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Maintenance

Inspection and maintenance schedules

5.4.7 Service level 2 — Engine Service, TBO 24000 hours for COP —

Advanced maintenance - 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

SL204

Valves clearance

3000

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 injectors

8000

Replace.

SL206 Combustion cham‐

bers

8000

Done at the time the injectors are replaced. Use a

borescope to identify condition of combustion

chamber (piston crown, liner hatches, fire deck,

etc.).

SL2-13

Torsional vibration

damper

4000

Replace.

SL209 HP fuel pump and

LP fuel pump

Inspect for leaks. 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, housings, etc.) every 4000 hours.

Replace the exhaust gas turbocharger at the indi‐

cated service interval.

SL215

LT coolant pump

12000

18Y X

Replace.

SL216

HT coolant pump

12000

18Y X

Replace.

SL217

Coolant thermo‐

stats

12000

18Y X

Replace.

SL218 Auxiliary belt drive

- PTO

12000

18Y X

Replace.

SL219

Rubber sleeves

12000

18Y X

Replace all rubber hose connections on the engine:

e.g., coolant hoses for ECU cooling, hose connec‐

tions for crankcase ventilation.

SL220

Charge air cooler

12000

18Y

Check visually for leaks. If shown, identify reason.

Replace component if needed.

SL221

Oil cooler

12000

18Y

Inspect the oil cooler.

SL222

Recommended:

Starter

12000

18Y

Inspect the starter (winding insulation, relay, condi‐

tion of the gear teeth, etc.).

KD62V12 33521030301_8_1 EN_US 2022-09

Содержание KD62V12

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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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