Kohler KD36V16 Operation And Maintenance Manual

Operation and Maintenance Manual

Translation of the original instructions

Diesel engine

KD36V16

From serial number 2017 17 0001

EN

33521029701_1_1

08-2018

Preface Operation and Maintenance Manual

Preface

Only for the United States of America:

WARNING:

This product can expose you to chemicals, including carbon monoxide and
benzene, which are known to the State of California to cause cancer and birth
defects or other reproductive harm.

For more information go to www.p65warnings.ca.gov/.

WARNING:

Breathing diesel engine exhaust exposes you to chemicals known to the State of
California to cause cancer and birth defects or other reproductive harm.

- Always start and operate the engine in a well-ventilated area.

- If in an enclosed area, vent the exhaust to the outside.

- Do not modify or tamper with the exhaust system.

- Do not idle the engine except as necessary.

For more information go to www.p65warnings.ca.gov/diesel.

This Operating and Maintenance Manual has been written for the operator and
maintenance personnel of the Diesel engine.

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.

The Service and Repair 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.

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.

© 2018 by Kohler Co. All rights reserved.

2

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Preface

In extreme conditions, more frequent maintenance than scheduled in the
inspection plan can be required.

Changes, conditions, copyright

This document is protected by copyright. The copyright is held by:
– Kohler Co.

Subject to changes in the interests of technical progress.

Proprietary notice ISO 16016: “The reproduction, distribution and utilization of this
document as well as the communication of its contents to others without express
authorization is prohibited. Offenders will be held liable for the payment 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

33521029701_0_1 2017 17 0001 First version October 2017

33521029701_1_1 2017 17 0001 Various changes August 2018

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

3

Preface Operation and Maintenance Manual

© 2018 by Kohler Co. All rights reserved.

4

KD36V16 33521029701_1_1 en 2018-08-01

Contents

Service Assistance

1 Product description

1.1 Technical description

1.1.1 Design overview

1.1.2 Overview of sensors

1.1.3 Explanation of the type designation

1.2 Technical data

1.2.1 Diesel engine

1.2.2 Cylinder head

1.2.3 Coolant thermostat

1.2.4 Battery charging alternator

1.2.5 Starter

1.2.6 Flywheel housing

2 Safety

9

11

11

11

14

14

18

18

18

18

19

19

19

21

2.1 Identification of the warnings

2.2 Target audience

2.2.1 International standard classification of occupations

2.2.2 Occupational references

2.2.3 Unauthorized personnel

2.3 Intended use

2.4 Foreseeable misuse

2.5 General safety instructions

2.6 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)

21

22

22

22

23

24

24

25

25

25

26

26

26

26

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

5

Contents Operation and Maintenance Manual

2.6.6 Electrical energy

2.6.7 Danger due to noise

2.7 Personal protective equipment

2.8 Operating areas and maintenance areas

2.8.1 Safety instructions

2.8.2 Operating areas

2.8.3 Maintenance areas

2.8.4 Secure and release the diesel engine against accidental starting

2.8.5 Emergency stop

2.8.6 Signage

2.9 Prevent material damages

3 Handling, operation

3.1 Start-up procedure

3.1.1 Filling the operating fluids

27

27

27

28

28

29

29

30

31

31

32

33

33

33

3.1.2 Starting the engine

4 Operating faults

4.1 Faults – Cause – Solution

5 Operating fluids and maintenance

5.1 Fill quantities

5.1.1 Lubricants and operating materials

5.2 Lubricants and operating materials

5.2.1 Diesel fuels

5.2.2 Engine oils

5.2.3 Coolant

5.3 Maintenance

5.3.1 Maintenance schedule

5.3.2 Daily, weekly and monthly maintenance work - Version: 2018/06-1

5.4 Maintenance schedule — ESP Fuel optimized

33

35

35

41

41

41

42

42

43

45

47

47

48

49

5.4.1 ESP Fuel optimized — Service level 1 - Version: 2018/06-1

5.4.2 ESP Fuel optimized — Service level 2 - Version: 2018/06-1

5.5 Maintenance schedule — ESP Emission optimized

5.5.1 ESP Emission optimized — Service level 1 - Version: 2018/06-1

© 2018 by Kohler Co. All rights reserved.

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KD36V16 33521029701_1_1 en 2018-08-01

49

50

51

51

Operation and Maintenance Manual Contents

5.5.2 ESP Emission optimized — Service level 2 - Version: 2018/06-1

5.6 Maintenance schedule — ESP 50Hz emission optimized top power

5.6.1 ESP 50Hz emission optimized top power — Service level 1 - Version:
2018/06-1 53

5.6.2 ESP 50Hz emission optimized top power — Service level 2 - Version:
2018/06-1 54

5.7 Maintenance schedule — PRP Fuel optimized

5.7.1 PRP Fuel optimized — Service level 1 - Version: 2018/06-1

5.7.2 PRP Fuel optimized — Service level 2 - Version: 2018/06-1

5.8 Maintenance schedule — PRP Emission optimized

5.8.1 PRP Emission optimized — Service level 1 - Version: 2018/06-1

5.8.2 PRP Emission optimized — Service level 2 - Version: 2018/06-1

5.9 Maintenance schedule — COP Fuel optimized

5.9.1 COP Fuel optimized — Service level 1 - Version: 2018/06-1

5.9.2 COP Fuel optimized — Service level 2 - Version: 2018/06-1

5.10 Maintenance schedule — COP Emission optimized

52

53

55

55

56

57

57

58

59

59

60

61

5.10.1 COP Emission optimized — Service level 1 - Version: 2018/06-1

5.10.2 COP Emission optimized — Service level 2 - Version: 2018/06-1

5.11 Special tools for maintenance activities

5.12 Preparatory maintenance activities

5.13 Daily, weekly and monthly maintenance work

5.13.1 Perform visual inspection (leaks, damage, loose components) — SL000

5.13.2 Checking the engine oil level — SL001

5.13.3 Check coolant level — SL001

5.13.4 Check the ventilation holes on the water pump — SL003

5.13.5 Check/drain water trap on the primary fuel filter — SL004

5.14 Maintenance activities

5.14.1 Take oil sample and perform oil analysis — SL100

5.14.2 Replace diesel engine oil and oil filter — SL121

5.14.3 Replace the oil separator filter insert of the crankcase breather —
SL107 75

5.14.4 Replace main fuel filter — SL105

61

62

63

64

65

65

67

69

70

70

72

72

72

78

5.14.5 Replace the primary fuel filter — SL106

5.14.6 Take coolant sample and perform coolant analysis — SL120

5.14.7 Change air filter main element — SL108

5.14.8 Check state of fan drive belt drive and replace if necessary — SL118

KD36V16 33521029701_1_1 en 2018-08-01

79

79

80

80

© 2018 by Kohler Co. All rights reserved.

7

Contents Operation and Maintenance Manual

5.14.9 Check and change the V-ribbed belt for the battery charging alternator
— SL109 83

6 Transport and storage

6.1 Fastening during transport

6.2 Wooden transport stand

6.3 Steel transport stand

6.4 Suspension device

6.5 Storage

6.6.1 Storage for up to 6 months

6.7.1 Storage for over 6 and up to 24 months

7.1 Standard torques

7.1.1 Standard torques for screw connections

7.1.2 Standard torques for screw plugs and hollow screws

7.1.3 Standard torques for flange joints

7.1.5 Metric flange joints, series L (light) for aluminum

7.1.6 Standard torques for cutting ring flange joints

7.1.7 Standard torques for Triple Lok® flange joints

87

88

90

91

92

94

94

94

95

95

96

97

100

101

101

7.1.8 Standard torques for VSTI screw plugs

7.2 Special tool

7.3 Terms used (glossary)

Index

102

103

104

105

© 2018 by Kohler Co. All rights reserved.

8

KD36V16 33521029701_1_1 en 2018-08-01

Service Assistance

Please contact your nearest Kohler Power Systems distributor or dealer for
professional advice on the generator set power requirements and conscientious
service.

For Kohler generating sets:

– Visit the web site of Kohler Co. 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.
– In the USA and Canada, call toll-free 1-800-544-2444.
– Outside the USA and Canada, call the nearest regional office.

Headquarters in Europe, the Middle East and Africa (“EMEA”) India, Bangladesh, Sri Lanka

Kohler Power Systems Netherlands B.V. India Regional Office

Kristallaan 1 Bangalore, India

4761 ZC Zevenbergen Phone: [phone]

Netherlands (91) 80 3366231

Phone: [phone] Fax: [phone]

Fax: [phone]

Japan, Korea

Asia Pacific North Asia Regional Office

Kohler Asia Pacific Headquaters Tokyo, Japan

Singapore, Republic of Singapore Phone: [phone]

Phone: [phone] Fax: [phone]

Fax: [phone]

China

North China Regional Office, Beijing

Phone: [phone]

(86) 10 6518 7951

(86) 10 6518 7952

Fax: [phone]

East China Regional Office, Shanghai

Phone: [phone]

Fax: [phone]

Tab. 1

To order special tools, please refer to the cross reference list in the annex.

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

9

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.

– Call the nearest regional office.

SALES OFFICE FRANCE SOUTHWEST BRANCH OFFICES

WEST SDMO TOULOUSE SOUTH AFRICA

SDMO BREST TEL.: [phone] SDMO SOUTH AFRICA

TEL.: [phone] FAX: [phone] TEL.: [phone]

FAX: [phone]

FAX: [phone]

SUBSIDIARIES

MID-WEST GERMANY ALGERIA

SDMO CHOLET SDMO GMBH SDMO ALGIERS

TEL.: [phone] TEL.: [phone] TEL.: [phone]

FAX: [phone] FAX: [phone] FAX: [phone]

PARIS/NORTH & NORMANDY LATIN AMERICA & CARRIBEAN DUBAI

SDMO ARRAS TEL.: [phone] SDMO MIDDLE EAST

TEL.: [phone] FAX: [phone] TEL.: [phone]

FAX: [phone]

SDMO GENNEVILLIERS

BELGIUM

FAX: [phone]

TEL.: [phone] SDMO NV/SA EGYPT

FAX: [phone] TEL.: [phone] SDMO KAIRO

EAST

FAX: [phone] TEL./FAX: [phone]

BRAZIL KENYASDMO METZ

TEL.: [phone] KOHLER MAQUIGERAL SDMO NAIROBI

FAX: [phone] TEL.: [phone] TEL./FAX: [phone]

SOUTHEAST SPAIN RUSSIA

SDMO AIX-EN-PROVENCE SDMO INDUSTRIES IBERICA SDMO MOSCOW

TEL.: [phone] TEL.: [phone] TEL.:/FAX: [phone]

FAX: [phone] FAX: [phone]

TOGOSDMO VALENCE

UNITED KINGDOMTEL.: [phone] SDMO WEST AFRICA

FAX: [phone] SDMO ENERGY LTD. TEL.: [phone]

TEL.: [phone]

TURKEYFAX: [phone]

To order special tools, please refer to the cross reference list SDMO ISTANBUL

in the annex. TEL.: [phone]

Tab. 2

© 2018 by Kohler Co. All rights reserved.

