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.

6

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