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 - If in an enclosed area, vent the exhaust to the outside. - Do not modify or tamper with the exhaust system. - Do not idle the engine except as necessary. For more information, go to www.p65warnings.ca.gov/diesel © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 3 Kohler. If a component of the emission control system fails during the warranty period, it will be repaired or replaced under warranty and warranted for the remainder of the warranty period.
Page 4 During the warranty period, the owner of the stationary equipment engine is responsible for: – Premium or overtime labor costs. – Costs to investigate engine problems which are not caused by a defect in Kohler material or workmanship. – Kohler may deny warranty coverage if the stationary engine or a part thereof has failed due to abuse, neglect, improper maintenance, or unapproved modifications.
Page 5 Kohler. Failure to complete, sign, or return this form will not affect any owner’s rights or Kohl‐ er’s obligations under this warranty statement and will not result in denial of warranty coverage by Kohler.
Page 7 First G3.02 engine version 2019-02 documentation TB12 - Technical According to development and improvement 2021-07 documentation TB12 - Technical HVO introduction 2022-09 documentation According to development and improvement © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 9 For further explanation or information, the Customer Service and Customer Service training center departments of the Kohler Co. are available any time to answer any queries. The OMM facilitates the operator's familiarization with the diesel engine and prevents faults through incorrect operation.
Page 10 About this document Spare parts Only original KOHLER spare parts, or spare parts purchased by Kohler Co. should be used for repairing KOHLER Diesel engines. Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers, such as guarantees, service orders, etc.
Page 11: Table Of Contents
Recommended occupations according to International standards 2.2.3 Unauthorized personnel - servicing Intended use Limitation of liability Safety instructions 2.5.1 General safety instructions 2.5.2 Safety while commissioning 2.5.3 Safety when starting Preventing injuries © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 12 Transport 3.3.1 Safe transportation 3.3.2 Transport fastening 3.3.3 Transport devices 3.3.4 Transport conditions Storage 3.4.1 Storage conditions 3.4.2 Storage site foundation requirements 3.4.3 Storage up to 12 months © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 13 5.1.1 General information 5.1.2 Maintenance intervals 5.1.3 Time between overhaul (TBO) Generator set ratings 5.2.1 Continuous Operating Power (COP) 5.2.2 Prime Power (PRP) 5.2.3 Emergency Standby Power (ESP) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 14 5.9.5 Replacing centrifuge paper filter — SL102 5.9.6 Changing engine oil — SL101, SL121 5.10 Cooling system 5.10.1 Collecting coolant sample — SL120 5.10.2 Replacing coolant — SL116 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 15 Diagnosis principles Faults - Cause - Remedy Tools and devices Tools 7.1.1 Special tools 7.1.2 Turning device Appendix Technical design documents Error code Cleaning agents, thread-locking adhesives and greases © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 16 Power conversion factors 8.6.6 Moment of inertia and torque conversion factors 8.6.7 Factors of fuel consumption conversion 8.6.8 Flow conversion factors 8.6.9 Temperature conversion factors 8.6.10 Density conversion factors Prefix © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 17: Product Description
DE Driving end Exhaust gas turbocharger assembly Engine brackets Charge air cooler Flywheel Battery charging alternator Fuel filter Oil dipstick Crankcase breather system filter housing High-pressure fuel pump © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 18 Fig. 3: Diesel engine / view from the free end Free end Cylinder head cover Torsional vibration damper cover Charge air pipe Engine control unit Starter Straight air intake Oil pan © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 19 The following auxiliary units are also connected to the engine oil circuit: – Fuel high pressure pump(s) – Coolant pumps – Turbochargers – Air compressor (depending on application) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 20 Therefore a high contamination retention capacity between tank and engine is ensured. Injection system The high pressure fuel system is supplied by a high pressure pump. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 21 – Charge air temperature – Engine speed and position The engine actuators are interfaces for the following control functions: – Starters – Volume control valve – Pressure control valve © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 22: Conventions
Exhaust valves B1-Bn Series of cylinders – Bank B Intake valves Driving end Left engine side Free end Right engine side Direction of rotation Firing sequence: A1-B2-A2-B4-A4-B6-A6-B5-A5-B3-A3- B1 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 23: Engine Or Component Identification
Tab. 1: Engine type description Diesel engine nameplate Fig. 6: Engine nameplate Engine main values QR code area USA regulations references Notes regarding emissions exemptions, fuel, and application types © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 24 Depending on software updates in the field, it may be the case that this information is no longer up to date. u The real information can be viewed in the device display or read out with the diagnosis and service tool KoDIA. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 25 Fig. 10: Software nameplate Product designation Engine serial number Product type Engine control unit ID number Engine designation Certification ID number QR Code Data set ID number Delivery date © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 26: Diesel Engine Accessory Equipment
1.1.4 Diesel engine accessory equipment Information For more information about the accessories 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 battery charging alternator.
