Kohler KD27V12 Operation And Maintenance Manual
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Summary of Contents for Kohler KD27V12
- Page 1 Operation and Maintenance Manual Translation of the original instructions Diesel engine KD27V12 From serial number 2016 16 0001 33521029401_3_1 07-2017...
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Page 2: Esp Fuel Optimized - Service Level
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 3 Operation and Maintenance Manual Preface Kohler Co. will not allow any warranty claims that arise due to incorrect operation, insufficient maintenance, use of unapproved operating fluids or non-compliance with safety regulations. Kohler Co. will annul any obligations entered into by Kohler Co. and/or their dealers such as warranty assurances, service agreements etc.
- Page 4 Preface Operation and Maintenance Manual © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 5: Table Of Contents
General safety instructions Preventing personal injuries 2.6.1 Bruises 2.6.2 Burns and scalding 2.6.3 Fires and explosions 2.6.4 Poisoning 2.6.5 High-pressure injection (liquids at high pressure can squirt out) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 6 ESP Fuel optimized — Service level 1 5.4.2 ESP Fuel optimized — Service level 2 Maintenance schedule — ESP Emission optimized 5.5.1 ESP Emission optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
- Page 7 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 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 8: Index
Standard torques for cutting ring flange joints 7.1.7 Standard torques for Triple Lok® flange joints 7.1.8 Standard torques for VSTI screw plugs Special tool Terms used (glossary) Index © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 9: Service Assistance
Consult the Yellow Pages under the heading Generators-Electric. – Visit the web site of Kohler Power Systems at KOHLERPower.com. – Pay attention to the labels and decals on your Kohler product or review the appropriate literature or documents included with the product. -
Page 10: 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. -
Page 11: Product Description
Oil filler neck device (behind the fastening cooler piece) Flywheel Air intake from charge air Oil dipstick cooler Combustion air intake Oil module Oil drain shut-off valve Turbocharger Oil filter © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 12: Operation And Maintenance Manual
Belt for battery charging alternator and water pump Engine control unit Coolant inlet V-ribbed fan belt High pressure pump Fuel pump feed Fan drive High pressure rail Fuel pump return © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 13: Overview Of Sensors
Operation and Maintenance Manual Product description Technical description 1.1.2 Overview of sensors Fig. 3: Overview of sensors Temperature sensor Temperature sensor Rotational speed sensor Pressure sensor Service switch Temperature sensor © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 14: Explanation Of The Type Designation
The Emission control information label is attached on the left side of the crankcase as seen from the flywheel. Fig. 4: Position of the emission control information label © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 15: Operation And Maintenance Manual
Fig. 6: Engine serial number 2016 0001 Engine serial number 2016 Year of manufacture Engine type code: 16 = KD27V12 0001 Consecutive production number Tab. 4 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 16: Operation And Maintenance Manual
The real information can be viewed in the device display or read out using the KODIA diagnosis and service tool. Tab. 5 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 17: Technical Data
1.2.2 Cylinder head Description Unit Value Inlet valve clearance, cold 0.019 Outlet valve clearance, cold 0.023 1.2.3 Coolant thermostat Description Unit Value Opening start °C °F © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 18: Battery Charging Alternator
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 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 19: Safety
Tab. 7 Additional markings Information indicates useful information and tips. Tab. 8 2.2 Target audience Level 1 — Basic Maintenance Level 2 — Advanced Maintenance © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 20: International Standard Classification Of Occupations
For the SL2 maintenance of power generation engines: Technician In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group 7233 / ISCED-97 on at least one level, from 3 to 4) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 21: Unauthorized Personnel
2.3 Intended use – Only use the diesel engine for its intended purpose. – Observe the following conditions of the manufacturer: Operating conditions • • Servicing conditions • Maintenance conditions © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 22: Foreseeable Misuse
