Kohler KD27V12 User manual

Operation and Maintenance Manual
Translation of the original instructions
Diesel engine
KD27V12
From serial number 2016 16 0001
EN
33521029401_3_1
07-2017

Preface Operation and Maintenance Manual
Preface
Only for the United States of America:
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.
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© 2017 by Kohler Co. All rights reserved.
KD27V12 33521029401_3_1 en 2017-07-01

Operation and Maintenance Manual Preface
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.
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
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
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Preface Operation and Maintenance Manual
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© 2017 by Kohler Co. All rights reserved.
KD27V12 33521029401_3_1 en 2017-07-01

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 19
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 21
2.4 Foreseeable misuse 22
2.5 General safety instructions 22
2.6 Preventing personal injuries 23
2.6.1 Bruises 23
2.6.2 Burns and scalding 23
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 46
5.4 Maintenance schedule — ESP Fuel optimized 47
5.4.1 ESP Fuel optimized — Service level 1 47
5.4.2 ESP Fuel optimized — Service level 2 48
5.5 Maintenance schedule — ESP Emission optimized 49
5.5.1 ESP Emission optimized — Service level 1 49
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KD27V12 33521029401_3_1 en 2017-07-01

Operation and Maintenance Manual Contents
5.5.2 ESP Emission optimized — Service level 2 50
5.6 Maintenance schedule — ESP 50Hz emission optimized top power 51
5.6.1 ESP 50Hz emission optimized top power — Service level 1 51
5.6.2 ESP 50Hz emission optimized top power — Service level 2 52
5.7 Maintenance schedule — PRP Fuel optimized 53
5.7.1 PRP Fuel optimized — Service level 1 53
5.7.2 PRP Fuel optimized — Service level 2 54
5.8 Maintenance schedule — PRP Emission optimized 55
5.8.1 PRP Emission optimized — Service level 1 55
5.8.2 PRP Emission optimized — Service level 2 56
5.9 Maintenance schedule — COP Fuel optimized 57
5.9.1 COP Fuel optimized — Service level 1 57
5.9.2 COP Fuel optimized — Service level 2 58
5.10 Maintenance schedule — COP Emission optimized 59
5.10.1 COP Emission optimized — Service level 1 59
5.10.2 COP Emission optimized — Service level 2 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). 63
5.13.2 Checking the engine oil level 66
5.13.3 Check coolant level 68
5.13.4 Check/drain water trap on the primary fuel filter 68
5.14 Maintenance activities 69
5.14.1 Take oil sample and perform oil analysis 69
5.14.2 Replace diesel engine oil and oil filter 69
5.14.3 Replace the oil separator filter insert of the crankcase breather 72
5.14.4 Replace main fuel filter 76
5.14.5 Replace the primary fuel filter 77
5.14.6 Take coolant sample and perform coolant analysis. 77
5.14.7 Check state of fan drive belt drive and replace if necessary 78
5.14.8 Changing the crankcase breather V-ribbed belt 80
5.14.9 Checking and replacing the water pump belt drive and battery charging
alternator 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
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© 2017 by Kohler Co. All rights reserved.
KD27V12 33521029401_3_1 en 2017-07-01