Page 27 The cover of torsional vibration damper is a protective device fitted directly onto the front end of the engine. It ensures an overall protection to the torsional vibration damper environment while the engine is running. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 28 – Adapted fastening points – Captive screws technology to avoid fastener loss – Ease of (dis)-assembly, free of maintenance – Additional solution to fulfill the machine compliance with the applicable regulations © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 29: Technical Data
Designation Value Low Temperature Opening start 45 °C (LT) Thermostat 113 °F Completely open 57 °C 135 °F High Temperature Opening start 71 °C (HT) Thermostat 160 °F © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 30: Battery Charging Alternator
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 table — starter Information In standard configuration, two starters are installed. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 32: Safety
The short time is generally 30 minutes. 2.1.2 Additional identifications Note Indicates helpful advice and tips. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 33: Additional Rules And Directives
Follow these instructions and observe any additional or local rules and directives. Note the following points: – Safety regulations applicable on site – Guidelines provided by professional associations © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 34: Target Audience
14 years u Supplying the required tools and spare parts Information The Customer Service training center departments of the Kohler Co. provides several training programs. Please contact your nearest authorized Kohler service representative for queries. 2.2.2 Recommended occupations according to International standards The international standard classification of occupations (ISCO-08) of the International Labor Office (ILO) determines occupational unit groups.
Page 35 Tasks include: – Fitting, installing, examining, servicing, and repairing engines, machinery, and mechanical equipment © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 36: Unauthorized Personnel - Servicing
The Diesel engines produced by Kohler Co. are partly completed machinery according to Machi‐ nery Directive 2006/42/EC Article 2 g (only for European Union). The Kohler Co. products described in these instructions are intended for use according to the followings: –...
Page 37: Limitation Of Liability
Any other use above and beyond this is considered to be improper use. In this case, Kohler Co. is not liable for any damage. The risk is borne solely by the user.
Page 38: Safety Instructions
Risk of engine failure by use of non-compliant operating fluids! Use of non-compliant operating fluids will lead to engine main failure. u Use only operating fluids tested and approved by Kohler Co. NOTICE Risk of engine failure by use of non-original spare parts! The use of original spare parts guarantees the compliance with the technical requirements established by Kohler Co.
Page 39: Safety When Starting
Vibrations generated by the engine could result in death or serious injuries. u Standing in the vicinity of the engine while starting or operating the equipment is forbidden. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 40 Standing in the vicinity of the engine while starting or operating the machinery is forbidden. u Wear proper personal protective equipment. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 41: Preventing Injuries
Check operating fluid levels only once the temperature has cooled down enough so that surfaces can be touched with bare hands. u Carefully open the cover in order to first reduce the excessive pressure. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 42: Preventing Fires And Explosion Hazards
According to local regulations, the manufacturer of the specific application is responsible to design adapted fire protection system. Information Engines provided by Kohler Co. are not intended to be used in potentially explosive atmos‐ pheres according to Directive 2014/34/EC. © 2022 by Kohler Co. All rights reserved.
Page 43: Preventing Intoxication And Poisoning Hazards
Noise reduction systems adapted to the machinery must be designed by the manufacturer, to comply with the local regulations. u In case of abnormal noises, rectify it immediately. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 44: Preventing Vibrations Hazards
The manufacturer of the machinery shall define the safe conditions, including the personal protective equipment to wear before starting to work on the engine. u The manufacturer of the machinery shall forbid any accessories and loose clothing. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 45 Must be worn in the direct vicinity of the engine Safety goggles Protection against flying objects and chemical splashes Must be worn when handling operating materials and during mechanical opera‐ tions Tab. 11: Personal protective equipment © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 46: Accessible Areas
Fig. 32: Areas in operation — view from above and driving end Access to the following areas is forbidden: Engine free end Above the engine Engine sides Below the engine Engine driving end © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 47: Engine In Commissioning - Test Run
Tagging out the system by attaching or using an information tag or indicator. Verifying isolation by visually inspecting the system and engaging or activating system controls (push buttons, switches, etc.). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 48: Emergency Stop
For example: the signs for the United States market shall comply with ANSI Z535.4. The following warning signs must be clearly visible and mounted in the accessible areas: © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 49 Provide documentation to the personnel according to the “Target audience”. Tab. 12: Engine area signs requirement © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 50: Prevent Property Damage
Switch over to appropriate backup/emergency functions for additional, restricted operation of the engine (for example, constant limp-home speed). u Make sure that the faults are immediately repaired. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 51: Safety Instructions For The Fuel System
Before starting any task on the fuel system, ensure the build-up pressure in the circuit has been released, and the temperature of the engine has cooled down. u Keep the engine away from heat, sparks, open flame, or any other ignition source. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 52: Cleanliness Standards And Safety
Never use contaminated cleaning or testing fluids. u Remove new components from the original packaging immediately before use. u Use the original packaging of the new parts to ship removed parts. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 53: Disposal And Environment Protection
Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is prohibited. u Dispose all scrap materials only at official locations in an environment-friendly manner. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 54: Transportation - Storage
Several adapted lifting devices are available. Follow the instructions manual of the hoisting beam, handling devices and the local safety regulations. For further information, please contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 55: Dimensions And Weight
Falling/hanging lifting devices could result in property damage by impacts or tearing. u Check and replace the lifting devices according to local regulations. u Move the lifting devices near the engine cautiously. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 56 From RFOB to center of gravity 857 mm 913 mm 2.81 ft 3 ft From RFOB to lifting point - right side 334 mm 334 mm 1.1 ft 1.1 ft © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 57 Maximum angles of lifting devices — α1–α2 15° 15° side view Maximum angles of lifting devices — β1–β2 15° 15° front view Tab. 13: Dimensions and weight of engine - values © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 58: Transport
3.3.2 Transport fastening Information u For transportation, the engine should be deposited on adapted stands. u Kohler Co. provides one wooden stand with engine. For transportation and storage use the provided stand. © 2022 by Kohler Co. All rights reserved.
