Kohler KD62V12 Operation And Maintenance Manual

Hide thumbs Also See for KD62V12:

Manual (296 pages)

Service and repair manual (290 pages)

Operation and maintenance manual (210 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

page of 132

/ 132
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

Operation and Maintenance Manual

Translation of the original instructions

Diesel engine

KD62V12

From serial number 2016730001

33521030301_1_1

12-2016

Table of Contents

Need help?

Do you have a question about the KD62V12 and is the answer not in the manual?

Questions and answers

Summary of Contents for Kohler KD62V12

Page 1 Operation and Maintenance Manual Translation of the original instructions Diesel engine KD62V12 From serial number 2016730001 33521030301_1_1 12-2016...
Page 2 For further explanation or information, the Customer Service and Customer Service training center departments of the KOHLER Company 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 3 Third-party products are used in or on KOHLER engines at the user's own discre- tion. KOHLER does not offer any warranty or accept any liability for losses of any kind caused by failures of or damage to KOHLER engines attributable to the use of third-party products.
Page 5: Table Of Contents
International standard classification of occupations 2.2.2 Occupational references 2.2.3 For the operation of power generation engines: Operator 2.2.4 Unauthorized personnel Intended use Reasonably foreseeable misuse Signs on the engine © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 6 2.27 Prevent material damages Control and operation Operation 3.1.1 Filling lubricants and operating fluids 3.1.2 Starting the engine 3.1.3 Bleeding the fuel system Operating faults Faults - Cause - Remedy © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 7 5.7.4 Inspecting low temperature circuit (charge air cooler) — SL002 5.7.5 Checking relieve bores — water/coolant pump — SL003 5.7.6 Draining off water from fuel prefilter — SL004 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 8 Metric thread unions L series (up to 500 bar/7252 Psi) for aluminum 6.1.6 Standard torques for cutting ring flange joints 6.1.7 Standard torques for triple lock flange joints 6.1.8 Standard torques for VSTI screw plugs Glossary Abbreviations © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 9 Moment of inertia and torque conversion factors 6.4.7 Fuel consumption conversion factors 6.4.8 Flow conversion factors 6.4.9 Temperature conversion factors 6.4.10 Density conversion factors Prefix Special tools Index © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 11: Service Assistance
Consult the Yellow Pages under the heading Generators—Electric. – Visit the KOHLER Power Systems website at KOHLERPower.com. – Look at the labels and stickers on your KOHLER product or review the appro- priate literature or documents included with the product.
Page 12 Operation and Maintenance Manual For KOHLER-SDMO generating sets: – Visit our website at www.kohlersdmo.com. – Look at the labels and stickers on your KOHLER-SDMO Industries product or review the appropriate literature or documents included with the product. – Call the nearest regional office.
Page 13 Fax: +33 (0) 4 75 81 31 10 Tel.: +44 (0) 16 06 83 81 20 Tel.: +90 53 07 35 09 Fax: +44 (0) 16 06 83 78 63 Tab. 2: KOHLER-SDMO Service Assistance To order special tools, please refer to the cross reference list in the annex. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 15: Product Description
Fig. 1: Diesel engine / view from the flywheel side Flywheel Oil dipstick Turning device Battery charging alternator Crankcase ventilation filter Engine brackets housing Turbocharger assembly Oil centrifuge assembly Charge air cooler Fuel pump © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 16 Oil cooler ture Thermostat housing low tempera- Spin-on oil filter (lubrication ture system) Engine control unit (ECU) Prelubricating pump Exhaust gas connection Oil pan Air intake elbow (optional) © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 17: Cylinder Designation, Direction Of Rotation
Low fuel consumption and exhaust gas emis- sions by optimized combustion process adapted to the emission requirements. Minimized maintenance obtained by optimized engine components and accesso- ries lead to higher availability and increased efficiency. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 18 High/low temperatures coolant circuits Thermostatically controlled coolant with separate pumps for high and low tempera- ture coolant. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 19: Diesel Engine Accessory Equipment
1.1.4 Diesel engine accessory equipment Battery charging alternator The engine is equipped with a battery charging alternator: V. / 140A. Fig. 4: Battery charging alternator © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 20: Additional Safety Components
