Kohler KD27V12 Operation And Maintenance Manual Download Page 7

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Operation and Maintenance Manual

Contents

5.5.2

ESP Emission optimized — Service level 2

5.6

Maintenance schedule — ESP 50Hz emission optimized top power

5.6.1

ESP 50Hz emission optimized top power — Service level 1

5.6.2

ESP 50Hz emission optimized top power — Service level 2

5.7

Maintenance schedule — PRP Fuel optimized

5.7.1

PRP Fuel optimized — Service level 1

5.7.2

PRP Fuel optimized — Service level 2

5.8

Maintenance schedule — PRP Emission optimized

5.8.1

PRP Emission optimized — Service level 1

5.8.2

PRP Emission optimized — Service level 2

5.9

Maintenance schedule — COP Fuel optimized

5.9.1

COP Fuel optimized — Service level 1

5.9.2

COP Fuel optimized — Service level 2

5.10 Maintenance schedule — COP Emission optimized

5.10.1 COP Emission optimized — Service level 1

5.10.2 COP Emission optimized — Service level 2

5.11 Special tools for maintenance activities

5.12 Preparatory maintenance activities

5.13 Daily, weekly and monthly maintenance work

5.13.1 Perform visual inspection (leaks, damage, loose components).

5.13.2 Checking the engine oil level

5.13.3 Check coolant level

5.13.4 Check/drain water trap on the primary fuel filter

5.14 Maintenance activities

5.14.1 Take oil sample and perform oil analysis

5.14.2 Replace diesel engine oil and oil filter

5.14.3 Replace the oil separator filter insert of the crankcase breather

5.14.4 Replace main fuel filter

5.14.5 Replace the primary fuel filter

5.14.6 Take coolant sample and perform coolant analysis.

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

5.14.8 Changing the crankcase breather V-ribbed belt

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

alternator

KD27V12 33521029401_3_1 en 2017-07-01

Summary of Contents for KD27V12

Page 1: ...Operation and Maintenance Manual Translation of the original instructions Diesel engine KD27V12 From serial number 2016 16 0001 EN 33521029401_3_1 07 2017...

Page 2: ...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 inter...

Page 3: ...ges 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 reproduct...

Page 5: ...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...

Page 6: ...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 an...

Page 7: ...ssion 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 i...

Page 8: ...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 a...

Page 9: ...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 Ph...

Page 10: ...RRAS 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...

Page 11: ...w 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...

Page 12: ...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...

Page 13: ...scription 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 KD27V12 335210...

Page 14: ...anufacturer 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...

Page 15: ...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...

Page 16: ...ar 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 de...

Page 17: ...39 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...

Page 18: ...2 197 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 Descri...

Page 19: ...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 cou...

Page 20: ...ard 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 Occu...

Page 21: ...ectrical control centers which control the production and distribution of electrical or other power in transmission networks The work includes Operating monitoring and inspecting various types of ener...

Page 22: ...d maintenance manual has been drawn up in accordance with applicable standards and regulations in accordance with state of the art technology Kohler Co assumes no liability for Failure to observe thes...

Page 23: ...or any emergency that may occur Keep fire extinguishers and first aid boxes close by Keep the emergency telephone numbers close by Make sure that the workplace is well lit Only perform assembly work i...

Page 24: ...losed rooms if these are sufficiently ventilated Open doors and windows if a bigger supply of fresh air is needed Never ingest any operating materials Do not use drinking bottles for storage purposes...

Page 25: ...equipment Wear protective equipment during direct access to diesel engines Ensure that The protective equipment is in a good condition The protective function is guaranteed The following protective e...

Page 26: ...he Diesel engine is ready for use or running Risk of severe injury or death Keep away from engines that are ready for use Wear personal protective equipment Technicians may enter the safety zone A for...

Page 27: ...e unit carrier side A Safety zone next to engine B Safety zone flywheel side C Safety zone above engine D Safety zone below engine E 2 8 3 Maintenance areas Maintenance areas are the safety zones that...

Page 28: ...the diesel engine against accidental starting Access to the maintenance areas must be secured against accidental starting before entering the safety zones Procedure Secure the diesel engine against a...