Page 59 Transportation - Storage Transport Fig. 39: Example of wood stand on undercarriage Fig. 40: Example of transportation fixing © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 60: Transport Devices
Lifting beam Lifting hook Lifting point 3.3.4 Transport conditions Transport conditions should comply with the following minimum requirements: Land transport: In a freight wagon or a closed lorry. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 61 In the hatch of the boat with 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 representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 62: Storage
The generator set owner shall measure the foundation performances before storing the engine. (For more information see: 3.2 Dimensions and weight, page 55.) Information Kohler Co. provides one wooden stand with engine. For transportation and storage use the provided stand. Steel stands are available for long term storage.
Page 63: Storage Over 12 Months
Transportation - Storage Storage 3.4.4 Storage over 12 months For storage longer than 12 months, please contact your nearest authorized Kohler service repre‐ sentative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 64: Unpacking And Depreservation
Check for damage or deformations to the fittings. u Check for dislocation from the fittings. u Leave all opening seals until connection. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 65: Depreservation
Troubleshooting By damage u Register the date of unpacking u Please contact your nearest authorized Kohler service representative. 3.5.2 Depreservation After an extended storage period, observe the following procedures to bring the engine out of preservation status before putting it into service: Engine oil system u Drain the long-term storage engine oil.
Page 66 – After 15 minutes at rated speed, begin adding load to the engine. – Add load in 20% increments until 100% load is reached. Maintain each interval for 15 minutes. – Monitor the engine operation for issues. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 67: Suspension Of Activity
Follow the procedure for the suspension of activity in the Instructions of the application set. To start engine after 12 months of suspension of activity: u Follow the starting procedure according to the Instructions of the application set. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 68: Preservation, Packaging
– ISO 6749 - Earth-moving machinery - Preservation and storage – EN ISO 780 - Packaging - Pictorial marking for the handling of goods © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 70: Control And Operation
Fill with approved diesel fuels, diesel exhaust fluids (DEF), and fuel additives only. (For more information see: 5.14.2 Approved diesel fuels, diesel exhaust fluids (DEF), and fuel additives, page 142.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 71: Starting The Engine
Once the engine has started, carry out the following checks: u Perform a visual check for any leaks in the lines. u Check for KoDIA error messages. u Check for error messages on the generator set. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 72: Starting In Cold Temperatures
Using starting aids containing ether could cause serious injury or death by inhalation of toxic gases. 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 starting performance at low temperatures. Precautions: u Check battery charging.
Page 73: Monitoring The Running Engine
Engine is under load at rated speed. Information Kohler diesel engines have been approved for running at low loads. Operating the engine at low loads for extended periods of time can increase deposits/carbon buildup (intensified at low ambient temperature). This can be detrimental to the longevity and compliance of the engine. If your operating profile has a prolonged low load duration, it is necessary to contact your genset supplier to take the necessary precautions.
Page 74: Stopping The Engine
Initiating an emergency stop: u Press the emergency stop button. After an emergency stop: u Remedy to the emergency situation. u Acknowledge the emergency stop button and signals. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 75: Initial Starting After Out Of Service Period
Check visually the starter, battery charging alternator. u Check belt, and replace if necessary. Refer to chapter Maintenance. u Vent the fuel system. Refer to Operation and Maintenance Manual of generator set. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 76: Dismantling
Remove any coolant, lubricants and fuel connections. u Collect and dispose of waste, coolant, lubricants and fuel. u Disassemble the component or engine according to general mechanics procedures. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 77: Components Disposal
– Insulating material – Cables and wires – Electrical waste – Plastics – Lubricants and lubricating greases – Fuels – Coolant – Paint residues – Cleaning agents and rags © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 78: Packaging Material Disposal
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 materials © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 80: Maintenance
A maintenance task is carried out as soon as a deadline is reached, hourly or calendar. 5.1.3 Time between overhaul (TBO) Time between overhaul (TBO) designates the average duration until the diesel engine is revised. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 81: Generator Set Ratings
Over 24 hours, the average power output cannot exceed 70% of the ESP, unless otherwise agreed by the engine manufacturer. Always observe the maintenance intervals and procedures prescribed by the manufacturer. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 82: Service Level Definition
Information u The information on the engine nameplate corresponds to the delivery status (ex-works Kohler Co.). Refer to the generator set ratings to know which maintenance schedule to use. (For more information see: 5.2 Generator set ratings, page 81.) Preventive Maintenance Corrective Maintenance Level 2 - Advanced Main‐...
