Kohler KD45V20 Operation And Maintenance Manual Download

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Operation and Maintenance Manual

Operating fluids and maintenance

Maintenance activities

Filling with diesel engine oil

Fig. 54: Example of oil dipstick and oil filler neck

Fill with oil through the oil filler neck

up to between the min and max marks on

the dipstick

Clean the refueling cap, place on the oil filler neck

and tighten.

Start the diesel engine.

Check the oil pressure (diesel engine oil pressure display unit) and check the oil
filter for leaks.

Turn the Diesel engine off.

Check the oil level on the dipstick after 10 minutes.

If the engine oil level is not between min and max:

Correct the oil level.

5.14.3 Replace the oil separator filter insert of the crankcase

breather — SL107

Make sure that:

Four new oil separator filter inserts with new O-rings are on hand.

KD45V20 33521030001_4_1 en 2018-08-01

Summary of Contents for KD45V20

Page 1: ...Operation and Maintenance Manual Translation of the original instructions Diesel engine KD45V20 From serial number 2016 18 0001 EN 33521030001_4_1 08 2018 ...

Page 2: ...ne 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 Th...

Page 3: ...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 ...

Page 5: ...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 Po...

Page 6: ...ating 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 Fue...

Page 7: ...ission 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 coolan...

Page 8: ...nd 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 ...

Page 9: ...h 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 3315972 Fax 31 168 331631 Japan Korea Asia Pacific North Asia Regional Office Kohler Asia Pacific Headquaters Tokyo Japan Singapore Republic of Singapore Phone 813 3440 4515 Phone 65 6264 6422 Fax 813 34...

Page 10: ...ARRAS 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 NV SA EGYPT FAX 33 0 1 41 88 38 37 TEL 32 36 46 04 15 SDMO KAIRO EAST FAX 32 36 46 06 25 TEL FAX 20 2 22 67 12 78 BRAZIL KENYA SDMO METZ TEL 33 0 3 87 37 88 50 KOHLER MAQUIGERAL SDMO NAIROBI FAX 33 ...

Page 11: ...wn Fig 1 Overview of flywheel side 1 Combustion air intake 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 Engine control unit 8 High pressure pump KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 11 ...

Page 12: ...on to coolant cooling 5 Combustion air intake 9 V ribbed fan belt 2 Charge air connecting line from charge air cooler 6 Charge air line 10 Oil filter 3 Crankcase breather 7 Main fuel filter 4 Exhaust gas turbocharger 8 Coolant connection from coolant cooling 12 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 13: ...2 Overview of sensors Fig 3 Overview of sensors 1 Rotational speed sensor 4 Rotational speed sensor 7 Rotational speed sensor 2 Service switch 5 Temperature sensor 3 Temperature sensor 6 Pressure sensor KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 13 ...

Page 14: ... 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 engin...

Page 15: ...gine 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 1 Software nameplate 2 Hardware nameplate KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 15 ...

Page 16: ...cation 4 Control unit description 8 ID 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 16 2018 by Kohler Co All rights reserved ...

Page 17: ... 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 Val...

Page 18: ... 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 18 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 19: ...ous 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 Info...

Page 20: ... 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 w...

Page 21: ...wer 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 electrical 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 energy gener...

Page 22: ... 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 misuse The operating and 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...

Page 23: ...e 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 clean and tidy Take precautions for 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...

Page 24: ...es 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 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 Escaping liquids can...

Page 25: ...ing 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 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 equipment is necessary to ...

Page 26: ...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 are ready for use Wear personal protective equipment Technicians may enter the safety zone A for measuring purposes unless otherwise indicated by the system manufacturer Hot parts when the Diesel engin...

Page 27: ...ne 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 have to be accessed for maintenance work and troubleshooting WARNING Hot parts during maintenance work Risk of burns Can cause severe injury or death u Allow the engine to cool down sufficiently u W...

Page 28: ...e 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 any unexpected start up Disconnect diesel fuel supply Label cut off point Disconnect electrical power supply and secure against reactivation Label cut off point Make the diesel engine ready for operat...