Page 29: ...le u Additional warnings or adaptations to product standards ISO 8528 13 are possible ISO 7010 W012 Warning of dangerous electrical voltage Only persons who are familiar with the risks of electricity...

Page 30: ...und in the Standard torques chapter Replace self locking screw connections Clean the diesel engine connections and screw connections thoroughly of oil fuel or care products before assembly Use lint fr...

Page 31: ...ting the engine Prerequisites q The oil level is OK q Engine is filled with coolant q Charge air is connected q Exhaust system is connected q Electrical power supply is ready q Fuel supply is connecte...

Page 32: ...y battery voltage Final check Once the engine has started carry out the following checks and top up with operating materials if necessary u Check the oil level u Check the coolant level u Perform a vi...

Page 33: ...ck that the causes have been eliminated Cancel the fault 4 1 Errors Cause Remedy Malfunction error Cause Remedy The starter does not turn over The main fuse has blown Replace the fuse The battery conn...

Page 34: ...he Diesel engine s compression is too low Contact your nearest authorized Kohler service representative See Service Assistance section There is a fault in the electronic system Read out the error memo...

Page 35: ...ized Kohler service representative See Service Assistance section The fuel temperature is too high Contact your nearest authorized Kohler service representative See Service Assistance section The inje...

Page 36: ...gine is overloaded Contact your nearest authorized Kohler service representative See Service Assistance section The exhaust gases are blue The oil level in the Diesel engine is too high Check and corr...

Page 37: ...s may be jammed Contact your nearest authorized Kohler service representative See Service Assistance section The lubricant pressure is too low The oil level in the oil sump is too low Fill oil to pres...

Page 38: ...s too high Check the fan air supply and breather The charge air pressure is too low The air filter is blocked Check the air filter s service display if equipped The charge air cooler is dirty Contact...

Page 39: ...nd operating materials Description Quantity Engine oil 101 l 1 5 l per filter 26 68 US gal 0 4 US gal per filter Coolant 55 l 14 5 US gal Tab 10 Fill quantities in the Diesel engine guide values KD27V...

Page 40: ...ad Diesel ASTM D 975 2D S5000 HFFR 460 m without AEG On Road Diesel ASTM D 975 4D HFFR 460 m without AEG EU Diesel EN 590 Max 10 biodiesel content Heating oil DIN 51603 Without AEG GTL DIN 15940 If AS...

Page 41: ...EA E7 or API CI 4 Plus or DHD 1 or JASO DH 1 SAE 10W 40 SAE 10W 30 SAE 5W 30 Synthetic 1 Lubricant category 2 1 ACEA E6 or ACEA E9 or API CJ 4 or JASO DH 2 SAE 5W 30 SAE 10W 40 SAE 10W 30 Synthetic 1...

Page 42: ...ed Difficulty factors Difficulty factors can be Frequent cold starts Environmental influences Operating temperature Dust High humidity Long standstill times If there are difficulty factors or difficul...

Page 43: ...schedule are compatible with this very high sulfur content Special lubrication oil must be used TBN 12 MgKOH g Tab 15 Sulfur content table Engine oil analysis The engine oil can be monitored by means...

Page 44: ...YSANTIN G40 change interval 6 years BASF GLYSANTIN G48 change interval 4 years The recommended coolant concentration is 40 to 50 The coolant can be monitored by means of an coolant analysis and the ch...

Page 45: ...iable power sequencing under the given operating conditions whereby the maintenance intervals and work are carried out in accordance with the manufacturer s specifications The permissible average powe...

Page 46: ...uel filter and drain water if necessary Perform before start SL006 Air filter Daily X Check the air filter s display Perform before start See the generator set s operating manual SL007 Engine in opera...

Page 47: ...SL106 Primary fuel filter 1000 2 X Replace the primary fuel filter SL121 Engine oil and oil filter with lubricant Category 3 1000 2 X Replace Diesel engine oil and oil filter insert at least every 2 y...

Page 48: ...arging alternator 4000 X Replace the battery charging alternator SL225 Viscous damper 4000 X Replace the viscous damper SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust gas turboc...

