Kohler KD62V12 Operation And Maintenance Manual Download Page 84

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Maintenance

Inspection and maintenance schedules

Task iden

tification

Component

Schedule

Service

Type

Task description

Time limit (h)

Calendar limit (y

ear)

eplacemen

erhaul

Inspection/Clean R

epair

/Adjus

tmen

SL008

Month

Test run (if parameters are in the setting range) at

more than a 1/3 load and at least until steady-state

temperature is reached (monthly).

Tab. 15: Daily maintenance activities — Engine operation - Version: 2020-10-06

5.4.2 Service level 1 — Engine Service, TBO 4000 hours for ESP — Engine

Operation - Version: 2021-07

Task iden

tification

Component

Schedule

Service

Type

Task description

Time limit (h)

Calendar limit (y

ear)

eplacemen

erhaul

Inspection/Clean R

epair

/Adjus

tmen

SL100

Oil sampling

100

Collect and send oil sample for analysis every 100

hours on ESP or 250 hours (in PRP and COP applica‐

tions). If the results are not within the requested

parameters, repeat analysis at shorter intervals. In

case of use of high sulfure rate (>0.5%). No oil

Category 1 in case of K175.

(For more information

see: 5.9.1 Collecting and analyzing oil sample —

SL100, page 111.)

SL120

Coolant sampling

Check coolant quality.

(For more information see:

5.10.1 Collecting coolant sample — SL120,

page 123.)

SL122

Recommended:

First 250 service

hours for a new or

overhauled engine

250

Engine oil replacement.

(For more information see:

5.9.6 Changing engine oil — SL101, SL121,

page 118.)

Oil filters and oil filters for cooling jet replacement.

(For more information see: 5.9.4 Changing oil filters

— SL101, page 113.)

It is recommended to check the engine oil charac‐

teristics at the same time.

(For more information

see: 5.9.1 Collecting and analyzing oil sample —

SL100, page 111.)

Perform all check before starting and perform a

test run.

(For more information see: 5.7.3 Testing

engine in operation (ESP application only) — SL008,

page 104.)

KD62V12 33521030301_8_1 EN_US 2022-09

Summary of Contents for KD62V12

Page 1: ...Operation and Maintenance Manual Original Operation and Maintenance Manual Diesel engine KD62V12 From serial number 2020730163 EN_US 33521030301_8_1 09 2022...

Page 2: ...iesel 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 are...

Page 3: ...ered to the initial owner and upon any sale of the engine by such initial owner to a subsequent owner the warranty period does not restart but rather the remaining balance of the warranty period trans...

Page 4: ...upplied or approved by Kohler Damage resulting from fire accident negligence act of God or other events beyond the control of Kohler Consequential damage such as loss of use of the engine or equipment...

Page 5: ...n design or add any improvements on its products at any time without incurring any obligation to install same on units previously delivered If the original owner sells the engine and machine the remai...

Page 7: ...t 2018 07 06 TB12 Technical documentation First G3 02 engine version 2019 02 07 TB12 Technical documentation According to development and improvement 2021 07 08 TB12 Technical documentation HVO introd...

Page 9: ...through incorrect operation The machinery owner is responsible for supplementing the operating instructions of the engine with its machinery and with instructions based on existing national regulatio...

Page 10: ...e user s own discretion Kohler Co does not offer any warranty or accept any liability for losses of any kind caused by failures of or damage to KOHLER engines attributable to the use of third party pr...

Page 11: ...f the warnings 32 2 1 1 Warnings 32 2 1 2 Additional identifications 32 2 1 3 Additional rules and directives 33 2 2 Target audience 34 2 2 1 Responsibility of machinery owner 34 2 2 2 Recommended occ...

Page 12: ...agout 47 2 8 4 Emergency stop 48 2 8 5 Signage recommendations 48 2 9 Prevent property damage 50 2 9 1 Safety instructions for engine control unit ECU 50 2 9 2 Alarm conditions 50 2 9 3 Safety instruc...

Page 13: ...ing the running engine 73 4 4 Stopping the engine 74 4 4 1 Shutting down the engine 74 4 4 2 Emergency stop 74 4 5 Initial starting after out of service period 75 4 5 1 Preparation of initial starting...

Page 14: ...s 98 5 6 Post maintenance activities 99 5 6 1 Spray painting 99 5 7 Daily or monthly maintenance activities 101 5 7 1 Inspecting engine overall condition SL000 101 5 7 2 Inspecting engine running at i...

Page 15: ...ending on configuration 135 5 13 Exhaust gas aftertreatment system depending on configuration 136 5 13 1 Replacing diesel exhaust fluid filter SL1 5320 136 5 14 Lubricants and operating fluids 141 5 1...

Page 16: ...screw plugs for steel and iron cast part 198 8 4 10 Standard torques for VSTI screw plugs for aluminium 199 8 4 11 Assembling pipes with DKO connectors EL ET EW GZ GZR RED 201 8 4 12 Standard torques...

Page 17: ...end DE Driving end 5 Exhaust gas turbocharger assembly 1 Engine brackets 6 Charge air cooler 2 Flywheel 7 Battery charging alternator 3 Fuel filter 8 Oil dipstick 4 Crankcase breather system filter h...

Page 18: ...rmostat housing 16 Oil cooler 12 Low temperature coolant pump 17 Oil filter 13 Low temperature thermostat housing Fig 3 Diesel engine view from the free end FE Free end 21 Cylinder head cover 18 Torsi...

Page 19: ...n crankcase has an upper section with optimized structure and an oil pan as lower section Four valve single cylinder heads benefit from flow optimized ports as well as replaceable valve seats and valv...

Page 20: ...mperatures cooling systems The coolant is thermostatically controlled with separate pumps for high and low temperature Each cylinder is individually supplied via distribution channels cast into the cr...

