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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© 2017 by Kohler Co. All rights reserved.
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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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© 2017 by Kohler Co. All rights reserved.
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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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© 2017 by Kohler Co. All rights reserved.
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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© 2017 by Kohler Co. All rights reserved.
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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