10

KD36V16 33521029701_1_1 en 2018-08-01

1 Product description

1.1 Technical description

1.1.1 Design overview

This section contains an overview of the diesel engine with the names of the parts
shown.

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

11

Product description Operation and Maintenance Manual

Technical description

Fig. 1: Overview of flywheel side

1 Intake stack 5 Oil module 9 Fastening point for turning

device

2 Charge air line 6 Battery charging alternator 10 Flywheel
3 Pressure line rail 7 Oil drain shut-off valve 11 Flywheel housing
4 Engine control unit 8 HP pump (two)

12

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description

Technical description

Fig. 2: Overview of power unit support side

1 Coolant connection to coolant

4 Exhaust gas turbocharger 7 Coolant connection from

cooling

2 Charge air connecting line

5 Oil filter 8 V-ribbed fan belt

from charge air cooler

3 Crankcase breather 6 Main fuel filter

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

coolant cooling

13

Product description Operation and Maintenance Manual

Technical description

1.1.2 Overview of sensors

Fig. 3: Overview of sensors

1 Rotational speed sensor 4 Temperature sensor 7 Rotational speed sensor
2 Service switch 5 Pressure sensor
3 Temperature sensor 6 Temperature sensor

1.1.3 Explanation of the type designation

Type description

K D 36 V 16 - 5 A F C Engine type designation

K Manufacturer

D Diesel engine

36 Total displacement: 36 l

© 2018 by Kohler Co. All rights reserved.

14

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description

Technical description

K D 36 V 16 - 5 A F C Engine type designation

V V-engine

16 No. of cylinders

5 Frequency: 5=50 Hz; 6=60 Hz

A Power level: A where 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 engine company nameplate and the
crankcase.

Fig. 5: Engine serial number

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

15

Product description Operation and Maintenance Manual

Technical description

2016 18 0001 Engine serial number

2017 Year of manufacture

17 Engine type code: 17= KD36V16

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

Fig. 7: Example of an engine control unit nameplate

1 Delivery date 5 Engine serial number
2 2D code bar 6 Control unit ID number
3 Engine type 7 ID number certification
4 Control unit description 8 ID number parameter set

16

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description

Technical description

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

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

17

Product description Operation and Maintenance Manual

Technical data

1.2 Technical data

1.2.1 Diesel engine

Description Unit Value

Design V-Diesel engine

No. of cylinders 16

Firing order according to DIN 73021 1-15-6-13-8-4-16-7-

11-5-9-2-14-10-3-12

Firing order according to ISO 1204 B10–A6–B7–A1–

B3–A4–B9–A8–B5–
A2–B1–A5–B4–
A10–B8–A7–B2–
A3–B6–A9

Bore mmin135

5.31

Stroke mmin157

Displacement l

Compression ratio 15 :1

Direction of rotation of the Diesel engine (seen
from flywheel)

Power specification as per ISO 3046–1

Rated power See company

Rated speed See company

Emission limit stage See engine

1.2.2 Cylinder head

Description Unit Value

6.18

35,956

gal

9.4986

Counterclockwise

nameplate

nameplate

emissions
nameplate

18

Inlet valve clearance, cold mmin0.5

0.019

Outlet valve clearance, cold mmin0.6

0.023

1.2.3 Coolant thermostat

Description Unit Value

Opening start °C 82

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Product description

Technical data

Description Unit Value

°F 179

Completely open °C°F92

197

1.2.4 Battery charging alternator

Description Unit Value

Voltage V 28

Current A 140

1.2.5 Starter

Description Unit Value

Voltage V 24

Output per start system kW 8.4

1.2.6 Flywheel housing

Description Unit Value

Connection SAE 0

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

19

Product description Operation and Maintenance Manual

Technical data

20

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

2 Safety

2.1 Identification of the warnings

This is a warning sign. It warns you of the risk of possible injury.
Follow all of the instructions that accompany this warning sign to
avoid any injuries or death.

Tab. 6

This warning sign only appears in conjunction with the signal words:

DANGER

WARNING

CAUTION

DANGER indicates a hazardous situation which, if not

WARNING indicates a hazardous situation which, if not

CAUTION indicates a hazardous situation which, if not

NOTICE indicates a hazardous situation which, if not

Tab. 7

Additional markings

Information indicates useful information and tips.

Tab. 8

avoided, will result in death or serious injury.

avoided, could result in death or serious injury.

avoided, could result in minor or moderate injury.

avoided, could result in material damages.

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

21

Safety Operation and Maintenance Manual

Target audience

2.2 Target audience

Level 1 — Basic Maintenance Level 2 — Advanced Maintenance

Daily checks, inspection and maintenance tasks which
can be carried out in intervals between operation
without dismantling parts from engine. For example: oil
and fuel refilling

By customer or nearest authorized Kohler service
representative.

Tab. 9: Definition of service levels

Information

The operator of the Diesel engine is responsible for:

Checking the personnel's know-how and skills

u

Defining the necessary additional, refresher and further qualifications

u

Defining the responsibilities and authorizations

u

Applying ILO – "C138 – Minimum Age Convention, 1973" with a minimum age

u

for the work permit of 14 years

Providing the necessary tools and spare parts

u

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.

Maintenance tasks involving partial disassembly of the
engine on site (mid-life service). For example: change
of pump, injectors, heads...

By customer or nearest authorized Kohler service
representative.

2.2.2 Occupational references

The occupations listed perform the following work in accordance with the "General
safety instructions" chapter:
– The main tasks described in this manual or these instructions
– The tasks identified as requirements to prepare the main tasks

For the Service Level 1 maintenance of power
generation engines:

Maintenance Technician

In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group
7233 / ISCED-97 level 2)

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
– Location of defects
– Recording the repair and maintenance work performed

22

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Safety

Target audience

For the Service Level 2 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)

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
– Location of defects
– Dismantling and reassembly of the machine as well as the mechanical and

electronic equipment
– Ensuring compliance with standards and specifications
– Recording the repair and maintenance work performed

2.2.3 Unauthorized personnel

All other persons, including operators, supervisors and trainees, are classified as
"unauthorized personnel" for maintenance work.

They are not allowed to service the engine or access the engine compartment or
engine cover.

For the operation of power generation engines:

Operator

In relation to ILO – Power Production Plant Operators – unit group 3131 /
ISCED-97 on at least one level, from 2 to 4)

Power production plant operators operate, monitor and maintain switchboards and
related equipment in electrical control centers that control the production and
distribution of electrical or other power in transmission networks. The work
includes:
– Operating, monitoring and inspecting various types of energy-generating power

plants
– Operating and controlling power-generating systems and equipment
– Controlling start-up and shut-down of power plant equipment
– Controlling switching operations, regulating water levels
– Communicating with systems operators to regulate and coordinate transmission

loads, frequency and line voltages
– Taking readings from charts, meters and gages at established intervals,

troubleshooting and performing corrective action as necessary
– Completing and maintaining station records, logs and reports, and

communicating with other plant personnel to assess the equipment operating

status
– Cleaning and maintaining equipment such as the battery charging alternator,

pumps or compressors in order to prevent defects or damage to the

equipment 

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

23

Safety Operation and Maintenance Manual

Foreseeable misuse

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

– Make sure that the following work is only carried out by personnel in

accordance with the target audience definition:

•

Using the diesel engine.

•

Servicing the diesel engine.

•

Maintaining the diesel engine.

Please refer to the “Target audience” chapter for additional information.

– Install all of the guards and protective devices and check their functions before

commissioning.
– Pay attention to the safety and operating instructions.
– Only operate the engine if it is in perfect working order.
– Only operate the engine in the speed range specified by the manufacturer.
– Bolt the engine to the machine or the corresponding place of use by the fitted

engine mounts and the corresponding tensioning instructions.
– If engine mounts are used that have not been fitted by the manufacturer these

have to be approved by the manufacturer.
– The engine 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:
– Failure to observe these instructions
– Incorrect use
– The employment of personnel who do not satisfy the target audience

requirements.
– Alterations and conversions of the diesel engine that have been carried out

without the consent of 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.
– Circumvention of and non-compliance with the safety regulations
– Failure to observe international and national regulations on occupational health

and safety
– Failure to observe international and national regulations on environmental

protection
– Unauthorized modifications to the diesel engine
– Manipulations to the injection and control system

24

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Safety

Preventing personal injuries

2.5 General safety instructions

– Requirements to be met by the target audiences for work. See the “Target

audience” chapter.

– To guarantee assistance after an accident: make sure a second person is in

attendance or that the emergency situation is detected and help provided.

– Before any assembly work, make sure that the personnel are familiar with the

operating and maintenance manual.

– Only allow personnel undergoing training to work on the diesel engine under the

constant supervision of an experienced person

– Check that personnel are conscious of safety and the hazards involved in their

work on the following conditions:

•

Observe accident prevention regulations.

•

Observe generally accepted occupational health and safety regulations.

•

Observe the operating and maintenance manual.
– Ensure that the personnel wear safe working clothes.
– Make sure that the following are not worn:

•

Rings

•

Wristwatches

•

Ties

•

Scarves

•

Open jackets

•

Loose clothing
– Make sure 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 lit.
– Only perform assembly work if the Diesel engine has been secured.
– Ensure that the Diesel engine is not started by unauthorized persons.