Page 21: ...programmable engine control unit The ECU controls the actuators and reads values from the sensors to ensure optimal engine performance The ECU is programmed according to configuration and application...

Page 22: ...Cylinder A1 and cylinder B1 are located on the driving end of the diesel engine Direction of rota tion is counterclockwise as seen from the driving end of the diesel engine Fig 5 Cylinder designation...

Page 23: ...vel A power level designation where A the lowest power level B next higher power level C next higher power level F Emissions or fuel optimization F Fuel Opti mized E Emissions Optimized C Application...

Page 24: ...ion number Tab 2 Engine serial number Fig 8 Serial number on nameplate 1 Serial number Engine control nameplates Information u The information on the engine control unit nameplate corresponds to the d...

Page 25: ...Hardware nameplate Fig 10 Software nameplate 1 Product designation 6 Engine serial number 2 Product type 7 Engine control unit ID number 3 Engine designation 8 Certification ID number 4 QR Code 9 Dat...

Page 26: ...sories attached on auxiliary drives and their respective range of use of engine contact your nearest authorized Kohler service representative Battery charging alternator The engine is equipped with a...

Page 27: ...front side Features Protection device ensuring isolation of moving parts Adapted fastening points Captive screws technology to avoid fastener loss Ease of dis assembly free of maintenance Additional s...

Page 28: ...s Protection device ensuring isolation of moving parts Adapted fastening points Captive screws technology to avoid fastener loss Ease of dis assembly free of maintenance Additional solution to fulfill...

Page 29: ...nameplate Rated speed See nameplate Emission control information See nameplate Flywheel housing connection SAE 00 Tab 3 Technical data table diesel engine 1 2 2 Cylinder head Designation Value Inlet v...

Page 30: ...rnator Designation Value Voltage 28 V Current 140 A Tab 6 Technical data table battery charging alternator 1 2 5 Starter Designation Value Voltage 24 V Power per starter 9 kW Tab 7 Technical data tabl...

Page 32: ...result in minor or moderate injury Tab 9 Warning signs The NOTICE signal word indicates a risk not related to personal injury The risks of engine failure are classified according to ISO 2710 2 Critica...

Page 33: ...of an action Listing Identifies a listing Torque value Identifies special tightening torque or specification Tab 10 Additional symbols 2 1 3 Additional rules and directives Follow these instructions...

Page 34: ...pation unit groups perform the following work in accordance with the General safety instructions chapter For more information see 2 5 1 General safety instructions page 38 Main tasks described in this...

Page 35: ...evel 2 required Power production plant operators operate monitor and maintain switchboards and related equipment in electrical control centers which control the production and distribution of elec tri...

Page 36: ...s and maintenance performed 2 2 3 Unauthorized personnel servicing All other persons including operators supervisors and trainees are classified as unauthorized personnel for maintenance work They are...

Page 37: ...ather than those specified Improper use of fuels lubricants starting aids and coolants Use of the engine manipulated overspeeds controls Modifications of the engine mounting and suspensions Lifting of...

Page 38: ...Manual of the machinery before commissioning the machine Develop document implement and enforce a safety and health program adapted to the machinery and its environment and comply with the local regu...

Page 39: ...ING Hazards generated by exposure to environments temperatures Exposure to radiant heat sources in the engine compartment could result in death or serious injuries u The manufacturer of the machinery...

Page 40: ...ng to the instructions in the instruc tions manual of the machinery u Ensure that the engine is started after all display units and control devices have been checked u Ensure that the engine is only r...

Page 41: ...while operating the engine u Avoid any contact with the engine parts carrying hot coolant or oil the exhaust system the turbocharger the heat protection the battery the covers and the ECU u Proceed w...

Page 42: ...Ensure a good ventilation while refueling or prior to accessing to the engine u Regularly check all lines hoses and screw connections for leaks and damage Immediately rectify the leaks and replace the...

Page 43: ...maged parts Safety instructions of the fluids have to be considered 2 6 5 Preventing electrical hazards WARNING Hazards by electrical shocks Contact with live conductor could result in death or seriou...

Page 44: ...tromagnetic sensitive devices in the vicinity of the engine especially artificial health assist devices 2 6 9 Preventing falling risks CAUTION Hazards by slipping and falling Climbing on the engine or...

Page 45: ...alling objects and from entanglement Additional protection against slipping Must be worn in the direct vicinity of the engine Safety gloves Protection against hot elements and chemicals Must be worn w...

Page 46: ...cted to the flywheel u Ensure the integrity of the machine and the engine before starting u All openings must be closed and the safe conditions established by the manufacturer of the machinery must be...

Page 47: ...e a padlock on an isolation device for example a circuit breaker or a line valve to isolate energy by engaging a position that prevents system energization Tagout is a labeling process that is always...

Page 48: ...acknowledge buttons are described in the generator set manual NOTICE Property damage by misuse of emergency stops Misusing the emergency stops to stop the engine could lead to property damage u Initia...

Page 49: ...ovement ISO 7010 M002 Mandatory action sign Refer to instruction manual booklet In order to ensure that all residual risks are known by the personnel the system documentation must be read and understo...

Page 50: ...ug connectors u Connecting the sensors or actuators individually to or between external voltage sources for testing purposes is prohibited Risk of destruction or malfunction of the engine Connect the...

Page 51: ...hen the engine is running the fuel lines are under a constant pressure of up to 2000 bar 29 007 40 psi Fuel escaping under pressure can penetrate the skin or vaporize and explode when an ignition sour...

Page 52: ...d insulation material with suitable equip ment u Cover the areas of the engine compartment which could produce dirt particles with a new and clean covering film u Before beginning the dismantling work...

