Kohler KD36V16 Operation And Maintenance Manual Download Page 103

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Operation and Maintenance Manual

Special tool

7.2 Special tool

Description

ID no.

Order number

TURNING DEVICE 10123791

230610006

1 Hoisting beam

12204231

230610044

Tab. 47: Special tool with identification number

KD36V16 33521029701_1_1 en 2018-08-01

103

Summary of Contents for KD36V16

Page 1: ...Operation and Maintenance Manual Translation of the original instructions Diesel engine KD36V16 From serial number 2017 17 0001 EN 33521029701_1_1 08 2018...

Page 2: ...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 O...

Page 3: ...roduction 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...

Page 5: ...Safety 21 2 1 Identification of the warnings 21 2 2 Target audience 22 2 2 1 International standard classification of occupations 22 2 2 2 Occupational references 22 2 2 3 Unauthorized personnel 23 2...

Page 6: ...ing faults 35 4 1 Faults Cause Solution 35 5 Operating fluids and maintenance 41 5 1 Fill quantities 41 5 1 1 Lubricants and operating materials 41 5 2 Lubricants and operating materials 42 5 2 1 Dies...

Page 7: ...ssion optimized Service level 1 Version 2018 06 1 61 5 10 2 COP Emission optimized Service level 2 Version 2018 06 1 62 5 11 Special tools for maintenance activities 63 5 12 Preparatory maintenance ac...

Page 8: ...up to 24 months 94 7 1 Standard torques 95 7 1 1 Standard torques for screw connections 95 7 1 2 Standard torques for screw plugs and hollow screws 96 7 1 3 Standard torques for flange joints 97 7 1...

Page 9: ...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 3315...

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: ...on 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 KD36V16 33521029701_1_1 en 2018 08 01 2018 by Kohler Co All...

Page 12: ...1 Intake stack 5 Oil module 9 Fastening point for turning device 2 Charge air line 6 Battery charging alternator 10 Flywheel 3 Pressure line rail 7 Oil drain shut off valve 11 Flywheel housing 4 Engin...

Page 13: ...e 1 Coolant connection to coolant cooling 4 Exhaust gas turbocharger 7 Coolant connection from coolant cooling 2 Charge air connecting line from charge air cooler 5 Oil filter 8 V ribbed fan belt 3 Cr...

Page 14: ...perature sensor 7 Rotational speed sensor 2 Service switch 5 Pressure sensor 3 Temperature sensor 6 Temperature sensor 1 1 3 Explanation of the type designation Type description K D 36 V 16 5 A F C En...

Page 15: ...ed 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 name...

Page 16: ...ntrol unit nameplate Fig 6 Position of the engine control unit nameplate 1 Software nameplate 2 Hardware nameplate Fig 7 Example of an engine control unit nameplate 1 Delivery date 5 Engine serial num...

Page 17: ...eplate 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 u...

Page 18: ...157 6 18 Displacement l gal 35 956 9 4986 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 co...

Page 19: ...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 8 4 1 2 6 Flywheel housing Des...

Page 21: ...us 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 hazard...

Page 22: ...essary 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 O...

Page 23: ...LO Power Production Plant Operators unit group 3131 ISCED 97 on at least one level from 2 to 4 Power production plant operators operate monitor and maintain switchboards and related equipment in elect...

Page 24: ...may only be operated in areas that cannot be accessed by the general public in other words the engine may only be operated in conjunction with an enclosure or engine compartment cover 2 4 Foreseeable...

Page 25: ...that the following equipment is available for assembly and that it is clean complete and undamaged Basic tools Necessary devices Necessary special tools Replace any damaged tools Keep the workplace c...

Page 26: ...s Remove any cleaning rags that are soaked with flammable liquids Disconnect the power supply when working on the electrical system 2 6 4 Poisoning Only run the Diesel engine in closed rooms if these...

Page 27: ...ng However if a technician has to approach an unprotected engine for troubleshooting work he must wear hearing protection suitable for the noise level 2 7 Personal protective equipment Wear protective...

Page 28: ...nance areas 2 8 1 Safety instructions Trapping hazard and flying mechanical parts hazard when the Diesel engine is ready for use or running Risk of severe injury or death Keep away from engines that a...

Page 29: ...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 30: ...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 31: ...ycle 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 electricit...

Page 32: ...n be found in the Standard torques chapter Replace self locking flange joints Clean the Diesel engine connections and flange joints thoroughly of oil fuel or care products before assembly Use lint fre...

Page 33: ...rting 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 connect...

Page 34: ...ly battery voltage Final check Once the engine has started carry out the following checks and top off with operating materials if necessary u Check the oil level u Check the coolant level u Perform a...