The battery charging alternator cover is a protective device fixed directly behind the battery charging alternator. It ensures a global protection to the alternator environ- ment while the engine is running. Fig. 5: Battery charging alternator cover © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 21 The vibration damper cover is a protective device fixed directly into the front end of the engine. It ensures a global protection to the vibration damper environment while the engine is running. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 22 Fig. 7: Vibration damper cover Fig. 8: Vibration damper cover details Screw Distance sleeve Lock washer Cover plate Protection plate Screw Screw Option features – Protection device ensuring insulation of moving parts © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 23: Engine Type Description
Tab. 3: Engine type description Diesel engine nameplate Fig. 9: Engine nameplate Engine main values Notes regarding emissions exemptions, fuel and application types USA regulations references Country of assembly QR code area © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 24 Information u The information on the engine control unit nameplate corresponds to the delivery status (ex: works KOHLER®). 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 KOHLER diagnosis and service tool Kodia.
Page 25: Technical Data
57 / 134.6 High Temperature (HT) Opening start °C/°F 86 / 186.8 Thermostat Completely open °C/°F 96 / 204.8 Tab. 6: Technical data table – Coolant thermostat technical data © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 26: Generator
Output per start system Tab. 8: Technical data table – Starter 1.2.6 Flywheel housing Designation Unit Values Connection SAE 00 Tab. 9: Technical data table – Flywheel housing © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 27: Safety
▶ Action Identifies an action which has to be carried out ▷ Result Identifies the result of an action – Listing Identifies a listing Tab. 12: Additional symbols © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 28: Additional Rules And Directives
14 years. u Supply the required tools and spare parts. Information u The Customer Service training center departments of the KOHLER Company provides several training programs. u Please contact KOHLER - customer service for queries.
Page 29: For The Operation Of Power Generation Engines: Operator
– Operating, monitoring and inspecting various types of energy-generating power plants – Operating and controlling power-generating systems and equipment – Controlling start-up and shut-down of power plant equipment – Controlling switching operations, regulating water levels © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 30: Unauthorized Personnel
– Power supply to the equipment (electric generator) and to equipment auxiliaries as specified by customer. – The Diesel engines produced by KOHLER are partly completed machinery according to Machinery Directive 2006/42/EC Article 2 g (EU only). They are intended for installation in machineries.
Page 31: Reasonably Foreseeable Misuse
– Attach external cables and wires on Diesel engine cables and pipes. – Drawing power from the damper side, – Unauthorized modifications to the Diesel engine. In this case, KOHLER is not liable for any damages. The risk is borne solely by the user. 2.5 Signs on the engine 2.5.1 Information and safety and plates...
Page 32: Nameplates
This is especially to be repeated for the operators which occa- sionally operate the machinery. Information u Use only operating fluids that have been approved by KOHLER. The use of original spare parts guarantees the compliance with the technical requirements established by the engine manufacturer KOHLER.
Page 33: Safety When Commissioning
– All openings must be closed and the safe conditions established by the manu- facturer of the machinery must be fulfilled. – The appropriate ventilation of the engine compartment has been defined by the owner of the machinery. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 34: Preventing Injuries
– Keep the engine clean and free from accumulation of dust and flammable liquids. – Keep the insulation free of operating fluids contamination. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 35: Preventing Intoxication And Poisoning Hazards
Information u Engines provided by KOHLER are not intended to be used in potentially explo- sive atmospheres according to Directive 94/9/EC (UE only). 2.12 Preventing intoxication and poisoning hazards Exhaust gases emissions increase the likelihood of cancers.
Page 36: Preventing Vibrations
2.18 Safety instructions for engine control unit (ECU) Improper installation or misuse of the engine leads to damages. Follow these safety instructions to avoid damages due to non-adapted installation or operation: © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 37: Safety Instructions For The Fuel System
