
without dismantling parts from engine. For example: oil
and fuel refilling
Maintenance tasks involving partial disassembly of the
engine on site (mid-life service). For example: change
of pump, injectors, heads...
By customer or nearest authorized Kohler service
representative.
By customer or nearest authorized Kohler service
representative.
Tab. 9: Definition of service levels
Information
The machine's manufacturer is responsible for:
u
Checking the personnel's know-how and skills
u
Defining the necessary additional, refresher and further qualifications
u
Defining the responsibilities and authorizations
u
Applying ILO – "C138 – Minimum Age Convention, 1973" with a minimum age
for the work permit of 14 years
u
Providing the necessary tools and spare parts
2.2.1 International standard classification of occupations
In accordance with the International Standard Classification of Occupations
(ISCO-08) of the International Labor Office (ILO), the following unit groups are
listed as references to define the target audiences, occupations and joint tasks.
2.2.2 Occupational references
The occupations listed perform the following work in accordance with the "General
safety instructions" chapter:
the main tasks described in this manual or these instructions
the tasks identified as requirements to prepare the main tasks
For the SL1 maintenance of power generation engines:
Maintenance Technician
In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group
7233 / ISCED-97 level 2)
The work on engines, equipment as well as mechanical and electronic equipment
includes:
Operating the machine and facilities
Performance of scheduled maintenance work
Assembly, installation, assessment, adjustment, testing and maintenance
Location of defects
Recording the repair and maintenance work performed
20
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Kohler KD1500 Operating instructions

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Engine
Type
Operating instructions
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