Page 49: ...ry 3 500 2 X Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL105 Main fuel filter 1000 2 X Replace main fuel filter S...

Page 50: ...Water pump 4000 X Replace the water pump SL223 Battery charging alternator 4000 X Replace the battery charging alternator SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust gas turb...

Page 51: ...ubricant Category 3 500 2 X Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL105 Main fuel filter 1000 2 X Replace mai...

Page 52: ...p SL215 Water pump 4000 X Replace the water pump SL223 Battery charging alternator 4000 X Replace the battery charging alternator SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust...

Page 53: ...6 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lubricant Category 3 1000 2 X Replace Diesel engine oil and oil filter insert at least every 2 years P...

Page 54: ...Replace the exhaust gas turbocharger rubber sleeve SL205 Injection 7500 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 7500 X Replace the exhaust gas turbocharger SL215 Water pump 7...

Page 55: ...y 3 500 2 X Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL...

Page 56: ...X Replace the exhaust gas turbocharger rubber sleeve SL205 Injection 7500 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 7500 X Replace the exhaust gas turbocharger SL215 Water pump...

Page 57: ...6 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lubricant Category 3 1000 2 X Replace Diesel engine oil and oil filter insert at least every 2 years P...

Page 58: ...ce the viscous damper SL205 Injection 10000 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 10000 X Replace the exhaust gas turbocharger SL215 Water pump 10000 8 X Replace the water...

Page 59: ...3 500 2 X Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL10...

Page 60: ...place the viscous damper SL205 Injection 10000 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 10000 X Replace the exhaust gas turbocharger SL215 Water pump 10000 8 X Replace the wat...

Page 61: ...nd maintenance Special tools for maintenance activities 5 11 Special tools for maintenance activities Fig 44 Turning device ID no Description 10123791 Turning device Tab 32 KD27V12 33521029401_3_1 en...

Page 62: ...le performing maintenance work See the Safety chapter Maintenance position The diesel engine is in the maintenance position when The Diesel engine is horizontal The Diesel engine is turned off The die...

Page 63: ...nts Fig 45 Overview of visual inspection 1 Turbocharger 4 Engine control unit 7 Oil module 2 High pressure pump connectors 5 Main fuel filter 8 Oil filter 3 High pressure pump leakage 6 Crankcase brea...

Page 64: ...eration and Maintenance Manual Daily weekly and monthly maintenance work Fig 46 Water pump location 9 Water pump u Check area around water pump 9 for leaks 64 2017 by Kohler Co All rights reserved KD2...

Page 65: ...g 47 Inspection overview 10 Vent line 12 Overflow oil line 11 Pressure line 13 Fuel line u Visually check hoses for leaks ensure that they are not damaged installed friction free and that fastening is...

Page 66: ...1 for damage friction free installation and regulation compliant fastening u Visually check belt drive 2 for damage friction free installation and regulation compliant fastening 5 13 2 Checking the en...

Page 67: ...50 u Remove the oil dipstick again and check the oil level The oil level must be between the min and max marks If the oil level is too low u Remove the oil refueling cap and top off with oil u Fill th...

Page 68: ...primary fuel filter Make sure that q A reservoir with the required capacity is ready The primary fuel filter with water trap and manual fuel feed pump is some distance from the Diesel engine and is a...

Page 69: ...q A reservoir with the required capacity is ready q A suitable sample bottle is ready Fig 52 Oil removal point 1 Oil removal point u Refer to the generator set manual for procedure when taking oil sa...

Page 70: ...esel engine oil is on hand Diesel engine oil amount see the Fill quantities table chapter Please refer to the Lubricants and operating fluids chapter for the lube oil specifications Draining the diese...

Page 71: ...urns Can cause injuries u Avoid skin contact with the engine oil u Wear protective gloves when changing the engine oil u Dispose of oil filter observe country specific regulations u Oil seal on the oi...

Page 72: ...tart the diesel engine u Check the oil pressure diesel engine oil pressure display unit and check the oil filter for leaks u Turn the Diesel engine off u Check the oil level on the dipstick after 10 m...

