Page 1 Operation and Maintenance Manual (Original Operation and Maintenance Manual) Diesel engine KD62V12A From serial number 2023730031 EN_US 33521061401_1_1 10-2023...
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 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 3 If any warranted part that is scheduled for replacement as required maintenance fails prior to the first scheduled replacement point for that part, that part will be repaired or replaced by 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 Operator’s Manual has been used. This warranty is in addition to the Kohler Standard Warranty and any extended warranty (if applicable) for the equipment and engine involved. Remedies under this warranty are limited to the provisions as specified in this warranty statement.
Page 5 Kohler . Failure to complete, sign, or return this form will not affect any owner’s rights or Kohler’s obligations under this warranty statement and will not result in denial of warranty coverage by Kohler.
Page 7 Revision history Version Author Modification Date TB12 - Technical documentation First G4.02 version 2023-07 TB12 - Technical documentation Update of maintenance 2023-10 intervals According to develop‐ ment and improvement © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 9 Preface Disclaimer Modifications, conditions, copyright Kohler Co. reserves the right to make modifications in the course of technical development, without issuing prior notification. The aforementioned provisions do not extend the warranty and liability conditions in the general terms and conditions of business of Kohler Co..
Page 10 For further explanation or information, the Customer Service and Customer Service training center departments of Kohler Co. are available any time to answer any queries. KOHLER engines are subject to continuous development and improvement. The Operation and Maintenance Manual facilitates the operator's familiarization with the engine and prevents faults through incorrect operation.
Page 11 Action Identifies an action which has to be carried out. Result Identifies the result of an action. Listing Identifies a listing. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 12 Preface About this document Torque value Identifies special tightening torque or specification. Additional symbols © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 13 Norms and standards The respective national laws and ordinances or regulations of the respective site of operation must be observed during the installation and operation of KOHLER engines and their compo‐ nents. In this respect, the regulations for the serial product are the responsibility of the manufacturer of the application.
Page 14 The owner is required to have warranty and recall services paid for by Kohler Co. performed by an authorized Kohler Co. dealer/service center.
Page 15 Warranty Warranty 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. null and void without advance notice, if spare parts other than original KOHLER spare parts or spare parts purchased by Kohler Co.
Page 17: Table Of Contents
Intended use 2.3.2 Foreseeable misuse Safety instructions 2.4.1 General safety instructions 2.4.2 Safety when starting Preventing injuries 2.5.1 Preventing bruising 2.5.2 Preventing burns 2.5.3 Preventing fires and explosion hazards © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 18 Safe handling Dimensions and weight Lifting device Diesel engine storage 3.4.1 Storage, transportation, and duration definitions 3.4.2 Initial packaging Unpacking and depreservation 3.5.1 Unpacking 3.5.2 Depreservation Suspension of activity © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 19 Service level 0 — Daily maintenance activities, TBO 24000 hours for COP — Engine Operation - Version: 2023/07-03 5.3.9 Service level 1 — Engine Service, TBO 24000 hours for COP — Engine Operation - Version: 2023/07-03 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 20 Replacing fuel pre-filter — SL1-4110 5.9.3 Replacing fuel main filter — SL1-4120 5.9.4 Inspecting HP/LP fuel pump — SL1-4221, SL1-4311 5.10 5000 - Combustion air and exhaust gas system © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 21 Turning device 7.1.3 Diagnostic tools Appendix Technical design documents Error code Cleaning agents, thread-locking adhesives and greases 8.3.1 Cleaning agents and thread-locking adhesives 8.3.2 Greases Standard tightening torques © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 22 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 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 23: Product Description
1.1.1 Design overview Engine equipment Fig. 1: Fuel system DE Driving end Injector High-pressure/low-pressure (HP/LP) fuel pump Double-walled piping (fuel high pressure Fuel filter line) Single-walled piping (fuel return line) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 24 Fig. 2: Lubricating oil system DE Driving end Free end Oil filler neck Oil pan Oil dipstick Oil cooler Crankcase breather oil separator Spin-on oil filter Oil pump Oil pressure regulator © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 25 Product description Technical description Fig. 3: Cooling system Free end High temperature thermostat housing Oil cooler Low temperature thermostat housing Tandem coolant pump Charge air cooler © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 26 Exhaust gas turbocharger Straight air intake Charge air cooler Cold charge air line Information Actual number of exhaust gas turbochargers and straight air intakes depends on engine config‐ uration. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 27 Exhaust elbow from exhaust gas turbo‐ charger Information Actual number of exhaust gas turbochargers and exhaust elbows depends on engine configura‐ tion. Design of exhaust manifolds depends on engine configuration. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 28 Technical description Fig. 6: Electrical and control system Free end Engine control unit (ECU) Battery charging alternator Starter Wiring harness Information Actual number of starters depends on engine configuration. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 29: Conventions
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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 30: Engine Or Component Identification