Page 35: ...Check that the causes have been eliminated Cancel the fault 4 1 Faults Cause Solution Malfunction error Cause Remedy The starter does not turn over The main fuse has blown Replace the fuse The batter...

Page 36: ...ance The Diesel engine s compression is too low Contact your nearest Kohler Co service representative See the Section Service Assistance The heating flange is faulty at low temperatures Read out the e...

Page 37: ...earest Kohler Co service representative See the Section Service Assistance The fuel temperature is too high Contact your nearest Kohler Co service representative See the Section Service Assistance The...

Page 38: ...The engine is overloaded Contact your nearest Kohler Co service representative See the Section Service Assistance The exhaust gases are blue The oil level in the Diesel engine is too high Correct the...

Page 39: ...ubricant pressure is too low The oil level in the oil sump is too low Fill oil to prescribed mark The lubricant is too thin oil diluted by Diesel fuel Drain the oil and refill with the specified oil T...

Page 40: ...k the air filter s service display if equipped The charge air cooler is dirty Contact your nearest Kohler Co service representative See the Section Service Assistance The turbocharger outlet is faulty...

Page 41: ...nd operating materials Description Quantity Engine oil 150 l 1 5 l per filter 39 6 US gal 0 4 US gal per filter Coolant 124 l 32 8 US gal Tab 10 Fill quantities in the Diesel engine guide values KD36V...

Page 42: ...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 43: ...JASO DH 1 SAE 10W 40 SAE 10W 30 SAE 5W 30 Synthetic Group 2 and or 3 Base oils 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 Group 2 a...

Page 44: ...tervals according to oil category must be observed Difficulty factors Difficulty factors can be Frequent cold starts Environmental influences Operating temperature Dust High humidity Long standstill t...

Page 45: ...adjusted if required 5 2 3 Coolant Information Mixing different anticorrosion antifreeze agents can make the properties of the coolant worse u Do not combine different products u Silicate based and no...

Page 46: ...of an coolant analysis and the change interval can be adjusted if required Control parameter for the coolant Analysis Standard Unit Value Visual appearance Typical color clear normal smell like new co...

Page 47: ...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 48: ...inary fuel filter and drain water if necessary Perform before start SL005 Fuel system Daily X Check differential pressure gage Perform before start SL006 Air filter Daily X Check the air filter s disp...

Page 49: ...Main fuel filter 1000 2 X Replace main fuel filter 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...

Page 50: ...X Replace water pump SL225 Viscous damper 4000 X Replace the viscous damper SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 4500 X Replace the exhaust gas turbo...

Page 51: ...105 Main fuel filter 1000 2 X Replace main fuel filter 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 Die...

Page 52: ...4000 X Replace water pump SL225 Viscous damper 4000 X Replace the viscous damper SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 4500 X Replace the exhaust gas...

Page 53: ...belt tension SL121 Engine oil and oil filter with lubricant 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...

Page 54: ...ter pump 4000 X Replace water pump SL225 Viscous damper 4000 X Replace the viscous damper SL205 Injection 4500 X Replace fuel lines and injectors SL213 Exhaust gas turbocharger 4500 X Replace the exha...

Page 55: ...e year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL106 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lube oil Category 3 1000 2 X Repla...

Page 56: ...ace the exhaust gas turbocharger SL215 Water pump 7500 8 X Replace the water pump SL219 A Exhaust gas turbocharger 7500 X Replace the exhaust gas turbocharger rubber sleeve SL219 B Coolant lines 7500...

Page 57: ...r one year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL106 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lube oil Category 3 1000 2 X R...

Page 58: ...place the exhaust gas turbocharger SL215 Water pump 7500 8 X Replace the water pump SL219 A Exhaust gas turbocharger 7500 X Replace the exhaust gas turbocharger rubber sleeve SL219 B Coolant lines 750...

Page 59: ...e year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL106 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lube oil Category 3 1000 2 X Repla...

Page 60: ...L206 Cylinder 10000 X Clean cumbastion chambers SL213 Exhaust gas turbocharger 10000 X Replace the exhaust gas turbocharger SL215 Water pump 10000 8 X Replace the water pump SL219 A Coolant lines 1000...

Page 61: ...er one year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL106 Primary fuel filter 1000 2 Replace the primary fuel filter SL121 Engine oil and oil filter with lube oil Category 3 1000 2 X...

Page 62: ...SL206 Cylinder 10000 X Clean cumbastion chambers SL213 Exhaust gas turbocharger 10000 X Replace the exhaust gas turbocharger SL215 Water pump 10000 8 X Replace the water pump SL219 A Coolant lines 10...

Page 63: ...nd maintenance Special tools for maintenance activities 5 11 Special tools for maintenance activities Fig 43 Turning device ID no Description 10123791 Turning device Tab 31 KD36V16 33521029701_1_1 en...