Page 83: Inspection And Maintenance Schedules
(faulty parameters, unusual SL007 Daily noise, vibration, exhaust gas color, etc.). (For more start information see: 5.7.2 Inspecting engine running at idle speed — SL0-007, page 104.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 84: Service Level 1 - Engine Service, Tbo 4000 Hours For Esp - Engine Operation - Version: 2021-07
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.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 85 3). 1<fuel sulfur rate <1.5%: requires additional “Category 3” approval. No oil Category 1 in case of K175. (For more information see: 5.9.6 Changing engine oil — SL101, SL121, page 118.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 86 Change diesel exhaust fluid at an interval fluid according to the specification. The warning alarm for filter change will occur at 1300h. Filter must be replaced before 1500h in order to avoid engine shutdown. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 87: Service Level 2 - Engine Service, Tbo 4000 Hours For Esp - Advanced Maintenance - Version: 2021-07
Check overall condition (compressor blades, leaks, Exhaust gas turbo‐ connections, housings, etc.) every 4000 hours. SL213 chargers Replace the exhaust gas turbocharger at the indi‐ cated service interval. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 88: Service Level 1 - Engine Service, Tbo 15000 Hours For Prp - Engine Operation - Version: 2021-07
(>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.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 89 Replace filters. Clean the seal area before removal Engine oil filters the old filter to prevent oil contamination. (For more SL101 standard information see: 5.9.4 Changing oil filters — SL101, page 113.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 90 5.8.3 Replacing drive belt — SL 109, page 108.) Visual inspection of the tensioner. Replace if Alternator belt SL110 1500 necessary. (For more information see: 5.8.4 tensioner Replacing tensioning device — SL110, page 109.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 91: Service Level 2 - Engine Service, Tbo 15000 Hours For Prp - Advanced Maintenance - Version: 2021-07
Proceed in the same way after cylinder head repair work. The warning alarm for filter change will occur at 1300h. Filter must be replaced before 1500h in order to avoid engine shutdown. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 92 Inspect the starter (winding insulation, relay, condi‐ SL222 7500 Starter tion of the gear teeth, etc.). Battery charging Replace. SL223 7500 alternator SL224 Cylinder heads 7500 Replace. SL2-53 Diesel exhaust Replace. 5000 fluid injectors © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 93: Service Level 1 - Engine Service, Tbo 24000 Hours For Cop - Engine Operation - Version: 2021-07
(For more information overhauled engine see: 5.9.1 Collecting and analyzing oil sample — SL100, page 111.) Perform all check before starting and perform a test run. Without centrifugal oil filter © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 94 5.9.6 Changing engine oil — SL101, SL121, page 118.) Replace main fuel filter cartridge. (For more infor‐ SL105 Fuel main filter 1000 mation see: 5.11.3 Replacing main filter - SL105, page 132.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 95 Tab. 20: Service level 1 — PRP — Basic maintenance - Version: 2021-07 The warning alarm for filter change will occur at 1300h. Filter must be replaced before 1500h in order to avoid engine shutdown. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 96: Service Level 2 - Engine Service, Tbo 24000 Hours For Cop - Advanced Maintenance - Version: 2021-07
Replace component if needed. SL221 Oil cooler 12000 Inspect the oil cooler. Recommended: Inspect the starter (winding insulation, relay, condi‐ SL222 12000 Starter tion of the gear teeth, etc.). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 97 SL2-53 Diesel exhaust Replace. 10000 fluid pump SL2-54 Engine by-pass Replace. 12000 flap Tab. 21: Service level 2 — COP — Advanced maintenance - Version: 2021-07 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 98: Preparatory Maintenance Activities
Secure the area according to local lockout/tagout procedures. u Turn off battery main switch. u If present, remove main switch key. u Let the engine cool down to ambient temperature. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 99: Post Maintenance Activities
Make sure that the spray paint can is at ambient temperature. q Make sure that all areas not to be painted are masked. Consumables and equipment – Spray paint can - black color (12692707) – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 100 Turn the spray can upside down and bleed the valve after finishing the paint work. Information In optimal conditions (20 °C (68 °F), 65% of humidity), the paint is completely dry after 24 hours. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 101: Daily Or Monthly Maintenance Activities
– Failure to comply with the installation requirements – Damage or deformation to fittings – Dislocation of hoses from fittings – Corrosion on fittings u Inspect all the points shown in the pictures below. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 102 Record and report any defect. u Make sure that authorized service personnel correct the defect. Fig. 44: Visual inspection of engine (1) Crankshaft flange — Shaft seal Injection system Crankcase breather system © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 103 Spin-on oil filters Thermostat low temperature Thermostat high temperature Engine control unit (ECU) Coolant pump high temperature Charge air cooler Fig. 46: Visual inspection of engine (3) Rubber hose Compensator © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 104: Inspecting Engine Running At Idle Speed - Sl0-007
Operating test is planned and agreed with the responsible person for the electrical network. q Electrical load is available for the test. q Generator set is ready for operation. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 105 Record and report any anomaly found on generator set display (for example: faulty param‐ eter). u Make sure that authorized service personnel correct the defect. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 106: Generic Maintenance Activities
(For more information see: 5.5 Preparatory maintenance activities, page 98.) u Unscrew and remove screws 1. u Remove cover 3 with screws and lock washers 2. Information Perform assembly in reverse sequence. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 107: Checking Drive Belt - Sl109
– Traverse cracks in several ribs Fig. 50: Damage to the drive belt The belt attachment is self-tensioning and maintenance-free. The belt drive is located at the engine damper side. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 108 Pivot back tensioning device 1 against the spring force to the limit stop. u Insert guiding pin (8 mm (0.31 in) diameter) to block the tensioning device. u Install new drive belt 2. u Remove guiding pin. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 109: Replacing Drive Belt - Sl
106.) q Drive belt is removed. (For more information see: 5.8.3 Replacing drive belt — SL 109, page 108.) q New tensioning device is available. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 110 Tighten screw (M10) 2 to standard torque. Information Install battery charging alternator cover in reverse sequence. (For more information see: 5.8.1 Removing the battery charging alternator cover, page 106.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 111: Lubricating System
For more information, refer to the instructions of the application. u Take oil sample from the sampling point. u Ensure analyses according to the instructions of the application. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 112: Checking Prelubricating Pump (Optional) - Sl103
5.9.3 Checking the engine oil level — SL001 q Engine stopped since at least 30 minutes. q Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory maintenance activities, page 98.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 113: Changing Oil Filters - Sl101
Clean filling cap and close the filler neck. 5.9.4 Changing oil filters — SL101 q Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory maintenance activities, page 98.) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 114: Replacing Centrifuge Paper Filter - Sl102
Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory maintenance activities, page 98.) q Original KOHLER oil filters with the seals are available. q A suitable drainage container is available. q The required quantity of approved oil is available.