Type designation Designation Description A - 5 A F C Engine type description Engine manufacturer Fuel type (D=Diesel) Total displacement in liter Cylinder configuration Number of cylinders Revision © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 31 Fig. 9: Arrangement of signs on the engine Engine serial number The engine serial number is recorded onto the emission control information label of the engine. Designation Description 20## 0001 Engine serial number © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 32 – If you are replacing a metallic nameplate, completely remove the nameplate and apply spray-paint to prevent rust before sticking the new label. (→ 5.5.2 Spray painting, p. 101) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 33 Some safety stickers are not implemented on every engine depending on implemented options or engine usage. Sticker Description Indicates additional safety precautions, which have to be taken. Tab. 3: Safety stickers on the engine © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 34 The real information can be viewed in the device display or read out with the diagnosis and service tool KODIA. Fig. 13: Engine control unit nameplates location Software nameplate Hardware nameplate © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 35 QR Code Data set ID number Delivery date Fig. 15: Hardware nameplate Product designation Serial number Engine control unit ID number Supplier number Hardware version QR Code Delivery date © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 36: Technical Data
Opening start 71 °C (160 °F) (HT) Thermostat Completely open 81 °C (178 °F) Tab. 6: Technical data table — coolant thermostat 1.2.4 Starter Designation Value Voltage 24 V © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 37: Battery Charging Alternator
In standard configuration, two starters are installed. 1.2.5 Battery charging alternator Designation Value Voltage 28 V Current 140 A Tab. 8: Technical data table — battery charging alternator © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 39: Target Audience
14 years u Supplying the required tools and spare parts Information The Customer Service training center departments KOHLER provides several training programs. Please contact your nearest authorized Kohler Co. 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 40 – Oiling and greasing stationary engines and machinery – Inspecting and testing new machinery and mechanical equipment for conformity with stand‐ ards and specifications – Disassembling machinery and equipment to remove parts and make repairs © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 41: Unauthorized Personnel
2.2.3 Unauthorized personnel All other persons, including operators, supervisors and trainees, are classified as “unauthorized personnel”. They are not allowed to access the engine, its compartment or covers. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 42: Use Limits
Any resulting damage, injuries, or environmental impacts are placed solely on the user. Any other use above and beyond this is considered to be improper use. In this case, KOHLER is not liable for any damage. The risk is borne solely by the user.
Page 43 – Drawing of power from the damper side except if mechanical fan drive is mounted as orig‐ inal equipment – Unauthorized modifications to the engine In this case, KOHLER is not liable for any damage. The risk is borne solely by the user. NOTICE Risk of engine failure.
Page 44: 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 45: Safety When Starting
All openings must be closed and the safe conditions established by the manufacturer of the machinery must be fulfilled. u Standing in the vicinity of the engine while starting or operating the manufacturer’s machi‐ nery is forbidden. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 46 Materials and substances processed, used or exhausted could result in death or serious injuries by intoxication or poisoning. u The manufacturer of the machinery shall design and implement an adapted extraction system. u Wear proper personal protective equipment. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 47 Standing in the vicinity of the engine while starting or operating the machinery is forbidden. u Wear proper personal protective equipment. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 48: Preventing Injuries
Risk of death or injury by scald. u Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Wear proper personal protective equipment. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 49: Preventing Fires And Explosion Hazards
According to local regulations, the manufacturer of the specific application is responsible for designing adapted fire protection system. Information Engines provided by KOHLER are not intended to be used in potentially explosive atmospheres according to Directive 2014/34/EC. © 2023 by Kohler Co. All rights reserved.
Page 50: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 51: Preventing Vibrations Hazards
In case of leak, correct deficiencies discovered immediately, clean and dry the operating fluids contaminated area. u The manufacturer of the machinery must provide adapted stairs and gangways to work in safe conditions. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 52: Safety Instructions For The Fuel System
Protection against hot elements and chemicals Must be worn when handling hot parts, chemicals, operating fluids Hearing protection Protection against noise Must be worn in the direct vicinity of the engine © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 53 (ISO 7010) 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 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 54: Accessible Areas
Engine driving end Engine sides Above the engine Access to the following areas is forbidden: Below the engine 2.7.3 Low idle conditions For commissioning and test run tasks only! © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 55: Emergency Stop
Information Accessing or standing in the vicinity of the running engine is considered as foreseeable misuse. In this case, KOHLER is not liable for any damage or injuries. The risk is borne solely by the user. Information The low idle condition is defined by: Engine speed <...
