Kohler KD62V12 User manual

Operation and Maintenance Manual
Original Instructions
Diesel engine
KD62V12
From serial number 2019730018
EN_US
33521030301_6_1
02-2019

Operation and Maintenance Manual
For United States only
WARNING: This product can expose you to chemicals,
including carbon monoxide and benzene, which are known to
the State of California to cause cancer and birth defects or
other reproductive harm.
For more information go to www.p65warnings.ca.gov/
WARNING: Breathing diesel engine exhaust exposes you
to chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area.
- 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
2© 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Service Assistance
For professional advice on generator set power requirements and conscientious service, please
contact your nearest Kohler distributor or dealer.
– Visit the KOHLER Co. website at KOHLERPower.com.
– Look at the labels and decals on your KOHLER product or review the appropriate literature or
documents included with the product.
– Call toll free in the US and Canada 1-800-544-2444.
– Outside the US and Canada, call the nearest regional office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
China
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
To order special tools, please refer to the cross reference list in the appendix.
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 3

Operation and Maintenance Manual
For KOHLER-SDMO power generating sets:
– Visit the website the site of KOHLER-SDMO at www.kohlersdmo.com.
– Pay attention to the labels and stickers on your KOHLER-SDMO product or check the corre-
sponding literature or documents included with the product's scope of delivery.
– Call the nearest regional office.
SALES OFFICE FRANCE
WEST
SDMO BREST
Tel.: [phone]
Fax: [phone]
SOUTHWEST
SDMO TOULOUSE
Tel.: [phone]
Fax: [phone]
BRANCH OFFICES
SOUTH AFRICA
SDMO SOUTH AFRICA
Tel.: [phone]
Fax: [phone]
MID-WEST
SDMO CHOLET
Tel.: [phone]
Fax: [phone]
SUBSIDIARIES
GERMANY
SDMO GMBH
Tel.: [phone]
Fax: [phone]
ALGERIA
SDMO ALGIERS
Tel.: [phone]
Fax: [phone]
PARIS/NORTH & NORMANDY
SDMO ARRAS
Tel.: [phone]
Fax: [phone]
SDMO GENNEVILLIERS
Tel.: [phone]
Fax: [phone]
LATIN AMERICA & CARRIBEAN
Tel.: [phone]
Fax: [phone]
DUBAI
SDMO MIDDLE EAST
Tel.: [phone]
Fax: [phone]
BELGIUM
SDMO NV/SA
Tel.: [phone]
Fax: [phone]
EGYPT
SDMO KAIRO
Tel./Fax: [phone]
EAST
SDMO METZ
Tel.: [phone]
Fax: [phone]
BRAZIL
KOHLER MAQUIGERAL
Tel.: [phone]
KENYA
SDMO NAIROBI
Tel./Fax: [phone]
00
SOUTH ESAT
SDMO AIX-EN-PROVENCE
Tel.: [phone]
Fax: [phone]
SDMO VALENCE
Tel.: [phone]
Fax: [phone]
SPAIN
SDMO INDUSTRIES IBERICA
Tel.: [phone]
Tel./Fax: [phone]
RUSSIA
SDMO MOSCOW
Tel./Fax: [phone]
UK
SDMO ENERGY LTD.
Tel.: [phone]
Fax: [phone]
TOGO
SDMO WEST AFRICA
Tel.: [phone]
TURKEY
SDMO ISTANBUL
Tel.: [phone]
Please consult the cross-reference list in the appendix when ordering special tools.
4© 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Revision history
Version Author Modification Date
05 MUA California Proposal 65,
Service assistance,
Maintenance plan,
Lubricants and operating fluids,
Error code
Spelling mistakes
30th of July2018
06 MUA First 3.02 engine version,
Spelling mistakes, 22th of February 2019
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 5