Page 29: ...cycle 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 may work within the identified area Unauthorized persons may only enter the safety zone after the electrical power supply has been disconnected ISO 7010 W017 Warning of hot surfaces The Diesel engi...

Page 30: ...ound 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 free cleaning rags Do not touch electric contacts The connection is affected by dirt or components may be destroyed by electrostatic discharges ESD Before cleaning the Diesel engine cover or tape shut ...

Page 31: ...arting 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 connected WARNING Unexpected movement of the equipment Can cause serious injuries or the death of persons u There may be no persons in the safety zones of the diesel engine u Bring all of the protective dev...

Page 32: ...ply 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 visual check for any leaks in the lines u Check for KODIA error messages u Check for generator sets error messages 32 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 33: ... in accordance with the User Manual Check 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 connections are loose or corroded Clean and tighten the loose connections The battery voltage is too low Charge or replace the battery The starter s circuit is fault...

Page 34: ...eak test visual inspection contact KOHLER Co to have the engine checked The Diesel engine s compression is too low Contact your nearest authorized Kohler service representative See Service Assistance section The heating flange is faulty at low temperatures Read out the error memory of the engine control unit Contact KOHLER Co The Diesel engine switches off suddenly The power supply has been interr...

Page 35: ...e Service Assistance section The fuel temperature is too high Contact your nearest authorized Kohler service representative See Service Assistance section The injection nozzles are faulty or do not vaporize Contact your nearest authorized Kohler service representative See Service Assistance section The Diesel engine s compression is too low Contact your nearest authorized Kohler service representa...

Page 36: ... engine 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 Correct the oil level Lubricant enters the combustion chamber and is burnt Contact your nearest authorized Kohler service representative See Service Assistance section The bearing gasket on the turbocharger is f...

Page 37: ...gs 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 prescribed mark The lubricant is too thin oil diluted by Diesel fuel Drain the oil and refill with the specified oil The pressure sensor is faulty Check the oil pressure and replace the damaged oil press...

Page 38: ...is 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 your nearest authorized Kohler service representative See Service Assistance section The turbocharger outlet is faulty Contact your nearest authorized Kohler service representative See Service Assist...

Page 39: ...and operating materials Description Quantity Engine oil 180 l 1 5 l per filter 47 6 US gal 0 4 US gal per filter Coolant 143 l 37 8 US gal Tab 10 Fill quantities in the Diesel engine guide values KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 39 ...

Page 40: ... Diesel ASTM D 975 2D S5000 HFFR 460 µm without AEG On Road Diesel ASTM D 975 4D HFFR 460 µm without AEG EU Diesel EN 590 Max 10 biodiesel content Heating oil DIN 51603 Without AEG GTL DIN 15940 If ASTM D 975 approved NATO fuel NATO F 34 HFFR 460 µm without AEG with additive S 1750 NATO fuel NATO F 35 HFFR 460 µm without AEG with additive S 1750 NATO fuel NATO F 54 HFFR 460 µm NATO fuel NATO F 63 ...

Page 41: ...r 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 and or 3 Base oils 1 Lubricant category 3 standard today ACEA E4 12 or both ACEA E4 and ACEA E7 SAE 5W 30 SAE 10W 40 SAE 10W 30 SAE 5W 40 Synthetic Group 3 and or 4 VI 160 and Longlife additive 2 Lubr...

Page 42: ...ntervals 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 times If there are difficulty factors or difficult usage conditions the oil change and filter change must be performed according to the following table Engine oil change intervals The change intervals...

Page 43: ... 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 non silicate based coolants must never be mixed this may damage the cooling system Requirements for water Make sure that the water used meets the following requirements Fully de ionized water should be...

Page 44: ... 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 coolant pH value DIN EN ISO 10523 2012 04 6 7 9 0 Chloride ions mg l 100 Sulfate mg l 100 Bacteria and toxic constituents without Tab 15 Control parameter 44 2018 by Kohler Co All rights reserved KD45V...

Page 45: ...riable 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 power output with 24 hour operation should not be more than 85 percent of the nominal ESP value Prime power PRP The maximum output that a power generating unit is able to supply continuously over an unli...