Kohler Co. – Operating and auxiliary materials that have not been approved by Kohler Co. – The use of non-Kohler spare parts that have not been officially approved by Kohler Co., including the resulting consequential damages. -
Page 23: Preventing Personal Injuries
– Fasten and secure individual parts and larger assemblies carefully with suitable lifting gear during their replacement. – Use Kohler lifting gear in accordance with its operating manual. – Observe the regulations on the lifting points. – Do not use any load handling devices that are damaged or that have an inadequate carrying capacity. -
Page 24: Fires And Explosions
– Do not disconnect any pressurized fuel lines or hoses. – Protect hands, face and body against escaping liquids when looking for leaks in pressurized lines and hoses. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 25: Electrical Energy
Wear safety gloves during work with operating materials. (Please refer to the manufacturer's specifications for the operating materials and the safety data sheet for the operating material.) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 26: Operating Areas And Maintenance Areas
– Only those target audiences authorized as per the relevant definitions may enter the safety zones during maintenance. – Disconnect from the electrical power supply. – Wear personal protective equipment. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 27: Operating Areas
WARNING Hot parts during maintenance work. Risk of burns! Can cause severe injury or death. u Allow the engine to cool down sufficiently. u Wear personal protective equipment. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 28: Secure And Release The Diesel Engine Against Accidental Starting
– Make sure that all foreign bodies have been removed. – All of the protective devices are installed and are working properly. – Make sure that no external persons stand or walk in the danger zones. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 29: Emergency Stop
– Possible EMC radiation that may affect heart pacemakers and implanted defibrillators. People with a heart pacemaker or implanted defibrillator: keep a minimum distance of 20cm (8 inches) from the operational Diesel engine. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 30: Prevent Material Damages
– Use suitable test leads for measurements at plug connections. – Protect the engine control unit against dust and water if no mating plug has been connected. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 31: Handling, Operation
Information Engine damage due to inadequate lubrication. u The oil pressure has to build up immediately after the diesel engine is started (oil-pressure warning lamp goes out). © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 32: Operation And Maintenance Manual
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 system error messages. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 33: Operating Faults
Charge or replace the battery. The battery connections are loose or Clean and tighten the loose corroded. connections. The outside temperature is too low. Take appropriate action for Winter operation. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 34: Operation And Maintenance Manual
There is a fault in the electronic Read out the error memory of the system. engine control unit. Contact your nearest authorized Kohler service representative. See "Service Assistance" section. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 35: Operation And Maintenance Manual
Kohler service representative. See "Service Assistance" section. The thermostat is faulty. Check this and replace if necessary. Contact your nearest authorized Kohler service representative. See "Service Assistance" section. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 36: Operation And Maintenance Manual
Check the fuel system and the drain pre-filter. There is a leak in the charge air Contact your nearest authorized cooler. Kohler service representative. See "Service Assistance" section. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 37: Operation And Maintenance Manual
Contact your nearest authorized Kohler service representative. See "Service Assistance" section. Leak in the oil cooler or oil cooler Contact your nearest authorized plate. Kohler service representative. See "Service Assistance" section. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 38: Operation And Maintenance Manual
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 Assistance" section. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 39: Operating Fluids And Maintenance
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) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 40: Lubricants And Operating Materials
HFRR < 460 µm max. 10% Biodiesel Aviation kerosene Jet A-1 HFFR < 460 µm without AEG with additive S-1750 UK Diesel BS 2869 A2 Max 10% biodiesel content Tab. 11: Approved fuel qualities © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 41: Engine Oils