Operation and Maintenance Manual
6© 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Preface
About this document
This Operation and Maintenance Manual (OMM) has been written for the Diesel engine's operator
and maintenance personnel.
This OMM provides information regarding:
–Safety Regulations
–Handling and operation
–Maintenance
Anyone involved in working with or on the Diesel engine must read and follow the instructions in
the OMM carefully before the first commissioning and at regular intervals.
Work with the Diesel engine includes :
–Handling, storing of the components.
–Servicing, including inspections and preventive maintenance.
Information
uFor any information concerning the machinery in which the engine is mounted, refer to the
instructions of the generator set.
uFor further explanation or information, the Customer Service and Customer Service training
center departments of the Kohler Co. are available any time to answer any queries.
The OMM facilitates the operator's familiarization with the Diesel engine and prevents faults
through incorrect operation.
The machinery owner is responsible for supplementing the operating instructions of the engine with
its machinery and with instructions based on existing national regulations on accident prevention
and environmental protection. In addition to these operating instructions and the regulations on
accident prevention applicable in the user's country and at the place of use, it is also necessary to
comply with the recognized technical rules on safety and technically proficient working.
Some sections of this operating manual do not apply to all machines.
Some illustrations in this manual may show details and implements that are different from your
machine.
Protective devices and covers have been removed to provide a clearer representation in some
illustrations.
KOHLER engines are subject to continuous development and improvement.
This may result in modifications to your engine which may not be referred to in this OMM.
If you require further explanations or information, please contact your nearest authorized Kohler
service representative.
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 7

Preface Operation and Maintenance Manual
About this document
Spare parts
Only original KOHLER spare parts, or spare parts purchased by Kohler Co. should be used for
repairing KOHLER Diesel engines.
Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers,
such as guarantees, service orders, etc. null and void without advance notice, if spare parts other
than original KOHLER spare parts or spare parts purchased by Kohler Co. are used for mainte-
nance or repair.
Fuels, lubricants and coolants
Only fuels, lubricants and coolants approved by Kohler Co. may be used for the operation of
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 fuel, lubricants and
coolants other than fuel, lubricants and coolants approved by Kohler Co. are used for maintenance
or repair.
Liability and warranty
Due to the wide variety of products offered by other manufacturers (e.g. service products, lubri-
cants, tool attachments and spare parts), Kohler Co. cannot examine the general suitability and
absence of defects in third-party products which are used in or on KOHLER products. The same
applies to possible interactions between third-party products and products approved by Kohler Co.
Third-party products are used in or on KOHLER engines at the user's own discretion. Kohler Co.
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.
Furthermore, Kohler Co. will not recognize any warranty claims attributable to incorrect operation,
inadequate or insufficient maintenance or use of unapproved operating fluids or non-compliance
with safety regulations.
Kohler Co. will cancel any obligations entered into by Kohler Co. and/or its dealers, such as guar-
antees, service contracts etc., without advance notice if any parts other than original KOHLER
parts or spare parts purchased from Kohler Co. are used for maintenance and repairs.
The aforementioned provisions do not extend the warranty and liability conditions in the general
terms and conditions of business of Kohler Co.
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.
Copyright - Proprietary notice ISO16016
The reproduction, distribution and utilization of this document as well as the communication of its
contents to others without express authorization is prohibited
Offenders will be held liable for the payment of damages.
All rights reserved in the event of the grant of a patent, utility model or design.
8© 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Contents
1 Product description 17
1.1 Technical description 17
1.1.1 Design overview 17
1.1.2 Cylinder designation, direction of rotation 22
1.1.3 Nameplates 22
1.1.4 Diesel engine accessory equipment 25
1.2 Technical data 29
1.2.1 Diesel engine 29
1.2.2 Cylinder head 29
1.2.3 Coolant thermostat 29
1.2.4 Battery charging alternator 30
1.2.5 Starter 30
1.2.6 Flywheel housing 30
2 Safety 31
2.1 Identification of the warnings 31
2.1.1 Warnings 31
2.1.2 Additional identifications 31
2.1.3 Additional rules and directives 32
2.2 Target audience 33
2.2.1 Responsibility of machinery owner 33
2.2.2 International standard classification of occupations 33
2.2.3 Occupational references 33
2.2.4 For the SL1 maintenance of power generation engines: Maintenance
Technician 33
2.2.5 For the SL2 maintenance of power generation engines: Technician 34
2.2.6 For the SL3 maintenance of power generation engines: Mechanical
Technician 34
2.2.7 For the operation of power generation engines: Operator 34
2.2.8 Unauthorized personnel - servicing 35
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 9