Page 53: ...als u Before disposing or recycling waste products ask for the correct method at the responsible environmental or recycling center u When handling waste lubricants and fuel make sure that none is disp...

Page 54: ...between components of the engine and suspension devices by putting protec tion between them u Prevent the load from swinging u Before handling or lifting the load warn all employees in the immediate v...

Page 55: ...e serious injury or death by crushing impact or parts ejection Failure of lifting devices could cause serious injury or death by ejection of parts crushing and impact u It is forbidden to guide the lo...

Page 56: ...gine EATS configuration Overall length 2633 mm 8 64 ft 2633 mm 8 64 ft Overall width 1647 mm 5 4 ft 1650 mm 5 41 ft Overall height 2167 mm 7 11 ft 2168 mm 7 11 ft From RFOB to center of gravity X1 857...

Page 57: ...305 mm 1 ft 312 4 mm 1 02 ft Axis to lifting point Y2 729 mm 2 39 ft 729 mm 2 39 ft From center of gravity to lifting point Z1 645 mm 2 12 ft 645 mm 2 12 ft Distance between engine lifting points Z2 1...

Page 58: ...Fix or remove any loose part on the engine u Before readjust the lifting devices warn all employees in the immediate vicinity u Only readjust the lifting devices when the load is on the floor and the...

Page 59: ...Transportation Storage Transport Fig 39 Example of wood stand on undercarriage Fig 40 Example of transportation fixing KD62V12 33521030301_8_1 EN_US 2022 09 2022 by Kohler Co All rights reserved 59...

Page 60: ...the lifting devices on the engine 1 Engine 3 Lifting beam 2 Lifting hook 4 Lifting point 3 3 4 Transport conditions Transport conditions should comply with the following minimum requirements Land tran...

Page 61: ...th the measures to prevent the penetration of water Air transport In a closed air freight container Information For further information please contact your nearest authorized Kohler service representa...

Page 62: ...y of the air in a closed and air conditioned warehouse should not exceed 70 3 4 2 Storage site foundation requirements Information The storage site foundation is part of the scope of the generator set...

Page 63: ...e Storage 3 4 4 Storage over 12 months For storage longer than 12 months please contact your nearest authorized Kohler service repre sentative KD62V12 33521030301_8_1 EN_US 2022 09 2022 by Kohler Co A...

Page 64: ...endly manner CAUTION Cutting or scratches hazards by contact with sharpen surfaces tools or materials Contact with sharpen surfaces tools or materials could result in minor or moderate injuries by cut...

Page 65: ...w The engine cooling system is ready for operation Fuel system u The corrosion inhibitor B0 fuel mixture can be run through the engine upon initial startup u Replace the mixture with an approved diese...

Page 66: ...engine running fluids observe the following start up process Connect all batteries and other electric connections that were disconnected before preser vation Perform engine over crank procedure This p...

Page 67: ...t require depreservation u In an environmentally friendly manner reuse the packaging to send back the engine or other components u Clean the engine and remove any rust u Spray or apply corrosion inhib...

Page 68: ...he machinery and dismounting of the engine preserve pack and store the engine according to the following standards ISO 6749 Earth moving machinery Preservation and storage EN ISO 780 Packaging Pictori...

Page 70: ...s and lubricating oil additives only For more information see 5 14 3 Approved lubricating oils and lubricating oil additives page 147 4 1 2 Coolant Filling Refer to the generator set manual for more d...

Page 71: ...start attempt NOTICE Fire Overheating of starter or prelube pump due to excessive run time Property damage Risk of destruction of the machine or the engine u Observe specified maximal consecutive star...

Page 72: ...ases u Using starting aids containing ether is forbidden The KOHLER generators are equipped with a preheating system Fig 43 Precautions at cold temperatures The following precautions improve the start...

Page 73: ...Investigate any alarm according to operating conditions and make sure that authorized personnel correct the defect at first opportunity Make sure that the following preconditions are met q Engine is...

Page 74: ...idle speed for 3 minutes u Shut down the engine 4 4 2 Emergency stop The emergency stop button and signals as the acknowledge buttons are described in the the application set manual NOTICE Misuse of e...

Page 75: ...ction Refer to chapter Maintenance u Check coolant level Refer to chapter Maintenance u Drain off water and sediment of fuel tank Refer to Operation and Maintenance Manual u Check water separator of f...

Page 76: ...quality of the dismantling process u Disconnect the electrical power supply u Remove any electronic control or electrical connections u Drain all fluids u Remove any coolant lubricants and fuel connec...

Page 77: ...g waste lubricants and fuel make sure that none is disposed into the environ ment u Collect and dispose waste lubricants and fuel in separate suitable properly designated containers u Use adapted leak...

Page 78: ...ation Use the original packaging of the new parts to ship removed parts Recover packaging material as follows Wood impregnated wood Packaging foils Board Tinplate Adhesive tape Contaminated packaging...

Page 80: ...regulations applicable in the country of use must be adhered to 5 1 2 Maintenance intervals The time intervals during which a component can remain in operation between two servicing are divided into T...

Page 81: ...Prime power PRP is the maximum power which the generator set can deliver continuously while supplying a variable electrical load Prime power PRP can be operated for an unlimited number of hours per y...

Page 82: ...s involving partial disas sembly of the engine in situ mid life service For example change of pump injectors heads Operations for which the procedures entail expert knowledge of a specific technique o...

Page 83: ...e circuit charge air cooler SL002 page 126 SL003 Daily Befor e start X Check relieve bores water coolant pump For more information see 5 10 4 Checking relief bores coolant pump SL003 page 127 SL004 Da...

Page 84: ...within the requested parameters repeat analysis at shorter intervals In case of use of high sulfure rate 0 5 No oil Category 1 in case of K175 For more information see 5 9 1 Collecting and analyzing o...