The following table is intended to help select the right engine oil based on the total base number (TBN). This measurement value is important for reducing combustion gases that are greatly influenced by the sulfur content in the fuel. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 42: Operation And Maintenance Manual
The basic oil change interval is defined in the maintenance tables. The factor “oil category”: Lubricant category Oil change factor (factor 1) “1/4” => reduces the maintenance interval Lubricant category 1 by one quarter © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 43: Coolant
The cooling circuit must remain within the following parameters: – Hardness of water < 12 dH – pH value 6.7 to 9.0 – Chloride and sulfate < 100 mg/l © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 44: Operation And Maintenance Manual
<80 Nitrite DIN EN 12014 mg/kg <500 pH value DIN EN ISO 8.1 — 9.0 10523:2012-04 Freezing point DIN ISO 3016, ASTM °C 5985 Tab. 16: Control parameter © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 45: Maintenance
Time between overhauls (TBO) The average period until Diesel engines have to be overhauled. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 46: Daily, Weekly And Monthly Maintenance Work
SL008 Test run at more than 1/3 load. See the generator set’s Monthly operating manual. Tab. 17: Maintenance schedule — Daily maintenance activities — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 47: Maintenance Schedule - Esp Fuel Optimized
SL120 Coolant analysis X Take coolant sample and perform coolant analysis. SL116 Coolant Replace coolant. Tab. 18: ESP Fuel optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 48 Exhaust gas Replace the exhaust gas turbocharger rubber sleeve. turbocharger SL219 Lines Check and replace lines and hoses if necessary. Tab. 19: ESP Fuel optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 49: Maintenance Schedule - Esp Emission Optimized
SL120 Coolant analysis X Take coolant sample and perform coolant analysis. SL116 Coolant Replace coolant. Tab. 20: ESP Emission optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 50: Esp Emission Optimized - Service Level
Exhaust gas Replace the exhaust gas turbocharger rubber sleeve. turbocharger SL219 Lines Check and replace lines and hoses if necessary. Tab. 21: ESP Emission optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 51: Maintenance Schedule - Esp 50Hz Emission Optimized Top Power
SL120 Coolant analysis X Take coolant sample and perform coolant analysis. SL116 Coolant Replace coolant. Tab. 22: ESP 50Hz emission optimized top power — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 52 Replace the exhaust gas turbocharger rubber sleeve. turbocharger SL219 Lines Check and replace lines and hoses if necessary. Tab. 23: ESP 50Hz emission optimized top power — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 53: Maintenance Schedule - Prp Fuel Optimized
SL116 Coolant 6000 Replace coolant. SL120 Coolant analysis X Take coolant sample and perform coolant analysis. Tab. 24: PRP Fuel optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 54 Check and replace lines and hoses if necessary. 7500 SL223 Battery charging Replace the battery charging alternator. 7500 alternator Tab. 25: PRP Fuel optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 55: Maintenance Schedule - Prp Emission Optimized
SL120 Coolant analysis X Take coolant sample and perform coolant analysis. SL116 Coolant Replace coolant. Tab. 26: PRP Emission optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 56 Check and replace lines and hoses if necessary. 7500 SL223 Battery charging Replace the battery charging alternator. 7500 alternator Tab. 27: PRP Emission optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 57: Maintenance Schedule - Cop Fuel Optimized
SL116 Coolant 6000 Replace coolant. SL120 Coolant analysis X Take coolant sample and perform coolant analysis. Tab. 28: COP Fuel optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 58 SL223 Battery charging Replace the battery charging alternator. 10000 alternator SL209 High pressure Replace the HP pump. 20000 pump Tab. 29: COP Fuel optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 59: Maintenance Schedule - Cop Emission Optimized
SL116 Coolant 6000 Replace coolant. SL120 Coolant analysis X Take coolant sample and perform coolant analysis. Tab. 30: COP Emission optimized — Service level 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 60 SL223 Battery charging Replace the battery charging alternator. 10000 alternator SL209 High pressure Replace the HP pump. 20000 pump Tab. 31: COP Emission optimized — Service level 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 61: Special Tools For Maintenance Activities
Operation and Maintenance Manual Operating fluids and 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 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 62: Preparatory Maintenance Activities
– 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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 63: Daily, Weekly And Monthly Maintenance Work