Contents Operation and Maintenance Manual
2.3 Intended use 35
2.4 Limitation of liability 36
2.5 Safety instructions 37
2.5.1 General safety instructions 37
2.5.2 Safety while commissioning 37
2.5.3 Safety when starting 38
2.6 Preventing injuries 40
2.6.1 Preventing bruising 40
2.6.2 Preventing burns 40
2.6.3 Preventing fires and explosion hazards 41
2.6.4 Preventing intoxication and poisoning hazards 42
2.6.5 Preventing electrical hazards 42
2.6.6 Preventing noise hazards 42
2.6.7 Preventing vibrations hazards 43
2.6.8 Preventing electro-magnetic hazards 43
2.6.9 Preventing falling risks 43
2.7 Personal Protective Equipment (PPE) 43
2.8 Accessible areas 45
2.8.1 Engine ready for use or in operation 45
2.8.2 Engine in commissioning — test-run 46
2.8.3 Emergency stop 46
2.8.4 Signage recommendations 47
2.9 Prevent property damages 48
2.9.1 Safety instructions for engine control unit (ECU) 48
2.9.2 Alarm conditions 48
2.9.3 Safety instructions for the fuel system 49
2.9.4 Cleanliness standards and safety 50
2.10 Disposal and environment protection 51
3 Transportation - Storage 53
3.1 Safe handling 53
3.2 Dimensions and weight 54
3.3 Transport 56
3.3.1 Safe transportation 56
3.3.2 Transport fastening 56
10 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Operation and Maintenance Manual Contents
3.3.3 Transport devices 58
3.3.4 Transport conditions 58
3.4 Storage 60
3.4.1 Storage conditions 60
3.4.2 Storage site foundation requirements 60
3.4.3 Storage up to 12 months 60
3.4.4 Storage over 12 months 60
3.5 Unpacking/Depreservation 61
3.5.1 Unpacking 61
3.5.2 Depreservation 62
3.6 Suspension of activity 63
3.7 Preservation, packaging 64
3.7.1 Preservation 64
4 Control and operation 65
4.1 Filling lubricants and operating fluids 65
4.1.1 Engine oil 65
4.1.2 Coolant 65
4.1.3 Fuel 65
4.2 Starting the engine 66
4.2.1 Final check 66
4.2.2 Starting in cold temperatures 67
4.2.3 Monitoring the running engine 67
4.2.4 Exhaust 68
4.2.5 Drainage 68
4.2.6 Air filter 68
4.2.7 Engine and coolant pumps — Charge air cooler 68
4.2.8 Stopping the Diesel engine 69
4.2.9 Initial starting/test run/after out of service period 69
4.3 Dismantling 70
4.4 Components disposal 71
4.5 Packaging material disposal 72
5 Maintenance 73
5.1 Inspection and maintenance schedule 73
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 11

