Operation And Maintenance Manual - Kohler Co. - Free Download PDF

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Operation and Maintenance ManualOriginal InstructionsDiesel engineKD62V12From serial number 2019730018EN US33521030301 6 102-2019a

Operation and Maintenance ManualFor United States onlyWARNING: This product can expose you to chemicals,including carbon monoxide and benzene, which are known tothe State of California to cause cancer and birth defects orother reproductive harm.For more information go to www.p65warnings.ca.gov/WARNING: Breathing diesel engine exhaust exposes youto chemicals known to the State of California to cause cancerand 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 2019 by Kohler Co. All rights reserved.2KD62V12 33521030301 6 1 EN US2019-02

Service AssistanceFor professional advice on generator set power requirements and conscientious service, pleasecontact 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 ordocuments 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 HeadquartersNetherlands B.V.Kristallaan 14761 ZC ZevenbergenThe NetherlandsPhone: (31) 168 331630Fax: (31) 168 331631ChinaEast China Regional Office, ShanghaiPhone: (86) 21 6288 0500Fax: (86) 21 6288 0550Asia PacificKohler Asia Pacific HeadquartersSingapore, Republic of SingaporePhone: (65) 6264-6422Fax: (65) 6264-6455India, Bangladesh, Sri LankaIndia Regional OfficeBangalore, IndiaPhone: (91) 80 3366208(91) 80 3366231Fax: (91) 80 3315972ChinaNorth China Regional Office, BeijingPhone: (86) 10 6518 7950(86) 10 6518 7951(86) 10 6518 7952Fax: (86) 10 6518 7955Japan, KoreaNorth Asia Regional OfficeTokyo, JapanPhone: (813) 3440-4515Fax: (813) 3440-2727To order special tools, please refer to the cross reference list in the appendix.KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.3

Operation and Maintenance ManualFor 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 corresponding literature or documents included with the product's scope of delivery.– Call the nearest regional office.SALES OFFICE FRANCEWESTSDMO BRESTTel.: 33 (0) 2 98 41 13 48Fax: 33 (0) 2 98 41 13 57SOUTHWESTSDMO TOULOUSETel.: 33 (0) 5 61 24 75 75Fax: 33 (0) 5 61 24 75 79BRANCH OFFICESSOUTH AFRICASDMO SOUTH AFRICATel.: 27 (0) 8 32 33 55 61Fax: 33 (0) 1 72 27 61 51MID-WESTSDMO CHOLETTel.: 33 (0) 2 41 75 96 70Fax: 33 (0) 2 41 75 96 71SUBSIDIARIESGERMANYSDMO GMBHTel.: 49 (0) 63 32 97 15 00Fax: 49 (0) 63 32 97 15 11ALGERIASDMO ALGIERSTel.: 213 (0) 21 68 12 12Fax: 213 (0) 21 68 14 14PARIS/NORTH & NORMANDYSDMO ARRASTel.: 33 (0) 3 21 73 38 26Fax: 33 (0) 3 21 73 14 59SDMO GENNEVILLIERSTel.: 33 (0) 1 41 88 38 00Fax: 33 (0) 1 41 88 38 37LATIN AMERICA & CARRIBEAN DUBAITel.: 1 (305) 863 0012SDMO MIDDLE EASTFax: 1 (954) 432 8330Tel.: 971 4 458 70 20Fax: 971 4 458 69 85BELGIUMSDMO NV/SATel.: 32 36 46 04 15Fax: 32 36 46 06 25EGYPTSDMO KAIROTel./Fax: 20 (2) 22 67 12 78EASTSDMO METZTel.: 33 (0) 3 87 37 88 50Fax: 33 (0) 3 87 37 88 59BRAZILKOHLER MAQUIGERALTel.: 55 (11) 37 89 60 00KENYASDMO NAIROBITel./Fax: 25 (47) 07 60 5400SOUTH ESATSDMO AIX-EN-PROVENCETel.: 33 (0) 4 42 52 51 60Fax: 33 (0) 4 42 52 51 61SDMO VALENCETel.: 33 (0) 4 75 81 31 00Fax: 33 (0) 4 75 81 31 10SPAINSDMO INDUSTRIES IBERICATel.: 34 (9) 35 86 34 00Tel./Fax: 34 (9) 35 80 31 36RUSSIASDMO MOSCOWTel./Fax: 7 495 665 16 98UKSDMO ENERGY LTD.Tel.: 44 (0) 16 06 83 81 20Fax: 44 (0) 16 06 83 78 63TOGOSDMO WEST AFRICATel.: 228 22 22 65 65TURKEYSDMO ISTANBULTel.: 90 53 07 35 09 10Please consult the cross-reference list in the appendix when ordering special tools. 2019 by Kohler Co. All rights reserved.4KD62V12 33521030301 6 1 EN US2019-02