Page 56: Signage Recommendations
Provide documentation to the personnel according to the “Target audience”. Tab. 12: Engine area signs requirement © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 57: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 58 The ECU generates the signals and error codes for the engine. The messages and codes are displayed on the generator set display. See the generator set manual for more details. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 59: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 60: Disposal And Environment Protection
– Insulating material – Cables and wires – Electrical waste – Plastics – Lubricants and greases – Fuels – Coolant – Paint residue – Cleaning agents and rags © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 61: 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 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 62: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 63: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 64 RFOB to driving end lifting point — left side 297 mm (11.69 in) Driving end lifting point to free end lifting point — right side 1040 mm (3.41 ft) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 65 Maximum angles of lifting devices — front view β1–β2 15° Tab. 13: Dimensions and weight of engine - values Fig. 34: Dimensions and weight of engine - var. B — 3 exhaust gas turbochargers © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 66 Maximum angles of lifting devices — side view α1–α2 15° Maximum angles of lifting devices — front view β1–β2 15° Tab. 14: Dimensions and weight of engine - values © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 67: Lifting Device
Transportation - Storage Lifting device 3.3 Lifting device Fig. 35: Example of fixing the lifting device on the engine Lifting hook Lifting beam © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 68: Diesel Engine Storage
The relative humidity in an air-conditioned storehouse should not exceed 70%. Transportation Information D category transportation (ship deck at sea) is prohibited. We consider the following categories for transportation conditions: © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 69: Initial Packaging
Tab. 17: Storage durations 3.4.2 Initial packaging Kohler Co. diesel engines are usually delivered in one of these three packagings: – Standard freight packaging suitable for B transportation, B storage, and midterm duration – Marine freight packaging suitable for C transportation, B storage, and long-term duration –...
Page 70 However, the crate is designed and reinforced to allow its handling either with adequate forklift trucks or by lifting it with slings. This packaging allows storage up to 24 months in an air-conditioned storehouse (B category storage). © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 71: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 72: 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 73 – 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 74: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 76: Control And Operation
4.1.1 Final check Before starting the engine, carry out the following checks and top off with operating materials if necessary: u Check the oil level. u Check the coolant level. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 77: 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. 36: Precautions at cold temperatures The following precautions improve the starting performance at low temperatures. Precautions: u Check battery charging.
Page 78: Monitoring
Engine is operated under usual customer conditions. 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 79 Control and operation Monitoring u Check exhaust gas color. If defect is detected: u Record and report any defect. u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 80: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 82: Maintenance
Advanced and repair coolant pump nician nent replace‐ maintenance manual replacement (Kohler Co. affili‐ ment or use of ates) service kit © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 83: Task Identification
2000 Lubricating oil system 3000 Cooling system 4000 Fuel system 5000 Combustion air and exhaust gas system 6000 Electrical and control system 7000 Accessories Tab. 20: System description © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 84: Generator Set Ratings
Emergency standby power can be operated for up to 200 hours per year under the agreed operating conditions. Always observe the maintenance intervals and procedures prescribed by the manufacturer. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 85: Maintenance Information
Check prelubricating oil pump operation at SL0-2011 Oil system engine start (displayed pressure). Take corrective action if defect is present. (→ 5.7.1 Inspecting oil system overall condition — SL0-2011, p. 138) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 86 (→ 5.10.1 Inspecting air intake system overall condition — SL0-5011, p. 165) Tab. 21: Service level 0 — ESP — Monthly maintenance - Version: 2023/07-01 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 87: Service Level 1 - Engine Service, Tbo 4000 Hours For Esp - Engine Operation - Version: 2023/07-01
4) The table shows the standard time limit when using “category 2” engine oil. Multiply the time limit by 2 when using “category 3” engine oil (see specification). 5) KD62V12A-5*ES engines without centrifugal oil filter: standard time limit is 125h. © 2023 by Kohler Co. All rights reserved.
Page 88 Belt drive system pulley. Replace if defect is present. SL1-6231 of battery charging (→ 5.11.3 Inspecting belt drive system of alternator battery charging alternator — SL1-6231, p. 172) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 89: Service Level 2 - Engine Service, Tbo 4000 Hours For Esp - Advanced Maintenance - Version: 2023/07-01
SL2-5120 Charge air cooler Replace. Exhaust gas turbo‐ Replace. SL2-5410 charger SL2-7410 Rubber hoses Replace. Tab. 23: Service level 2 — ESP — Advanced maintenance - Version: 2023/07-01 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 90: Service Level 0 - Daily Maintenance Activities, Tbo 15000 Hours For Prp - Engine Operation - Version: 2023/07-02
/ indicator for check monitoring (when fitted). Take corrective action if defect is present. (→ 5.9.1 Inspecting fuel system overall condi‐ tion — SL0-4011, SL0-5311, p. 159) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 91: Service Level 1 - Engine Service, Tbo 15000 Hours For Prp - Engine Operation - Version: 2023/07-02
7) Engines with centrifugal oil filter: multiply the time limit by 2. When using centrifugal oil filter and “category 3” engine oil, multiply the time limit by 4. 8) KD62V12A-5*EP engines only: standard time limit is 125h. © 2023 by Kohler Co. All rights reserved.
Page 92 7) Engines with centrifugal oil filter: multiply the time limit by 2. When using centrifugal oil filter and “category 3” engine oil, multiply the time limit by 4. 8) KD62V12A-5*EP engines only: standard time limit is 125h. 9) KD62V12A-5*EP engines only: standard time limit is 250h.