Contents Operation and Maintenance Manual
5.2 Maintenance plan use 74
5.3 Generator set ratings 75
5.3.1 Continuous Operating Power (COP) 75
5.3.2 Prime Power (PRP) 75
5.3.3 Emergency Standby Power (ESP) 75
5.3.4 Time between overhaul (TBO) 75
5.4 Service level definition 76
5.4.1 Daily or monthly maintenance activities (Level 1) - Version: 2018/07-2 76
5.4.2 Service level 1 — Engine Service, TBO 4000 hrs for ESP — Engine
Operation - Version: 2018/07-2 78
5.4.3 Service level 2— Engine Service, TBO 4000 hrs for ESP — Advanced
maintenance - Version: 2018/07-2 81
5.4.4 Service level 1 — Engine Service, TBO 15000 hrs for PRP — Engine
Operation - Version: 2018/07-2 82
5.4.5 Service level 2— Engine Service, TBO 15000 hrs for PRP — Advanced
maintenance - Version: 2018/07-2 85
5.4.6 Service level 1 — Engine Service, TBO 24000 hrs for COP — Engine
Operation - Version: 2018/07-2 86
5.4.7 Service level 2— Engine Service, TBO 24000 hrs for COP — Advanced
maintenance - Version: 2018/07-2 89
5.5 Preparatory maintenance activities 91
5.6 Daily or monthly maintenance activities 92
5.6.1 Visual inspection — SL000 92
5.6.2 Observation of the engine while running — SL007 95
5.6.3 Removal of the battery charging alternator cover 95
5.6.4 Checking drive belt — SL109 96
5.6.5 Replacing V-ribbed belt — SL 109 97
5.6.6 Replacing tensioning device — SL110 98
5.6.7 Test run — SL008 99
5.7 Lubricating system 100
5.7.1 Oil sampling and analyze — SL100 100
5.7.2 Checking prelubricating pump (optional) — SL103 101
5.7.3 Checking the engine oil level — SL001 101
5.7.4 Changing oil filters — SL101 bis 103
5.7.5 Replacing centrifuge paper filter — SL102 104
5.7.6 Changing Diesel engine oil — SL101, SL101bis, SL121 107
5.8 Cooling system 112
12 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Operation and Maintenance Manual Contents
5.8.1 Coolant sampling — SL120 112
5.8.2 Checking coolant level — SL001 112
5.8.3 Inspecting low temperature circuit (charge air cooler) — SL002 113
5.8.4 Checking relieve bores — water/coolant pump — SL003 114
5.8.5 Coolant drain points — SL116 115
5.9 Fuel system 117
5.9.1 Draining off water from fuel prefilter — SL004 117
5.9.2 Drain off water and sediment of fuel tank 117
5.9.3 Replacing main filter - SL105 117
5.9.4 Bleeding the fuel system 118
5.9.5 Checking differential pressure — fuel prefilter — SL005 118
5.10 Air system 119
5.10.1 Check service indicator on air filter — SL006 119
5.10.2 Replace crankcase breather — SL107 119
5.11 Lubricants and operating fluids 120
5.11.1 Handling lubricants and operating fluids 120
5.11.2 Filling volume 121
5.11.3 Diesel fuels 121
5.11.4 Diesel engine lubricants 125
5.11.5 Diesel engine coolant 129
6 Operating faults 135
6.1 Diagnosis principles 135
6.2 Faults - Cause - Remedy 136
7 Tools and devices 141
7.1 Tools 141
7.1.1 Special tools 141
8 Appendix 145
8.1 Technical design documents 145
8.2 Error code 146
8.3 Cleaning agents, thread-locking adhesives and greases 158
8.3.1 Cleaning agents and thread-locking adhesives 158
8.3.2 Greases 158
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 13

Contents Operation and Maintenance Manual
8.4 Standard tightening torques 159
8.4.1 Screws pre-tightening, reuse and marking 159
8.4.2 Standard torques for hexagonal / socket / flange screws 161
8.4.3 Standard torques for internal drive pipe plug with conical thread 162
8.4.4 Standard torques for locking screws and banjo bolts 163
8.4.5 Standard torques for metric flange joints 164
8.4.6 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) 164
8.4.7 Standard torques for metric thread unions S series (up to 800 bar/
11603 Psi) 165
8.4.8 Standard torques for imperial thread unions L series (up to 500 bar/
7252 Psi) 166
8.4.9 Standard torques for imperial thread unions S series (up to 800 bar/
11603 Psi) 167
8.4.10 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) for aluminum 167
8.4.11 Standard torques for cutting ring flange joints 168
8.4.12 Standard torques for triple lock flange joints 169
8.4.13 Standard torques for VSTI screw plugs 170
8.5 Abbreviations - Acronyms 173
8.6 Unit conversion tables 175
8.6.1 Length conversion factors 175
8.6.2 Mass conversion factors 175
8.6.3 Pressure conversion factors 175
8.6.4 Volume conversion factors 175
8.6.5 Power conversion factors 176
8.6.6 Moment of inertia and torque conversion factors 176
8.6.7 Fuel consumption conversion factors 176
8.6.8 Flow conversion factors 176
8.6.9 Temperature conversion factors 176
8.6.10 Density conversion factors 176
8.7 Prefix 178
14 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 15

Operation and Maintenance Manual
16 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

1 Product description
1.1 Technical description
1.1.1 Design overview
Fig. 1: Diesel engine / view from the flywheel side
CS Coupling side (flywheel side) 6Charge air cooler
1Engine brackets (x4) 7Battery charging alternator
2Flywheel 8Oil dipstick
3Fuel filter 9Oil centrifuge assembly
4Crankcase ventilation filter housing 10 High pressure fuel pump (x2)
5Turbocharger assembly (x3)
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 17