Page 46: ...minary 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 display Perform before start See the generator set s operating manual SL007 Engine in operation Daily X Observe the engine operation Record and report any abnormality found faulty parameters unusual nois...

Page 47: ... 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 engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert SL118 V ribbed ...

Page 48: ...0 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 turbocharger SL219 _A Exhaust gas turbocharger 1 X Replace the exhaust gas turbocharger rubber sleeve SL219 _B Coolant lines 4 X X Check and replace coolant lines and hoses if necessary Tab 18 ESP Fuel op...

Page 49: ...L105 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 engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert SL118 V rib...

Page 50: ...p 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 turbocharger SL219 Exhaust gas turbocharger 1 X Replace the exhaust gas turbocharger rubber sleeve SL219 Coolant lines 4 X X Check and replace coolant lines and hoses if necessary Tab 20 ESP Emission...

Page 51: ...k 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 one year SL105 Main fuel filter 1000 2 X Replace main fuel filter SL106 Primary fuel filter 1000 2 X Replace the primary fuel filter SL107 Crankcase breather 2000 2 X Replace oil separator filter ins...

Page 52: ...ater 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 exhaust gas turbocharger SL219 Exhaust gas turbocharger 1 X Replace the exhaust gas turbocharger rubber sleeve SL219 Coolant lines 4 X X Check and replace coolant lines and hoses if necessary Tab 22 ESP ...

Page 53: ...ne 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 Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert SL118...

Page 54: ...lace 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 4 X X Check and replace coolant lines and hoses if necessary SL223 Battery charging alternator 7500 X Replace the battery charging alternator SL225 Viscous damper 7500 X Replace the viscous damper SL...

Page 55: ...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 Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert S...

Page 56: ...eplace 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 4 X X Check and replace coolant lines and hoses if necessary SL223 Battery charging alternator 7500 X Replace the battery charging alternator SL225 Viscous damper 7500 X Replace the viscous damper ...

Page 57: ...ne 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 Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert SL118...

Page 58: ...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 10000 4 X X Check and replace coolant lines and hoses if necessary SL223 Battery charging alternator 10000 X Replace the battery charging alternator SL225 Viscous damper 10000 X Replace the viscous dampe...

Page 59: ...ter 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 Replace Diesel engine oil and oil filter insert at least every 2 years Perform once after 250 hours At the latest after one year SL107 Crankcase breather 2000 2 X Replace oil separator filter insert ...

Page 60: ...s 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 10000 4 X X Check and replace coolant lines and hoses if necessary SL223 Battery charging alternator 10000 X Replace the battery charging alternator SL225 Viscous damper 10000 X Replace the viscous dam...

Page 61: ...and 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 KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 61 ...

Page 62: ...ile 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 diesel engine has cooled down to the ambient temperature Disconnect electrical power supply and secure against reactivation Label cut off point 62 2018 by Kohler Co All rights reserved KD45V20 335210300...

Page 63: ...tion 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 engine for leaks ensure that it is not damaged and that the fastenings comply with regulations u Visually check V space area under high pressure pump and lines for moisture KD45V20 33521030001_4_1 en 2...

Page 64: ...ance 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 compliance with regulations 64 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 65: ...harness 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 engine oil level SL001 Oil dipstick and oil filler neck are located on the right as seen from the flywheel KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 65 ...

Page 66: ... 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 the oil through the oil filler neck 2 u Do not fill the Diesel engine with oil to above the max mark u Clean the refueling cap place on the filler neck and tighten 66 2018 by Kohler Co All rights reser...

Page 67: ...arts 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 protective equipment Fig 49 See generator set manual for procedure to check coolant level KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 67 ...

Page 68: ...for 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 pump is some distance from the Diesel engine and is attached differently depending on the device design See the generator sets operating manual for the procedure 68 2018 by Kohler Co All rights reser...

Page 69: ...es 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 inspection work only when the Diesel engine has been shut down KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 69 ...

Page 70: ...t 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 sample and performing oil analysis 5 14 2 Replace diesel engine oil and oil filter SL121 Make sure that q The Diesel engine is horizontal q The Diesel engine is turned off 70 2018 by Kohler Co All righ...