Page 115 The oil centrifuge is equipped with a stop valve which stops the oil inlet. Replacing centrifuge paper filter Fig. 58: Oil centrifuge Centrifuge base Rotor cylinder V-clamp Paper filter Rotor Rotor base Cover Rotor cover © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 116 The thickness of mud deposit inside the rotor should not be more than 45 mm (1.77 in). Other‐ wise: u Reduce maintenance intervals and operate oil analysis. u Clean all components of oil centrifuge. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 117 Fig. 62: Paper filter preparation u Insert paper filter 6 tabs in slot A and slot B. Fig. 63: Inserting paper filter u Insert paper filter 6 in rotor cylinder 5. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 118: Changing Engine Oil - Sl101, Sl121
(For more information see: 5.5 Preparatory maintenance activities, page 98.) q A container with the required capacity is ready. q Original KOHLER oil filters with the seals are available. q A suitable drainage container is available. © 2022 by Kohler Co. All rights reserved.
Page 119 Hot engine oil could 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. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 120 Fig. 66: Principal oil drain point - engine rear side Oil drain on oil pan Fig. 67: Oil drain - engine left side Oil drain aggregate support. Engine right Oil drain aggregate support. Engine left side side © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 121 Refit the plug and/or close the valve. u Tighten plug according to standard torque. Filling engine oil q Engine oil drained. q Filters replaced. q Draining plugs and valves closed. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 122 After 2 to 3 minutes, check oil level on the dipstick. (For more information see: 5.9.3 Checking the engine oil level — SL001, page 112.) u Replenish if necessary. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 123: Cooling System
Filler cap ejected by operating fluid under pressure will result in death or serious injury by impact. u Only perform maintenance and inspection work on the cooling system when the engine has cooled down to ambient temperature. u Wear proper personal protective equipment. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 124 Check operating fluid levels only once the temperature has cooled down enough so that surfaces can be touched with bare hands. u Carefully open the cover in order to first reduce the excessive pressure. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 125 The following procedure shall be adapted by the manu‐ facturer of the machinery according to its cooling system design. Use only operating fluids that have been tested and approved by Kohler. Proper operation of the engine requires a bubble-free cooling system.
Page 126: Inspecting Low Temperature Circuit (Charge Air Cooler) - Sl002
Check coolant level on the expansion tank. u If necessary, top up coolant. 5.10.3 Inspecting low temperature circuit (charge air cooler) — SL002 Fig. 73: Drain holes of low temperature circuit © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 127: Checking Relief Bores - Coolant Pump - Sl003
Only perform maintenance and inspection work on the cooling system when the engine has cooled down to ambient temperature. u Wear proper personal protective equipment. Fig. 74: Relief bores on coolant pumps Coolant pump high temperature Coolant pump low temperature © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 128: Bleeding The Ht/Lt Coolant System
Following procedure shall be adapted by the manufac‐ turer of the machinery according to its cooling system design. Use only operating fluids that have been tested and approved by KOHLER. A pressurized and bubble-free system ensures the performance and function of a cooling system.
Page 129 Maintenance Cooling system Fig. 75: Bleeding point on HT coolant pump Fig. 76: Bleeding point on flywheel housing © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 130 Close the valve cover on the LT expansion tank. Rechecking the HT/LT coolant levels: u Start the engine. u Operate the engine until the HT coolant temperature has reached > 60 °C (140 °F). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 131 Maintenance Cooling system u Check the expansion tank coolant level of HT and LT systems. u Top up the expansion tanks if necessary. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 132: Fuel System
(For more information see: 5.5 Preparatory maintenance activities, page 98.) q A container with the required capacity is ready. q Original KOHLER main fuel filters are available. q A suitable drainage container is available. q A fuel filter ribbon spanner is available.