– Electrical welding nearby the engine is forbidden, especially near the ECU. In case of necessity, please contact KOHLER after sales service. – Switch off the electrical system before connecting or disconnecting the ECU. Apply to the prescribed tightening torque to tighten the fixing screws of the inter- face plugs.
Page 38: Disposal And Environment Protection
Wear proper personal protective equipment when working on the engine. Wearing accessories and loose clothing is forbidden. A risk of injury hazards exists. Following personal protective equipment is necessary: © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 39: Accessible Areas
– A - Engine front (damper side) – B – Engine sides – C – Engine rear (flywheel side) – D – Above the engine – E – Below the engine © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 40: Engine In Commissioning - Test-Run
Following warning signs must be clearly visible and mounted in the accessible areas. ISO 7010/W012 – Warning sign - High voltage Lethal or heavy injury due to electrical shocks ▶Refer to 2.15 “Preventing electrical hazards” © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 41: Secure And Release The Diesel Engine Against Unexpected Starting
– All of the protective devices are installed and are working properly. – Make sure that no external persons stand or walk in the danger zones. – Remove the label from the fuel supply. – Reconnect the fuel supply. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 42: Emergency Stop
– Use suitable test leads for measurements at plug connections. – Protect the engine control unit against dust and water if no mating plug has been connected. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 43: Control And Operation
Bring all of the protective devices into their protective position. Housing is closed. u Secure external parts against unexpected movements. Remove all persons from the danger zones. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 44 Check for KODIA error messages. u Check for error messages on the device side. Starting in cold temperatures The KOHLER generators are equipped with a preheating system. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 45 To ensure Diesel engine performance and endurance, the following tasks must be fulfil when operating the machinery: Engine under load at rated speed – Check for leaks. In case of leaks, rectify immediately according to chapter “Maintenance”. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 46 “Safety instructions” : u Disconnect the electrical power supply. u Remove any electronic control or electrical connections. u Drain all fluids. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 47: Bleeding The Fuel System
Remove any coolant, lubricants and fuel connections. u Collect and dispose of waste, coolant, lubricants and fuel. u If there are any doubts or concerns, contact KOHLER and wait for further instructions. Initial starting/test run/after out of service period...
Page 49: Operating Faults
Battery voltage too low. Recharge or replace battery. Battery connections loose or Clean and tighten loose connec- corroded. tions. Exterior temperature too low. Implement measures for winter oper- ation. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 50 Injection nozzles stuck or do not Contact KOHLER. vaporize. Diesel engine compression too low. Contact KOHLER. Fault in electronic system. Read out fault logs of engine control unit, contact KOHLER. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 51 Warm up the engine until operating temperature is reached. Water in fuel system. Check fuel system and drain prefilter. Charge air cooler leaking. Contact KOHLER. Diesel engine rattles. Combustion faults. Contact KOHLER. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 52 Air filter congested. Check air filter service indicator. Charge air cooler contaminated. Contact KOHLER. Turbocharger exhaust defect. Contact KOHLER. Coolant leaks on charge air cooler. Leaking, breaking. Contact KOHLER. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 53: Maintenance
Consult the “service package” in the spare parts catalogue. This contains the list of spare parts required for maintenance work. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 54: Maintenance Plan Use
– Calendar limit is the maximal duration in years. A maintenance task is carried out as soon as a deadline is reached, hourly or calendar. The first reached deadline reached is applied. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 55: Generator Set Ratings
5.3.4 Time between overhaul (TBO) The designation of the average duration until the Diesel engine is revised. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 56: Service Level Definition