2.6

Preventing personal injuries

2.6.1 Bruises

– Do not lift heavy parts by hand.
– Fasten and secure individual parts and larger assemblies carefully with suitable

– 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

– Make sure that no persons stand or walk under loads.
– If the Diesel engine is running, make sure that no objects can come into contact

KD36V16 33521029701_1_1 en 2018-08-01

lifting gear during their replacement.

inadequate carrying capacity.

with rotating parts. Objects may be flung back.

© 2018 by Kohler Co. All rights reserved.

25

Safety Operation and Maintenance Manual

Preventing personal injuries

2.6.2 Burns and scalding

The Diesel engine is hot at its operating temperature.
– Only work on the Diesel engine after it has cooled down.
– Only touch hot parts with suitable thermal protection gloves.

The cooling system is hot and under pressure when the Diesel engine is at its
operating temperature.
– Only touch hot parts with suitable thermal protection gloves.
– Avoid any contact with parts carrying cooling water.
– Check the cooling water level when the end cover of the expansion tank has

cooled down.

– Open the cover carefully to release the excess pressure.

The engine oil is hot when the Diesel engine is at its operating temperature.
– Avoid any skin contact with hot oil or parts carrying oil.

2.6.3 Fires and explosions

– Smoking is prohibited in the direct vicinity of the Diesel engine.
– Avoid any fires, sparks or open flames when handling fuels and flammable

liquids.

– Start the Diesel engine in accordance with the regulations in the operating and

maintenance manual and the assembly manual.

– Repair any leaks and replace damaged components.

Fuel and oil that squirts out of leaks can lead to fires.
– Wear safety goggles and gloves when working on batteries.
– 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 penetrate the skin and cause blood poisoning.
– Do not open any pressurized lines or hoses.
– Do not disconnect any pressurized lines or hoses.
– Protect hands, face and body against escaping liquids when looking for leaks in

pressurized lines and hoses.

2.6.5 High-pressure injection (liquids at high pressure can squirt out)

When the Diesel engine is running the fuel lines are under a constant fuel pressure
of up to 2400 bar. Escaping liquids can penetrate the skin and lead to injuries.

– Only work on the fuel and injection systems when the diesel engine has been

switched off.
Wait at least 20 minutes after turning the Diesel engine off until the pressure in

the injection system has been released before starting work.
– Check the drop in pressure with the KODIA diagnostic program.
– 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.

26

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Safety

Personal protective equipment

– 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.

2.6.6 Electrical energy

– The safety zones around the operational Diesel engine may not be accessed by

persons with a heart pacemaker.
– Do not touch any live parts.
– Disconnect the power supply before any work on the electrical system.

2.6.7 Danger due to noise

Permanent hearing impediments are possible at noise levels above 84dB(A).
Sound level up to 110dB(A) possible!

– Keep all sound-absorbing guards on the equipment closed when the engine is

running.
– Do not stand near the running engine without hearing protection that is suitable

for the noise level.
– Pay attention to the hearing protection measures in accordance with the diesel

engine's operating manual.

2.7

The operators and unauthorized personnel may not enter the safety zones when
the engine is ready for use or running. However, if a technician has to approach an
unprotected engine for troubleshooting work he must wear hearing protection
suitable for the noise level.

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 access the Diesel engine:

Protective work wear

– Close-fitting, non-tear-resistant protective clothing as protection against injuries

and simple chemical substances.

Wear protective work gear in the direct vicinity of the engine.

Safety helmet

– Protection against falling or flying objects and against knocks to the head.

Wear safety helmet in the direct vicinity of the engine.

Safety shoes

– Protect feet against falling objects and from getting caught in heavy parts.

Safety gloves

– Protection against hot elements and chemicals.

KD36V16 33521029701_1_1 en 2018-08-01

Additional protection against slipping.

Wear safety shoes in the direct vicinity of the engine.

Wear safety gloves during work with hot parts. (For example: shrink-fitting the

crown gear on the flywheel.)

© 2018 by Kohler Co. All rights reserved.

27

Safety Operation and Maintenance Manual

Operating areas and maintenance areas

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.)

Hearing protection

– Protection against noise.

Wear hearing protection near running engines.

Safety goggles

– Protection against flying splinters and chemical splashes.

Wear safety goggles when handling operating materials. (Please refer to the
manufacturer's specifications for the operating materials and the safety data
sheet for the operating material.)
Wear safety goggles during mechanical operations. (For example when using
compressed air.)

2.8 Operating areas and maintenance 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 engine is ready for use or in operation.

Risk of burns.

– Keep away from engines that are ready for use.
– Wear personal protective equipment.
– Leave the engine to cool down sufficiently.

Hazardous voltage. May result in severe injury or death.

Risk of burns from electric shock.

– 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.

28

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Safety

Operating areas and maintenance areas

2.8.2 Operating areas

Fig. 20: Safety zones of engines that are ready for use or running

a Horizontal projection (viewed from

above)

Access is prohibited to the following areas:

– Safety zone, 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.

Allow the engine to cool down sufficiently.

u

Wear personal protective equipment.

u

b Upright projection (viewed from

the flywheel side)

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

29

Safety Operation and Maintenance Manual

Operating areas and maintenance areas

Fig. 21: Safety zones during maintenance and repairs

a Horizontal projection (viewed from

above)

Access is allowed to the following areas:

– Safety zone, unit carrier side A
– Safety zone next to engine B
– Safety zone, flywheel side C
– Safety zone, above engine D

Access is prohibited to the following areas:

– Safety zone, below engine E

Access to the maintenance areas must be secured against accidental starting
before entering the safety zones.

b Upright projection (viewed from

the flywheel side)

2.8.4 Secure and release 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.

30

Make the diesel engine ready for operation (release):
– The following work has been completed:

•

Installation activities

•

Maintenance activities

•

Repair activities
– 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.

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Safety

Operating areas and maintenance areas

– Remove the label from the fuel supply.

– Reconnect the fuel supply.

– Remove the label from the electrical power supply.

– Establish the electrical power supply.

2.8.5 Emergency stop

An emergency stop is provided for hazardous situations that call for an immediate

shutdown of the Diesel engine. The power supply to the Diesel engine is

interrupted immediately. Only the engine control unit still receives current.

Examples of hazardous situations:

– Fire

– Persons having suffered an electric shock

– Diesel engine does not stop

– Diesel engine accelerates uncontrollably

Only use the emergency stop in emergencies. Triggering an emergency stop can

cause permanent damage to the Diesel engine. The emergency stop may not be

used to stop the Diesel engine for operational purposes.

2.8.6 Signage

Information

The following required signs must be clearly visible and attached in the direct

u

vicinity of the safety zones.

The preceding required signs must be able to withstand the ambient conditions.

u

The end user must ensure that these are kept visible and legible over the entire
life cycle.

Additional warnings or adaptations to product standards (ISO 8528-13) are

u

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 engine has hot surfaces that are not immediately recognizable as

such.
Wait for a sufficient time until the engine has cooled down.
Only touch components that may be hot with suitable protective gloves.

ISO 7010 / W025 Warning of entanglement hazard

– There are potential trapping hazards on the engine in the area of the V-ribbed

ISO 7010 / P007 No access for persons with heart pacemakers or implanted

defibrillators

– Possible EMC radiation that may affect heart pacemakers and implanted

KD36V16 33521029701_1_1 en 2018-08-01

belts and battery charging alternator.
Attach a warning sign if traps are not secured through guards (optional).
Enter the safety zone only after the Diesel engine has been turned off.
Secure the Diesel engine against any unexpected start-up.

defibrillators.
People with a heart pacemaker or implanted defibrillator: keep a minimum
distance of 20cm (8 inches) from the operational Diesel engine.

© 2018 by Kohler Co. All rights reserved.

31

Safety Operation and Maintenance Manual

Prevent material damages

ISO 7010 / M002 Observe the instructions

– In order to ensure that all residual risks are known by the personnel, the system

documentation must be read and understood.
Make sure that all residual risks according to the risk assessment of the system
manufacturer are reflected in the system documentation.
Provide documentation to the personnel according to the "target audience"
definitions without restrictions.

2.9 Prevent material damages

– Replace jointing material (e.g. O-rings, seals etc.).
– Check reusable removed parts for re-usability; see the relevant information in

the Service Manual and repair instructions.
– Replace any removed parts that cannot be re-used.
– If no specific torques and tensioning instructions are specified: Flange joints are

to be tightened with the standard torques. Additional information can be found in

the "Standard torques" chapter.
– Replace self-locking flange joints.
– Clean the Diesel engine, connections and flange joints thoroughly of oil, fuel or

care products before assembly.
– Use lint-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 all openings into which

water, steam or detergents must not penetrate due to safety or functional

reasons.
– Remove the covers/seals after cleaning.
– Check the fuel lines, Diesel engine oil lines and hydraulic lines for the following

defects:

•

Leaks

•

Loose connections

•

Chafe marks

•

Damage
– Make sure the electrical power supply is firmly connected when starting.
– Make sure the engine is switched off before disconnecting the electrical power

supply.
– 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.

32

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

3 Handling, operation

3.1 Start-up procedure

3.1.1 Filling the operating fluids

Fill the following operating fluids before the initial commissioning:

– Diesel engine oil

For suitable lubricating oil for the Diesel engine, see the chapter “Lubricants and
operating fluids”.

– Coolant

For coolant composition, see the chapter “Lubricants and operating fluids”.

– Diesel fuel

Diesel fuels must comply with the approved fuel specifications, see the chapter
“Lubricants and operating fluids”.

After filling the operating fluids, perform the following work:

Vent fuel system. Please refer to the generator sets' operating manual.

u

3.1.2 Starting the engine

Prerequisites:

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

q

WARNING

Unexpected movement of the equipment.
Can cause serious injuries or the death of persons.

There may be no persons in the safety zones of the diesel engine.

u

Bring all of the protective devices into their protective position (housing is

u

closed), if equipped.

Secure external parts against unexpected movements. Remove all persons

u

from the danger zones.

Information

Engine damage due to inadequate lubrication.

u

KD36V16 33521029701_1_1 en 2018-08-01

The oil pressure has to build up immediately after the diesel engine is started
(oil-pressure warning lamp goes out).

© 2018 by Kohler Co. All rights reserved.