Page 133: Bleeding The Fuel System
5.11.4 Bleeding the fuel system Refer to the generator set manual for more details. 5.11.5 Checking differential pressure — fuel pre-filter — SL005 Refer to the generator set manual for more details. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 134: Air System
Actual number and location of crankcase breather filters may depend on application set. Removal u Remove screws 1. u Remove filter element 2. u Remove seal 3. Installation u Screw filter element 2 with screws 1 and seal 3. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 135: Inspecting Engine By-Pass Flap - Sl1-5461 (Depending On Configuration)
Inspect connections to cooling system and check for coolant leaks. If defect is detected: u Record and report any defect. u Make sure that authorized service personnel correct the defect. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 136: Exhaust Gas Aftertreatment System (Depending On Configuration)
Fig. 81: Disconnecting the heating mat u Disconnect the electrical connector of the filter heating mat. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 137 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. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 138 Fill 3/4 of the new filter with diesel exhaust fluid. Information Before installing the new filter, make sure that all sealing surfaces are clean. u Install the new filter. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 139 Install the heating mat on the filter. Fig. 87: Installing the heating mat screws u Install the heating mat screws (M6). u Tighten the heating mat screws to 6 Nm (4 ft-lb). ±1 ±1 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 140 After replacing the filter, take a snapshot with KoDIA. Note the ID of the filter in the comment of the snapshot. Send the snapshot to Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 141: Lubricants And Operating Fluids
5.14.1 Handling lubricants and operating fluids Information u Only operating fluids approved by Kohler Co. may be used for the operation of Kohler Co. engines. Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers, such as guarantees, service orders, etc. null and void without advance notice, if fuel and lubricants other than fuel and lubricants approved by Kohler Co.
Page 142: Approved Diesel Fuels, Diesel Exhaust Fluids (Def), And Fuel Additives
LHV (Lower Heating Value). Diesel fuels Sulfur content and biodiesel content: Only diesel fuels with a sulfur content lower than 1.5% (15000 ppm) are allowed in Kohler KD diesel engines. Information For emission-certified engines (Tier 2, USA EPA CARB Tier 4 final, 97/68/EC Stage IIIA), only ultra low sulfur diesel fuels (ULSD) with a sulfur content lower than 0.0015% (15 ppm) are...
Page 143 DIN 51603 CSR 4.4.06 Fuel filtration Tab. 24: KD approved heating-oil fuels Reinforced fuel primary filtration system, including water separator between main storage and daily tank, is mandatory. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 144 Tab. 26: KD approved aviation kerosene fuels Biofuels Due to the wide range of fuels available on the market, please contact your Kohler Co. repre‐ sentative before any use of synthetic fuels not included in the following list. Exchange interval of fuel filters is reduced (1/2), lifespan of fuel line components may be reduced, fuel consumption is not guaranteed anymore.
Page 145 Only diesel fuels with a biodiesel content lower than 10% are allowed in Kohler KD diesel engines. Information Diesel fuels with a biodiesel content between 10% and 20% may be used, but Kohler do not recommend it as the operating costs linked to maintenance will drastically increase. Perform‐...
Page 146 Tab. 30: KD approved diesel exhaust fluids Fuel additives Kohler KD diesel engines are designed in such a way that the use of general additives is not necessary nor recommended. However, under specific circumstances, biocide additives may be used according to the supplier recommendations.
Page 147: Approved Lubricating Oils And Lubricating Oil Additives
Lubricating oils essential characteristics and maintenance SAPS and lubricating oil quality Kohler classifies synthetic lubricating oils among two main categories for SAPS level and three subcategories for quality level. SAPS stands for Sulfated Ash, Phosphorus, and Sulfur. Phosphorus and sulfur are often incor‐...
Page 148 (W stands for Winter); the second number indicates oil viscosity at operating conditions (usually considered at 100 °C (212 °F)). The lubricating oils presenting these viscosity grades are approved for use in Kohler KD diesel engines: ©...
Page 149 · Oil change intervals must be confirmed through analysis process. As a reminder, Kohler KD diesel engines must not be operated with fuels having a sulfur content higher than 1.5% (15000 ppm). Emission-certified engines must not be operated with fuel having a sulfur content higher than 0.0015% (15 ppm).
Page 150 Minimum TBN Recommended TBN TAN ratio Kohler does not recommend any specific TAN for the lubricating oil to be used in KD diesel engines. However, the user must pay a particular attention to the TAN and ensures that the following criteria are always true: TAN <...
Page 151 – Standard oil change interval is indicated in the technical documentation of the diesel engine. – Oil category factor is defined in the table on KD lubricating oil category factors (see: tab. 37, page 153). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 152 Potassium is now incorporated in new-generation lubricating oils; conclusion must be drawn only by having initial composition and evolution available. Mineral lubricating oils The use of mineral lubricating oils is strictly forbidden in Kohler KD diesel engines. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 153: Approved Coolants
Coolant specification Kohler KD diesel engines are designed to operate with either SI, SI-OAT or hybrid technology with ethylene glycol basis products as coolant. The user can choose a ready-to-use preparation or prepare their own blend of water with anti‐...
Page 154 Lubricants and operating fluids Water specification When the user wants to blend their own mixture, Kohler recommends the use of fully deionized water. If the user wants to use tap water, this water must fulfill the requirements for drinking water according to 2006 WHO (World Health Organization) guideline.