Check differential pressure gauge of fuel prefilter. If Daily start applicable, see supplier's manual. SL006 Before Inspect service indicator of air filter - customer provi- Daily start sion (if applicable). © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 57 SL105 Fuel main filter 1000 Replace fuel filter SL107 Crankcase breather Replace filter inserts. Replace oil separator for crank- filters — case breather system. Clean wire meshes of crank- case breathers. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 58 Turbocharger at 12000 SL215 LT Water pump — Replacement SL216 HT Water pump — Replacement SL217 Coolant thermostats — Replacement SL219 Rubber sleeves — Replace all rubber sleeves © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 59 Measure and record thickness of the sludge accumulated on paper if above limits SL103 Oil pre-lube pump X Check for leaks and function SL105 Fuel main filter 1000 Replace fuel filter © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 60 Check overall condition (compressor blades, leaks, connections, housings, etc.) every 4000 hrs. Replace Turbocharger at 12000 SL215 LT Water pump 7500 Replacement SL216 HT Water pump 7500 Replacement © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 61 SL102 Centrifugal oil filter Replace the paper (sleeve) for sludge at each oil — Filter paper change. Measure and record thickness of the sludge accumulated on paper if above limits © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 62 SL212 Cold start oil cooler Replacement 12000 by-pass valve SL213 Turbochargers Check overall condition (compressor blades, leaks, 12000 connections, housings, etc.) every 4000 hrs. Replace Turbocharger at 12000 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 63 SL223 Battery charging Check / Replace battery charging alternator 12000 alternator SL224 Cylinder Heads 12000 Replace cylinder heads Tab. 22: Service level 2— Advanced maintenance © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 64: Fuels, Lubricants And Operating Fluids
5.5 Fuels, lubricants and operating fluids Information u Only fuels, lubricants and operating fluids approved by KOHLER may be used for the operation of KOHLER Diesel engines. KOHLER will declare all possible undertakings carried out by KOHLER and/or their dealers, such as guarantees, service orders, etc.
Page 65: Diesel Engine Coolant
– BASF GLYSANTIN® G40™ change interval 6 years – BASF GLYSANTIN® G48™ change interval 4 years The recommended coolant concentration is 50-60%. Control parameter for the coolant: Analysis Standard Unit Value © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 66 DIN EN 12014 mg/kg <500 Nitrite DIN EN 12014 mg/kg <80 pH value ISO 10523:2012-04 8.1 – 8.7 Freezing point ISO 3016, ASTM 5985 °C unspecified Tab. 24: Control parameter © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 67: Preparatory Maintenance Activities
– The Diesel engine is not in operation. – The Diesel engine is at ambient temperature. – The battery main switch, if present, is turned off and the main switch key is removed. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 68: Daily Maintenance Activities
In this chapter, operations of maintenance on the engine correspond to Service Level 1 (SL1). In SL1, daily checks, inspection and maintenance tasks can be done by customer or KOHLER affiliate in regular intervals without dismantling parts from engine. The following maintenance activities are suitable for customer. Make sure that: q The Diesel engine is in maintenance position.
Page 69 Damper — Shaft seal Oil cooler Water pump low temperature Spin-on oil filter Thermostat low temperature Thermostat high temperature See next page for continuation of the image legend © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 70 Spin-on oil filter Fig. 44: Visual inspection of engine (3) Rubber sleeve Compensator Compensator Fig. 45: Visual inspection of engine (4) Oil return (Turbocharger — Crank- Exhaust line case) © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 71: Checking The Engine Oil Level - Sl001
Fig. 47: Oil dipstick marking Information u The Started side of the dipstick is not relevant for generator sets. If the oil level is too low: u Remove oil filling cap. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 72: Checking Coolant Level - Sl001
Fill up with approved engine coolant inhibitors. See chapter “Diesel engine coolant” for water quality. u Fill up with KOHLER anti-freeze premixed in other cases. u Respect the level marks on the level indicator window. © 2016 by Kohler Co. All rights reserved.
Page 73: Inspecting Low Temperature Circuit (Charge Air Cooler) - Sl002
Air leakage is normal. Troubleshooting If water mixed with antifreeze is coming out: u Inspect charge air cooler for leaks. If necessary, have the leaks repaired by the competent personnel. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 74: Checking Relieve Bores - Water/Coolant Pump - Sl003