33

Handling, operation Operation and Maintenance Manual

Start-up procedure

If all of the safety instructions in the “Safety” chapter have been taken into account:

Switch on the electrical power supply (battery voltage).

u

Final check

Once the engine has started, carry out the following checks and top off with
operating materials if necessary

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.

u

34

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

4 Operating faults

Please consult the table “Faults – Cause – Solution” for certain engine problems
with possible causes and corrective action.

Information

Engine errors are shown on the diagnosis and service tool as an error code for
diagnostic purposes.

The following table shows basic logical steps to diagnose the problem:
– Familiarize yourself with the engine and related systems.
– Investigate the problem carefully.
– Correlate the symptoms with your current knowledge of the engine and

systems.
– Diagnose the problem, starting with the most obvious assumptions.
– Carry out detailed analyses before taking the engine apart.
– Identify the causes and thoroughly perform any repair work.

After the repair:
– run the engine in accordance with the User Manual.
– Check that the causes have been eliminated.
– Cancel the fault.

4.1

Malfunction / error Cause Remedy

The starter does not turn over. The main fuse has blown. Replace the fuse.

Faults – Cause – Solution

The battery connections are loose or
corroded.

The battery voltage is too low. Charge or replace the battery.

The starter’s circuit is faulty or the
contacts are corroded.

The starter is faulty. Contact your nearest Kohler Co.

Clean and tighten the loose
connections.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

service representative. See the
Section "Service Assistance".

The starter turns over slowly. The battery voltage is too low. Charge or replace the battery.

The battery connections are loose or
corroded.

The outside temperature is too low. Take appropriate action for Winter

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Clean and tighten the loose
connections.

operation.

35

Operating faults Operation and Maintenance Manual

Faults – Cause – Solution

Malfunction / error Cause Remedy

The Diesel engine cannot be started
and/or stops again immediately.

The fuel tank is empty. Refuel and vent the fuel system.

The fuel filter is blocked. Replace the fuel filter.

The fuel line, pre-cleaner or screen
in the fuel tank are blocked.

There is a leak in the fuel system or
filter.

The outside temperature is too low. Take appropriate action for Winter

Trouble starting the Diesel engine. There is a leak in the low-pressure

circuit or the pressure is too low.

The Diesel engine’s compression is
too low.

The heating flange is faulty (at low
temperatures).

Clean and vent the fuel system.

Seal this and vent the system.

operation.

Carry out a leak test (visual
inspection). Contact your nearest
Kohler Co. service representative to
have the engine checked. See the
Section "Service Assistance".

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

Read out the error memory of the
engine control unit. Contact your
nearest Kohler Co. service
representative. See the Section
"Service Assistance".

The Diesel engine switches off
suddenly.

The power supply has been
interrupted.

There is a leak in the low-pressure
circuit or the pressure is too low.

There is a fault in the electronic
system.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

Carry out a leak test (visual
inspection). Contact your nearest
Kohler Co. service representative to
have the engine checked. See the
Section "Service Assistance".

Read out the error memory of the
engine control unit. Contact your
nearest Kohler Co. service
representative. See the Section
"Service Assistance".

36

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating faults

Faults – Cause – Solution

Malfunction / error Cause Remedy

Low output of the Diesel engine
(reduced performance).

There is a fault in the fuel system
(blockage, leak).

Carry out a visual inspection for
leaks, replace the filter. Contact your
nearest Kohler Co. service
representative. See the Section
"Service Assistance".

The charge pressure is too low. The terminals are loose, the seals

and hoses are faulty, the air filter is
dirty, the turbocharger is faulty.
Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The charge air temperature is too
high.

The charge air cooler is dirty, the
fan’s performance is reduced, the
ambient temperature is too high.
Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The coolant temperature is too high. Check the cooler for soiling, check

the fan and thermostat, check the
coolant level. Contact your nearest
Kohler Co. service representative.
See the Section "Service
Assistance".

The Diesel engine is too hot
(according to the coolant
temperature display).

The fuel temperature is too high. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

The injection nozzles are faulty or do
not vaporize.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The Diesel engine’s compression is
too low.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

There is a fault in the electronic
system.

Read the error logs of the engine
control unit. Contact your nearest
Kohler Co. service representative.
See the Section "Service
Assistance".

The coolant level is too low. Fill up with coolant.

The cooler is dirty or calcified. Clean or descale. Contact your

nearest Kohler Co. service
representative. See the Section
"Service Assistance".

The thermostat is faulty. Check this and replace if necessary.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

37

Operating faults Operation and Maintenance Manual

Faults – Cause – Solution

Malfunction / error Cause Remedy

The charge current display comes
on when the Diesel engine is

Inadequate tension of the V-ribbed
belt.

running.

The V-ribbed belt is worn. Replace the V-ribbed belt.

The cable connections are loose or
separated.

The battery charging alternator,
rectifier or controller are faulty.

Black smoke emitted from the Diesel
engine.

The injection nozzles are faulty or
inefficient.

Fault in the turbocharger (charge
pressure too low).

The engine is overloaded. Contact your nearest Kohler Co.

The exhaust gases are blue. The oil level in the Diesel engine is

too high.

Lubricant enters the combustion
chamber and is burnt.

Check the tension of the V-ribbed
belt and replace the tightening roller
if necessary.

Fasten or replace the cable.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

service representative. See the
Section "Service Assistance".

Correct the oil level.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The bearing gasket on the
turbocharger is faulty.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The crankcase breather is faulty. Check this and replace if necessary.

The exhaust gases are white. Fuel injection begins too late. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

The operating temperature is not
achieved.

Run the engine until it reaches its
operating temperature.

There is water in the fuel system. Check the fuel system and the drain

pre-filter.

There is a leak in the charge air
cooler.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

38

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating faults

Faults – Cause – Solution

Malfunction / error Cause Remedy

The Diesel engine knocks. There is a fault in the combustion. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

There is an error in the valve
clearance.

The injection nozzles are damaged
or carbonized.

Bearing damages. Contact your nearest Kohler Co.

The piston rings are worn or faulty,
the pistons are eroded.

Abnormal noises from the engine. There are leaks in the intake and

exhaust gas lines that cause a
whistling noise.

The turbine or compressor wheel
rubs against the housing; foreign
bodies have penetrated the
compressor or turbine; bearings may
be jammed.

The lubricant pressure is too low. The oil level in the oil sump is too

low.

Adjust the valve clearance.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

service representative. See the
Section "Service Assistance".

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

Seal the leaks and replace the
gaskets if necessary.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

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 pressure transducer.
Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The pressure limiting valve does not
work properly or is dirty.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

There is lubricant in the cooling
system.

Leak in the oil cooler or oil cooler
plate.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

There is coolant in the lubricant. Leaks in the cylinder seals. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

Leak in the oil cooler or oil cooler
plate.

Contact your nearest Kohler Co.
service representative. See the
Section "Service Assistance".

The charge air temperature is too
high.

The charge air cooler is dirty. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

KD36V16 33521029701_1_1 en 2018-08-01

The inlet air temperature is too high. Check the fan, air supply and

breather.

© 2018 by Kohler Co. All rights reserved.

39

Operating faults Operation and Maintenance Manual

Faults – Cause – Solution

Malfunction / error Cause Remedy

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 Kohler Co.

service representative. See the
Section "Service Assistance".

The turbocharger outlet is faulty. Contact your nearest Kohler Co.

service representative. See the
Section "Service Assistance".

40

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

5 Operating fluids and

maintenance

5.1 Fill quantities

5.1.1 Lubricants and operating materials

Description Quantity

Engine oil 150 l (1.5 l per filter)

39.6 US gal (0.4 US gal per filter)

Coolant 124 l

32.8 US gal

Tab. 10: Fill quantities in the Diesel engine (guide values)

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

41

Operating fluids and maintenance Operation and Maintenance Manual

Lubricants and operating materials

5.2 Lubricants and operating materials

5.2.1 Diesel fuels

Approved fuel qualities

Due to different sulfur content of these fuels, the engine oil change interval and
quality must be taken into account when selected.

Fuel Fuel quality Description

On-Road Diesel ASTM D 975 1D-

S15

On-Road Diesel ASTM D 975 1D-

S500

On-Road Diesel ASTM D 975 1D-

S5000

On-Road Diesel ASTM D 975 2D-

S15

On-Road Diesel ASTM D 975 2D-

S500

On-Road Diesel ASTM D 975 2D-

S5000

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

NATO fuel NATO F-35 HFFR < 460 µm without AEG with

HFFR < 460 µm

HFFR < 460 µm without AEG

HFFR < 460 µm without AEG

HFFR < 460 µm

HFFR < 460 µm without AEG

HFFR < 460 µm without AEG

additive S-1750

additive S-1750

42

NATO fuel NATO F-54 HFFR < 460 µm

NATO fuel NATO F-63 HFFR < 460 µm without AEG with

additive S-1750

NATO fuel XF-63 HFFR < 460 µm without AEG with

additive S-1750

NATO fuel XF-10 HFFR < 460 µm without AEG

NATO fuel XF-51 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

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Lubricants and operating materials

Minimum requirement for quality

Requirement for the fuel Parameter

Lubrication capability at 60°C (HFRR) 460 µm

Minimum cetane number 45

Purity class according to ISO 4406 20/17/14

Tab. 12: Minimum requirement for Diesel

5.2.2 Engine oils

Performance requirements of the quality categories

Engine oil additives are not approved, since if they are incorrectly matched with the
engine oil they may cause damage.

Lubricant

category

Lubricant

category 1

Lubricant

category 2

Lubricant

category 2.1

Lubricant

category 3

(standard today)

Lubricant

category 3.1

(standard today)

Tab. 13: Lubricant category

Minimum standards

ACEA E5-02 or API CH-4

ACEA E4 ACEA E7 or API

CI-4 Plus or DHD-1 or

ACEA E6 or ACEA E9 or

API CJ-4 or JASO DH-2

ACEA E4-12 or both ACEA

E4 and ACEA E7

ACEA E6-12 or both ACEA

E6 and ACEA E9 or API

Recommended viscosity

class

SAE 10W-40; SAE

or DHD-1

JASO DH-1

CK-4

10W-30; SAE 15W-40

SAE 10W-40; SAE

10W-30; SAE 5W-30

SAE 5W-30; SAE 10W-40;

SAE 10W-30

SAE 5W-30; SAE 10W-40;

SAE 10W-30; SAE 5W-40

SAE 5W-30; SAE 10W-40;

SAE 10W-30; SAE 5W-40

Selecting the engine oil

Effect caused by the sulfur content in the fuel

Type of lubricant

Mineral oil (Group 1 & 2

Base oils)

Synthetic (Group 2 and /

or 3 Base oils)

Synthetic (Group 2 and /

or 3 Base oils)

Synthetic (Group 3 and /

or 4), VI > 160, and

Longlife additive

Synthetic (Group 3 and /

or 4), VI > 160, and

Longlife additive

Oil

change

factor

1/4

1

1

2

2

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.