Page 71: ...iesel 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 diesel engine oil Fig 52 Oil drain shut off valve u Open oil drain shut off valve 1 u Drain the oil into the container provided u Close oil drain shut off valve 1 u Dispose of oil observe country specific...

Page 72: ...burns 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 oil filter Use engine oil u Screw on new oil filter 1 until the sealing contacts the oil module u Tighten oil filter 1 by hand 1 2 of a revolution w Torque 25 Nm 72 2018 by Kohler Co All rights reserve...

Page 73: ...tighten 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 after 10 minutes If the engine oil level is not between min and max u Correct the oil level 5 14 3 Replace the oil separator filter insert of the crankcase breather SL107 Make sure that q Four new oi...

Page 74: ...tenance Operation and Maintenance Manual Maintenance activities Crankcase breather position Fig 55 Crankcase breather position 1 Crankcase breather 74 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 75: ... 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 Remove regulating valve cover 2 u Pull off filter insert 4 Install oil separator filter insert Fig 57 Install filter insert KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 75 ...

Page 76: ...s 3 u Push on hose and tighten hose clamps 5 14 4 Replace main fuel filter SL105 Make sure that q A reservoir with the required capacity is ready q The main fuel filter is on hand q Strap wrench or similar tool is on hand The main fuel filter is on the left as seen from the flywheel WARNING Open flames Injuries fire and explosion Can cause injuries or death u Avoid open flames or other ignition so...

Page 77: ...lean and make sure that the thread adapter fits firmly in the filter module If the filter module is dirty u Clean filter module Information Dirt Can destroy the common rail system u Make sure that no dirt enters the clean side of the filter u Leave the residual diesel fuel in the filter housing u Never reuse a main fuel filter after it has been used once u Pay attention to the special instructions...

Page 78: ... at some distance from the diesel engine and is mounted differently depending on the device design See the generator sets operating manual for the procedure WARNING Open flames Injuries fire and explosion Can cause 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...

Page 79: ...ator 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 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 KD45V20 33521030001_4_1 en 2018 08 01 201...

Page 80: ...ning 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 nearest authorized Kohler Co customer service Replacing the belt Make sure that q A new belt is on hand q A suitable frequency device is on hand WARNING Rotating parts Risk of injury Can cause serious i...

Page 81: ... 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 2 M10 10 9 until tensioned w Check tension with an appropriate frequency device Own frequency is 111 Hz u Tighten hex screw 1 M12 8 8 u Start the engine and let it run for 30 minutes u Turn off engin...

Page 82: ...f 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 sure that q A new belt is on hand WARNING Rotating parts Risk of injury Can cause serious injuries u Turn the Diesel engine off u Secure the engine against unexpected starting 82 2018 by Kohler Co All r...

Page 83: ...g 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 if necessary KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 83 ...

Page 84: ...der 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 service Refer to the chapter on Service Assistance u With the tightening device pivoted back place new V ribbed belt on all belt pulleys and tightening roller making sure that it is properly seated u M...

Page 85: ...correct 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 oxidation u Store the Diesel engine only in dry places u Do not expose the Diesel engine to great fluctuations in temperature u Remove the transport protection film only shortly before installation ...

Page 86: ...uring 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 transportation Mortal danger Will cause serious injuries or death u Transport the Diesel engine only with the transport stand u The transport stand used must be in perfect technical condition u Secure the tran...

Page 87: ...death 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 used please use the hoisting beam u There may be no persons within the danger zones of the Diesel engine during loading and unloading u Pay attention to the center of gravity KD45V20 33521030001_4...

Page 88: ...ng 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 stand Information u Wooden transport stands do not have to be returned to Kohler Co Keep for later use 88 2018 by Kohler Co All rights reserved KD45V20 33521030001_4_1 en 2018 08 01 ...

Page 89: ... 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 the transport stand Information u Return the steel transport stand to Kohler Co KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 89 ...

Page 90: ...serve 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 attention to the safety instructions warnings in the Operating Manual for the hoisting beam u Do not work under suspended loads Fig 69 Suspension device 90 2018 by Kohler Co All rights reserved KD45V20 3...