Page 93 3000 (→ 5.11.4 Replacing belt of battery charging alternator alternator — SL1-6232, p. 173) Tab. 25: Service level 1 — PRP — Basic maintenance - Version: 2023/07-02 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 94: Service Level 2 - Engine Service, Tbo 15000 Hours For Prp - Advanced Maintenance - Version: 2023/07-02
Inspect engine overall condition. Record and report any anomaly. For example: SL0-1011 Engine (stopped) leak, damage, loose part, etc. (→ 5.6.1 Inspecting engine overall condition — SL0-1011, p. 105) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 95 (→ 5.10.1 Inspecting air intake system overall condition — SL0-5011, p. 165) Tab. 27: Service level 0 — COP — Daily maintenance - Version: 2023/07-03 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 96: Service Level 1 - Engine Service, Tbo 24000 Hours For Cop - Engine Operation - Version: 2023/07-03
11) Engines with centrifugal oil filter: multiply the time limit by 2. When using centrifugal oil filter and “category 3” engine oil, multiply the time limit by 4. 12) KD62V12A-5*EC engines only: standard time limit is 125h. © 2023 by Kohler Co. All rights reserved.
Page 97 10) The table shows the standard time limit when using “category 2” engine oil. Multiply the time limit by 2 when using “category 3” engine oil (see specification). 13) KD62V12A-5*EC engines only: standard time limit is 250h. © 2023 by Kohler Co. All rights reserved.
Page 98: Service Level 2 - Engine Service, Tbo 24000 Hours For Cop - Advanced Maintenance - Version: 2023/07-03
Inspect combustion chambers with borescope SL2-1211 8000 bers including cylinder head fire deck. Silicon oil of Collect and send silicon oil sample for analysis. SL2-1345 torsional vibration 3000 damper © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 99 Charge air cooler 12000 Replace. Exhaust gas turbo‐ Replace. SL2-5410 12000 charger SL2-7410 Rubber hoses 12000 Replace. Tab. 29: Service level 2 — COP — Advanced maintenance - Version: 2023/07-03 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 100: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 101: Post Maintenance Activities
Wear proper personal protective equipment. u Refer to the local regulations and the product associated data to safely handle, store, and use these products. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 102: Post-Maintenance Bleeding
Make sure that the following preconditions are met: q Maintenance activities are completed. q Covers and guards are reinstalled. q Lockout/tagout procedure is completed. (→ Lockout/tagout, p. 44) Specific safety advice Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 103 For more information, see: Operation and Maintenance Manual. Final check u Make sure that all caps and open connections are closed. u Check visually for leaks in engine oil, fuel, or cooling systems. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 104: Post-Maintenance Engine Starting
In the report of the intervention, include at least operating hours, replaced parts, additional interventions required if necessary. If necessary, place an order to restock the parts used during maintenance activities. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 105: 1000 - Base Engine
(for example: delamination, blister formation) – Leaks – Damage or deformation to fittings – Dislocation of hoses from fittings – Corrosion on fittings © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 106 Oil filler neck Double-walled piping (high-pressure fuel Oil dipstick line) Single-walled piping (fuel return line) Wiring harness Information Actual number of oil separator filters 3 depends on engine configuration. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 107 Inspect the cold charge air line. u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 108 Request an inspection of the exhaust gas turbochargers. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 109 Inspect the single-walled piping (fuel return line). u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 110 Search for possible leaks between the fuel filter head and the filter. u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 111 Search for unplugged connectors. u Search for uninsulated conductors. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 112 Oil cooler Starter Engine Control Unit (ECU) Spin-on oil filter Wiring harness Oil pressure regulator Information Actual number of spin-on oil filters and oil coolers depends on engine configuration. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 113 Search for leaks between the torsional vibration damper and the aggregate support. u Check for loose connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 114 Inspect overall condition of the starters. u Check for loose cable connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 115 Inspect the oil pressure regulator. u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 116 If defect is detected: u Make sure that authorized service personnel correct the defect. Tandem coolant pump Fig. 50: Tandem coolant pump u Inspect the tandem coolant pump. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 117 Request an inspection of the coolant pumps. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 118 Inspect the low temperature thermostat housing. u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 119 Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. Oil cooler Fig. 55: Oil cooler u Inspect the oil cooler. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 120 Make sure that authorized service personnel correct the defect. Engine Control Unit (ECU) Fig. 56: ECU Fig. 57: ECU - Rubber sleeves Information Actual number of ECU depends on engine configuration. u Inspect the ECU. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 121 Coolant venting line Hose (coolant from charge air cooler) Exhaust gas turbocharger cooling line Hose (air to charge air cooler) Lubricating oil line of exhaust gas turbo‐ charger Exhaust manifold © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 122 Inspect the lubricating oil line of exhaust gas turbocharger. u Search for possible leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 123: Inspecting Engine Running At Idle Speed - Sl0-1021
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, unusual exhaust gas color). © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 124: Removing And Installing Access Panel Of Cylinder Head Cover - Sl1
Property damage - Risk of critical engine failure. u Use new seals after any dismantling. Consumables and equipment Make sure that the following consumables and equipment are available: – Seal © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 125 Installation Fig. 60: Installing access panel of cylinder head cover u Install a new seal 2 on access panel 3. u Install access panel 3 with screws 4. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 126: Checking Valve Clearance - Sl1-1122