Product description Operation and Maintenance Manual
Technical description
Fig. 2: Diesel engine / view from the vibration damper side
CCS Counter coupling side (vibration damper
side) 5Exhaust gas connection (x3)
1Water pump high temperature 6Lifting lug (x4)
2Oil filter cartridge (piston cooling jets) 7Oil cooler
3Water pump low temperature 8Oil filter cartridge (lubrication system)
4Thermostat housing low temperature
Fig. 3: Diesel engine / view from the vibration damper side
CCS Engine front (vibration damper side) 12 Cylinder head cover
See next page for continuation of the image legend
18 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02

Operation and Maintenance Manual Product description
Technical description
9Vibration damper cover 13 Charge air pipe
10 Engine control unit - ECU 14 Starter (x2)
11 Air intake (x4) 15 Oil pan
Design
Water-cooled V12 Diesel engine with common rail (CR), exhaust gas turbo charging and air to
water charge air cooling.
Characteristics
A robust basic design and generous dimensioning form the basis for high operational safety and a
long service life. Low fuel consumption and exhaust gas emissions by optimized combustion
process adapted to the emission requirements. Minimized maintenance obtained by optimized
engine components and accessories lead to higher availability and increased efficiency.
Driving gear
The V12 Diesel engine has a quench tempered steel crankshaft with inductively hardened pins and
fillets. A torsional vibration damper is mounted on the crankshaft on the engine damper side.
Precisely forged con-rod, driving gear bearings are sputtered. Steel top weld pistons with stage
support and cooling duct
Housing
Rigid, laterally drawn down crankcase upper section with optimized structure and an oil pan as
lower section. Four–valve single cylinder heads with flow optimized ports as well as replaceable
valve seats and valve guide. Brackets, flywheel housing, aggregate support and oil pan on the
bottom close the Diesel engine.
Drive control
Two inlet and outlet valves mounted in the cylinder head for each cylinder. Actu-ated through steel
camshaft via cam follower, push rod and rocker arm.
Driven by gears on the flywheel side:
– Camshaft
– High pressure pump
– Fuel pre-feed pump
– Oil pump
Driven by gear train on the damper side:
– Water pumps
– Battery charging alternator
Lubrication
Force-feed lubrication with lubricating oil pump for crankshaft bearing, con-rod bearing and
camshaft bearing as well as piston pin bushings, cam followers, rocker arms and gear bearings.
Oil filtration depending on requirements such as automatic oil filter with centrifugal filter (optional).
Following auxiliary units are also connected to the Diesel engine — lubricant oil circuit:
– High pressure pumps
– Coolant pumps
– Turbochargers
– Air compressor (depending on machinery)
KD62V12 33521030301_6_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 19

Product description Operation and Maintenance Manual
Technical description
Crankcase ventilation
As modular arrangement depending on requirements, up to four high efficiency passive filter units
are mounted on top of the engine.
The blow by gases leaving the filter system are fed back to the turbocharger intake by pipes made
of galvanized steel.
Oil sampling location — SL100
Fig. 4: Oil sampling point on engine left side
1Sampling point
See the Application Set manual for more details.
High/low temperatures coolant circuits
Thermostatically controlled coolant with separate pumps for high and low tempera-ture coolant.
Individual supply of each cylinder unit via distribution channels cast into the crank-case.
Pistons are cooled by the engine lubricating system. Each piston is supplied with oil by piston
cooling jets.
Fuel filters
Depending on requirements, several filters combinations such as prefilter unit or working filter
ensure the fuel conditioning.
Therefore a high contamination retention capacity between tank and engine is ensured.
Injection system
The high pressure fuel system is supplied by a high pressure pump.
The low pressure system is supplied by the fuel pre-feed pump which ensures the circulation from
the tank and pre-feeds the high pressure system.
The high pressure system leads the pressurized fuel from high pressure pump to the injectors.
The high pressure system is secured by a pressure control valve.
20 © 2019 by Kohler Co. All rights reserved. KD62V12 33521030301_6_1 EN_US 2019-02