Page 85: ...th centrifugal oil filter SL101 Engine oil filters standard 500 2Y X Replace filters Clean the seal area before removal the old filter to prevent oil contamination For more information see 5 9 4 Chang...

Page 86: ...heck belt tension For more information see 5 8 3 Replacing drive belt SL 109 page 108 SL110 Alternator belt tensioner 1000 2Y X Visual inspection of the tensioner Replace if necessary For more informa...

Page 87: ...Adjustment SL204 Valves clearance 2000 2Y X Clearance check and adjustment First inspection at 1000 hours second at 1500 hours Proceed in the same way after cylinder head repair work SL205 Fuel injec...

Page 88: ...ter winding insulation relay condi tion of the gear teeth etc SL223 Battery charging alternator 18Y X Replace SL224 Cylinder heads 18Y X Replace Tab 17 Service level 2 ESP Advanced maintenance Version...

Page 89: ...s Clean the seal area before removal the old filter to prevent oil contamination For more information see 5 9 4 Changing oil filters SL101 page 113 SL121 Engine oil change with engine oil Category 2 2...

Page 90: ...case of K175 For more information see 5 9 6 Changing engine oil SL101 SL121 page 118 Engine oil change with engine oil Category 3 1000 2Y X SL105 Fuel main filter 1000 2Y X Replace main fuel filter c...

Page 91: ...0 page 136 SL1 53 10 Diesel exhaust fluid X Change diesel exhaust fluid at an interval according to the specification SL1 54 61 Engine by pass flap 3000 2Y X Inspect overall condition including proper...

Page 92: ...condition compressor blades leaks connections housings etc every 4000 hours Replace the exhaust gas turbocharger at the indi cated service interval SL215 LT coolant pump 7500 18Y X Replace SL216 HT co...

Page 93: ...within the requested parameters repeat analysis at shorter intervals In case of use of high sulfure rate 0 5 No oil Category 1 in case of K175 For more information see 5 9 1 Collecting and analyzing o...

Page 94: ...Clean the seal area before removal the old filter to prevent oil contamination For more information see 5 9 4 Changing oil filters SL101 page 113 SL102 Centrifugal oil filter paper filter 500 2Y X Rep...

Page 95: ...see 5 8 4 Replacing tensioning device SL110 page 109 SL116 Cooling system 6000 4Y X Replace coolant at least every 4 years for coolant formulated with Glysantin G48 Respect fluids and lubricants speci...

Page 96: ...eaks Replace pump if necessary SL212 Cold start oil cooler by pass valve 12000 18Y X Replace SL213 Exhaust gas turbo chargers 12000 18Y X Check overall condition compressor blades leaks connections ho...

Page 97: ...tment SL223 Battery charging alternator 12000 18Y X Replace SL224 Cylinder heads 12000 18Y X Replace SL2 53 30 Diesel exhaust fluid injectors 5000 X Replace SL2 53 40 Diesel exhaust fluid pump 10000 X...

Page 98: ...the engine page 74 u Make sure that all parts are stopped u Secure all parts against unexpected movements Information The application set owner shall develop document implement and enforce lockout ta...

Page 99: ...otective equipment u Refer to the local regulations and the product associated data to safely handle store and use these products WARNING Risk of injuries by explosion of pressurized container Explosi...

Page 100: ...in making a criss cross pattern u Spray enough layers to cover the whole unpainted area u Turn the spray can upside down and bleed the valve after finishing the paint work Information In optimal cond...

Page 101: ...minate the risk of contamination Search for loose components Prevent engine damage The lines and hoses must be free of the following defects Damage to the outer layer for example scratches cuts and te...

Page 102: ...and report any defect u Make sure that authorized service personnel correct the defect Fig 44 Visual inspection of engine 1 1 Crankshaft flange Shaft seal 3 Injection system 2 Crankcase breather syst...

Page 103: ...pump low temperature 10 Spin on oil filters 6 Thermostat low temperature 11 Thermostat high temperature 7 Engine control unit ECU 12 Coolant pump high temperature 8 Charge air cooler Fig 46 Visual in...

Page 104: ...dle speed u Record and report any defect found on the engine for example leak unusual noise unusual vibration unusual exhaust gas color u Record and report any anomaly found on generator set display f...

Page 105: ...remain within expected range no alarm u Monitor the running engine and the generator set display u Record and report any defect found on the engine for example leak unusual noise unusual vibration unu...

Page 106: ...r details 1 Screw M8 3 Cover 2 Lock washer Preparatory maintenance activities are fulfilled For more information see 5 5 Preparatory maintenance activities page 98 u Unscrew and remove screws 1 u Remo...

Page 107: ...ective equipment u Use assembly and lifting devices Examples of damage to the drive belt are the following Rip breaks Rubber nodules in the belt base Deposits of dirt and or stones Ribs detached from...

Page 108: ...t Fig 51 Removing drive belt u Install ratchet wrench on tensioning device 1 u Pivot back tensioning device 1 against the spring force to the limit stop u Insert guiding pin 8 mm 0 31 in diameter to b...

Page 109: ...he same way Information Install battery charging alternator cover in reverse sequence For more information see 5 8 1 Removing the battery charging alternator cover page 106 5 8 4 Replacing tensioning...

Page 110: ...oning device 1 Installing tensioning device u Install tensioning device 1 with screw M10 2 u Tighten screw M10 2 to standard torque Information Install battery charging alternator cover in reverse seq...

Page 111: ...ld result in death or serious injuries by burns or skin penetrating oil u Avoid skin contact with the engine oil u Wear proper personal protective equipment Fig 54 Oil sampling point on engine left si...

Page 112: ...ctions u Identify and report any failure Make sure that authorized service personnel correct the defect 5 9 3 Checking the engine oil level SL001 q Engine stopped since at least 30 minutes q Preparato...