If you got an alarm on the ECU display related to an air filter clogged, then the filter has to be cleaned or changed. For the procedure, see the device manufacturer's documentation. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 75: Observation Of The Engine While Running - Sl007
The application parameters are within the set range u Run the engine at more than a 1/3 load and at least until steady-state tempera- ture is reached. u Note and report any abnormalities. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 76: Basic Maintenance
In this chapter, operations of maintenance on the engine correspond to Service Level 1 (SL1). In SL1, daily checks, inspection and maintenance tasks can be done by customer or KOHLER affiliate in regular intervals without dismantling parts from engine. The following maintenance activities are suitable for KOHLER affiliate. Make sure that: q The Diesel engine is in maintenance position.
Page 77: Coolant Sampling - Sl120
Depending on the application and the operating conditions of the engine, sampling and analysis must be carried out more frequently. KOHLER recommends carrying out the analysis of the used coolant according to the parameters in the chapter. © 2016 by Kohler Co. All rights reserved.
Page 78: Changing Diesel Engine Oil And Oil Filter Insert - Sl101, Sl101 Bis, Sl121
The Diesel engine is warm. q A container with the required capacity is ready. q Original KOHLER oil filter inserts with the seals are provided. q A suitable drainage house from the device manufacturer is available. q Diesel engine oil is provided. For the Diesel engine quantity, see chapter “Filling volume”.
Page 79 Draining off Diesel engine oil Fig. 52: Oil drain - engine front side Oil drain aggregate support. Oil drain on oil pan Engine left side Oil drain aggregate support. Engine right side © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 80 Basic maintenance Fig. 53: Oil drain - engine rear side Oil drain on oil pan Fig. 54: Oil drain - engine left side Oil drain on oil cooler © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 81 Spin-on oil filter Collecting tab Filter head Seal Fig. 56: Spin-on oil filter — Piston cooling jets Spin-on oil filter Collecting tab Filter head Seal Spin-on oil filter removal © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 82 Remove oil filling cap. u Fill with oil via the filler neck 2 until between “min.” and “max.” marks on the dipstick 1 (stopped side of the dipstick). © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 83: Replacing Centrifuge Paper Filter - Sl102
The Diesel engine is warm. q A container with the required capacity is ready. q Original KOHLER oil filter inserts with the seals are provided. q A suitable drainage house from the device manufacturer is available. q Diesel engine oil is provided. For the Diesel engine quantity, see chapter “Filling volume”.
Page 84 Basic maintenance Replacing centrifuge paper filter — SL102 Fig. 59: Oil centrifuge Centrifuge base Rotor cylinder V-clamp Paper filter Rotor Rotor base Cover Rotor cover Opening the centrifuge © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 85 Recycle paper filter 6 and mud according to specific national regulations. Information The thickness of mud deposit inside the rotor should not be more than 45 mm. Otherwise: u Reduce maintenance intervals and operate oil analysis. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 86 Fig. 63: Paper filter preparation u Insert paper filter 6 tabs in slot A and slot B. Fig. 64: Inserting paper filter u Insert paper filter 6 in rotor cylinder 5. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 87 Install and tighten V-clamp 2 to 7 Nm. u Start and run Diesel engine for three minutes. u Check engine oil level. See chapter “Checking the engine oil level — SL001”. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 88: Checking Prelubricating Pump (Depending On Machinery) - Sl103
Make sure that: q A container with the required capacity is ready. q Two original KOHLER fuel filter inserts are available. q A suitable drainage house from the device manufacturer is available. q A fuel filter ribbon spanner is available.
Page 89: Replacing The Crankcase Breather Filters - Sl107
5.8.7 Replacing the crankcase breather filters — SL107 Make sure that: q A container with the required capacity is ready. q Original KOHLER crankcase breather filter inserts are available. The crankcase breather filters are located on the flywheel side of the Diesel engine.
Page 90 Make sure that no dirt gets onto the clean side of the filter. u Never reuse a crankcase breather filter once used. u Use only original KOHLER crankcase breather filters. u Screw in and tighten crankcase breather filter with housing lid (torque 20 Nm).
Page 91: Replacement And/Or Checking Drive Belt (Alternator