Page 155 – Use the approved products to clean the components (see: tab. 42, page 156). Manufacturer Product- Concentration Packin Order # name Kluthe Hakutex 111 2% by volume Liquid X00065751 Hakupur 2% by volume Liquid X00055629 50-706-3 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 156 Porodox 5 to 10% by Powder - weight Kluthe Hakutex 60 100% by volume Liquid X00056750 (25 kg (55.11 lb) Tab. 42: KD cooling system components cleaners © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 157: Filling Volume
Filling volume in the engine — high temperature circuit 254 l 67.1 gal Filling volume in the engine — low temperature circuit 102 l 26.95 gal Tab. 43: Filling volume in the engine (indicative value) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 158: Operating Faults
Identify the causes and thoroughly perform any repair work. After correction: u Check for rectification of the causes. u Close the incident. u Run the engine according to Operation and Maintenance Manual. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 159: Faults - Cause - Remedy
Diesel engine compression too low. Contact your nearest authorized Kohler service representative. Fault in electronics. Read out fault memory of engine control unit. Contact your nearest authorized Kohler service represen‐ tative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 160 Thermostat failure. Check, replace if necessary, contact your nearest authorized Kohler service representative. Coolant temperature thermocouple Check, replace if necessary, failure. contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 161 Turbine or compressor wheel Contact your nearest authorized rubbing against the housing; Kohler service representative. foreign bodies in the compressor or turbine; seized up bearings of rotating parts. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 162 Kohler service representative. Turbocharger exhaust defect. Contact your nearest authorized Kohler service representative. Coolant leaks on charge air cooler. Leaking, breaking. Contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 164: Tools And Devices
230611637 Locking device 11343230 230612868 Guiding rod M30x2 - Cylinder head 11133371 230610035 Guiding rod M28x2 - Damper 11133372 230610036 Guiding rod M24x2 - Intermediate gear 11133373 230610037 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 165 Guiding rod M12 - Oil cooler 11133377 230610040 Guiding rod M10 - Exhaust line 11133379 230610041 Guiding rod M12 coolant pump 12427300 230610042 Guiding rod M12 Thermostat 12465862 230611638 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 166 230612680 Torque Reaction Arm for Manual Torque 12227989 230612681 Multiplier Spare Battery pack 12226992 230612682 Battery Charger 110V 12226970 230612683 Battery Charger 230V 12226972 230612684 Adapter 11343096 230612685 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 167: Turning Device
Before using the turning device, warn the personnel in the vicinity of the engine. u Use the turning device under the supervision of another authorized technician. u Before and during use of the turning device, stay away from the engine. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 168 Position turning device 2. u Mount and tighten screws 1 according to standard torque values. Information For queries, please contact your nearest authorized Kohler service representative. Operation Make sure that the following preconditions are met: q Turning device is mounted on the engine.
Page 169 Remove turning device 2. u Position cover 3. u Mount and tighten screws 4 according to standard torques values. Information For queries, please contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 170: Appendix
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 representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 171: Error Code
Error code list extracted from engine control unit software version 21.12.10 and dataset revision The following error code table is indicative. Refer to the technical data sheet of your engine for the latest software version. For further information, please contact your nearest authorized Kohler service representative. Abbreviations: – SPN - Suspect Parameter Number –...
Page 172 Coolant temperature at intercooler - Overtemperature warning Coolant temperature sensor - Open circuit Coolant temperature sensor - Short circuit to battery Coolant temperature sensor - Short circuit to ground © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 173 Engine control unit CAN 4 - Short circuit Engine coolant - Critical overtemperature Engine coolant - Level low Engine coolant - Overtemperature warning 4076 Engine coolant 2 - Level low Engine oil - Critical overtemperature © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 174 Heating flange 1 - Short circuit to ground high side 516305 Heating flange 1 - Short circuit to ground low side Heating flange 2 - Critical high output current © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 175 Injector 12 - Current Rise time too long Injector 12 - No current rise time measured Injector 12 - Open circuit Injector 12 - Short circuit to battery © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 176 Injector 19 - Short circuit to battery Injector 19 - Short circuit to ground Injector 2 - Current Rise time too long Injector 2 - No current rise time measured © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 177 Injector 8 - Current Rise time too long Injector 8 - No current rise time measured Injector 8 - Open circuit Injector 8 - Short circuit to battery Injector 8 - Short circuit to ground © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 178 Oil pressure sensor - Short circuit to battery Oil pressure sensor - Short circuit to ground or open circuit Oil pressure sensor - Supply voltage out of range Oil temperature sensor - Open circuit © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 179 Pressure control valve 2 - Open circuit 516220 Pressure control valve 2 - PWM signal - High limit reached 516221 Pressure control valve 2 - PWM signal - Plausibility error © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 180 Starter digital input 2 - Starter inhibition due to short circuit 516264 Starter digital input 2 - Supply voltage out of range 516511 Starters - Not connected in the output 1 to engine control unit © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 181 Wastegate valve - Short circuit to battery low side 5386 Wastegate valve - Short circuit to ground high side 516266 Wastegate valve - Short circuit to ground low side Water in fuel sensor - Open circuit © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 182 6301 Water in fuel sensor 2 - Supply voltage out of range 6301 Water in fuel sensor 2 - Water in fuel detected Tab. 45: Error code table © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 183: Cleaning Agents, Thread-Locking Adhesives And Greases