Page 113: ...and determine the oil level w The oil level must be between the min and max marks on the dipstick If the oil level is too low u Remove oil filling cap u Replenish oil via the oil filler neck 2 u Do no...

Page 114: ...t the filters u In the absence of prelubricating pump disconnect TDC sensor flywheel and start engine until oil pressure shows up u Reconnect TDC sensor u Check for leaks and damage u Retighten if nec...

Page 115: ...ith the engine oil u Wear proper personal protective equipment Information The oil centrifuge is equipped with a stop valve which stops the oil inlet Replacing centrifuge paper filter Fig 58 Oil centr...

Page 116: ...ly the rotator cylinder 5 so that the mud remains in the cylinder u Recycle paper filter 6 and mud according to specific national regulations Information The thickness of mud deposit inside the rotor...

Page 117: ...r disk 9 u Clean bearing tube 10 and rotor base 7 u Replace seals of rotor base 7 and bearing tube 10 u Insert deflector disk 9 Fig 62 Paper filter preparation u Insert paper filter 6 tabs in slot A a...

Page 118: ...o 15 2 Nm 11 1 ft lb u Start and run engine for three minutes u Check engine oil level For more information see 5 9 3 Checking the engine oil level SL001 page 112 5 9 6 Changing engine oil SL101 SL121...

Page 119: ...operating fluids page 141 WARNING Hazards by ejection of hot engine oil Hot engine oil could result in death or serious injuries by burns or skin penetrating oil u Avoid skin contact with the engine...

Page 120: ...pal oil drain point engine rear side 1 Oil drain on oil pan Fig 67 Oil drain engine left side 1 Oil drain aggregate support Engine right side 2 Oil drain aggregate support Engine left side 120 2022 by...

Page 121: ...he container u Wait until no more oil drips u Clean the drain hole plug or valve and the surrounding area with a clean rag u Refit the plug and or close the valve u Tighten plug according to standard...

Page 122: ...il level on the stopped side u Clean oil filling cap place on the filler neck and tighten by hand u Start the engine u Check oil pressure engine oil pressure display unit and check oil filter for leak...

Page 123: ...lable q Required quantity of approved coolant is available For more information see 5 14 Lubri cants and operating fluids page 141 DANGER Hazards by ejection of hot operating fluids or filler cap Hot...

Page 124: ...proved coolant w Usually a level indicator is present and coolant level must be between the min and max marks Bleeding coolant DANGER Hazards by hot operating fluids under pressure Burns or skin penet...

Page 125: ...ent friendly manner Information Bleeding the cooling system is part of the scope of the manufacturer of the machinery and depends on the cooling system design The following procedure shall be adapted...

Page 126: ...it until it is bubble free u Close the fast coupling on the flywheel housing u Close the bleeding connections on vent tube assembly u Close the cap on the expansion tank u Operate the engine until the...

Page 127: ...For more information see 5 5 Preparatory maintenance activities page 98 DANGER Hazards by ejection of hot operating fluids or filler cap Hot fluid spray from a pressurized cooling system will result i...

Page 128: ...nt and health by neglect of environmental regulations Neglect environmental regulations will result in death or serious injury u Observe the country specific regulations regarding environmental protec...

Page 129: ...Maintenance Cooling system Fig 75 Bleeding point on HT coolant pump Fig 76 Bleeding point on flywheel housing KD62V12 33521030301_8_1 EN_US 2022 09 2022 by Kohler Co All rights reserved 129...

Page 130: ...olant system venting block until bubble free u Tighten the HT connection venting block u Top up the HT expansion tank up to the MAX level marking u Close the valve cover on the HT expansion tank Bleed...

Page 131: ...enance Cooling system u Check the expansion tank coolant level of HT and LT systems u Top up the expansion tanks if necessary KD62V12 33521030301_8_1 EN_US 2022 09 2022 by Kohler Co All rights reserve...

Page 132: ...ventilation while refueling or prior to accessing to the engine u Regularly check all lines hoses and screw connections for leaks and damage Immediately rectify the leaks and replace the damaged parts...

Page 133: ...ate filter seal with engine oil u Screw fuel filter 1 in filter head 2 until it contacts base u Tighten filter by hand by 3 4 to 1 turn u Check for leaks and damage u Retighten if necessary u Bleed th...

Page 134: ...SL107 Fig 79 Crankcase ventilation 1 Screw M10 3 Seal 2 Filter element Information Actual number and location of crankcase breather filters may depend on application set Removal u Remove screws 1 u Re...

Page 135: ...the engine by pass flap u Inspect overall condition of the engine by pass flap u Inspect the compensator and check for potential deformation u To make sure that the flap rotates freely rotate the com...

Page 136: ...fluid filter new o ring and filter spanner are available q The exhaust gas aftertreatment system is free of blockage Replacing diesel exhaust fluid filter Information Actual number of diesel exhaust f...

Page 137: ...nding on configuration Fig 82 Removing the heating mat screws u Remove the heating mat screws M6 Fig 83 Removing the heating mat u Remove the heating mat from the filter KD62V12 33521030301_8_1 EN_US...

Page 138: ...ket Fig 85 Installing the filter u Lubricate the new o ring with diesel exhaust fluid u Install the new o ring on the filter bracket u Fill 3 4 of the new filter with diesel exhaust fluid Information...

Page 139: ...with the filter bracket then use the filter spanner to tighten the filter an additional 120 Fig 86 Installing the heating mat u Install the heating mat on the filter Fig 87 Installing the heating mat...

Page 140: ...filter heating mat u Run the system for 30 minutes to confirm successful priming and leak free operation Information After replacing the filter take a snapshot with KoDIA Note the ID of the filter in...