Page 91: ... 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 hoisting beam KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 91 ...

Page 92: ...be 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 can be expected if these measures are ignored and the conserved Diesel engine is exposed to less favorable conditions situated outdoors for longer periods of time or stored in damp unventilated locatio...

Page 93: ...M 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 20 390 290 560 410 650 480 M 22 530 390 750 550 880 650 M 24 670 490 960 710 1120 830 M 27 1000 740 1400 1030 1650 1220 M 30 1350 1000 1900 1400 2250 1660 M 33 1850 1360 2600 1920 3000 2210 M 36 2350 1730 3300 2430 3900...

Page 94: ... 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 3390 5300 3910 Tab 33 7 1 2 Standard torques for screw plugs and hollow screws For hollow screws in accordance with DIN 7643 with copper sealing ring in accordance with DIN 7603 Screw plug in accordan...

Page 95: ...ing 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 seal Form E with flat ED seal Form F with 0 ring Nm ft lb Nm ft lb Nm ft lb Nm ft lb 6 M 10 x 1 0 9 6 6 18 13 18 13 15 11 8 M 12 x 1 5 20 15 30 22 25 18 25 18 10 M 14 x 1 5 35 26 45 33 45 33 35 26 1...

Page 96: ... 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 M 22 x 1 5 65 48 170 120 135 100 20 M 27 x 2 0 90 66 270 200 180 130 25 M 33 x 2 0 150 110 410 300 310 230 30 M 42 x 2 0 240 180 540 400 450 330 38 M 48 x 2 0 290 210 700 520 540 400 Tab 37 Tube diam...

Page 97: ...G 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 290 210 630 470 540 400 Tab 39 Tube diameter X Thread Y WH TH SWVE Nm ft lb Nm ft lb Nm ft lb 6 G 1 8A 18 13 18 13 18 13 8 G 1 4A 45 33 45 33 40 29 10 G 1 4A 45 33 45 33 40 29 12 G 3 8A 70 52 70 52 65 48 ...

Page 98: ...ter 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 2A 120 88 120 88 90 66 20 G 3 4A 230 170 230 170 125 92 25 G 1A 320 240 320 240 30 G 1 1 4A 540 400 540 400 38 G 1 1 2A 700 520 700 520 Tab 42 7 1 5 Metric flange joints series L light for aluminum Tu...

Page 99: ...2 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 2 750 550 Tab 44 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 extension u Tighten b...

Page 100: ...1 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 extension u Tighten box nut to aforementioned torque 7 1 8 Standard torques for VSTI screw plugs Thread Nm ft lb Thread Nm ft lb M 10 x 1 10 7 4 M 26 x 1 5 100 74 M 12 x 1 5 20 15 M 27 x 2 120 88 M 14 x ...

Page 101: ...l 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 KD45V20 33521030001_4_1 en 2018 08 01 2018 by Kohler Co All rights reserved 101 ...

Page 102: ...e 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 the chapter on Operating and maintenance areas Maintenance areas Maintenance areas are the safety zones that have to be accessed for maintenance work and troubleshooting Tab 48 102 2018 by Kohler Co A...

Page 103: ...y factors 42 Draining the diesel engine oil 71 E Electrical energy 25 Emergency standby power system ESP 45 Emergency stop 29 Engine control unit nameplate 15 Engine oil analysis 43 Engine oil change intervals 42 Engine oils 41 Engine serial number 14 Errors Cause Remedy 33 ESP 50Hz emission optimized top power Service level 1 Version 2018 06 1 51 ESP 50Hz emission optimized top power Service leve...

Page 104: ...1 56 PRP Fuel optimized Service level 1 Version 2018 06 1 53 PRP Fuel optimized Service level 2 Version 2018 06 1 54 R Remove oil separator filter insert 75 Replace diesel engine oil and oil filter SL121 70 Replace main fuel filter SL105 76 Replace the oil separator filter insert of the crankcase breather SL107 73 Replace the primary fuel filter SL106 78 Replacing the belt 80 82 Replacing the oil ...

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Kohler KD45V20, Operation And Maintenance Manual

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