1000 / 33.8 Molykote Staburags NBU 30 1200 / 40.6 Kübler Copper Paste; Motorex 14 850 / 28.7 Motorex Optimol White T 100 / 3.4 Castrol Tab. 48: Greases © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 184: Standard Tightening Torques
Unless otherwise noted, use the standard torque values into the column of screws quality class “8.8” to tighten screws and bolts. The screws quality classes “10.9” and “12.9” are always indicated with the “Nm” symbol. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 185 For every maintenance task, when a sequence is specified, achieve step 1 for all the sequence before starting step 2. Fig. 115: Standard sequence for four, five, and six screws. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 186 Except components listed below, and otherwise noted, u Marking on screws or nuts to track their reuse is not required. Fig. 116: Examples of markings on screws and HP pipe nut © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 187: Standard Torques For Hexagonal / Socket / Flange Screws And Hexagonal / Flange Nuts
100 Nm 110 Nm 52 ft-lb 55 ft-lb 74 ft-lb 81 ft-lb 165 Nm 183 Nm 240 Nm 270 Nm 122 ft-lb 135 ft-lb 177 ft-lb 199 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 188: Standard Torques For Internal Drive Pipe Plug With Conical Thread
– Hexagon head screw plugs with collar - Cylindrical thread according to DIN 910 – Internal drive screw plugs with collar - Cylindrical thread according to DIN 908 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 189 240 Nm M 65 x 2 620 Nm 52 ft-lb 177 ft-lb 457 ft-lb Tab. 53: Tightening torques for screws according to DIN 7643, DIN 910, DIN 908 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 190: Standard Torques For Flange Joints
540 Nm 260 Nm 214 ft-lb 465 ft-lb 398 ft-lb 192 ft-lb Tab. 54: Standard torques for metric thread unions L series, for steel and iron cast part © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 191 According to ISO1179-1 / DIN 3852-T2-Form X / DIN 3852-T3-Form X BSP threading. Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 193 432 Nm 208 Nm 171 ft-lb 372 ft-lb 319 ft-lb 153 ft-lb Tab. 58: Standard torques for metric thread unions L series, for aluminium – see figure above © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 194 According to ISO1179-1 / DIN 3852-T2-Form X / DIN 3852-T3-Form X BSP threading. Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 196: Assembling Pipes With Cutting Rings
Fig. 132: Cutting ring lubrication Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). Fig. 133: Cutting ring tightening © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 197: Standard Torques For Triple Lock Flange Joints
5/16 1/2-20 20 Nm 40 Nm 15 ft-lb 30 ft-lb 9/16-18 30 Nm 60 Nm 22 ft-lb 44 ft-lb 3/4-16 60 Nm 115 Nm 44 ft-lb 85 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 198: Standard Torques For Vsti Screw Plugs For Steel And Iron Cast Part
Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). Fig. 135: VSTI screw plugs with ED seal (left), with o-ring (right) © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 199: Standard Torques For Vsti Screw Plugs For Aluminium
Tab. 64: VSTI screw plug tightening torques for steel and iron cast parts Do not use hydropneumatic screwdriver. 8.4.10 Standard torques for VSTI screw plugs for aluminium According to DIN EN ISO 6149-2 / ISO 11926-2, metric threading. © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 200 127 ft-lb M33x2 180 Nm 250 Nm 133 ft-lb 184 ft-lb M42x2 290 Nm 265 Nm 214 ft-lb 195 ft-lb M48x2 290 Nm 335 Nm 214 ft-lb 247 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 201: Assembling Pipes With Dko Connectors (El, Et, Ew, Gz, Gzr, Red)
Alternatively, refer to the following table for tightening sequence of the nut: Size Equivalent specification Size Equivalent specification 20 Nm 25 Nm 15 ft-lb 18 ft-lb 30 Nm 40 Nm 22 ft-lb 30 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 202: Standard Torques For Collar Clamps
5 ft-lb 25 mm 12 Nm 0.98 in 9 ft-lb 30 mm 30 Nm 1.18 in 22 ft-lb Tab. 67: Tightening torques for collar clamps according to DIN 3017-3 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 203: Standard Torques For Pipe Clamps According To Din 3015
148 ft-lb 168 mm (6.61 in)-220 mm (8.66 in) 180 Nm 350 Nm 133 ft-lb 258 ft-lb Tab. 68: Tightening torques for pipe clamps according to DIN 3015 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 204: Abbreviations - Acronyms
Top Dead Center Top Dead Center Volume Control Valve Volume Control Valve Tab. 69: Abbreviations table Acronym Designation Translation ANSI American National Standards Institute American National Standards Institute © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 205 International Standard Classification of International Standard Classification of Education Education Society of Automotive Engineers Society of Automative Engineers World Health Organization World Health Organization Tab. 70: Acronyms table © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 206: Unit Conversion Tables
Tab. 73: Pressure conversion factors 8.6.4 Volume conversion factors Convert from Multiply by 61023.744 35.315 Imperial gallon 219.969 US gallon 264.172 l (liter) 1000 Tab. 74: Volume conversion factors © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 207: Power Conversion Factors
F = 9/5*C + 32 °C K = C + 273.15 Tab. 79: Temperature conversion factors 8.6.10 Density conversion factors Convert from Multiply by Kg/m lb/US gallon 0.00834 Kg/m lb/imperial gallon 0.01002 © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 208 Appendix Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 80: Density conversion factors © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...
Page 209: Prefix
Appendix Prefix 8.7 Prefix Name Symbol Factor tera giga mega kilo milli micro μ nano Tab. 81: Common prefix multipliers table © 2022 by Kohler Co. All rights reserved. KD62V12 33521030301_8_1 EN_US 2022-09...

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