Page 141: ...correct disposal Incorrect waste disposal leads to environment and water supply pollution and could result in minor or moderate injuries by hazards from related actions u Observe the country specific...

Page 142: ...ambient temperatures These crystals increase the flow resistance in the fuel filters and deteriorate the fuel feed to the diesel engine To prevent property damage use only diesel fuels adequate to yo...

Page 143: ...o Additional required criteria Compat ible with EATS Perform ance alter ation Reduced mainte nance interval EN 590 CSR 4 1 03 10 OK No BS 2869 A2 10 OK No Tab 23 KD approved non road diesel fuels Heat...

Page 144: ...to EN 590 CSR 4 0 02 4 1 03 460 m 18 11 th 10 OK Yes5 XF 63 460 m 18 11 th With additive S 1750 No Yes5 Tab 25 KD approved military fuels Aviation kerosene Fuel standard norm Fuel quality norm comple...

Page 145: ...ydrotreated Vegetable Oils are renewable GTLs Gas To Liquids are fossil paraffinic fuels The use of paraffinic fuels results in lower emissions but also slightly higher fuel consumption and lower perf...

Page 146: ...S coupled with KD diesel engines DEF standard norm DEF quality norm complement Additional required criteria ISO 22241 DIN 70070 32 5 of urea in mass Cleanliness according to ISO 4406 18 16 13 needing...

Page 147: ...ed as part of additives to increase oil performances for example anti wear anti oxidiza tion cleanliness sulfated ashes are the result of the combustion of the additives in a running diesel engine SAP...

Page 148: ...explicitly fulfilled before considering the oil as approved for use in KD diesel engines Parameter Unit Expected value Methods Without EATS With EATS Visual appearance Clear Clear Visual Viscosity mi...

Page 149: ...lubricating oil condition Lubricating oil soot is a by product of the combustion comprised of roughly 98 of carbon in mass It forms on the coolest part of the combustion chamber Then soot is dragged i...

Page 150: ...be initiated x Fuel sulfur content ppm y Total Base Number TBN 1 Minimum TBN 2 Recommended TBN TAN ratio Kohler does not recommend any specific TAN for the lubricating oil to be used in KD diesel engi...

Page 151: ...ation The following types of operation are considered as severe Frequent cold starts Extended non operated period standstill Severe ambient conditions Extreme operating temperatures cold or hot High h...

Page 152: ...lubricating oil oil must be changed immediately Criteria group Criteria Maximum values Contaminants Aluminum 15 ppm Iron 40 ppm Chromium 10 ppm Copper 20 ppm Lead 25 ppm Silicon 15 ppm Sodium 20 ppm P...

Page 153: ...14 4 Approved coolants Coolant function Diesel engine coolant fulfills three functions Heat transfer from the diesel engine and its components to the radiators without fluid cavi tation Corrosion pro...

Page 154: ...us forbidden Should your appli cation need additional antifreeze protection arctic conditions please contact your Kohler Co representative for additional information Coolant monitoring Kohler recommen...

Page 155: ...of fresh coolant added with biocides is suitable The following products are approved Manufacturer Product name Concentration Packin g Order Sch lke Mayr Gmbh Grotan WS Plus 0 15 by volume Liquid X0006...

Page 156: ...cooling system flushing chemicals Manufacturer Product name Concentration Packin g Order Henkel P3 FD 3 to 5 by weight Powder Porodox 5 to 10 by weight Powder Kluthe Hakutex 60 100 by volume Liquid X0...

Page 157: ...ation see 8 Appendix page 170 Description Quantity max Quantity min Engine oil 335 l 88 5 gal 272 l 71 85 gal Coolant Filling volume in the engine high temperature circuit 254 l 67 1 gal Filling volum...

Page 158: ...or diagnosis are as following u Know the engine and the associated systems u Thoroughly analyze the problem u Relate symptoms to current knowledge about the engine and the systems u Diagnose problem s...

Page 159: ...art and or stops immediately Fuel tank empty Refuel the engine Fuel filter blocked Replace fuel filter Fuel line precleaner or sieve in fuel tank blocked Clean and vent fuel system Fuel system or filt...

Page 160: ...e Coolant temperature too high Check cooler for contamination check fan and thermostat check coolant level contact your nearest authorized Kohler service represen tative Fuel temperature too high Cont...

Page 161: ...rating temperature not reached Warm up the engine until operating temperature is reached Water in fuel system Check fuel system and drain pre filter Charge air cooler leaking Contact your nearest auth...

Page 162: ...representative Cooling water in the lubricant oil Cylinder liners seals leaking Contact your nearest authorized Kohler service representative Oil cooler or oil cooler plate leaking Contact your neare...

Page 164: ...ent number Turning device 1 11133437 230611637 Locking device 1 11343230 230612868 Guiding rod M30x2 Cylinder head 2 11133371 230610035 Guiding rod M28x2 Damper 2 11133372 230610036 Guiding rod M24x2...

Page 165: ...2 11133375 230610038 Guiding rod M16 Oil cooler support 2 11133376 230610039 Guiding rod M12 Oil cooler 2 11133377 230610040 Guiding rod M10 Exhaust line 2 11133379 230610041 Guiding rod M12 coolant...

Page 166: ...612675 Sampling Tube for each liquid sampling 1 7002475 230612676 Handling bar 1 11344345 230612677 Electric Torque Multiplier 1 12226986 230612678 Torque Reaction Arm for Electric Torque Multiplier 1...

Page 167: ...gine operation Property damage Risk of engine major failure u Dismount immediately the turning device and mount the cover on the flywheel housing WARNING Use of turning device Risk of death or injury...

Page 168: ...turning device are available for maintenance task only Please contact your nearest authorized Kohler service representative Installation Fig 110 Mounting the turning device 1 Screws M16x35 8 8 3 Cove...