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

43

Operating fluids and maintenance Operation and Maintenance Manual

Lubricants and operating materials

Fig. 27: The correlation between TBN and sulfur in fuel

1 TBN 3 If TBN <8 mgKOH/g, the

engine oil should be replaced
as soon as possible.

2 ppm sulfur 4 with TBN [mg KOH/g]

Viscosity class:

The viscosity class has to be selected on the basis of the cold start temperature.
The following viscosity classes are permitted for the engines: 5W30, 5W40,
10W30, 10W40 and 15W40. The change intervals 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.

5 recommended TBN [mg

KOH/g]

44

Engine oil change intervals:

The change intervals are defined as follows:

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”:

Factor “sulfur content”:

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Lubricants and operating materials

Sulfur content in % Oil change factor (factor 2)

0 < sulfur content ≤ 0.5

0.5 < sulfur content ≤ 1 limited to
lubricant category 2 and 3

1 < sulfur content ≤ 1.5 limited to

lubricant category 2 and 3

Tab. 14: Sulfur content table

Engine oil analysis

The engine oil can be monitored by means of an engine oil analysis and the
change interval can be adjusted if required.

5.2.3 Coolant

“1” => no change on the maintenance

interval

“1/2” => reduces the maintenance interval

by one half

“1/4” => reduces the maintenance interval

by one quarter. The use of sulfur in the

ratio of more than 1% requires an

additional approval of the engine

manufacturer to ensure that all engine

options, the used lubricant, and the

maintenance schedule are compatible with

this very high sulfur content. Special

lubrication oil must be used => TBN > 12

MgKOH/g.

Information

Mixing different anticorrosion antifreeze agents can make the properties of the
coolant worse.

Do not combine different products!

u

Silicate-based and non-silicate based coolants must never be mixed; this may

u

damage the cooling system!

Requirements for water

Make sure that the water used meets the following requirements:
– Fully de-ionized water should be used.
– Corresponds to the 2006 WHO (World Heath Organization) guideline for

drinking water.

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

Requirements of the coolant

Use only pre-mixed cooling water of the same kind to avoid problems with the
cooling circuit.

An SI-OAT or hybrid technology with ethylene glycol is to be used as coolant, since
this technology provides the necessary cooling performance and cooling function
for engines.

Approved products:
– BASF GLYSANTIN® G40™ change interval 6 years

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

45

Operating fluids and maintenance Operation and Maintenance Manual

Lubricants and operating materials

– BASF GLYSANTIN® G48™ change interval 4 years

The recommended coolant concentration is 40% to 50%.

The coolant can be monitored by means of an coolant analysis and the 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

6.7 — 9.0

10523:2012-04

Chloride (ions) mg/l < 100

Sulfate mg/l < 100

Bacteria and toxic

without

constituents

Tab. 15: Control parameter

46

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance

5.3 Maintenance

5.3.1 Maintenance schedule

Using the maintenance schedule

The intervals during which a component can remain in operation between two
maintenances are in classified as follows:

Interval is the operating period in hours.
Limit interval is the maximum operating period in years.

Maintenance work is performed as soon as an interval (operating hours or time
period) is reached. The first interval that occurs applies.

Nominal values for the power generating unit

Power generating units that satisfy the requirements of ISO 8528-1:2005 are used
to generate current for continuous, peak load and stand-by applications. The
classifications according to ISO 8528-1:2005 should help improve the
understanding between manufacturer and customer.

Emergency standby power system (ESP)

The maximum available output that a power generating unit is able to supply if the
mains current fails or under test conditions up to 200 hours of operation a year
during variable 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 unlimited number of hours a year under the agreed operating conditions
with a variable electric load, 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 75 percent
of the nominal ESP value.

Continuous operating power (COP)

The maximum output that the power generating unit is able to supply continuously
over an unlimited number of hours a year under the agreed operating conditions
with a constant electric load, whereby the maintenance intervals and work are
carried out in accordance with the manufacturer’s specifications.

Time between overhauls (TBO)

The average period until Diesel engines have to be overhauled.

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

47

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance

5.3.2 Daily, weekly and monthly maintenance work - Version: 2018/06-1

SL000 Diesel engine

SL001 Engine oil and

coolant

SL002 Cooling system

SL003 Cooling system Daily X Check the ventilation holes on the water pump.

SL004 Fuel system

SL005 Fuel system Daily X Check differential pressure gage. Perform before start.

SL006 Air filter

SL007 Engine in

operation

Diesel engine

SL008

Daily X

Daily X

Daily X

Daily X

Daily X

Daily X

Weekly X

Monthly X

Perform visual inspection (leaks, damage, loose
components). Perform before start.

Check engine oil and coolant level. Refill if necessary.
Perform before start.

Inspect low temperature circuit, intercooler, water pump
and vent line. Perform before start.

Check water trap on the preliminary fuel filter and drain
water if necessary. Perform before start.

Check the air filter's display. Perform before start. See the
generator set’s operating manual.

Observe the engine operation. Record and report any
abnormality found (faulty parameters, unusual noises,
vibrations, exhaust gas color). See the generator set’s
operating manual.

Perform visual inspection (leaks, contamination, damage,
belt drive, cable harness)

Test run at more than 1/3 load. See the generator set’s
operating manual.

Tab. 16: Maintenance schedule — Daily maintenance activities — Service level 1

© 2018 by Kohler Co. All rights reserved.

48

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — ESP Fuel optimized

5.4 Maintenance schedule — ESP Fuel optimized

5.4.1 ESP Fuel optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with
lubricant
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with
lubricant
“Category 2”

SL105 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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

250 1 X

250 2 X

500 2 X

1000 2 X

2000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). At the latest after one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 Belt for battery

charging
alternator and
water pump

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

SL116 Coolant

(Glysantin G48) 4 X

Tab. 17: ESP Fuel optimized — Service level 1

KD36V16 33521029701_1_1 en 2018-08-01

2 X

© 2018 by Kohler Co. All rights reserved.

Check state of belt drive, replace if necessary.

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

49

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — ESP Fuel optimized

5.4.2 ESP Fuel optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL209 High pressure

pump

SL215 Water 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

SL219_AExhaust gas

turbocharger

SL219_BCoolant lines

Tab. 18: ESP Fuel optimized — Service level 2

1000 2 X

4000 8 X

4500 X

1 X

4 X X

Check / set valve clearance.

Replace the HP pump.

Replace the exhaust gas turbocharger.

Replace the exhaust gas turbocharger rubber sleeve.

Check and replace coolant lines and hoses if necessary.

50

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — ESP Emission optimized

5.5 Maintenance schedule — ESP Emission optimized

5.5.1 ESP Emission optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with
lubricant
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with
lubricant
“Category 2”

SL105 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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

250 1 X

250 2 X

500 2 X

1000 2 X

2000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). At the latest after one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 Belt for battery

charging
alternator and
water pump

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

SL116 Coolant

(Glysantin G48) 4 X

Tab. 19: ESP Emission optimized — Service level 1

KD36V16 33521029701_1_1 en 2018-08-01

2 X

© 2018 by Kohler Co. All rights reserved.

Check state of belt drive, replace if necessary.

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

51

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — ESP Emission optimized

5.5.2 ESP Emission optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL209 High pressure

pump

SL215 Water 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

SL219 Exhaust gas

turbocharger

SL219 Coolant lines 4 X X Check and replace coolant lines and hoses if necessary.

Tab. 20: ESP Emission optimized — Service level 2

1000 2 X

4000 8 X

4500 X

1 X

Check / set valve clearance.

Replace the HP pump.

Replace the exhaust gas turbocharger.

Replace the exhaust gas turbocharger rubber sleeve.

52

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — ESP 50Hz emission optimized top power

5.6 Maintenance schedule — ESP 50Hz emission optimized top power

5.6.1 ESP 50Hz emission optimized top power — Service level 1 - Version: 2018/06-1

SL121 Engine oil and oil

filter with
lubricant
“Category 1”

SL100 Oil analysis

SL121 Engine oil and oil

filter with
lubricant
“Category 2”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with
lubricant
“Category 3”

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

SL118 V-ribbed fan belt 2000 2 X Replace belt.

125 2 X

250 1 X

250 2 X

500 2 X

2000 2 X

Replace Diesel engine oil and oil filter insert (at least every
2 years). At the latest after one year.

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 Belt for battery

charging
alternator and
water pump

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

SL116 Coolant

(Glysantin G48) 4 X

Tab. 21: ESP 50Hz emission optimized top power — Service level 1

KD36V16 33521029701_1_1 en 2018-08-01

2 X

© 2018 by Kohler Co. All rights reserved.

Check state of belt drive, replace if necessary.

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

53

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — ESP 50Hz emission optimized top power

5.6.2 ESP 50Hz emission optimized top power — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL209 High pressure

pump

SL215 Water 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

SL219 Exhaust gas

turbocharger

SL219 Coolant lines 4 X X Check and replace coolant lines and hoses if necessary.

Tab. 22: ESP 50Hz emission optimized top power — Service level 2

1000 2 X

4000 8 X

4500 X

1 X

Check / set valve clearance.

Replace the HP pump.

Replace the exhaust gas turbocharger.

Replace the exhaust gas turbocharger rubber sleeve.

54

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — PRP Fuel optimized

5.7 Maintenance schedule — PRP Fuel optimized

5.7.1 PRP Fuel optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with lube oil
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with lube oil
“Category 2”

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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 V-ribbed belt for

battery charging
alternator

250 2 X

250 2 X

500 2 X

1000 2 X

2000 2 X

4000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

Check state of belt drive, replace if necessary.