Page 64: ...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 65: ...ion leaks damage loose components SL000 Fig 44 1 Turbocharger 4 Main fuel filter 7 Engine control unit 2 High pressure pump connectors 5 Oil module 3 Oil filter 6 Water pump u Visually check Diesel en...

Page 66: ...nce work Fig 45 8 Vent line 10 Overflow oil line 9 Pressure line 11 Fuel line u Visually check hoses for leaks ensure that they are not damaged installed friction free and that fastening is in complia...

Page 67: ...arness 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...

Page 68: ...48 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 69: ...rts and hot cooler fluid Risk of burns Will cause serious injuries and death u Perform maintenance and inspection work on the cooling system only when the Diesel engine has cooled down u Wear protecti...

Page 70: ...or leakage 5 13 5 Check drain water trap on the primary fuel filter SL004 Make sure that q A reservoir with the required capacity is ready The primary fuel filter with water trap and manual fuel feed...

Page 71: ...s fire and explosion Can cause serious injury and death u Avoid open flames or other ignition sources when performing maintenance or inspection work on the fuel system u Perform maintenance and inspec...

Page 72: ...q A reservoir with the required capacity is ready q A suitable sample bottle is ready Fig 51 Oil removal point 1 Oil removal point u Refer to the generator set manual for procedure when taking oil sa...

Page 73: ...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 74: ...ause 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 oil filter U...

Page 75: ...ighten u Start 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...

Page 76: ...breather position 1 Crankcase breather Remove oil separator filter insert Fig 56 Remove filter insert u Pull off hose clamps 1 and hose from the regulating valve cover 2 u Loosen lever screws 3 u Remo...

Page 77: ...e oil u Insert new filter insert u Fit new O ring 5 on the regulating valve cover 2 u Lubricate O ring with engine oil u Position regulating valve cover 2 alignment power unit support side observe flo...

Page 78: ...se 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 engi...

Page 79: ...ain fuel filter by hand 3 4 of a revolution u Vent fuel system 5 14 5 Replace the primary fuel filter SL106 Make sure that q A reservoir with the required capacity is ready q A primary fuel filter ins...

Page 80: ...tor set manual for procedure to replace the air filter main element 5 14 8 Check state of fan drive belt drive and replace if necessary SL118 Damage to the V ribbed belt includes Broken ribs Rubber no...

Page 81: ...ing 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 damaged parts Please contact the nea...

Page 82: ...wear on the belt pulleys w Replace the damaged parts Contact Kohler u Place new V ribbed belts on all belt pulleys and tightening roller making sure that they are properly seated u Turn rigging screw...

Page 83: ...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 63 Damage to the V ribbed belt Replacing the belt Make sur...

Page 84: ...64 V ribbed belt drive u Remove fan See the generator set s operating manual u Remove the V ribbed belt fan 1 For the procedure please refer to the chapter Check state of fan drive belt drive replace...

Page 85: ...er and check their play for example worn out bearings on the tightening roller or tread wear on the belt pulleys w Replace the damaged parts Please contact the nearest authorized Kohler Co customer se...

Page 87: ...orrect 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...

Page 88: ...ring transport Fig 66 Example of transport fastening wood transport stand DANGER Mortal danger due to instability during transportation of the Diesel engine The engine can come loose during transporta...

Page 89: ...eath 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...

Page 90: ...g transportation of the Diesel engine The engine can come loose during transportation Mortal danger Will cause serious injuries or death u The Diesel engine must be securely bolted to the transport st...

Page 91: ...instability during transportation of the Diesel engine The engine can come loose during transportation Mortal danger Will cause serious injuries or death u The Diesel engine must be securely bolted to...

Page 92: ...erve 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 atte...

Page 93: ...1 Hoisting beam ID no 12204231 A Power unit support side 2 Lifting gear B Flywheel side Information u Please read and observe the safety instructions in the system description before commissioning the...

Page 94: ...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 95: ...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 96: ...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 97: ...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 98: ...ED 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...

Page 99: ...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 100: ...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 101: ...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 102: ...2 12 450 330 470 350 Tab 45 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 103: ...7 2 Special tool Description ID no Order number TURNING DEVICE 10123791 230610006 1 Hoisting beam 12204231 230610044 Tab 47 Special tool with identification number KD36V16 33521029701_1_1 en 2018 08...

Page 104: ...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 105: ...factors 44 Draining the diesel engine oil 73 E Electrical energy 27 Emergency standby power system ESP 47 Emergency stop 31 Engine control unit nameplate 16 Engine oil analysis 45 Engine oil change in...

Page 106: ...58 PRP Fuel optimized Service level 1 Version 2018 06 1 55 PRP Fuel optimized Service level 2 Version 2018 06 1 56 R Remove oil separator filter insert 76 Replace diesel engine oil and oil filter SL1...

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