Page 73: ...t unexpected starting Fig 56 V ribbed belt drive u Remove fan from the fan drive 1 See the generator set s operating manual u Remove the V ribbed belt fan 2 For the procedure please refer to the chapt...

Page 74: ...nkcase breather While another person operates the turning device u Remove the V ribbed belt crankcase ventilation 4 u Loosen hose clips 5 u Remove line 6 u Release hex screws 7 M8 8 8 u Remove the cra...

Page 75: ...n hex screws 7 M8 8 8 u Fasten line 6 u Tighten hose clips 5 While another person operates the turning device u lay on new V ribbed belt crankcase breather 4 and ensure it is correctly seated u Instal...

Page 76: ...injuries or death u Avoid open flames or other ignition sources when performing maintenance or inspection work on the fuel system u Perform maintenance and inspection work only when the Diesel engine...

Page 77: ...hten main fuel filter by hand 3 4 of a revolution u Vent fuel system 5 14 5 Replace the primary fuel filter Make sure that q A reservoir with the required capacity is ready q A primary fuel filter ins...

Page 78: ...nt sample 5 14 7 Check state of fan drive belt drive and replace if necessary Damage to the V ribbed belt includes Broken ribs Rubber nodules in the base of the belt Dirt and or stone deposits Ribs br...

Page 79: ...t the belt pulleys and tightening roller are in perfect working order and check their play for example worn out bearings on the tightening roller or tread wear on the belt pulleys w Replace the damage...

Page 80: ...t pulleys and tensioning device are in perfect working order and check their play for example tread wear on the belt pulleys w Replace the damaged parts u With the tightening device pivoted back place...

Page 81: ...ning and maintenance free Replacing the V ribbed belt Make sure that q A new V ribbed belt is on hand q Turning device ID no 10123791 is available q Another person is present WARNING Rotating parts Ri...

Page 82: ...set s operating manual u Remove the V ribbed belt fan 2 For the procedure please refer to the chapter Check state of fan drive belt drive replace if necessary Procedure for removing the fan drive asse...

Page 83: ...her While another person operates the turning device u fit the new V ribbed belt making sure that it is properly seated Procedure for mounting the fan drive assembly 4 u Mount fan drive assembly 4 u T...

Page 84: ...er nodules in the base of the belt Dirt and or stone deposits Ribs broken off the base of the belt Transverse cracks on the back Transverse cracks in several ribs Fig 66 Damage to the V ribbed belt Th...

Page 85: ...erator set s operating manual u Remove the V ribbed belt fan 2 For the procedure please refer to the chapter Check state of fan drive belt drive replace if necessary u Dismantle the bracket 3 Please r...

Page 86: ...ation and Maintenance Manual Maintenance activities Fig 68 While another person operates the turning device u Remove the V ribbed belt crankcase ventilation 5 86 2017 by Kohler Co All rights reserved...

Page 87: ...r tread wear on the belt pulleys w Replace the damaged parts Please contact the nearest authorized Kohler Co customer service Refer to the chapter on Service Assistance u With the tightening device pi...

Page 89: ...rect setting down of the Diesel engine Engine damage u Do not stand the Diesel engine on the oil sump u Place the Diesel engine on the appropriate fastening pieces NOTICE Incorrect storage Damage by o...

Page 90: ...tening during transport Fig 70 Example of fastening during transport DANGER Mortal danger due to instability during transportation of the Diesel engine The engine can come loose during transportation...

Page 91: ...th u The Diesel engine may only be loaded unloaded by suitably trained and authorized personnel u If a crane or forklift truck is used this must be designed for the weight to be lifted u If a crane is...

Page 92: ...ing transportation of the Diesel engine The engine can come loose during transportation Mortal danger Causes serious injuries or death u The Diesel engine must be securely bolted to the transport stan...

Page 93: ...o instability during transportation of the Diesel engine The engine can come loose during transportation Mortal danger Causes serious injuries or death u The Diesel engine must be securely bolted to t...

Page 94: ...ve a maximum deviation of 10 between the perpendicular and the engine axis u Use the Kohler lifting device u Dismantle the generator or other add on parts before lifting the Diesel engine u Pay attent...