SL116 Coolant

(Glysantin G48) 6000 4 X

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

Tab. 23: PRP Fuel optimized — Service level 1

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

55

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — PRP Fuel optimized

5.7.2 PRP Fuel optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL205 Injection 7500 X Replace fuel lines and injectors.

SL206 Cylinder 7500 X Clean cumbastion chambers.

SL213 Exhaust gas

turbocharger

SL215 Water pump 7500 8 X Replace the water pump.

SL219–AExhaust gas

turbocharger

SL219–BCoolant lines

SL223 Battery charging

alternator

SL225 Viscous damper 7500 X Replace the viscous damper.

SL209 High pressure

pump

Tab. 24: PRP Fuel optimized — Service level 2

1000 2 X

7500 X

7500 X

7500 4 X X

7500 X

15000 8 X

Check / set valve clearance.

Replace the exhaust gas turbocharger.

Replace the exhaust gas turbocharger rubber sleeve.

Check and replace coolant lines and hoses if necessary.

Replace the battery charging alternator.

Replace the HP pump.

56

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — PRP Emission optimized

5.8 Maintenance schedule — PRP Emission optimized

5.8.1 PRP Emission optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with lube oil
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with lube oil
“Category 2”

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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 V-ribbed belt for

battery charging
alternator

250 2 X

250 2 X

500 2 X

1000 2 X

2000 2 X

4000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

Check state of belt drive, replace if necessary.

SL116 Coolant

(Glysantin G48) 6000 4 X

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

Tab. 25: PRP Emission optimized — Service level 1

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

57

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — PRP Emission optimized

5.8.2 PRP Emission optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL205 Injection 7500 X Replace fuel lines and injectors.

SL206 Cylinder 7500 X Clean cumbastion chambers.

SL213 Exhaust gas

turbocharger

SL215 Water pump 7500 8 X Replace the water pump.

SL219–AExhaust gas

turbocharger

SL219–BCoolant lines

SL223 Battery charging

alternator

SL225 Viscous damper 7500 X Replace the viscous damper.

SL209 High pressure

pump

Tab. 26: PRP Emission optimized — Service level 2

1000 2 X

7500 X

7500 X

7500 4 X X

7500 X

15000 8 X

Check / set valve clearance.

Replace the exhaust gas turbocharger.

Replace the exhaust gas turbocharger rubber sleeve.

Check and replace coolant lines and hoses if necessary.

Replace the battery charging alternator.

Replace the HP pump.

58

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — COP Fuel optimized

5.9 Maintenance schedule — COP Fuel optimized

5.9.1 COP Fuel optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with lube oil
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with lube oil
“Category 2”

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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 V-ribbed belt for

battery charging
alternator

250 2 X

250 2 X

500 2 X

1000 2 X

2000 2 X

4000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

Check state of belt drive, replace if necessary.

SL116 Coolant

(Glysantin G48) 6000 4 X

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

Tab. 27: COP Fuel optimized — Service level 1

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

59

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — COP Fuel optimized

5.9.2 COP Fuel optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL219–BExhaust gas

turbocharger

SL205 Injection 10000 X Replace fuel lines and injectors.

SL206 Cylinder 10000 X Clean cumbastion chambers.

SL213 Exhaust gas

turbocharger

SL215 Water pump 10000 8 X Replace the water pump.

SL219–ACoolant lines

SL223 Battery charging

alternator

SL225 Viscous damper 10000 X Replace the viscous damper.

SL209 High pressure

pump

Tab. 28: COP Fuel optimized — Service level 2

1000 2 X

7500 X

10000 X

10000 4 X X

10000 X

20000 8 X

Check / set valve clearance.

Replace the exhaust gas turbocharger rubber sleeve.

Replace the exhaust gas turbocharger.

Check and replace coolant lines and hoses if necessary.

Replace the battery charging alternator.

Replace the HP pump.

60

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance schedule — COP Emission optimized

5.10 Maintenance schedule — COP Emission optimized

5.10.1 COP Emission optimized — Service level 1 - Version: 2018/06-1

SL100 Oil analysis

SL121 Engine oil and oil

filter with lube oil
“Category 1”

V-ribbed fan belt 500 X Check belt tension.

SL121 Engine oil and oil

filter with lube oil
“Category 2”

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”

SL107 Crankcase

breather

SL118 V-ribbed fan belt 2000 2 X Replace belt.

SL108 Air filter 3000 2 X Replace air filter main element.

SL109 V-ribbed belt for

battery charging
alternator

250 2 X

250 2 X

500 2 X

1000 2 X

2000 2 X

4000 2 X

Take oil sample and perform oil analysis. Carry out after
500 h for category 3 and 2 lubricant.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace Diesel engine oil and oil filter insert (at least every
2 years). Perform once after 250 hours. At the latest after
one year.

Replace oil separator filter insert.

Check state of belt drive, replace if necessary.

SL116 Coolant

(Glysantin G48) 6000 4 X

SL120 Coolant analysis 2 X Take coolant sample and perform coolant analysis.

Tab. 29: COP Emission optimized — Service level 1

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Replace coolant. For coolant formulated with Glysantin
G40, the extension up to 8000h / 6Y is possible after
analysis.

61

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance schedule — COP Emission optimized

5.10.2 COP Emission optimized — Service level 2 - Version: 2018/06-1

SL204 Cylinder head

valves

SL219–BExhaust gas

turbocharger

SL205 Injection 10000 X Replace fuel lines and injectors.

SL206 Cylinder 10000 X Clean cumbastion chambers.

SL213 Exhaust gas

turbocharger

SL215 Water pump 10000 8 X Replace the water pump.

SL219–ACoolant lines

SL223 Battery charging

alternator

SL225 Viscous damper 10000 X Replace the viscous damper.

SL209 High pressure

pump

Tab. 30: COP Emission optimized — Service level 2

1000 2 X

7500 X

10000 X

10000 4 X X

10000 X

20000 8 X

Check / set valve clearance.

Replace the exhaust gas turbocharger rubber sleeve.

Replace the exhaust gas turbocharger.

Check and replace coolant lines and hoses if necessary.

Replace the battery charging alternator.

Replace the HP pump.

62

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids 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

KD36V16 33521029701_1_1 en 2018-08-01

© 2018 by Kohler Co. All rights reserved.

63

Operating fluids and maintenance Operation and Maintenance Manual

Preparatory maintenance activities

5.12 Preparatory maintenance activities

Safety precautions for maintenance

The safety regulations must be observed while 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.

64

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KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Daily, weekly and monthly maintenance work

5.13 Daily, weekly and monthly maintenance work

Make sure that:

The Diesel engine is in the maintenance position.

q

5.13.1 Perform visual inspection (leaks, damage, loose components) — SL000

Fig. 44

1 Turbocharger 4 Main fuel filter 7 Engine control unit
2 High pressure pump

connectors

3 Oil filter 6 Water pump

KD36V16 33521029701_1_1 en 2018-08-01

5 Oil module

Visually check Diesel engine for leaks, ensure that it is not damaged and that

u

the fastenings comply with regulations.

Visually check V-space (area under high pressure pump and lines) for moisture.

u

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65

Operating fluids and maintenance Operation and Maintenance Manual

Daily, weekly and monthly maintenance work

Fig. 45

8 Vent line 10 Overflow-oil line
9 Pressure line 11 Fuel line

Visually check hoses for leaks, ensure that they are not damaged, installed

u

friction-free, and that fastening is in compliance with regulations.

© 2018 by Kohler Co. All rights reserved.

66

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Operation and Maintenance Manual Operating fluids and maintenance

Daily, weekly and monthly maintenance work

Fig. 46: Inspection overview

1 Cable harness 2 V-ribbed belt

Visually check cable harness 1 for damage, friction-free installation, and

u

regulation-compliant fastening.

Visually check belt drive 2 for damage, friction-free installation, and regulation-

u

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.

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67

Operating fluids and maintenance Operation and Maintenance Manual

Daily, weekly and monthly maintenance work

Fig. 47: Example of oil dipstick / oil filler neck

Pull out oil dipstick 1, wipe with a clean cloth and reinsert to the limit stop.

u

Fig. 48

Remove the oil dipstick again and check the oil level. The oil level must be

u

between the “min” and “max” marks.

If the oil level is too low:

Remove the oil refueling cap and top off with oil.

u

Fill the oil through the oil filler neck 2.

u

68

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.

u

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Daily, weekly and monthly maintenance work

5.13.3 Check coolant level — SL001

DANGER

Hot cooler parts and hot cooler fluid!
Risk of burns! Will cause serious injuries and death.

Perform maintenance and inspection work on the cooling system only when the

u

Diesel engine has cooled down.

Wear protective equipment.

u

Fig. 49

See generator set manual for procedure to check coolant level.

KD36V16 33521029701_1_1 en 2018-08-01

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69

Operating fluids and maintenance Operation and Maintenance Manual

Daily, weekly and monthly maintenance work

5.13.4 Check the ventilation holes on the water pump — SL003

Fig. 50: Water pump location

1 Ventilation bore

Check ventilation bore 1 for leakage.

u

5.13.5 Check/drain water trap on the primary fuel filter — SL004

Make sure that:

A reservoir with the required capacity is ready.

q

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.

70

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Operation and Maintenance Manual Operating fluids and maintenance

Daily, weekly and monthly maintenance work

WARNING

Open flames!
Injuries, fire and explosion! Can cause serious injury and death.

Avoid open flames or other ignition sources when performing maintenance or

u

inspection work on the fuel system.

Perform maintenance and inspection work only when the Diesel engine has

u

been shut down.

KD36V16 33521029701_1_1 en 2018-08-01

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71

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

5.14 Maintenance activities

Make sure that:

The Diesel engine is in the maintenance position.

q

5.14.1 Take oil sample and perform oil analysis — SL100

Ensure that:

A reservoir with the required capacity is ready.

q

A suitable sample bottle is ready.

q

72

5.14.2

Fig. 51: Oil removal point

1 Oil removal point

Refer to the generator set manual for procedure when taking oil sample and

u

performing oil analysis.

