Kohler KD900 Operating instructions

Operation and Maintenance Manual

Translation of the original instructions

Diesel engine

KD27V12

From serial number 2016 16 0001

EN

33521029401_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

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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

design.”

List of changes

Version from serial number Comments Date

33521029401_1_1 2016 16 0001 First version December 2016

33521029401_2_1 2016 16 0001 Various changes April 2017

33521029401_3_1 2016 16 0001 Change of maintenance

schedule

August 2017

33521029401_4_1 2016 16 0001 Various changes August 2018

KD27V12 33521029401_4_1 en 2018-08-01

3

Preface Operation and Maintenance Manual

4

KD27V12 33521029401_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

17

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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5

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

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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

66

5.13.3 Check coolant level — SL001

68

5.13.4 Check/drain water trap on the primary fuel filter — SL004

68

5.14 Maintenance activities

69

5.14.1 Take oil sample and perform oil analysis — SL100

69

5.14.2 Replace diesel engine oil and oil filter — SL 121

69

5.14.3 Replace the oil separator filter insert of the crankcase breather —

SL107 72

5.14.4 Replace main fuel filter — SL105

76

5.14.5 Replace the primary fuel filter — SL106

77

5.14.6 Take coolant sample and perform coolant analysis — SL120

77

5.14.7 Check state of fan drive belt drive and replace if necessary — SL118

78

5.14.8 Changing the crankcase breather V-ribbed belt — SL117

80

5.14.9 Checking and replacing the water pump belt drive and battery charging

alternator — SL109 84

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Contents Operation and Maintenance Manual

6 Transport and storage

89

6.1 Fastening during transport

90

6.2 Wooden transport stand

92

6.3 Steel transport stand

93

6.4 Suspension device

94

6.5 Storage

97

6.6.1 Storage for up to 6 months

97

6.7.1 Storage for over 6 and up to 24 months

97

7.1 Standard torques

99

7.1.1 Standard torques for screw connections

99

7.1.2 Standard torques for screw plugs and hollow screws

100

7.1.3 Standard torques for flange joints

101

7.1.5 Metric flange joints, series L (light) for aluminum

104

7.1.6 Standard torques for cutting ring flange joints

105

7.1.7 Standard torques for Triple Lok® flange joints

105

7.1.8 Standard torques for VSTI screw plugs

106

7.2 Special tool

107

7.3 Terms used (glossary)

108

Index

109

8

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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.

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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

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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 Fastening point for turning

device (behind the fastening

piece)

5 Air discharge to charge air

cooler

9 Oil filler neck

2 Flywheel 6 Air intake from charge air

cooler

10 Oil dipstick

3 Combustion air intake 7 Oil module 11 Oil drain shut-off valve

4 Turbocharger 8 Oil filter

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11

Product description Operation and Maintenance Manual

Technical description

Fig. 2: Overview of power unit support side

1 Crankcase breather 6 Starter 11 Main fuel filter

2 Crankcase breather belt 7 Coolant outlet 12 Belt for battery charging

alternator and water pump

3 Engine control unit 8 Coolant inlet 13 V-ribbed fan belt

4 High pressure pump 9 Fuel pump feed 14 Fan drive

5 High pressure rail 10 Fuel pump return

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Operation and Maintenance Manual Product description

Technical description

1.1.2 Overview of sensors

Fig. 3: Overview of sensors

1 Temperature sensor 3 Temperature sensor 5 Rotational speed sensor

2 Pressure sensor 4 Service switch 6 Temperature sensor

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Product description Operation and Maintenance Manual

Technical description

1.1.3 Explanation of the type designation

Type description

K D 27 V 12 - 5 A F C Engine type designation

K Manufacturer

D Diesel engine

27 Total displacement: 27 l

V V-engine

12 No. of cylinders

5 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 emission control information label

and the crankcase.

14

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Operation and Maintenance Manual Product description

Technical description

Fig. 5: Engine serial number

2016 16 0001 Engine serial number

2016 Year of manufacture

16 Engine type code: 16 = KD27V12

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

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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

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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 12

Firing order according to DIN 73021 1–12–2–11–3–10–

6–7–5–8–4–9

Firing order according to ISO 1204 B6–A1–B5–A2–B4–

A3–B1–A6–B2–A5–

B3–A4

Bore mm

in

135

5.31

Stroke mm

in

157

6.18

Displacement l

gal

26.967

7.1239

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

1.2.3 Coolant thermostat

Description Unit Value

Opening start °C

°F

82

179

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Product description Operation and Maintenance Manual

Technical data

Description Unit Value

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

KD27V12 33521029401_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

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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

KD27V12 33521029401_4_1 en 2018-08-01

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