Page 95: ...beam ID no 10815480 for 3 point suspension 2 Receiving tube ID no 11213360 for 4 point suspension Information u Please read and observe the safety instructions in the system description before commis...

Page 96: ...Transport and storage Operation and Maintenance Manual Suspension device Fig 75 Lifting lugs for 4 point suspension 96 2017 by Kohler Co All rights reserved KD27V12 33521029401_3_1 en 2017 07 01...

Page 97: ...e waterproof and rest loosely against the Diesel engine so that air can circulate around the Diesel engine thus preventing the formation of any condensation A shorter conservation protection period ca...

Page 99: ...7 16 12 23 17 27 20 M 8 23 17 34 25 40 29 M 10 46 34 68 50 79 58 M 12 79 58 117 86 135 100 M 14 125 92 185 140 215 160 M 16 195 140 280 210 330 240 M 18 280 210 390 290 460 340 M 20 390 290 560 410 65...

Page 100: ...2150 3420 2520 M 33 x 2 2000 1470 2800 2060 3300 2430 M 36 x 1 5 2680 1980 3820 2820 4470 3300 M 36 x 3 2500 1840 3500 2580 4100 3020 M 39 x 1 5 3430 2530 4890 3610 5720 4220 M 39 x 3 3200 2360 4600 3...

Page 101: ...ng torques specified in the table 10 u Oil the screw in thread with engine oil before screwing in Metric flange joints series L light Tube diameter X Thread Y Form A with sealing ring Form B with edge...

Page 102: ...D seal Nm ft lb Nm ft lb Nm ft lb 6 M 12 x 1 5 20 15 35 26 40 29 8 M 14 x 1 5 35 26 55 41 40 29 10 M 16 x 1 5 45 33 70 52 70 55 12 M 18 x 1 5 55 41 110 81 90 66 14 M 20 x 1 5 55 41 150 110 125 92 16 M...

Page 103: ...3 8A 45 33 70 52 70 52 15 G 1 2A 65 48 140 100 90 66 18 G 1 2A 65 48 100 75 90 66 22 G 3 4A 90 66 180 130 180 130 28 G 1A 150 110 330 240 310 230 35 G 1 1 4A 240 180 540 400 450 330 42 G 1 1 2A 290 2...

Page 104: ...er X Thread Y WH TH SWVE Nm ft lb Nm ft lb Nm ft lb 6 G 1 4A 45 33 45 33 40 29 8 G 1 4A 45 33 45 33 40 29 10 G 3 8A 70 52 70 52 65 48 12 G 3 8A 70 52 70 52 65 48 14 G 1 2A 120 88 120 88 90 66 16 G 1 2...

Page 105: ...1 5 105 77 44 18 M 26 1 5 150 110 63 22 M 30 2 200 150 28 M 36 2 250 180 35 M 45 2 450 330 42 M 52 2 600 440 S 16 M 24 1 5 150 110 20 M 30 2 250 180 25 M 36 2 450 330 30 M 42 2 600 440 38 M 52 2 750...

Page 106: ...2 12 450 330 470 350 Tab 47 Information Tighten screw on connection with set torque u Secure with screw on connection u Screw on box nut up to clearly noticeable increase in force without wrench exte...

Page 107: ...on ID no Order number TURNING DEVICE 10123791 230610006 1 HOISTING BEAM 10815480 230610025 2 RECEIVING TUBE F 4 POINT RETAINER 11213360 230610026 Tab 49 Special tool with identification number KD27V12...

Page 108: ...overall plant in which the Diesel engine is installed In operation The engine is running Safety zone Designated area around the engine access to which in the various operating modes is described in t...

Page 109: ...intervals 42 Engine oils 41 Engine serial number 15 Errors Cause Remedy 33 ESP 50Hz emission optimized top power Service level 1 51 ESP 50Hz emission optimized top power Service level 2 52 ESP Emissi...

Page 110: ...ase breather 72 Replace the primary fuel filter 77 Replacing the belt 79 Replacing the oil filter 71 Replacing the V ribbed belt 81 84 Requirements for water 43 Requirements of the coolant 44 S Safety...

Page 111: ......

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