(→ 5.4 Preparatory maintenance activities, p. 100) q Access panel of cylinder head cover is removed. (→ 5.6.4 Removing and installing access panel of cylinder head cover — SL1, p. 124) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 127 Make sure that the following special tools are available: – Turning device (→ 7.1.1 Special tools, p. 200) Consumables and equipment Make sure that the following consumables and equipment are available: – Feeler gauges © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 128 A1-An Series of cylinders - Bank A Exhaut valves B1-Bn Series of cylinders - Bank B Intake valves Driving end Left engine side Free end Right engine side Direction of rotation © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 129 There is a marking on the flywheel to set the valve order for checking clearance. The flywheel grooves 1 to 6 are identified in the following figure. The valve clearance must be checked in the correct position for the matching cylinder. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 130 No action No action A1, A2 2nd turn No action No action No action No action B4, B6 Tab. 31: Reference table for the flywheel positioning Top Dead Center © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 131 Step 6 u Rotate the crankshaft in direction of rotation past flywheel marking 5. Step 7 u Rotate the crankshaft in direction of rotation past flywheel marking 1. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 132 Set cylinder to overlap TDC position. u Check valve clearance of matching injection TDC cylinder. (→ Checking valve clearance, p. 133) u Repeat procedure for all cylinders. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 133 (→ Adjusting valve clearance, p. 133) Adjusting valve clearance Fig. 67: Adjusting valve clearance Valve bridge Exhaust rocker arm Rocker ball cap Feeler gauge See next page for continuation of the image legend © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 134 Mark the cylinder when clearance is correct on both intake and exhaust sides. Specific values Fig. 68: Valve clearance Reference Denomination Nominal value Intake valve clearance µm (19.69 +100/ -0 +3.94/ -0.00 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 135: Replacing Oil Separator Filter - Sl1-1661
5.6.6 Replacing oil separator filter — SL1-1661 Previous tasks Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 136 Keep the engine clean and free of dust accumulation. Consumables and equipment Make sure that the following consumables and equipment are available: – Original KOHLER oil separator filters with sealing parts Removal Fig. 70: Removing oil separator filter Screw (M8)
Page 137 Remove o-ring 3. u Check and clean the housing inside. Installation u Install oil separator filter 4 with a new o-ring 3. u Install cover 2 with screws 1. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 138: 2000 - Lubricating Oil System
Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Wear proper personal protective equipment. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 139 Make sure that the oil level is between the “min.” and “max.” marks on the dipstick. u Clean the oil filler neck cap and close the oil filler neck 2. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 140: Changing Engine Oil - Sl1-2020
Risk of death or injury by scald. u Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Wear proper personal protective equipment. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 141 Filling engine oil Make sure that the following preconditions are met: q Engine oil is drained. q Spin-on oil filters are replaced. q Draining plugs and valves are closed. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 142: Collecting And Analyzing Oil Sample - Sl1-2021
5.7.3 Collecting and analyzing oil sample — SL1-2021 Previous tasks Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 143 Take an oil sample from sampling point 1. u Analyze the oil sample. u Take recommended action according to analysis results. (→ 5.12.3 Approved engine oils and engine oil additives, p. 183) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 144: Replacing Spin-On Oil Filter - Sl1-2110
Wear proper personal protective equipment. Consumables and equipment Make sure that the following consumables and equipment are available: – Filter ribbon spanner – Original KOHLER spin-on oil filters © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 145 Operate prelubricating pump to vent the filters. In the absence of prelubricating pump, disconnect TDC sensor (on aggregate support) and crank the engine until oil pressure builds © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 146: Removing And Installing Centrifugal Oil Filter Cover And Cover Clamp - Sl1-2220, Sl1-2221
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. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 147: Inspecting And Replacing Centrifugal Oil Paper Filter - Sl1-2231, Sl1-2232
100) q Centrifugal oil filter cover and V-clamp are removed. (→ 5.7.5 Removing and installing centrifugal oil filter cover and cover clamp — SL1-2220, SL1-2221, p. 146) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 148 Property damage - Risk of critical engine failure. u Use new seals after any dismantling. Consumables and equipment Make sure that the following consumables and equipment are available: – Paper filter – Seals © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 149 Unscrew and remove the nut of rotor cover 3. u Lift carefully the rotor cylinder 4 so that the mud remains in the cylinder. u Recycle paper filter 5 and mud according to specific national regulations. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 150 Replace seals of rotor base 1 and bearing tube 7. u Insert deflector disk 6. Fig. 81: Paper filter preparation u Insert paper filter 5 tabs in slot A and slot B. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 151 Assemble rotor cylinder 4 on rotor base 1. u Mount rotor cover 3 and tighten nut to 40 Nm (30 ft-lb). Fig. 84: Installing rotor u Place rotor 2 in rotor base 1. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 152: Inspecting Oil Cooler - Sl1-2411
Inspect oil cooler for external leaks (engine oil or coolant). u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 153: 3000 - Cooling System
Make sure that no operating fluid comes into contact with a hot surface or an ignition source. NOTICE Use of non-approved coolant! Property damage - Risk of engine critical failure. u Use an approved coolant. (→ 5.12.4 Approved coolants, p. 190) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 154: Changing Coolant - Sl1-3020
(→ 5.12.1 Filling volume, p. 177) Topping up coolant level u Refer to the generator set documentation to check the coolant level. u Top up the cooling system with KOHLER approved engine coolant. (→ 5.12.4 Approved cool‐ ants, p. 190) 5.8.2 Changing coolant —...