Replace diesel engine oil and oil filter — SL121

Make sure that:

The Diesel engine is horizontal.

q

The Diesel engine is turned off.

q

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

The Diesel engine is warm, unlike in the maintenance position.

q

Strap wrench or similar tool is on hand.

q

A reservoir with the required capacity is ready.

q

Oil filters (4 pcs.) with seals are on hand.

q

Diesel engine oil is on hand. Diesel engine oil amount, see the “Fill quantities

q

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

u

u

u

KD36V16 33521029701_1_1 en 2018-08-01

Open oil drain shut-off valve 1.

Drain the oil into the container provided.

Close oil drain shut-off valve 1.

Dispose of oil (observe country-specific regulations).

© 2018 by Kohler Co. All rights reserved.

73

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

Replacing the oil filter

Fig. 53: Oil filter

Loosen the oil filter 1 with a strap wrench or similar tool and unscrew.

u

CAUTION

Hot engine oil!
Risk of burns! Can cause injuries.

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.

u

Torque 25 Nm. (Allen key SW 17 mm)

w

74

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KD36V16 33521029701_1_1 en 2018-08-01

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 2 up to between the min and max marks on

u

the dipstick 1.

Clean the refueling cap, place on the oil filler neck 2 and tighten.

u

Start the diesel engine.

u

Check the oil pressure (diesel engine oil pressure display unit) and check the oil

u

filter for leaks.

Turn the Diesel engine off.

u

Check the oil level on the dipstick after 10 minutes.

u

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

Correct the oil level.

u

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.

q

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75

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

Crankcase breather position

Fig. 55: Crankcase breather position

1 Crankcase breather

Remove oil separator filter insert

Fig. 56: Remove filter insert

76

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.

u

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

Install oil separator filter insert

Fig. 57: Install filter insert

Lubricate O-ring 6 of the new filter insert 4 with engine oil.

u

Insert new filter insert.

u

Fit new O-ring 5 on the regulating valve (cover) 2.

u

Lubricate O-ring with engine oil.

u

Position regulating valve (cover) 2; alignment power unit support side (observe

u

flow direction).

Fig. 58: Filter insert installed

u

u

KD36V16 33521029701_1_1 en 2018-08-01

Fix regulating valve in place with lever screws 3.

Push on hose and tighten hose clamps.

© 2018 by Kohler Co. All rights reserved.

77

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

5.14.4 Replace main fuel filter — SL105

Make sure that:

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.

q

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.

Avoid open flames or other ignition sources when performing maintenance or

u

inspection work on the fuel system.

Perform maintenance and inspection work only when the Diesel engine has

u

been shut down.

78

Fig. 59: Main fuel filter

Place a reservoir beneath the main fuel filter.

u

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).

u

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

Check that the filter module is clean and make sure that the thread adapter fits

u

firmly in the filter module.

If the filter module is dirty:

Clean filter module.

u

Information

Dirt!
Can destroy the common rail system.

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 for working on the common rail system,

u

see the “Safety” chapter.

Lightly oil the sealing ring on the main fuel filter. (Use engine oil).

u

Screw on new main fuel filter until the sealing ring contacts the filter module.

u

Tighten main fuel filter by hand 3/4 of a revolution.

u

Vent fuel system.

u

5.14.5 Replace the primary fuel filter — SL106

Make sure that:

A reservoir with the required capacity is ready.

q

A primary fuel filter insert is on hand.

q

The primary fuel filter with water trap and manual fuel feed pump is 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.

Avoid open flames or other ignition sources when performing maintenance or

u

inspection work on the fuel system.

Perform maintenance and inspection work only when the Diesel engine has

u

been shut down.

5.14.6 Take coolant sample and perform coolant analysis — SL120

CAUTION

Hot coolant!
Risk of burns! Can cause injuries.

u

KD36V16 33521029701_1_1 en 2018-08-01

Turn off engine and let it cool down.

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79

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

Fig. 60: Coolant sampling point

5.14.7 Change air filter main element — SL108

5.14.8 Check state of fan drive belt drive and replace if

See generator set manual for procedure to take coolant sample.

u

See generator set manual for procedure to replace the air filter main element.

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

80

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Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

Fig. 61: Damage to the V-ribbed belt

Checking the V-ribbed belt

WARNING

Rotating parts!
Risk of injury! Can cause serious injuries.

Turn the Diesel engine off.

u

Secure the engine against unexpected starting.

u

Check the belt for damage.

u

Check that the belt pulleys and tightening roller are in perfect working order and

u

check their play (for example, worn out bearings on the tightening roller or tread
wear on the belt pulleys).

Replace the damaged parts. Please contact the nearest authorized Kohler

w

Co. customer service.

Replacing the belt

Make sure that:

A new belt is on hand.

q

A suitable frequency device is on hand.

q

WARNING

Rotating parts!
Risk of injury! Can cause serious injuries.

u

u

KD36V16 33521029701_1_1 en 2018-08-01

Turn the Diesel engine off.

Secure the engine against unexpected starting.

© 2018 by Kohler Co. All rights reserved.

81

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

Fig. 62: V-ribbed belt drive

Remove fan. See the generator set’s operating manual.

u

Release hex screw 1 (M12 8.8).

u

Loosen rigging screw 2 (M10 10.9).

u

Remove the V-ribbed belt 3.

u

Check that the belt pulleys and tensioning device are in perfect working order

u

and check their play (for example, tread wear on the belt pulleys).

Replace the damaged parts. Contact Kohler.

w

Place new V-ribbed belts on all belt pulleys and tightening roller, making sure

u

that they are properly seated.

Turn rigging screw 2 (M10 10.9) until tensioned.

u

Check tension with an appropriate frequency device.

w

Own frequency is 111 Hz:

Tighten hex screw 1 (M12 8).

u

Start the engine and let it run for 30 minutes.

u

Turn off engine and check pretension. Retension if necessary.

u

Install the fan. See the generator set’s operating manual.

u

82

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KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

5.14.9 Check and change the V-ribbed belt for the battery charging alternator — SL109

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

Fig. 63: Damage to the V-ribbed belt

Replacing the belt

Make sure that:

A new belt is on hand.

q

WARNING

Rotating parts!
Risk of injury! Can cause serious injuries.

Turn the Diesel engine off.

u

Secure the engine against unexpected starting.

u

KD36V16 33521029701_1_1 en 2018-08-01

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83

Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

Fig. 64: V-ribbed belt drive

Remove fan. See the generator set’s operating manual.

u

Remove the V-ribbed belt (fan) 1. (For the procedure, please refer to the

u

chapter “Check state of fan drive belt drive, replace if necessary”.)

84

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Operation and Maintenance Manual Operating fluids and maintenance

Maintenance activities

Fig. 65

Insert a 1/2” socket wrench transition piece with lever on the tensioning pulley

u

screw 2(tensioning pulley screw has a left-handed thread).

Pivot the fastening device back counterclockwise against the spring force to the

u

limit stop.

Remove V-ribbed (battery charging alternator) 3.

u

Check that the belt pulleys and tightening roller are in perfect working order and

u

check their play (for example, worn out bearings on the tightening roller or tread
wear on the belt pulleys).

Replace the damaged parts. Please contact the nearest authorized Kohler

w

Co. customer service. Refer to the chapter on “Service Assistance”.

With the tightening device pivoted back, place new V-ribbed belt on all belt

u

pulleys and tightening roller, making sure that it is properly seated.

Mount belt (fan) 1. (For the procedure, please refer to the chapter “Check state

u

of fan drive belt drive, replace if necessary”.)

Install the fan. See the generator set’s operating manual.

u

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Operating fluids and maintenance Operation and Maintenance Manual

Maintenance activities

86

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KD36V16 33521029701_1_1 en 2018-08-01

6 Transport and storage

DANGER

Protective atmosphere against damage by oxidation inside the protective film.
Mortal danger, risk of suffocation! Will cause serious injuries or death.

Remove and store the protective film only in a well-ventilated area.

u

The protective film may be stored only in areas that are out of the reach of

u

children.

CAUTION

Incorrect waste disposal.
Environmental and health hazard.

Pay attention to national and international regulations on the disposal of waste

u

substances.

Dispose of all wastes in suitable containers.

u

Store wastes in dedicated storage places.

u

NOTICE

Incorrect setting down of the Diesel engine.
Engine damage.

Do not stand the Diesel engine on the oil sump.

u

Place the Diesel engine on the appropriate fastening pieces.

u

NOTICE

Incorrect storage.
Damage by oxidation.

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.

u

When the Diesel engine is removed:

cover with a new protective film and observe the climatic conditions for storage.

u

NOTICE

Storage conditions are part of the device manufacturer.

u

u

KD36V16 33521029701_1_1 en 2018-08-01

Comply with the standard ISO 6749-1984 for transportation and storage.

Please contact the Kohler customer service if anything is unclear.

© 2018 by Kohler Co. All rights reserved.

87

Transport and storage Operation and Maintenance Manual

Fastening during transport

NOTICE

The equipment owner is responsible for compliance with the maximum floor load.

Check the maximum floor load before setting the Diesel engine down on the

u

floor.

The weight data can be found in the technical data sheet.

u

Information

Use only preservation media approved by Kohler.

u

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. The
engine can come loose during transportation.
Mortal danger! Will cause serious injuries or death.

Transport the Diesel engine only with the transport stand.

u

The transport stand used must be in perfect technical condition.

u

Secure the transport stand against slipping and toppling over in every direction.

u

Pay attention to the center of gravity.

u

88

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Operation and Maintenance Manual Transport and storage

Fastening during transport

DANGER

Mortal danger due to the Diesel engine falling down/over. Incorrect handling during
loading/unloading of the Diesel engine.
Mortal danger! Will cause serious injuries or death.

The Diesel engine may only be loaded/unloaded by suitably trained and

u

authorized personnel.

If a crane or forklift truck is used this must be designed for the weight to be

u

lifted.

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

u

loading and unloading.

Pay attention to the center of gravity.

u

KD36V16 33521029701_1_1 en 2018-08-01

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89

Transport and storage Operation and Maintenance Manual

Wooden transport stand

6.2 Wooden transport stand

Fig. 67: Wooden 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.

The Diesel engine must be securely bolted to the transport stand.

u

Information

Wooden transport stands do not have to be returned to Kohler Co. Keep for

u

later use.

90

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KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Transport and storage

Steel transport stand

6.3 Steel transport stand

Fig. 68: Steel 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.