Removal of the battery charging alternator cover Fig. 70: Battery charging alternator cover details Cover Lock washer Screw u Remove bolts 2 andlock washers 3. u Remove the cover 1. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 92 – Traverse cracks on the back – Traverse cracks in several ribs The belt attachment is self-tensioning and maintenance-free. The belt drive is located at the engine damper side. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 93 There are a number of the ribs and builds up in causes, including misalign- the belt grooves. ment, new belt on worn pulleys, lack of tension or a combination of these factors. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 94 − similar to rib separation, etc). the way tyres wear out. Tab. 25: V-ribbed belt wear In case of wear, have the belt replaced immediately by the competent personnel. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 95 Tensioning device and V-ribbed belt removal u Mount socket wrench with lever to the corresponding tensioning device. u Pivot back the tensioning device against the spring force to the limit stop. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 96 Remove screw 3 with washer 2 and nut 1. u Remove and replace tensioning device. u Mount tensioning device with screw 3, washer 2 and nut 1 and tighten 50“+8/-7” Nm. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 97 Belt section Light beam u Check tension with adequate tool. The measured frequency value must be 178 Hz. In case of air conditioning compressor installed, proceed the same way. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 98: Coolant Draining - Sl116
Drain coolant from oil cooler and water pumps. u Refill with coolant. Adjust levels. For more details, refer to the Operation and Maintenance Manual of the machinery. u Vent coolant system. See venting connections below. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 99 Operation and Maintenance Manual Maintenance Basic maintenance Fig. 79: Venting connection on the water elbow Fig. 80: LT thermostat and HT thermostat venting connections © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 101: Transportation - Storage
5.9.2 Dimensions and weight WARNING Crushing hazards u It is forbidden to guide the load by hand. WARNING Falling/Hanging chains u Falling/Hanging chains on the engine may damage engine components © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 102 9300 kg/ 20503 lbs Maximal angles of lifting devices — side α1–α2 15° view Maximal angles of lifting devices — front β1–β2 15° view Tab. 26: Lifting designation © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 103 Operation and Maintenance Manual Maintenance Transportation — Storage Fig. 83: Examples of lifting, without and with packaging Fig. 84: Example of lifting device Engine Lifting beam Lifting hook Lifting point © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 104: Transport
5.9.3 Transport Information u For transportation, the engine should be deposit on adapted stands. u KOHLER provides one wooden stand with engine. For transportation and storage use the provided stand. Fig. 85: Example of wood stand on undercarriage Fig. 86: Example of transportation fixing ©...
Page 105: Storage
Storage conditions Information In the case of less favorable storage conditions, u A reduction in the storage time must be defined. Please contact KOHLER® Customer Service. Storage conditions should meet the following minimum requirements: © 2016 by Kohler Co. All rights reserved.
Page 106 Storage in a closed, dry and ventilated area ensures a conservation and storage life of 12 months. Storage over 12 months For storage longer than 12 months, please contact KOHLER® Customer Service. Storage site foundation requirements Information u The storage foundation is part of the scope of the machinery owner.
Page 107: Unpacking / Depreservation
To handle the engine or load, follow the instructions of section “Safe transporta- tion”. 5.9.5 Unpacking / Depreservation NOTICE Cutting or severing hazards! Risk of injuries. u Wear proper personal protective equipment. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 108: Suspension Of Activity
The measures set herein are used for protection against engine corrosion damages when suspended for up to 12 months. Divergent measures must be coordinated with KOHLER® Customer Service. The Diesel engine is installed. u Fill with operating fluids until it reaches the maximum level. Refer to chapter “Filling lubricants and operating fluids”.
Page 109 Operation and Maintenance Manual Maintenance Transportation — Storage For starting after 12 months of suspension of activity, u Follow the procedure in the chapter “Initial starting/test run/after out of service period”. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 111: Annexes