Page 155 Coolant drain on tandem coolant pump Coolant drain on oil cooler On each drain-off point: u Place a container to collect the used coolant. u Unscrew and remove plug or open valve. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 156: Collecting And Analyzing Coolant Sample - Sl1-3021
Remove the filler cap when it is cold or cooled enough to be touched with bare hands. u Loosen the filler cap to first stop to relieve pressure. u Wait until pressure drop. u Remove the filler cap. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 157: Inspecting Relief Bore On Coolant Pump - Sl1-3201
Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Wear proper personal protective equipment. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 158 In case of oil or coolant leak: u Record and report any leak. u Make sure that authorized service personnel replace the pump. Information Slight drops of coolant are not critical. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 159: 4000 - Fuel System
Property damage - Risk of engine major failure. u Use an approved diesel fuel. u Make sure that the fuel supply system guarantees fuel specification at the inlet of the engine. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 160: Replacing Fuel Pre-Filter - Sl1-4110
Topping up fuel level u Refer to the generator set documentation to check the fuel level. u Top up the fuel tank with KOHLER approved diesel fuel. (→ 5.12.2 Approved diesel fuels, diesel exhaust fluids (DEF), and fuel additives, p. 177) 5.9.2 Replacing fuel pre-filter —...
Page 161 Keep the engine clean and free of dust accumulation. Consumables and equipment Make sure that the following consumables and equipment are available: – Filter ribbon spanner – Original KOHLER fuel main filter © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 162 Trapped air in the fuel system prevents the high-pressure build-up and may lead to failed starts or poor running conditions. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 163: Inspecting Hp/Lp Fuel Pump - Sl1-4221, Sl1-4311
Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Before servicing the engine, make sure that the operating fluid pressures are relieved. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 164 Inspect overall condition of the fuel pump. u Search for potential leaks at connections. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 165: 5000 - Combustion Air And Exhaust Gas System
Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) Specific safety instructions See general instructions above. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 166: Cleaning Air Filter - Sl1-5021
Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) Specific safety instructions Not applicable. Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 167: Inspecting Exhaust Gas System - Sl1-5201
Previous tasks Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) Specific safety instructions Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 168: Inspecting Exhaust Gas Turbocharger - Sl1-5411
5.10.5 Inspecting exhaust gas turbocharger — SL1-5411 Previous tasks Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 169 If accessible, inspect compressor and turbine blades. u Search for external damage. u Record and report any defect. If defect is detected: u Make sure that authorized service personnel correct the defect. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 170: 6000 - Electrical And Control System
Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) Specific safety instructions Not applicable. Consumables and equipment Not applicable. Inspection Fig. 93: Starters © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 171: Inspecting Battery Charging Alternator - Sl1-6221
— SL1-6235, p. 175) Specific safety instructions Not applicable. Consumables and equipment Make sure that the following consumables and equipment are available: – Air blow gun © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 172: Inspecting Belt Drive System Of Battery Charging Alternator - Sl1-6231
Entanglement of fingers in the belt during the assembly of auxiliaries! Risk of injury by crush. u Observe local regulations, site rules, and safety notes. u Wear proper personal protective equipment. u Use assembly and lifting devices. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 173: Replacing Belt Of Battery Charging Alternator - Sl1-6232
(→ 5.4 Preparatory maintenance activities, p. 100) q Cover of battery charging alternator is removed. (→ 5.11.5 Removing and installing cover of battery charging alternator — SL1-6235, p. 175) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 174 Rotate crankshaft in the opposite direction of rotation with turning device. (→ 7.1.2 Turning device, p. 202) u Remove belt 1. Installation u Install turning device. (→ 7.1.2 Turning device, p. 202) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 175: Removing And Installing Cover Of Battery Charging Alternator - Sl1-6235
Previous tasks Make sure that the following preconditions are met: q Preparatory maintenance activities are fulfilled. (→ 5.4 Preparatory maintenance activities, p. 100) Consumables and equipment Not applicable. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 176 Screw (M8) Lock washer u Remove screws 3 and lock washers 2. u Remove cover 1. Installation u Screw cover 1 with lock washers 2 and screws 3. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 177: Lubricants And Operating Fluids
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 178 Reduced (norm) (norm complement) capacity biodiesel criteria EATS mainte‐ (max. ratio (%) nance HFRR) interval EN 590 CSR 4.1.09 BS 2869 Tab. 37: KD approved non-road diesel fuels © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 179 15) Reinforced fuel primary filtration system, including water separator between main storage and daily tank, is manda‐ tory. 16) Exchange interval of fuel filters is reduced (1/2), lifespan of fuel line components may be reduced, fuel consumption is not guaranteed anymore. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 180 (18.11 th) Tab. 40: 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. Biodiesels Only diesel fuels with a biodiesel content lower than 10% are allowed in Kohler KD diesel engines.
