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KD62V12
Kohler KD62V12 Operation And Maintenance Manual
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Maintenance
Exhaust gas aftertreatmen
t system (depending on configur
ation)
Fig. 82: Removing the heating mat scr
ews
u
Remove the heating mat scr
ews (M6).
Fig. 83: Removing the heating mat
u
Remove the heating mat fr
om the filter
.
KD62V12 33521030301_8_1 EN_US 2022-09
© 2022 by Kohler Co. All righ
ts reserved.
137
136
138
Table of Contents
Table of Contents
11
Product Description
17
Technical Description
17
Design Overview
17
Conventions
22
Engine or Component Identification
23
Diesel Engine Accessory Equipment
26
Technical Data
29
Diesel Engine
29
Cylinder Head
29
Coolant Thermostat
29
Battery Charging Alternator
30
Starter
30
Safety
32
Identification of the Warnings
32
Warnings
32
Additional Identifications
32
Additional Rules and Directives
33
Target Audience
34
Responsibility of Machinery Owner
34
Recommended Occupations According to International Standards
34
Unauthorized Personnel - Servicing
36
Intended Use
36
Limitation of Liability
37
Safety Instructions
38
General Safety Instructions
38
Safety While Commissioning
38
Safety When Starting
39
Preventing Injuries
41
Preventing Bruising
41
Preventing Burns
41
Preventing Fires and Explosion Hazards
42
Preventing Intoxication and Poisoning Hazards
43
Preventing Electrical Hazards
43
Preventing Noise Hazards
43
Preventing Vibrations Hazards
44
Preventing Electro-Magnetic Hazards
44
Preventing Falling Risks
44
Personal Protective Equipment (PPE)
44
Accessible Areas
46
Engine Ready for Use or in Operation
46
Engine in Commissioning - Test Run
47
Lockout/Tagout
47
Emergency Stop
48
Signage Recommendations
48
Prevent Property Damage
50
Safety Instructions for Engine Control Unit (ECU)
50
Alarm Conditions
50
Safety Instructions for the Fuel System
51
Cleanliness Standards and Safety
52
Disposal and Environment Protection
53
Transportation - Storage
54
Safe Handling
54
Dimensions and Weight
55
Transport
58
Safe Transportation
58
Transport Fastening
58
Transport Devices
60
Transport Conditions
60
Storage
62
Storage Conditions
62
Storage Site Foundation Requirements
62
Storage up to 12 Months
62
Storage over 12 Months
63
Unpacking and Depreservation
64
Unpacking
64
Depreservation
65
Suspension of Activity
67
Preservation, Packaging
68
Preservation
68
Control and Operation
70
Filling Lubricants and Operating Fluids
70
Lubricating Oil
70
Coolant
70
Diesel Fuel
70
Starting the Engine
71
Final Check
71
Starting in Cold Temperatures
72
Monitoring the Running Engine
73
Stopping the Engine
74
Shutting down the Engine
74
Emergency Stop
74
Initial Starting after out of Service Period
75
Preparation of Initial Starting
75
Dismantling
76
Components Disposal
77
Packaging Material Disposal
78
Maintenance
80
Maintenance Information
80
General Information
80
Maintenance Intervals
80
Time between Overhaul (TBO)
80
Generator Set Ratings
81
Continuous Operating Power (COP)
81
Prime Power (PRP)
81
Emergency Standby Power (ESP)
81
Service Level Definition
82
Inspection and Maintenance Schedules
83
Daily or Monthly Maintenance Activities (Level 1) - Version
83
Service Level 1 - Engine Service, TBO 4000 Hours for ESP - Engine Operation - Version: 2021-07
84
Service Level 2 - Engine Service, TBO 4000 Hours for ESP - Advanced Maintenance - Version: 2021-07
87
Service Level 1 - Engine Service, TBO 15000 Hours for PRP - Engine Operation - Version: 2021-07
88
Service Level 2 - Engine Service, TBO 15000 Hours for PRP - Advanced Maintenance - Version: 2021-07
91
Service Level 1 - Engine Service, TBO 24000 Hours for COP - Engine Operation - Version: 2021-07