Revision a Proposal 65,Service assistance,Maintenance plan,Lubricants and operating fluids,Error codeSpelling mistakes30th of July 201806MUAFirst 3.02 engine version,Spelling mistakes,22th of February 2019KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.5

Operation and Maintenance Manual 2019 by Kohler Co. All rights reserved.6KD62V12 33521030301 6 1 EN US2019-02

PrefaceAbout this documentThis Operation and Maintenance Manual (OMM) has been written for the Diesel engine's operatorand maintenance personnel.This OMM provides information regarding:– Safety Regulations– Handling and operation– MaintenanceAnyone involved in working with or on the Diesel engine must read and follow the instructions inthe 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.Informationu For any information concerning the machinery in which the engine is mounted, refer to theinstructions of the generator set.u For further explanation or information, the Customer Service and Customer Service trainingcenter 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 faultsthrough incorrect operation.The machinery owner is responsible for supplementing the operating instructions of the engine withits machinery and with instructions based on existing national regulations on accident preventionand environmental protection. In addition to these operating instructions and the regulations onaccident prevention applicable in the user's country and at the place of use, it is also necessary tocomply 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 yourmachine.Protective devices and covers have been removed to provide a clearer representation in someillustrations.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 Kohlerservice representative.KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.7

PrefaceOperation and Maintenance ManualAbout this documentSpare partsOnly original KOHLER spare parts, or spare parts purchased by Kohler Co. should be used forrepairing 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 otherthan original KOHLER spare parts or spare parts purchased by Kohler Co. are used for maintenance or repair.Fuels, lubricants and coolantsOnly fuels, lubricants and coolants approved by Kohler Co. may be used for the operation ofKOHLER 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 andcoolants other than fuel, lubricants and coolants approved by Kohler Co. are used for maintenanceor repair.Liability and warrantyDue to the wide variety of products offered by other manufacturers (e.g. service products, lubricants, tool attachments and spare parts), Kohler Co. cannot examine the general suitability andabsence of defects in third-party products which are used in or on KOHLER products. The sameapplies 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 ordamage 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-compliancewith safety regulations.Kohler Co. will cancel any obligations entered into by Kohler Co. and/or its dealers, such as guarantees, service contracts etc., without advance notice if any parts other than original KOHLERparts 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 generalterms and conditions of business of Kohler Co.Modifications, conditions, copyrightKohler Co. reserves the right to make modifications in the course of technical development, withoutissuing prior notification.The aforementioned provisions do not extend the warranty and liability conditions in the generalterms and conditions of business of Kohler Co.Copyright - Proprietary notice ISO16016The reproduction, distribution and utilization of this document as well as the communication of itscontents to others without express authorization is prohibitedOffenders 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. 2019 by Kohler Co. All rights reserved.8KD62V12 33521030301 6 1 EN US2019-02

Contents1Product description171.1Technical description171.1.1Design overview171.1.2Cylinder designation, direction of rotation221.1.3Nameplates221.1.4Diesel engine accessory equipment251.22Technical data291.2.1Diesel engine291.2.2Cylinder head291.2.3Coolant thermostat291.2.4Battery charging alternator301.2.5Starter301.2.6Flywheel housing30Safety312.1Identification of the warnings312.1.1Warnings312.1.2Additional identifications312.1.3Additional rules and directives322.2Target audience332.2.1Responsibility of machinery owner332.2.2International standard classification of occupations332.2.3Occupational references332.2.4For the SL1 maintenance of power generation engines: MaintenanceTechnician332.2.5For the SL2 maintenance of power generation engines: Technician342.2.6For the SL3 maintenance of power generation engines: MechanicalTechnician342.2.7For the operation of power generation engines: Operator342.2.8Unauthorized personnel - servicing35KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.9

