Kohler KD45V20 Operation And Maintenance Manual

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Operation and maintenance manual (108 pages)

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Operation and Maintenance Manual

Translation of the original instructions

Diesel engine

KD45V20

From serial number 2016 18 0001

33521030001_1_1

12-2016

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Summary of Contents for Kohler KD45V20

Page 1 Operation and Maintenance Manual Translation of the original instructions Diesel engine KD45V20 From serial number 2016 18 0001 33521030001_1_1 12-2016...
Page 2 The Operating Manual facilitates the operator's familiarization with the diesel engine and prevents faults through incorrect operation. Kohler Co. will not allow any warranty claims that arise due to incorrect operation, insufficient maintenance, use of unapproved operating fluids or non-compliance with safety regulations.
Page 3 Kohler Co. will annul any obligations entered into by Kohler Co. and/or their dealers such as warranty assurances, service agreements etc. without prior notice if spare parts other than original Kohler parts or parts purchased from Kohler Co. are used for maintenance and repairs.
Page 5 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) © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 6 Maintenance schedule — ESP Fuel optimized 5.4.1 ESP Fuel optimized — Service level 1 5.4.2 ESP Fuel optimized — Service level 2 Maintenance schedule — ESP Emission optimized © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 7 5.13.4 Change diesel engine oil and oil filter 5.13.5 Take coolant sample and perform coolant analysis. 5.13.6 Change air filter main element 5.13.7 Check state of fan drive belt drive and replace if necessary © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 8 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) Abbreviations used Index © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 9 Generators - Electric section of your Yellow Pages. – Visit the web site of Kohler Power Systems at www.KOHLERPower.com. – Pay attention to the labels and stickers on your Kohler Co. product or check the corresponding literature or documents included with the product's scope of delivery.
Page 10 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 Charge air line Alternator to charge the Flywheel battery Pressure line rail Oil drain shut-off valve Flywheel housing See next page for continuation of the image legend © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 12 V-ribbed belt fan cooling Charge air connecting line Charge air line Oil filter from charge air cooler Crankcase breather Fuel fine filter Exhaust gas turbocharger Coolant connection from coolant cooling © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 13 Operation and Maintenance Manual Product description Technical description Fig. 3: Overview of sensors Rotational speed sensor Rotational speed sensor Rotational speed sensor Service switch Temperature sensor Temperature sensor Pressure sensor © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 14 Tab. 3 Diesel engine company name plate The Diesel engine company name plate is mounted on the oil sump. A second company name plate is attached to the device. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 15 The engine serial number is stamped into the engine company name plate and the crankcase. Fig. 6: Engine serial number 2016 0001 Engine serial number 2016 Year of manufacture Engine type code: 18 = KD45V20 0001 Consecutive production number Tab. 4 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 16 The real information can be viewed in the device display or read out using the KODIA diagnosis and service tool. Tab. 5 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 17 See company name plate Emission limit stage See engine emis- sions type plate 1.2.2 Cylinder head Description Unit Value Inlet valve clearance, cold 0,019 Outlet valve clearance, cold 0,023 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 18 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 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 19 NOTICE indicates a hazardous situation which, if not avoided, could result in material damages. Tab. 7 Additional markings Information indicates useful information and tips. Tab. 8 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 20 The work on engines, equipment as well as mechanical and electronic equipment includes: – Operating the machine and facilities – Performance of scheduled maintenance work – Assembly, installation, assessment, adjustment, testing and maintenance © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 21 • Using the diesel engine. • Servicing the diesel engine. Maintaining the diesel engine. • Please refer to the “Target audience” chapter for additional information. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 22 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 – 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 inade- quate carrying capacity.
Page 24 – Use suitable protective equipment during work on the fuel and injection system (e.g. safety gloves, safety goggles, etc.). – Do not open any pressurized fuel lines or hoses. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 25 Wear safety shoes in the direct vicinity of the engine. Safety gloves – Protection against hot elements and chemicals Wear safety gloves during work with hot parts. (For example: shrink-fitting the crown gear on the flywheel.) © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 26 – 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 27 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. u Leave the engine to cool down sufficiently. u Wear personal protective equipment. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 28 – All of the protective devices are installed and are working properly. – Make sure that no external persons stand or walk in the danger zones. – Remove the label from the fuel supply. – Reconnect the fuel supply. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 29 – Possible EMC radiation that may affect heart pacemakers and implanted defib- rillators. People with a heart pacemaker or implanted defibrillator: keep a minimum distance of 20cm (8 inches) from the operational Diesel engine. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 30 – 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 31 Bring all of the protective devices into their protective position (housing is closed). u Secure external parts against unexpected movements. Remove all persons from the danger zones. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 32 Check the coolant level. u Perform a visual check for any leaks in the lines. u Check for KODIA error messages. u Check for error messages on the device side. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 33 Wait for at least five minutes after every subsequent attempt before re-trying. u ECU software can prevent the starting procedure as protection against over- heating depending on the start time and start attempts. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 35 Charge or replace the battery. The battery connections are loose or Clean and tighten the loose connec- corroded. tions. The outside temperature is too low. Take appropriate action for Winter operation. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 36 KOHLER Co. to have the engine checked. There is a fault in the electronic Read out the error memory of the system. engine control unit, contact KOHLER Co. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 37 The injection nozzles are blocked or Contact KOHLER Co. engine. inefficient. Fault in the turbocharger (charge Contact KOHLER Co. pressure too low). The engine is overloaded. Contact KOHLER Co. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 38 There is coolant in the lubricant. Leaks in the cylinder liner seals. Contact KOHLER Co. Leak in the oil cooler or oil cooler Contact KOHLER Co. plate. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 39 The charge air cooler is dirty. Contact KOHLER Co. The turbocharger outlet is faulty. Contact KOHLER Co. Coolant leaks from the charge air Leak, faulty. Contact KOHLER Co. cooler. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 41 180 l (1.5 l per filter) 47.6 US gal (0.4 US gal per filter) Coolant 143 l 37.8 US gal Tab. 9: Fill quantities in the Diesel engine (guide values) © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 42 HFFR < 460 µm without AEG with addi- tive S-1750 Tab. 10: Approved fuel qualities Minimum requirement for quality Requirement for the fuel Parameter Lubrication capability at 60°C (HFRR) 460 µm © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 43 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 44 Basic oil change interval * Factor oil category * Factor sulfur content = change interval The basic oil change interval is defined in the maintenance tables. The factor “oil category”: © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 45 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 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 46 <80 Nitrite DIN EN 12014 mg/kg <500 pH value DIN EN ISO 10523:2012-04 8.1 — 9.0 Freezing point DIN ISO 3016, ASTM 5985 °C Tab. 15: Control parameter © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 48 Perform visual inspection (leaks, contamination, damage, Weekly belt drive, cable harness) Monthly X Test run at more than 1/3 load. Tab. 16: Maintenance schedule — Daily maintenance activities — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 49 V-ribbed belt for alternator Check state of belt drive, replace if necessary. to charge the battery and water pump Coolant Replace coolant. Tab. 17: ESP Fuel optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 50 Water pump 4000 Replace the water pump. Alternator to charge the Change the alternator to charge the battery. 4000 battery Tab. 18: ESP Fuel optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 51 V-ribbed belt for alternator Check state of belt drive, replace if necessary. to charge the battery and water pump Coolant Replace coolant. Tab. 19: ESP Emission optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 52 Water pump 4000 Replace the water pump. Alternator to charge the Change the alternator to charge the battery. 4000 battery Tab. 20: ESP Emission optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 53 V-ribbed belt for alternator Check state of belt drive, replace if necessary. 4000 to charge the battery Coolant 6000 Replace coolant. Tab. 21: PRP Fuel optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 54 Change the alternator to charge the battery. 10000 battery High pressure pump 15000 Change the HP pump. Viscose damper 15000 Replace the viscose damper. Tab. 22: PRP Fuel optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 55 V-ribbed belt for alternator Check state of belt drive, replace if necessary. 4000 to charge the battery Coolant 6000 Replace coolant. Tab. 23: PRP Emission optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 56 Change the alternator to charge the battery. 10000 battery High pressure pump 15000 Change the HP pump. Viscose damper 15000 Replace the viscose damper. Tab. 24: PRP Emission optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 57 V-ribbed belt for alternator Check state of belt drive, replace if necessary. 4000 to charge the battery Coolant 6000 Replace coolant. Tab. 25: COP Fuel optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 58 Replace the water pump. High pressure pump 20000 Change the HP pump. Viscose damper 20000 Replace the viscose damper. Tab. 26: COP Fuel optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 59 V-ribbed belt for alternator Check state of belt drive, replace if necessary. 4000 to charge the battery Coolant 6000 Replace coolant. Tab. 27: COP Emission optimized — Service level 1 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 60 Replace the water pump. High pressure pump 20000 Change the HP pump. Viscose damper 20000 Replace the viscose damper. Tab. 28: COP Emission optimized — Service level 2 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 61 Operation and Maintenance Manual Operating fluids and maintenance Special tools for maintenance activities 5.10 Special tools for maintenance activities Fig. 42: Turning device ID no. Description 10123791 Turning device Tab. 29 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 62 – 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 63 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 64 Pressure line Fuel line u Visually check hoses for leaks, ensure that they are not damaged, that they are installed fiction-free, and that fastening is in compliance with regulations. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 65 Visually check cable harness and belt drive for damage, fiction-free installation, and regulation-compliant fastening. 5.12.2 Checking the engine oil level Oil dipstick and oil filler neck are located on the right as seen from the flywheel. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 66 Fill oil through the 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 67 Perform maintenance and inspection work on the cooling system only when the Diesel engine has cooled down. u Wear protective equipment. Fig. 48 See device documentation for procedure to check coolant level. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 68 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 69 Vibrations w Exhaust color 5.12.9 Test run (perform monthly) u Let the engine run at more than 1/3 load. w Let the engine run until the temperature stabilizes. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 70 Send the sample bottle with all necessary information about the machine and engine oil to a laboratory. u Check the engine oil level and top up with engine oil if necessary. See the “Checking the engine oil level” chapter. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 71 Never reuse a fuel fine filter after it has been used once. u Pay attention to the special instructions for working on the common rail system, see the “Safety” chapter. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 72 The oil drain shut-off valve is on the right side of the oil pan as seen from the flywheel. The oil filters are on the left and right as seen from the flywheel. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 73 Oil filter 1 use a strap wrench or similar tool to unscrew. CAUTION Hot engine oil! Injuries, burns! u Avoid skin contact with the engine oil. u Wear protective gloves when changing the engine oil. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 74 Check the oil level on the dipstick after 2 to 3 minutes. If the engine oil level is not between min and max: u Correct the oil level. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 75 – Transverse cracks on the back – Transverse cracks in several ribs Fig. 55: Damage to the V-ribbed belt The belt drive is located at the front of the Diesel engine. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 76 Turn the Diesel engine off. u Secure the engine against unexpected starting. u Pay attention to the run-on time: make sure that all parts have stopped moving before opening the covers. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 77 Start the engine and let it run for 30 minutes. u Turn off engine and check pretension. Retension if necessary. u See device documentation for mounting fan. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 78 Turn the Diesel engine off. u Secure the engine against unexpected starting. u Pay attention to the run-on time: make sure that all parts have stopped moving before opening the covers. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 79 Remove fan. See device documentation. u Remove V-ribbed belt (fan) 1 . (For the procedure, please refer to the chapter “Check state of fan drive belt drive, replace if necessary”.) © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 80 See device documentation for mounting fan. 5.13.9 Change the oil separator filter insert of the crankcase breather Make sure that: q Four new oil separator filter inserts with new O-rings are on hand. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 81 Operation and Maintenance Manual Operating fluids and maintenance Maintenance activities Crankcase breather position Fig. 60: Crankcase breather position Crankcase breather © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 82 Remove hose 1 clamps and hose Regulating valve (cover): 2 remove. u Lever screws: 3 loosen. u from regulating valve 2 (cover). u Remove filter 4 insert. Install oil separator filter insert Fig. 62: Install filter insert © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 83 Let the engine cool down before opening the filler neck. u Pay attention to overpressure when opening the filler neck. u Never fill the cooling system when the engine is hot. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 84 Pay attention to the manufacturer's instructions. u Wear rubber gloves and protective glasses when mixing coolants. u Rinse off any splashes in the eyes or on the skin immediately with water. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 85 Start the Diesel engine and let it warm up. u Check the coolant level again when the Diesel engine has cooled down and correct if necessary. See device documentation. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 87 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 in anything is unclear. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 88 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. 66: Example of transport fastening / wood transport stand DANGER Mortal danger due to instability during transportation of the Diesel engine.
Page 89 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 90 Mortal danger! 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. © 2016 by Kohler Co. All rights reserved.
Page 91 Mortal danger! u The Diesel engine must be securely bolted to the transport stand. Information u Return the steel transport stand to Kohler Co. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 92 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 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 93 Hoisting beam ID no. 12204231 Power unit support side Lifting gear Flywheel side Information u Please read and observe the safety instructions in the system description before commissioning the hoisting beam. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 94 (situated outdoors for longer periods of time or stored in damp, unventilated loca- tions 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. © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 101 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 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 103 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. 45: Special tool with identification number © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 104 "Operating and maintenance areas". Maintenance areas Maintenance areas are the safety zones that have to be accessed for maintenance work and troubleshooting. Tab. 46 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 105 Operation and Maintenance Manual Abbreviations used 7.4 Abbreviations used Short Long Explanation After-treatment of exhaust gases if nec. if necessary Service level Width across flats Tab. 47 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 107 International standard classification of occupations 20 Cylinder head 17 Limitation of liability 22 Daily maintenance work 48, 63 Lubricants and operating materials 41, 42 Danger due to noise 25 Design overview 11 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...
Page 108 Remove oil separator filter insert 82 Replace fuel fine filter. 71 Wooden transport stand 90 Replacing the coolant 83 Requirements for water 45 Requirements of the coolant 46 © 2016 by Kohler Co. All rights reserved. KD45V20 33521030001_1_1 en 2016-12-15...

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