Kohler KD62V12

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33521030301_8_1 EN_US 2022-09

LHID12566146

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Table of Contents11
Product Description17
Technical Description17
Design Overview17
Conventions22
Engine or Component Identification23
Diesel Engine Accessory Equipment26
Technical Data29
Diesel Engine29
Cylinder Head29
Coolant Thermostat29
Battery Charging Alternator30
Starter30
Safety32
Identification of the Warnings32
Warnings32
Additional Identifications32
Additional Rules and Directives33
Target Audience34
Responsibility of Machinery Owner34
Recommended Occupations According to International Standards34
Unauthorized Personnel - Servicing36
Intended Use36
Limitation of Liability37
Safety Instructions38
General Safety Instructions38
Safety While Commissioning38
Safety When Starting39
Preventing Injuries41
Preventing Bruising41
Preventing Burns41
Preventing Fires and Explosion Hazards42
Preventing Intoxication and Poisoning Hazards43
Preventing Electrical Hazards43
Preventing Noise Hazards43
Preventing Vibrations Hazards44
Preventing Electro-Magnetic Hazards44
Preventing Falling Risks44
Personal Protective Equipment (PPE)44
Accessible Areas46
Engine Ready for Use or in Operation46
Engine in Commissioning - Test Run47
Lockout/Tagout47
Emergency Stop48
Signage Recommendations48
Prevent Property Damage50
Safety Instructions for Engine Control Unit (ECU)50
Alarm Conditions50
Safety Instructions for the Fuel System51
Cleanliness Standards and Safety52
Disposal and Environment Protection53
Transportation - Storage54
Safe Handling54
Dimensions and Weight55
Transport58
Safe Transportation58
Transport Fastening58
Transport Devices60
Transport Conditions60
Storage62
Storage Conditions62
Storage Site Foundation Requirements62
Storage up to 12 Months62
Storage over 12 Months63
Unpacking and Depreservation64
Unpacking64
Depreservation65
Suspension of Activity67
Preservation, Packaging68
Preservation68
Control and Operation70
Filling Lubricants and Operating Fluids70
Lubricating Oil70
Coolant70
Diesel Fuel70
Starting the Engine71
Final Check71
Starting in Cold Temperatures72
Monitoring the Running Engine73
Stopping the Engine74
Shutting down the Engine74
Emergency Stop74
Initial Starting after out of Service Period75
Preparation of Initial Starting75
Dismantling76
Components Disposal77
Packaging Material Disposal78
Maintenance80
Maintenance Information80
General Information80
Maintenance Intervals80
Time between Overhaul (TBO)80
Generator Set Ratings81
Continuous Operating Power (COP)81
Prime Power (PRP)81
Emergency Standby Power (ESP)81
Service Level Definition82
Inspection and Maintenance Schedules83
Daily or Monthly Maintenance Activities (Level 1) - Version83
Service Level 1 - Engine Service, TBO 4000 Hours for ESP - Engine Operation - Version: 2021-0784
Service Level 2 - Engine Service, TBO 4000 Hours for ESP - Advanced Maintenance - Version: 2021-0787
Service Level 1 - Engine Service, TBO 15000 Hours for PRP - Engine Operation - Version: 2021-0788
Service Level 2 - Engine Service, TBO 15000 Hours for PRP - Advanced Maintenance - Version: 2021-0791
Service Level 1 - Engine Service, TBO 24000 Hours for COP - Engine Operation - Version: 2021-0793
Service Level 2 - Engine Service, TBO 24000 Hours for COP - Advanced Maintenance - Version: 2021-0796
Preparatory Maintenance Activities98
Post Maintenance Activities99
Spray Painting99
Daily or Monthly Maintenance Activities101
Inspecting Engine Overall Condition - SL000101
Inspecting Engine Running at Idle Speed - SL0-007104
Testing Engine in Operation (ESP Application Only) - SL008104
Generic Maintenance Activities106
Removing the Battery Charging Alternator Cover106
Checking Drive Belt - SL109107
Replacing Drive Belt - SL109
Replacing Tensioning Device - SL110109
Lubricating System111
Collecting and Analyzing Oil Sample - SL100111
Checking Prelubricating Pump (Optional) - SL103112
Checking the Engine Oil Level - SL001112
Changing Oil Filters - SL101113
Replacing Centrifuge Paper Filter - SL102114
Changing Engine Oil - SL101, SL121118
Cooling System123
Collecting Coolant Sample - SL120123
Replacing Coolant - SL116123
Inspecting Low Temperature Circuit (Charge Air Cooler) - SL002126
Checking Relief Bores - Coolant Pump - SL003127
Bleeding the HT/LT Coolant System128
Fuel System132
Draining off Water from Fuel Pre-Filter - SL004132
Draining off Water and Sediment of Fuel Tank132
Replacing Main Filter - SL105132
Bleeding the Fuel System133
Checking Differential Pressure - Fuel Pre-Filter - SL005133
Air System134
Checking Service Indicator on Air Filter - SL006134
Replacing Crankcase Breather - SL107134
Inspecting Engine By-Pass Flap - SL1-5461 (Depending on Configuration)135
Exhaust Gas Aftertreatment System (Depending on Configuration)136
Replacing Diesel Exhaust Fluid Filter - SL1-5320136
Lubricants and Operating Fluids141
Handling Lubricants and Operating Fluids141
Approved Diesel Fuels, Diesel Exhaust Fluids (DEF), and Fuel Additives142
Approved Lubricating Oils and Lubricating Oil Additives147
Approved Coolants153
Filling Volume157
Operating Faults158
Diagnosis Principles158
Faults - Cause - Remedy159
Tools and Devices164
Tools164
Special Tools164
Turning Device167
Appendix170
Technical Design Documents170
Error Code171
Cleaning Agents, Thread-Locking Adhesives and Greases183
Cleaning Agents and Thread-Locking Adhesives183
Standard Tightening Torques184
Lubricant and Threadlocker Application Rules184
Screws Pre-Tightening, Reuse, and Marking184
Standard Torques for Hexagonal / Socket / Flange Screws and Hexagonal / Flange Nuts187
Standard Torques for Internal Drive Pipe Plug with Conical Thread188
Standard Torques for Screws According to DIN 7643, DIN 910, DIN188
Standard Torques for Flange Joints190
Assembling Pipes with Cutting Rings196
Standard Torques for Triple Lock Flange Joints197
Standard Torques for VSTI Screw Plugs for Steel and Iron Cast Part198
Standard Torques for VSTI Screw Plugs for Aluminium199
Assembling Pipes with DKO Connectors (EL, ET, EW, GZ, GZR, RED)201
Standard Torques for Collar Clamps202
Standard Torques for Pipe Clamps According to DIN 3015203
Abbreviations - Acronyms204
Unit Conversion Tables206
Length Conversion Factors206
Mass Conversion Factors206
Pressure Conversion Factors206
Volume Conversion Factors206
Power Conversion Factors207
Moment of Inertia and Torque Conversion Factors207
Factors of Fuel Consumption Conversion207
Flow Conversion Factors207
Temperature Conversion Factors207
Density Conversion Factors207
Prefix209

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