The Diesel engine must be securely bolted to the transport stand.

u

Information

Return the steel transport stand to Kohler Co.

u

KD36V16 33521029701_1_1 en 2018-08-01

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91

Transport and storage Operation and Maintenance Manual

Suspension device

6.4 Suspension device

DANGER

Falling load.
Mortal danger! Will cause serious injuries or death.

Pay attention to the maximum weight for lifting points!

u

Observe a maximum deviation of 10° between the perpendicular and the engine

u

axis.

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

u

the hoisting beam!

Do not work under suspended loads!

u

92

Fig. 69: Suspension device

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KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual Transport and storage

Suspension device

Fig. 70: Hoisting beam

1 Hoisting beam ID no. 12204231 A Power unit support side
2 Lifting gear B Flywheel side

Information

Please read and observe the safety instructions in the system description

u

before commissioning the hoisting beam.

KD36V16 33521029701_1_1 en 2018-08-01

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93

Transport and storage Operation and Maintenance Manual

Storage

6.5 Storage

6.6.1 Storage for up to 6 months

The Diesel engine is preserved from the shipping date; under normal storage
conditions in a dry, well ventilated place, the conservation protection normally lasts
for 6 months.

If the Diesel engine is covered with an additional foil hood, it can also be stored
outdoors for up to one month.

The cover must 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
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.

94

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KD36V16 33521029701_1_1 en 2018-08-01

7.1 Standard torques

7.1.1 Standard torques for screw connections

For hex screws in accordance with:

– ISO 4014
– ISO 4017
– ISO 8765
– ISO 8676

For socket head screws in accordance with: ISO 4762.

For hexalobular internal screws (Torx screws) in accordance with: DIN 34800.

Values for a mean friction coefficient of µ = 0.12.

Standard

thread

M 4 3 2.2 4 3 5 3.7

M 5 6 4.4 8 6 10 7.4

M 6 10 7.4 14 10 17 12

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

Nm ft lb Nm ft lb Nm ft lb

8.8 10.9 12.9

M 30 1350 1000 1900 1400 2250 1660

M 33 1850 1360 2600 1920 3000 2210

M 36 2350 1730 3300 2430 3900 2880

M 39 3000 2210 4300 3170 5100 3770

Tab. 32

Fine thread Nm ft lb Nm ft lb Nm ft lb

M 8 x 1 25 18 36 27 43 32

M 9 x 1 36 27 53 39 62 46

KD36V16 33521029701_1_1 en 2018-08-01

8.8 10.9 12.9

© 2018 by Kohler Co. All rights reserved.

95

Standard torques

Operation and Maintenance Manual

Fine thread Nm ft lb Nm ft lb Nm ft lb

M 10 x 1 52 38 76 56 89 66

M 10 x 1.25 49 36 72 53 84 62

M 12 x 1.25 87 64 125 92 150 110

M 12 x 1.5 83 61 122 90 145 107

M 14 x 1.5 135 100 200 150 235 173

M 16 x 1.5 205 150 300 220 360 2 70

M 18 x 1.5 310 230 440 320 520 380

M 18 x 2 290 210 420 310 490 360

M 20 x 1.5 430 320 620 460 720 530

M 22 x 1.5 580 430 820 600 960 710

M 24 x 1.5 760 560 1090 800 1270 940

M 24 x 2 730 540 1040 770 1220 900

M 27 x 1.5 1110 820 1580 1170 1850 1370

M 27 x 2 1070 790 1500 1110 1800 1330

M 30 x 1.5 1540 1140 2190 1610 2560 1890

M 30 x 2 1490 1100 2120 1560 2480 1830

M 33 x 1.5 2050 1510 2920 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 accordance with DIN 910 with copper sealing ring in accordance with
DIN 7603.

Screw plug in accordance with DIN 908 with copper sealing ring in accordance with
DIN 7603.

96

Thread Nm ft lb Thread Nm ft lb

M 6 x 1 7 5.2 M 36 x 1.5 155 110

M 8 x 1 7.5 5.5 M 36 x 2 155 110

M 8 x 1.5 7.5 5.5 M 38 x 1.5 171 130

M 10 x 1 15 11 M 38 x 2 215 160

M 10 x 1.25 15 11 M 42 x 1.5 240 180

M 12 x 1.5 20 15 M 42 x 2 240 180

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual

Thread Nm ft lb Thread Nm ft lb

M 14 x 1.5 27 20 M 45 x 1.5 270 200

M 16 x 1.5 37 27 M 45 x 2 270 200

M 18 x 1.5 40 30 M 48 x 1.5 300 220

M 20 x 1.5 47 35 M 48x 2 300 220

M 22 x 1.5 57 42 M 52 x 1.5 380 280

M 24 x 1.5 68 50 M 52 x 2 380 280

M 26 x 1.5 75 55 M 56 x 2 430 320

M 27 x 2 87 64 M 60 x 2 510 380

M 30 x 1.5 115 85 M 64 x 2 570 420

M 30 x 2 115 85 M 65 x 2 620 460

M 33 x 2 120 88

Tab. 34

Standard torques

7.1.3 Standard torques for flange joints

Information

Tightening torques apply for mating material: steel.

u

Tolerance for the tightening torques specified in the table: + 10 %.

u

Oil the screw-in thread with engine oil before screwing in.

u

Metric flange joints, series L (light)

Tube

diameter X

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

12 M 16 x 1.5 45 33 65 48 55 41 40 29

15 M 18 x 1.5 55 41 80 59 70 52 45 33

18 M 22 x 1.5 65 48 140 100 125 92 60 44

Thread Y

Form A with

sealing ring

Nm ft lb Nm ft lb Nm ft lb Nm ft lb

Form B with edge

seal

Form E with flat

(ED) seal

Form F with 0-ring

22 M 26 x 1.5 90 66 190 140 180 130 100 74

28 M 33 x 2.0 150 110 340 250 310 230 160 120

35 M 42 x 2.0 240 180 500 370 450 330 210 150

42 M 48 x 2.0 290 210 630 460 540 400 260 190

Tab. 35

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

97

Standard torques

Operation and Maintenance Manual

Tube

diameter X

Thread Y

Nm ft lb Nm ft lb Nm ft lb

WH TH SWVE

6 M 10 x 1.0 18 13 18 13. 18 13

8 M 12 x 1.5 45 33 45 33 35 26

10 M 14 x 1.5 55 41 55 41 50 37

12 M 16 x 1.5 80 59 80 59 60 44

15 M 18 x 1.5 100 74 100 74 80 59

18 M 22 x 1.5 140 100 140 100 120 89

22 M 26 x 1.5 320 240 320 240 130 96

28 M 33 x 2.0 360 270 360 270

35 M 42 x 2.0 540 400 540 400

42 M 48 x 2.0 700 520 700 520

Tab. 36

Metric flange joints, series S (heavy)

Tube

diameter X

Thread Y

Form A with sealing ring Form B with edge seal Form E with flat (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

diameter X

Thread Y

Nm ft lb Nm ft lb Nm ft lb

WH TH SWVE

6 M 12 x 1.5 45 33 45 33 35 26

8 M 14 x 1.5 55 41 55 41 50 37

10 M 16 x 1.5 80 59 80 59 60 44

12 M 18 x 1.5 100 74 100 74 80 59

14 M 20 x 1.5 125 92 125 92 110 81

16 M 22 x 1.5 135 100 135 100 120 88

20 M 27 x 2.0 320 240 320 240 135 100

© 2018 by Kohler Co. All rights reserved.

98

KD36V16 33521029701_1_1 en 2018-08-01

Operation and Maintenance Manual

Standard torques

Tube

diameter X

Thread Y

Nm ft lb Nm ft lb Nm ft lb

WH TH SWVE

25 M 33 x 2.0 360 270 360 270

30 M 42 x 2.0 540 400 540 400

38 M 48 x 2.0 700 520 700 520

Tab. 38

Imperial flange joints, series L (light)

Tube

diameter X

Thread Y

6 G 1/8A 9 6.6 18 13 18 13

8 G 1/4A 35 26 35 26 35 26

10 G 1/4A 35 26 35 26 35 26

12 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

Form A with sealing ring Form B with edge seal Form E with flat (ED) seal

Nm ft lb Nm ft lb Nm ft lb

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

Nm ft lb Nm ft lb Nm ft lb

WH TH SWVE

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

15 G 1/2A 120 88 120 88 90 66

18 G 1/2A 120 88 120 88 90 66

22 G 3/4A 230 170 230 170 125 92

28 G 1A 320 240 320 240

35 G 1 1/4A 540 400 540 400

42 G 1 1/2A 700 520 700 520

Tab. 40

© 2018 by Kohler Co. All rights reserved.

KD36V16 33521029701_1_1 en 2018-08-01

99

Standard torques

Operation and Maintenance Manual

Imperial flange joints, series S (heavy)

Tube

diameter X

6 G 1/4A 35 26 55 41 40 29

8 G 1/4A 35 26 55 41 40 29

10 G 3/8A 45 33 90 66 80 59

12 G 3/8A 45 33 90 66 80 59

14 G 1/2A 65 48 150 110 115 85

16 G 1/2A 65 48 130 96 115 85

20 G 3/4A 90 66 270 200 180 130

25 G 1A 150 110 340 250 310 230

30 G 1 1/4A 240 180 540 400 450 330

38 G 1 1/2A 290 210 700 520 540 400

Tab. 41

Tube

diameter X

6 G 1/4A 45 33 45 33 40 29

Thread Y

Thread Y

Form A with sealing ring Form B with edge seal Form E with flat (ED) seal

Nm ft lb Nm ft lb Nm ft lb

WH TH SWVE

Nm ft lb Nm ft lb Nm ft lb

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

Tube

diameter X

6 M 10 x 1.0 15 11. 12 8.8

8 M 12 x 1.5

Thread Y

Form A with sealing ring Form B with edge seal Form E with flat (ED) seal

Nm ft lb Nm ft lb Nm ft lb

10 M 14 x 1.5 30 22 30 22

12 M 16 x 1.5 40 29 40 29 40 29

15 M 18 x 1.5

18 M 22 x 1.5 80 59 80 59

© 2018 by Kohler Co. All rights reserved.

100

KD36V16 33521029701_1_1 en 2018-08-01