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:
Consult the Yellow Pages under the heading Generators-Electric.
– Visit the web site of Kohler Power Systems 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: [phone]
Netherlands (91) 80 3366231
Phone: [phone] Fax: [phone]
Fax: [phone]
Japan, Korea
Asia Pacific North Asia Regional Office
Power Systems Asia Pacific Regional Office Tokyo, Japan
Singapore, Republic of Singapore Phone: [phone]
Phone: [phone] Fax: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
Tab. 1
To order special tools, please refer to the cross reference list in the annex.
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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.: [phone] SDMO SOUTH AFRICA
TEL.: [phone] FAX: [phone] TEL.: [phone]
FAX: [phone]
SUBSIDIARIES
FAX: [phone]
MID-WEST GERMANY ALGERIA
SDMO CHOLET SDMO GMBH SDMO ALGIERS
TEL.: [phone] TEL.: [phone] TEL.: [phone]
FAX: [phone] FAX: [phone] FAX: [phone]
PARIS/NORTH & NORMANDY LATIN AMERICA & CARRIBEAN DUBAI
SDMO ARRAS TEL.: [phone] SDMO MIDDLE EAST
TEL.: [phone] FAX: [phone] TEL.: [phone]
FAX: [phone]
BELGIUM
FAX: [phone]
SDMO GENNEVILLIERS
TEL.: [phone] SDMO NV/SA EGYPT
FAX: [phone] TEL.: [phone] SDMO KAIRO
EAST FAX: [phone] TEL./FAX: [phone]
BRAZIL KENYASDMO METZ
TEL.: [phone] KOHLER MAQUIGERAL SDMO NAIROBI
FAX: [phone] TEL.: [phone] TEL./FAX: [phone]
SOUTHEAST SPAIN RUSSIA
SDMO AIX-EN-PROVENCE SDMO INDUSTRIES IBERICA SDMO MOSCOW
TEL.: [phone] TEL.: [phone] TEL.:/FAX: [phone]
FAX: [phone] FAX: [phone]
TOGOSDMO VALENCE
UNITED KINGDOMTEL.: [phone] SDMO WEST AFRICA
FAX: [phone] SDMO ENERGY LTD. TEL.: [phone]
TEL.: [phone]
TURKEYFAX: [phone]
To order special tools, please refer to the cross reference list SDMO ISTANBUL
in the annex. TEL.: [phone]
Tab. 2
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© 2017 by Kohler Co. All rights reserved.
KD27V12 33521029401_3_1 en 2017-07-01

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
1Fastening point for turning
device (behind the fastening
piece)
5Air discharge to charge air
cooler
9Oil filler neck
2Flywheel 6Air intake from charge air
cooler
10 Oil dipstick
3Combustion air intake 7Oil module 11 Oil drain shut-off valve
4Turbocharger 8Oil filter
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Product description Operation and Maintenance Manual
Technical description
Fig. 2: Overview of power unit support side
1Crankcase breather 6Starter 11 Main fuel filter
2Crankcase breather belt 7Coolant outlet 12 Belt for battery charging
alternator and water pump
3Engine control unit 8Coolant inlet 13 V-ribbed fan belt
4High pressure pump 9Fuel pump feed 14 Fan drive
5High pressure rail 10 Fuel pump return
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KD27V12 33521029401_3_1 en 2017-07-01

Operation and Maintenance Manual Product description
Technical description
1.1.2 Overview of sensors
Fig. 3: Overview of sensors
1Temperature sensor 3Temperature sensor 5Rotational speed sensor
2Pressure sensor 4Service switch 6Temperature 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 Engine type designation
K Manufacturer
D Diesel engine
27 Total displacement: 27 l
V V-engine
12 No. of cylinders
Tab. 3
Emission control information label
The Emission control information label is attached on the left side of the crankcase
as seen from the flywheel.
Fig. 4: Position of the emission control information label
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KD27V12 33521029401_3_1 en 2017-07-01

Operation and Maintenance Manual Product description
Technical description
Fig. 5: Emission control information label
Engine serial number
The engine serial number is stamped into the emission control information label
and the crankcase.
Fig. 6: 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
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Product description Operation and Maintenance Manual
Technical description
Engine control unit nameplate
Fig. 7: Position of the engine control unit nameplate
1Software nameplate
2Hardware nameplate
Fig. 8: Example of an engine control unit nameplate
1Delivery date 5Engine serial number
22D code bar 6Control unit ID number
3Engine type 7ID number certification
4Control unit description 8ID 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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KD27V12 33521029401_3_1 en 2017-07-01

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 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
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KD27V12 33521029401_3_1 en 2017-07-01

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
2.2 Target audience
Level 1 — Basic Maintenance Level 2 — Advanced Maintenance
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Safety Operation and Maintenance Manual
Target audience
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: Service level definition
Information
The machine's manufacturer is responsible for:
uChecking the personnel's know-how and skills
uDefining the necessary additional, refresher and further qualifications
uDefining the responsibilities and authorizations
uApplying ILO – "C138 – Minimum Age Convention, 1973" with a minimum age
for the work permit of 14 years
uProviding 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
For the SL2 maintenance of power generation engines:
Technician
In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group
7233 / ISCED-97 on at least one level, from 3 to 4)
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© 2017 by Kohler Co. All rights reserved.
KD27V12 33521029401_3_1 en 2017-07-01