93
Service Level 2 - Engine Service, TBO 24000 Hours for COP - Advanced Maintenance - Version: 2021-07
96
Preparatory Maintenance Activities
98
Post Maintenance Activities
99
Spray Painting
99
Daily or Monthly Maintenance Activities
101
Inspecting Engine Overall Condition - SL000
101
Inspecting Engine Running at Idle Speed - SL0-007
104
Testing Engine in Operation (ESP Application Only) - SL008
104
Generic Maintenance Activities
106
Removing the Battery Charging Alternator Cover
106
Checking Drive Belt - SL109
107
Replacing Drive Belt - SL
109
Replacing Tensioning Device - SL110
109
Lubricating System
111
Collecting and Analyzing Oil Sample - SL100
111
Checking Prelubricating Pump (Optional) - SL103
112
Checking the Engine Oil Level - SL001
112
Changing Oil Filters - SL101
113
Replacing Centrifuge Paper Filter - SL102
114
Changing Engine Oil - SL101, SL121
118
Cooling System
123
Collecting Coolant Sample - SL120
123
Replacing Coolant - SL116
123
Inspecting Low Temperature Circuit (Charge Air Cooler) - SL002
126
Checking Relief Bores - Coolant Pump - SL003
127
Bleeding the HT/LT Coolant System
128
Fuel System
132
Draining off Water from Fuel Pre-Filter - SL004
132
Draining off Water and Sediment of Fuel Tank
132
Replacing Main Filter - SL105
132
Bleeding the Fuel System
133
Checking Differential Pressure - Fuel Pre-Filter - SL005
133
Air System
134
Checking Service Indicator on Air Filter - SL006
134
Replacing Crankcase Breather - SL107
134
Inspecting Engine By-Pass Flap - SL1-5461 (Depending on Configuration)
135
Exhaust Gas Aftertreatment System (Depending on Configuration)
136
Replacing Diesel Exhaust Fluid Filter - SL1-5320
136
Lubricants and Operating Fluids
141
Handling Lubricants and Operating Fluids
141
Approved Diesel Fuels, Diesel Exhaust Fluids (DEF), and Fuel Additives
142
Approved Lubricating Oils and Lubricating Oil Additives
147
Approved Coolants
153
Filling Volume
157
Operating Faults
158
Diagnosis Principles
158
Faults - Cause - Remedy
159
Tools and Devices
164
Tools
164
Special Tools
164
Turning Device
167
Appendix
170
Technical Design Documents
170
Error Code
171
Cleaning Agents, Thread-Locking Adhesives and Greases
183
Cleaning Agents and Thread-Locking Adhesives
183
Standard Tightening Torques
184
Lubricant and Threadlocker Application Rules
184
Screws Pre-Tightening, Reuse, and Marking
184
Standard Torques for Hexagonal / Socket / Flange Screws and Hexagonal / Flange Nuts
187
Standard Torques for Internal Drive Pipe Plug with Conical Thread
188
Standard Torques for Screws According to DIN 7643, DIN 910, DIN
188
Standard Torques for Flange Joints
190
Assembling Pipes with Cutting Rings
196
Standard Torques for Triple Lock Flange Joints
197
Standard Torques for VSTI Screw Plugs for Steel and Iron Cast Part
198
Standard Torques for VSTI Screw Plugs for Aluminium
199
Assembling Pipes with DKO Connectors (EL, ET, EW, GZ, GZR, RED)
201
Standard Torques for Collar Clamps
202
Standard Torques for Pipe Clamps According to DIN 3015
203
Abbreviations - Acronyms
204
Unit Conversion Tables
206
Length Conversion Factors
206
Mass Conversion Factors
206
Pressure Conversion Factors
206
Volume Conversion Factors
206
Power Conversion Factors
207
Moment of Inertia and Torque Conversion Factors
207
Factors of Fuel Consumption Conversion
207
Flow Conversion Factors
207
Temperature Conversion Factors
207
Density Conversion Factors
207
Prefix
209
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Kohler KD62V12 Specifications
General
Brand
Kohler
Model
KD62V12
Category
Engine
Language
English
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