Page 169: ...ver on the flywheel housing u Tighten the turning device cover bolts according to standard torques values Removal Fig 111 Dismounting the turning device 1 Screws M16x35 8 8 3 Cover 2 Turning device 4...

Page 170: ...ion The technical design documents are specific to the delivered engine Using those documents for other engines is forbidden For inquiry please contact your nearest authorized Kohler service represent...

Page 171: ...sensor Short circuit to ground 171 31 Ambient temperature sensor Supply voltage out of range 1176 1 Boost pressure Pressure too high 1176 0 Boost pressure Pressure too low 636 2 Camshaft position Plau...

Page 172: ...157 31 Common rail pressure sensor Supply voltage out of range 516133 11 Common rail pressure sensor 2 No signal variation 1349 3 Common rail pressure sensor 2 Short circuit to battery or open circui...

Page 173: ...d 1136 15 Engine control unit Overtemperature warning 516495 31 Engine control unit Runtime reached the maximum time without reset 1136 31 Engine control unit temperature sensor 1 Supply voltage out o...

Page 174: ...Fuel supply Overtemperature warning 94 3 Fuel supply pressure sensor Short circuit to battery 94 4 Fuel supply pressure sensor Short circuit to ground or open circuit 94 31 Fuel supply pressure senso...

Page 175: ...it to ground high side 516349 4 Heating flange status input 2 Short circuit to ground low side 516187 31 Ignition digital input Supply voltage out of range 516509 31 Injection data synchronization Err...

Page 176: ...8 Injector 16 No current rise time measured 666 5 Injector 16 Open circuit 666 3 Injector 16 Short circuit to battery 666 4 Injector 16 Short circuit to ground 667 0 Injector 17 Current Rise time too...

Page 177: ...4 Injector 4 Short circuit to ground 655 0 Injector 5 Current Rise time too long 655 8 Injector 5 No current rise time measured 655 5 Injector 5 Open circuit 655 3 Injector 5 Short circuit to battery...

Page 178: ...ensor Short circuit to ground or open circuit 102 31 Intake manifold pressure sensor Supply voltage out of range 1636 5 Intake manifold temperature sensor Open circuit 1636 3 Intake manifold temperatu...

Page 179: ...s above the set point 516209 17 Pressure control valve Current remains below the set point 5571 11 Pressure control valve Electrical error 5571 5 Pressure control valve Open circuit 516211 11 Pressure...

Page 180: ...7 6 Starter Critical high output current 677 11 Starter Electrical error 516342 31 Starter Locked due to overtemperature 677 5 Starter Open circuit 677 3 Starter Short circuit to battery high side 516...

Page 181: ...me control valve 2 Critical undercurrent 516256 11 Volume control valve 2 Current remains above the set point 516257 11 Volume control valve 2 Current remains below the set point 516336 11 Volume cont...

Page 182: ...n fuel sensor Water in fuel detected 6301 5 Water in fuel sensor 2 Open circuit 6301 11 Water in fuel sensor 2 Out of range 6301 3 Water in fuel sensor 2 Short circuit to battery 6301 4 Water in fuel...

Page 183: ...9 Loctite Loctite 243 250 8 4 Loctite Loctite 270 or Omnifit 200 M 250 8 4 Loctite Loctite 577 250 8 4 Loctite Loctite 648 or Omnifit 230 M 250 8 4 Loctite Loctite 5900 50 1 7 Loctite Loctite 5910 30...

Page 184: ...or nuts Improper pre tightening turning angle or reuse of screws or nuts could lead to the rupture of the screw or nut and lead to property damage by malfunction ejection fall or tilting of compo nen...

Page 185: ...rque wrench 2 mark the initial position aligned with the marking on the component u Use the torque wrench to tighten until the marking of the initial position is aligned with the marking on the compon...

Page 186: ...r each dismounting Counterweight u Untightening screws is forbidden Screw plugs u Replace screw plugs after each dismounting On fuel and HP injections pipes u Replace connections after first dismoutin...

Page 187: ...4014 ISO 4017 For socket screws in accordance with ISO 4762 For flange screws in accordance with EN 1665 For hexagonal nuts in accordance with ISO 4032 ISO 4034 ISO 4035 For flange nuts in accordance...

Page 188: ...ing torque Thread Tightening torque Thread Tightening torque M 6 x 1 5 Nm 4 ft lb1 M 14 x 1 5 57 Nm 42 ft lb M 20 x 1 5 98 Nm 72 ft lb M 8 x 1 12 Nm 9 ft lb M 16 x 1 5 68 Nm 50 ft lb M 36 x 1 5 280 Nm...

Page 189: ...ft lb M 30 x 1 5 115 Nm 85 ft lb M 48 x 1 5 300 Nm 221 ft lb M 10 x 1 25 15 Nm 11 ft lb M 30 x 2 115 Nm 85 ft lb M 48 x 2 300 Nm 221 ft lb M 12 x 1 5 20 Nm 15 ft lb M 33 x 2 120 Nm 89 ft lb M 52 x 1...

Page 190: ...0 Nm 22 ft lb 25 Nm 18 ft lb 25 Nm 18 ft lb M 14 x 1 5 35 Nm 26 ft lb 45 Nm 33 ft lb 45 Nm 33 ft lb 35 Nm 26 ft lb M 16 x 1 5 45 Nm 33 ft lb 65 Nm 48 ft lb 55 Nm 41 ft lb 40 Nm 30 ft lb M 18 x 1 5 55...

Page 191: ...ft lb M 20 x 1 5 55 Nm 41 ft lb 150 Nm 111 ft lb 125 Nm 92 ft lb 80 Nm 59 ft lb M 22 x 1 5 65 Nm 48 ft lb 170 Nm 125 ft lb 135 Nm 100 ft lb 100 Nm 74 ft lb M 27 x 2 0 90 Nm 66 ft lb 270 Nm 199 ft lb...