Page 181 18) Specific improved storage condition is mandatory. 19) Reinforced fuel primary filtration system, including water separator between main storage and daily tank, is manda‐ tory. 20) Polishing primary fuel filtration is mandatory. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 182 Tab. 44: 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 183: Approved Engine Oils And Engine Oil Additives
Engine oils essential characteristics and maintenance SAPS and engine oil quality Kohler classifies synthetic engine 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 184 Tab. 46: KD engine oil category factors Engine oil requirements Generally speaking, engine oils fulfilling the following criteria can be used in Kohler KD diesel engines. However, a careful check of the characteristics must be undertaken. This measure ensures that the criteria mentioned in the following sections are explicitly fulfilled before considering the engine oil as approved for use in KD diesel engines.
Page 185 · Engine 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 186 Recommended TBN TAN ratio Kohler does not recommend any specific TAN for the engine 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 < TBN - 2mgKOH / g.
Page 187 – Standard engine oil change interval is indicated in the technical documentation of the diesel engine. – Engine oil category factor is defined in the table on KD engine oil category factors (→ tab. 51, p. 189). © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 188 < V < 1.1 V ASTM D 7279 DIN 51562 = fresh engine oil viscosity Viscosity index 0.88 Vi < Vi < 1.12 ISO 2909 = fresh engine oil viscosity © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 189 Potassium is now incorporated in new-generation engine oils; conclusion must be drawn only by having initial composition and evolution available. Mineral engine oils The use of mineral engine oils is strictly forbidden in Kohler KD diesel engines. Synthetic engine oils Engine oil category...
Page 190: Approved Coolants
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 191 Coolant monitoring Kohler recommends a close monitoring of the coolant to prevent diesel engine damage by cavi‐ tation, corrosion, overheating, or freezing. Monitoring of the coolant can extend the exchange period of the fluid for up to 6000 hours or 4 years for SI-OAT-based and hybrid technology cool‐...
Page 192 Porodox 5 to 10% by Powder - weight Kluthe Hakutex 60 100% by volume Liquid X00056750 (25 kg (55.11 lb) Tab. 56: KD cooling system components cleaners © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 194: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 195: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 196 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 197 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 198 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 200: Tools And Devices
2230610042 L100 mm (3.94 in) Guide pin M12 - HT/LT thermostat housing 230611638 L230 mm (9.06 in) Guide pin M30x2 - Cylinder head 230610035 L460 mm (1.51 ft) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 201 L400 mm (1.31 ft) Lifting device for HP/LP fuel pump lifting device Upon request Power unit extracting and lifting device 230612871 Cylinder head lifting device Upon request Piston ring compressor 230613049 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 202: Turning Device
After the rotation of the flywheel, always take away the wrench tool from the turning device. u Dismount immediately the turning device and mount the cover on the flywheel housing. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 203 Dismount immediately the turning device and mount the cover on the flywheel housing. Information The wrench tool and the turning device are available for maintenance task only. Should you have any queries, please contact your authorized Kohler service representative. Installation Fig. 115: Mounting the turning device Screws (M16x35 -8.8)
Page 204: Diagnostic Tools
Position cover 3. u Mount and tighten screws 4 according to standard torques values. Information Should you have any queries, please contact your authorized Kohler service representative. 7.1.3 Diagnostic tools Kohler Co. proposes an advanced diagnosis software (KODIA) for its diesel engines.
Page 206: Appendix
Information 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 207: Error Code
Error code list extracted from engine control unit software version 21.16.55 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 208 Coolant level sensor - Short circuit to battery Coolant level sensor - Short circuit to ground or open circuit Coolant level sensor - Supply voltage out of range Engine coolant - Level low © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 209 1180 Exhaust temperature before turbocharger 1 - Overtemperature warning 1181 Exhaust temperature before turbocharger 2 - Critical overtem‐ perature 1181 Exhaust temperature before turbocharger 2 - Overtemperature warning © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 210 Cylinder head temperature sensor 12 - Internal error 1139 Cylinder head temperature sensor 3 - Internal error 1140 Cylinder head temperature sensor 4 - Internal error 1141 Cylinder head temperature sensor 5 - Internal error © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 211 Cylinder head temperature sensor 3 - Internal temperature error 1140 Cylinder head temperature sensor 4 - Internal temperature error 1141 Cylinder head temperature sensor 5 - Internal temperature error © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 212 Oil pressure sensor - Short circuit to ground or open circuit Engine oil - Critical overpressure Engine oil - Critical underpressure Oil pressure sensor - Supply voltage out of range © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 213 Water in fuel sensor - Open circuit Water in fuel sensor - Value out of range Water in fuel sensor - Short circuit to battery Water in fuel sensor - Short circuit to ground © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 214 Injector 2 - Open circuit Injector 3 - Open circuit Injector 4 - Open circuit Injector 5 - Open circuit Injector 6 - Open circuit Injector 7 - Open circuit © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 215 Injector 1 - Short circuit to ground Injector 10 - Short circuit to ground Injector 11 - Short circuit to ground Injector 12 - Short circuit to ground © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 216 Pressure control valve 2 - Critical overcurrent 516215 Pressure control valve 2 - Critical undercurrent 4210 Prelubrication pump - Short circuit to battery 4210 Prelubrication pump - Short circuit to ground © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 217 Volume control valve 2 - Short circuit to ground (low side) 516255 Volume control valve 2 - Load is short circuited 516255 Volume control valve 2 - Critical overcurrent © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 218 Turbine inlet temperature sensor 2 - Short circuit to battery 1181 Turbine inlet temperature sensor 2 - Supply voltage out of range 1181 Turbine inlet temperature sensor 2 - Open circuit Tab. 58 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 219: 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. 61: Greases © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 220: 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. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 221 For every maintenance task, when a sequence is specified, achieve step 1 for all the sequence before starting step 2. Fig. 120: Standard sequence for four, five, and six screws. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 222 Except components listed below, and otherwise noted, u Marking on screws or nuts to track their reuse is not required. Fig. 121: Examples of markings on screws and HP pipe nut © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 223: Standard Torques For Hexagonal / Socket / Flange Screws And Hexagonal / Flange Nuts
183 Nm 240 Nm (177 ft-lb) 270 Nm (135 ft-lb) (199 ft-lb) 320 Nm (236 ft-lb) 358 Nm 470 Nm (347 ft-lb) 525 Nm (264 ft-lb) (387 ft-lb) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 224: Standard Torques For Internal Drive Pipe Plug With Conical Thread
– Internal drive screw plugs with collar - Cylindrical thread according to DIN 908 Tab. 65: Hollow screw DIN 7643, Hexagon head screw DIN 910, Internal drive screw DIN 908 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US...