1400 1032.59 1650 1216.98 M 30 1350 995.71 1900 1401.37 2250 1659.51 M 33 1850 1364.49 2600 1917.66 3000 2212.69 M 36 2350 1733.27 3300 2433.96 3900 2876.49 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 112: For Locking Screws And Banjo Bolts
With copper sealing ring in accordance with DIN 7603: For banjo bolts in accordance with DIN 7643. For locking screws in accordance with DIN 910. For locking screws in accordance with DIN 908. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 113: Standard Torques For Metric Flange Joints
Fig. 89: Flange joints overview Information u Tightening torques applied to mating material: steel. u Tightening torques tolerances in the table: + 10 %. u Before screwing, lubricate thread with engine oil. © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 114 M 14 x 1,5 25.81 40.57 29.5 M 16 x 1,5 33.19 51.63 51.63 M 18 x 1,5 40.57 81.13 66.38 M 20 x 1,5 40.57 110.63 92.2 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 115: Standard Torques For Imperial Thread Unions
110.63 243.4 228.64 G 1 1/4A 177.01 398.28 331.9 G 1 1/2A 213.89 464.66 398.28 Tab. 34: Imperial thread unions L series, part 1 – see figure above © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 116 33.19 33.19 29.5 G 1/4A 33.19 33.19 29.5 G 3/8A 51.63 51.63 47.94 G 3/8A 51.63 51.63 47.94 G 1/2A 88.51 88.51 66.38 G 1/2A 88.51 88.51 66.38 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 117: Metric Thread Unions L Series (Up To 500 Bar/7252 Psi) For Aluminum
Tab. 38: Metric thread unions L series for aluminium – see figure above 6.1.6 Standard torques for cutting ring flange joints Pipe diameter Series Thread Z ft/lb M 10 × 1 10.33 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 118: Standard Torques For Triple Lock Flange Joints
14.75 29.5 9/16-18 22.13 44.25 3/4-16 44.25 84.82 14, 15, 16 7/8-14 55.32 106.95 18, 20 1 1/16-12 81.13 132.76 1 5/16-12 99.57 165.95 1 5/16-12 129.07 188.08 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 119: Standard Torques For Vsti Screw Plugs
206.52 M 22 x 1,5 M 42 x 2 258.15 M 24 x 1,5 66.38 M 48 x 2 295.02 Tab. 41: Standard torques for VSTI screw plugs © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 120: Glossary
5) Identification: Identifying safely the equipment so that interventions are made on the right equipment and not on another one. Tab. 42: Glossary table © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 121: Abbreviations
MultiMedia Card (used with digital cameras) Operation and Maintenance Manual Pressure control valve Personal Protective Equipment Power Take-Off Repair and Service Manual Society of Automotive Engineers Safe Work Procedure Top Dead Center © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 123: Unit Conversion Tables
Tab. 46: Pressure conversion factors table 6.4.4 Volume conversion factors Convert from Multiply by 61023.744 35.315 Imperial gallon 219.969 US gallon 264.172 l (liter) 1000 Tab. 47: Volume conversion factors table © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 124: Power Conversion Factors
°K K = C + 273.15 Tab. 52: Temperature conversion factors table 6.4.10 Density conversion factors Convert from Multiply by Kg/m lb/US gallon 0.00834 Kg/m lb/imperial gallon 0.01002 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 125 Operation and Maintenance Manual Annexes Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 53: Density conversion factors table © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 126: Prefix
Annexes Operation and Maintenance Manual Prefix 6.5 Prefix Name Symbol Factor tera giga mega kilo milli —3 micro µ —6 nano —9 Tab. 54: Common prefix multipliers table © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 127: Special Tools
Guiding rod M12 11133377 230610040 - Oil cooler Guiding rod M10 11133379 230610041 - Exhaust line Guiding rod M12 12427300 230610042 Water pump Tab. 55: Special tools © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 129: Index
Cylinder head 25 General safety instructions 32 Generator 26 Daily maintenance activities 68 Generator set ratings 55 Density conversion factors 124 Glossary 120 Design 17 Design overview 15 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 130 Signs on the engine 31 Occupational references 28 Special tools 127 Operating faults 49 Standard tightening torques 111 Operation 43 Standard torques for cutting ring flange joints 117 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...
Page 131 Type designation 23 Unauthorized personnel 30 Unit conversion tables 123 Unpacking / Depreservation 107 Vibration damper cover 21 Visual inspection — SL000 68 Volume conversion factors 123 Water requirements 65 © 2016 by Kohler Co. All rights reserved. KD62V12 33521030301_1_1 en 2016–12...

Kohler KD62V12 Operation And Maintenance Manual

Quick Links

Need help?

Questions and answers

Related Manuals for Kohler KD62V12

Summary of Contents for Kohler KD62V12

Table of Contents