Page 192: ...tandard torques for imperial thread unions L series for steel and iron cast part Standard torques for imperial thread unions S series up to 800 bar 11603 Psi for steel and iron cast part According to...

Page 193: ...B with sealing ring Form E with flat sealing Form F with O ring M 10 x 1 0 7 Nm 5 ft lb 14 Nm 10 ft lb 14 Nm 10 ft lb 12 Nm 9 ft lb M 12 x 1 5 16 Nm 12 ft lb 24 Nm 18 ft lb 20 Nm 15 ft lb 20 Nm 15 ft...

Page 194: ...ft lb M 20 x 1 5 44 Nm 32 ft lb 120 Nm 89 ft lb 100 Nm 74 ft lb 64 Nm 47 ft lb M 22 x 1 5 52 Nm 38 ft lb 136 Nm 100 ft lb 108 Nm 80 ft lb 100 Nm 74 ft lb M 27 x 2 0 72 Nm 53 ft lb 216 Nm 159 ft lb 144...

Page 195: ...ab 60 Standard torques for imperial thread unions L series for aluminium see figure above Standard torques for imperial thread unions S series up to 800 bar 11603 Psi for aluminium According to ISO117...

Page 196: ...m 266 ft lb G 1 1 2A 232 Nm 171 ft lb 560 Nm 413 ft lb 432 Nm 319 ft lb Tab 61 Standard torques for imperial thread union S series for aluminium see figure above 8 4 7 Assembling pipes with cutting ri...

Page 197: ...ft lb 90 12L 30 Nm 22 ft lb 90 12S 36 Nm 27 ft lb 90 15L 50 Nm 37 ft lb 90 14S 58 Nm 43 ft lb 90 18L 82 Nm 60 ft lb 90 16S 70 Nm 52 ft lb 90 22L 120 Nm 89 ft lb 90 20S 130 Nm 96 ft lb 90 28L 95 Nm 70...

Page 198: ...42 2 1 4 12 380 Nm 280 ft lb 400 Nm 295 ft lb 32 2 2 1 2 12 450 Nm 332 ft lb 470 Nm 347 ft lb Tab 63 Standard torques for triple lock flange joints Information To tighten the screwed socket u Hold scr...

Page 199: ...x1 5 90 Nm 66 ft lb 100 Nm 74 ft lb G 1 1 2 450 Nm 332 ft lb M24x1 5 90 Nm 66 ft lb M26x1 5 125 Nm 92 ft lb 3 4 16 UNF 70 Nm 52 ft lb M30x1 5 240 Nm 177 ft lb 7 8 1 4 UNF 100 Nm 74 ft lb M27x2 130 Nm...

Page 200: ...b 36 Nm 27 ft lb G 1 2 65 Nm 48 ft lb M16x1 5 40 Nm 30 ft lb 44 Nm 32 ft lb G 3 4 112 Nm 83 ft lb M18x1 5 52 Nm 38 ft lb 56 Nm 41 ft lb G 1 160 Nm 118 ft lb M20x1 5 60 Nm 44 ft lb 64 Nm 47 ft lb G 1 1...

Page 201: ...lubricate the thread before tightening these parts engine oil Information To assemble pipes with DKO connectors u When tightening the nut make sure that the connector does not rotate u Tighten the nut...

Page 202: ...5S 190 Nm 140 ft lb 35L 250 Nm 184 ft lb 30S 270 Nm 199 ft lb 42L 380 Nm 280 ft lb 38S 400 Nm 295 ft lb Tab 66 Alternative tightening torques for DKO connectors 8 4 12 Standard torques for collar clam...

Page 203: ...m 15 ft lb 2 19 mm 0 75 in 30 mm 1 18 in 12 Nm 9 ft lb 20 Nm 15 ft lb 3 30 mm 1 18 in 42 mm 1 65 in 15 Nm 11 ft lb 25 Nm 18 ft lb 4 M12 38 mm 1 5 in 66 mm 2 6 in 30 Nm 22 ft lb 40 Nm 30 ft lb 5 M16 70...

Page 204: ...e Monomer Ethylene Propylene Diene Monomer FE Free End Free End HFRR High Frequency Reciprocating Rig Meas ured value for the lubricity of diesel fuels High Frequency Reciprocating Rig Meas ured value...

Page 205: ...l Labor Organization International Labor Organization ISCED International Standard Classification of Education International Standard Classification of Education SAE Society of Automotive Engineers So...

Page 206: ...ctors Convert from To Multiply by kg lb 2 205 kg oz 35 274 Tab 72 Mass conversion factors 8 6 3 Pressure conversion factors Convert from To Multiply by kPa psi lbf in 0 145 kPa lbf ft 20 885 kPa inch...

Page 207: ...from To Multiply by g kWh g hph 0 736 g kWh lb hph 0 00162 Tab 77 Factors of fuel consumption conversion 8 6 8 Flow conversion factors Convert from To Multiply by m3 h liquid US gallon min 4 403 m3 h...

Page 208: ...Appendix Unit conversion tables Convert from To Multiply by Kg m3 lb ft3 0 0624 Tab 80 Density conversion factors 208 2022 by Kohler Co All rights reserved KD62V12 33521030301_8_1 EN_US 2022 09...

Page 209: ...fix Name Symbol Factor tera T 1012 giga G 109 mega M 106 kilo k 103 milli m 10 3 micro 10 6 nano n 10 9 Tab 81 Common prefix multipliers table KD62V12 33521030301_8_1 EN_US 2022 09 2022 by Kohler Co A...

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Kohler KD62V12, Operation And Maintenance Manual

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