Kohler KD45V20 User manual

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.
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© 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
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Preface Operation and Maintenance Manual
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© 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
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© 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
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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
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© 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: [phone]
Netherlands (91) 80 3366231
Phone: [phone] Fax: [phone]
Fax: [phone]
Japan, Korea
Asia Pacific North Asia Regional Office
Kohler Asia Pacific Headquaters 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.
KD45V20 33521030001_4_1 en 2018-08-01
© 2018 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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© 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
1Combustion air intake 5Oil module 9Fastening point for turning
device
2Charge air line 6Battery charging alternator 10 Flywheel
3Pressure line rail 7Oil drain shut-off valve 11 Flywheel housing
4Engine control unit 8High pressure pump
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Product description Operation and Maintenance Manual
Technical description
Fig. 2: Overview of power unit support side
1Coolant connection to coolant
cooling
5Combustion air intake 9V-ribbed fan belt
2Charge air connecting line
from charge air cooler
6Charge air line 10 Oil filter
3Crankcase breather 7Main fuel filter
4Exhaust gas turbocharger 8Coolant connection from
coolant cooling
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© 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
1Rotational speed sensor 4Rotational speed sensor 7Rotational speed sensor
2Service switch 5Temperature sensor
3Temperature sensor 6Pressure 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 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.
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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
1Software nameplate
2Hardware nameplate
KD45V20 33521030001_4_1 en 2018-08-01
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Product description Operation and Maintenance Manual
Technical description
Fig. 7: 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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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
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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
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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
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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:
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
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© 2018 by Kohler Co. All rights reserved.
KD45V20 33521030001_4_1 en 2018-08-01