ContentsOperation and Maintenance Manual2.3Intended use352.4Limitation of liability362.5Safety instructions372.5.1General safety instructions372.5.2Safety while commissioning372.5.3Safety when starting382.6402.6.1Preventing bruising402.6.2Preventing burns402.6.3Preventing fires and explosion hazards412.6.4Preventing intoxication and poisoning hazards422.6.5Preventing electrical hazards422.6.6Preventing noise hazards422.6.7Preventing vibrations hazards432.6.8Preventing electro-magnetic hazards432.6.9Preventing falling risks432.7Personal Protective Equipment (PPE)432.8Accessible areas452.8.1Engine ready for use or in operation452.8.2Engine in commissioning — test-run462.8.3Emergency stop462.8.4Signage recommendations472.93Preventing injuriesPrevent property damages482.9.1Safety instructions for engine control unit (ECU)482.9.2Alarm conditions482.9.3Safety instructions for the fuel system492.9.4Cleanliness standards and safety502.10 Disposal and environment protection51Transportation - Storage533.1Safe handling533.2Dimensions and weight543.3Transport563.3.1Safe transportation563.3.2Transport fastening56 2019 by Kohler Co. All rights reserved.10KD62V12 33521030301 6 1 EN US2019-02

Operation and Maintenance Manual3.43.543.3.3Transport devices583.3.4Transport conditions58Storage603.4.1Storage conditions603.4.2Storage site foundation requirements603.4.3Storage up to 12 months603.4.4Storage over 12 3.5.2Depreservation623.6Suspension of activity633.7Preservation, packaging643.7.164PreservationControl and operation654.1Filling lubricants and operating fluids654.1.1Engine oil654.1.2Coolant654.1.3Fuel654.25ContentsStarting the engine664.2.1Final check664.2.2Starting in cold temperatures674.2.3Monitoring the running engine674.2.4Exhaust684.2.5Drainage684.2.6Air filter684.2.7Engine and coolant pumps — Charge air cooler684.2.8Stopping the Diesel engine694.2.9Initial starting/test run/after out of service period694.3Dismantling704.4Components disposal714.5Packaging material disposal72Maintenance735.173Inspection and maintenance scheduleKD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.11

ContentsOperation and Maintenance Manual5.2Maintenance plan use745.3Generator set ratings755.3.1Continuous Operating Power (COP)755.3.2Prime Power (PRP)755.3.3Emergency Standby Power (ESP)755.3.4Time between overhaul (TBO)755.4Service level definition765.4.1Daily or monthly maintenance activities (Level 1) - Version: 2018/07-2765.4.2Service level 1 — Engine Service, TBO 4000 hrs for ESP — EngineOperation - Version: 2018/07-278Service level 2— Engine Service, TBO 4000 hrs for ESP — Advancedmaintenance - Version: 2018/07-281Service level 1 — Engine Service, TBO 15000 hrs for PRP — EngineOperation - Version: 2018/07-282Service level 2— Engine Service, TBO 15000 hrs for PRP — Advancedmaintenance - Version: 2018/07-285Service level 1 — Engine Service, TBO 24000 hrs for COP — EngineOperation - Version: 2018/07-286Service level 2— Engine Service, TBO 24000 hrs for COP — Advancedmaintenance - Version: 2018/07-2895.4.35.4.45.4.55.4.65.4.75.5Preparatory maintenance activities915.6Daily or monthly maintenance activities925.6.1Visual inspection — SL000925.6.2Observation of the engine while running — SL007955.6.3Removal of the battery charging alternator cover955.6.4Checking drive belt — SL109965.6.5Replacing V-ribbed belt — SL 109975.6.6Replacing tensioning device — SL110985.6.7Test run — SL008995.75.8Lubricating system1005.7.1Oil sampling and analyze — SL1001005.7.2Checking prelubricating pump (optional) — SL1031015.7.3Checking the engine oil level — SL0011015.7.4Changing oil filters — SL101 bis1035.7.5Replacing centrifuge paper filter — SL1021045.7.6Changing Diesel engine oil — SL101, SL101bis, SL121107Cooling system112 2019 by Kohler Co. All rights reserved.12KD62V12 33521030301 6 1 EN US2019-02