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 64: Operation And Maintenance Manual
Operating fluids and maintenance Operation and Maintenance Manual Daily, weekly and monthly maintenance work Fig. 46: Water pump location Water pump u Check area around water pump 9 for leaks. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 65: Operation And Maintenance Manual
Overflow-oil line Pressure line 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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 66: Checking The Engine Oil Level
Visually check belt drive 2 for damage, friction-free installation, and regulation- compliant fastening. 5.13.2 Checking the engine oil level Oil dipstick and oil filler neck are located on the right as seen from the flywheel. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 67: Operation And Maintenance Manual
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 68: Check Coolant Level
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 69: Maintenance Activities
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 Make sure that: q The Diesel engine is horizontal. q The Diesel engine is turned off. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 70: Operation And Maintenance Manual
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 regulations). © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 71: Operation And Maintenance Manual
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 72: Replace The Oil Separator Filter Insert Of The Crankcase Breather
5.14.3 Replace the oil separator filter insert of the crankcase breather Make sure that: q A new V-ribbed belt is on hand. q A new filter insert is on hand. q Another person is present. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 73: Operation And Maintenance Manual
“Check state of fan drive belt drive, replace if necessary”.) u Dismantle the bracket 3. (Please refer to the chapter on “Changing the crankcase breather belt” for the procedure.) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 74: Operation And Maintenance Manual
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 crankcase ventilation 8. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 75: Operation And Maintenance Manual
Mount belt (fan) 2. (For the procedure, please refer to the chapter “Check state of fan drive belt drive, replace if necessary”.) u Mount fan on the fan drive 1. See the generator set’s operating manual. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 76: Replace Main Fuel Filter
Clean the main fuel filter and surrounding area carefully. u Loosen the main fuel filter 1 with a strap wrench or similar tool and unscrew. u Dispose of used main fuel filter (observe country-specific regulations). © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 77: Replace The Primary Fuel Filter
5.14.6 Take coolant sample and perform coolant analysis. CAUTION Hot coolant! Risk of burns! Can cause injuries. u Turn off engine and let it cool down. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 78: Check State Of Fan Drive Belt Drive And Replace If Necessary
– 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 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 79: Operation And Maintenance Manual
Check that 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 damaged parts. Please contact the nearest authorized Kohler Co. customer service. Replacing the belt Make sure that: q A new belt is on hand. -
Page 80: Changing The Crankcase Breather V-Ribbed Belt
– 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 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 81: Operation And Maintenance Manual
Turning device ID no. 10123791 is available. q Another person is present. WARNING Rotating parts! Risk of injury! Causes serious injuries. u Turn the Diesel engine off. u Secure the engine against unexpected starting. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 82: Operation And Maintenance Manual
“Check state of fan drive belt drive, replace if necessary”.) Procedure for removing the fan drive assembly 4: u Loosen external hexalobular screws 3 (M18 10.9 E24). u Remove fan drive assembly 4. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 83: Operation And Maintenance Manual
Tighten external hexalobular screws 3 (M18 10.9 E24). Tightening instructions for external hexalobular screws (M18 10.9 E24) Step Torque 125 Nm 92 ft lb 250 Nm 184 ft lb Tab. 33: Tightening instructions © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 84: Checking And Replacing The Water Pump Belt Drive And Battery Charging Alternator
Turning device ID no. 10123791 is available. WARNING Rotating parts! Risk of injury! Causes serious injuries. u Turn the Diesel engine off. u Secure the engine against unexpected starting. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 85 “Check state of fan drive belt drive, replace if necessary”.) u Dismantle the bracket 3. (Please refer to the chapter on “Changing the crankcase breather belt” for the procedure.) © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01...