Page 225: Standard Torques For Metric Flange Joints
18 Nm (13 ft-lb) 15 Nm (11 ft-lb) M 12 x 1.5 20 Nm (15 ft-lb) 30 Nm (22 ft-lb) 25 Nm (18 ft-lb) 25 Nm (18 ft-lb) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 226 Standard torques for imperial thread unions L series (up to 500 bar/7252 Psi) for steel and iron cast part According to ISO 1179-1 / DIN 3852-T2-Form X / DIN 3852-T3-Form X BSP threading. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 227 290 Nm (214 ft-lb) 700 Nm (516 ft-lb) 540 Nm (398 ft-lb) Tab. 70: Standard torques for imperial thread union S series, for steel and iron cast part © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 228 108 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 Nm (106 ft-lb) 136 Nm (100 ft-lb) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 229 G 1/4A 28 Nm (21 ft-lb) 44 Nm (32 ft-lb) 32 Nm (24 ft-lb) G 1/4A 28 Nm (21 ft-lb) 44 Nm (32 ft-lb) 32 Nm (24 ft-lb) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 230: Assembling Pipes With Cutting Rings
Fig. 137: Cutting ring lubrication Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). Fig. 138: Cutting ring tightening © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 231: 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) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 232: 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. 140: VSTI screw plugs with ED seal (left), with o-ring (right) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 233: Standard Torques For Vsti Screw Plugs For Aluminum
Tab. 77: 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 aluminum According to DIN EN ISO 6149-2 / ISO 11926-2, metric threading. © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 234 (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) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 235: Assembling Pipes With Dko Connectors (El, Et, Ew, Gz, Gzr, Red)
25 Nm (18 ft-lb) 30 Nm (22 ft-lb) 40 Nm (30 ft-lb) 40 Nm (30 ft-lb) 50 Nm (37 ft-lb) 50 Nm (37 ft-lb) 60 Nm (44 ft-lb) © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 236: Standard Torques For Collar Clamps
30 Nm (22 ft-lb) Tab. 80: Tightening torques for collar clamps according to DIN 3017-3 8.4.13 Standard torques for pipe clamps according to DIN 3015 Fig. 145: Pipe clamps © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 237 200 Nm (148 ft-lb) 168 mm (6.61 in)-220 mm (8.66 in) 180 Nm (133 ft-lb) 350 Nm (258 ft-lb) Tab. 81: Tightening torques for pipe clamps according to DIN 3015 KD62V12A 33521061401_1_1 EN_US © 2023 by Kohler Co. All rights reserved. 2023-10...
Page 238: Abbreviations - Acronyms
SAPS Sulphated Ash, Phosphorus, and Sulfur Sulphated Ash, Phosphorus, and Sulfur Selective Catalytic Reduction Selective Catalytic Reduction Service and Repair Manual Service and Repair Manual Top Dead Center Top Dead Center © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 239 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. 83: Acronyms table © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 240: Unit Conversion Tables
Tab. 86: 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. 87: Volume conversion factors © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 241: Power Conversion Factors
F = 9/5*C + 32 °C K = C + 273.15 Tab. 92: 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 © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 242 Appendix Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 93: Density conversion factors © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...
Page 243: Prefix
Appendix Prefix 8.7 Prefix Name Symbol Factor tera giga mega kilo milli micro μ nano Tab. 94: Common prefix multipliers table © 2023 by Kohler Co. All rights reserved. KD62V12A 33521061401_1_1 EN_US 2023-10...

Kohler KD62V12A Operation And Maintenance Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Kohler KD62V12A

Summary of Contents for Kohler KD62V12A

Table of Contents