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Page 86: Operation And Maintenance Manual
Operating fluids and maintenance Operation and Maintenance Manual Maintenance activities Fig. 68 While another person operates the turning device, u Remove the V-ribbed belt (crankcase ventilation) 5. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 87: Operation And Maintenance Manual
(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”. -
Page 88: Operation And Maintenance Manual
Operating fluids and maintenance Operation and Maintenance Manual Maintenance activities © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 89: Transport And Storage
Storage conditions are part of the device manufacturer. u Comply with the standard ISO 6749-1984 for transportation and storage. u Please contact the Kohler customer service if anything is unclear. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 90: Fastening During Transport
Check the maximum floor load before setting the Diesel engine down on the floor. u The weight data can be found in the technical data sheet. Information u Use only preservation media approved by Kohler. 6.1 Fastening during transport Fig. 70: Example of fastening during transport DANGER Mortal danger due to instability during transportation of the Diesel engine. -
Page 91: Operation And Maintenance Manual
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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 92: Wooden Transport Stand
Mortal danger! Causes 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. © 2017 by Kohler Co. All rights reserved. -
Page 93: Steel Transport Stand
Mortal danger! Causes 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. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 94: Suspension Device
Pay attention to the safety instructions / warnings in the Operating Manual for the hoisting beam! u Do not work under suspended loads! Fig. 73: Suspension device © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 95: Operation And Maintenance Manual
Receiving tube ID no. 11213360 (for 3-point suspension) (for 4-point suspension) Information u Please read and observe the safety instructions in the system description before commissioning the hoisting beam. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 96: Operation And Maintenance Manual
Transport and storage Operation and Maintenance Manual Suspension device Fig. 75: Lifting lugs for 4-point suspension © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 97: Storage
(situated outdoors for longer periods of time or stored in damp, unventilated locations etc.). 6.7.1 Storage for over 6 and up to 24 months Please contact Field Service if planning storage over 6 months up to 24 months. © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 98: Operation And Maintenance Manual
Transport and storage Operation and Maintenance Manual Storage © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 99: Standard Torques
M 39 3000 2210 4300 3170 5100 3770 Tab. 34 Fine thread ft lb ft lb ft lb 10.9 12.9 M 8 x 1 M 9 x 1 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 100: Standard Torques For Screw Plugs And Hollow Screws
M 38 x 1.5 M 10 x 1 M 38 x 2 M 10 x 1.25 M 42 x 1.5 M 12 x 1.5 M 42 x 2 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 101: Standard Torques For Flange Joints
M 16 x 1.5 M 18 x 1.5 M 22 x 1.5 M 26 x 1.5 M 33 x 2.0 M 42 x 2.0 M 48 x 2.0 Tab. 37 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 102: Operation And Maintenance Manual
M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 20 x 1.5 M 22 x 1.5 M 27 x 2.0 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 103: Operation And Maintenance Manual
G 1/8A G 1/4A G 1/4A G 3/8A G 1/2A G 1/2A G 3/4A G 1A G 1 1/4A G 1 1/2A Tab. 42 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 104: Metric Flange Joints, Series L (Light) For Aluminum
M 10 x 1.0 M 12 x 1.5 M 14 x 1.5 M 16 x 1.5 M 18 x 1.5 M 22 x 1.5 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 105: Standard Torques For Cutting Ring Flange Joints
Tighten box nut to aforementioned torque. 7.1.7 Standard torques for Triple Lok® flange joints Series Tube diameter X Thread Z ft lb ft lb inch UN/UNF Steel Stainless steel © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 106: Standard Torques For Vsti Screw Plugs
M 33 x 2 M 20 x 1.5 M 38 x 1.5 M 22 x 1.5 M 42 x 2 M 24 x 1.5 M 48 x 2 Tab. 48 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 107: Special Tool
ID no. Order number TURNING DEVICE 10123791 230610006 1 HOISTING BEAM 10815480 230610025 2 RECEIVING TUBE F.4- 11213360 230610026 POINT RETAINER Tab. 49: Special tool with identification number © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 108: Terms Used (Glossary)
"Operating and maintenance areas". Maintenance areas Maintenance areas are the safety zones that have to be accessed for maintenance work and troubleshooting. Tab. 50 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 109: Index
Emergency stop 29 optimized top power 51 Emission control information label 14 Maintenance schedule — ESP Emission Engine control unit nameplate 16 optimized 49 Engine oil analysis 43 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... -
Page 110: Index
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 Safety 19 Safety instructions 26 © 2017 by Kohler Co. All rights reserved. KD27V12 33521029401_3_1 en 2017-07-01... - Page 112 33521029401_3_1 EN 07-2017 LHID11433940 ©2016 by Kohler Co. All rights reserved.
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