Operation and Maintenance Manual5.9Contents5.8.1Coolant sampling — SL1201125.8.2Checking coolant level — SL0011125.8.3Inspecting low temperature circuit (charge air cooler) — SL0021135.8.4Checking relieve bores — water/coolant pump — SL0031145.8.5Coolant drain points — SL116115Fuel system1175.9.1Draining off water from fuel prefilter — SL0041175.9.2Drain off water and sediment of fuel tank1175.9.3Replacing main filter - SL1051175.9.4Bleeding the fuel system1185.9.5Checking differential pressure — fuel prefilter — SL0051185.10 Air system1195.10.1 Check service indicator on air filter — SL0061195.10.2 Replace crankcase breather — SL1071195.11 Lubricants and operating fluids675.11.1 Handling lubricants and operating fluids1205.11.2 Filling volume1215.11.3 Diesel fuels1215.11.4 Diesel engine lubricants1255.11.5 Diesel engine coolant129Operating faults1356.1Diagnosis principles1356.2Faults - Cause - Remedy136Tools and devices1417.1141Tools7.1.18120Special tools141Appendix1458.1Technical design documents1458.2Error code1468.3Cleaning agents, thread-locking adhesives and greases1588.3.1Cleaning agents and thread-locking adhesives1588.3.2Greases158KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.13

ContentsOperation and Maintenance Manual8.4Standard tightening torques1598.4.1Screws pre-tightening, reuse and marking1598.4.2Standard torques for hexagonal / socket / flange screws1618.4.3Standard torques for internal drive pipe plug with conical thread1628.4.4Standard torques for locking screws and banjo bolts1638.4.5Standard torques for metric flange joints1648.4.6Standard torques for metric thread unions L series (up to 500 bar/7252Psi)164Standard torques for metric thread unions S series (up to 800 bar/11603 Psi)165Standard torques for imperial thread unions L series (up to 500 bar/7252 Psi)166Standard torques for imperial thread unions S series (up to 800 bar/11603 Psi)1678.4.78.4.88.4.98.4.10 Standard torques for metric thread unions L series (up to 500 bar/7252Psi) for aluminum1678.4.11 Standard torques for cutting ring flange joints1688.4.12 Standard torques for triple lock flange joints1698.4.13 Standard torques for VSTI screw plugs1708.5Abbreviations - Acronyms1738.6Unit conversion tables1758.6.1Length conversion factors1758.6.2Mass conversion factors1758.6.3Pressure conversion factors1758.6.4Volume conversion factors1758.6.5Power conversion factors1768.6.6Moment of inertia and torque conversion factors1768.6.7Fuel consumption conversion factors1768.6.8Flow conversion factors1768.6.9Temperature conversion factors1768.78.6.10 Density conversion factors176Prefix178 2019 by Kohler Co. All rights reserved.14KD62V12 33521030301 6 1 EN US2019-02

KD62V12 33521030301 6 1 EN US2019-02 2019 by Kohler Co. All rights reserved.15

Operation and Maintenance Manual 2019 by Kohler Co. All rights reserved.16KD62V12 33521030301 6 1 EN US2019-02

1 Product description1.1 Technical description1.1.1 Design overviewFig. 1: Diesel engine / view from the flywheel sideCS12345Coupling side (flywheel side)Engine brackets (x4)FlywheelFuel filterCrankcase ventilation filter housingTurbocharger assembly (x3)KD62V12 33521030301 6 1 EN US2019-02678910Charge air coolerBattery charging alternatorOil dipstickOil centrifuge assemblyHigh pressure fuel pump (x2) 2019 by Kohler Co. All rights reserved.17

Product descriptionOperation and Maintenance ManualTechnical descriptionFig. 2: Diesel engine / view from the vibration damper sideCCS Counter coupling side (vibration damperside)1Water pump high temperature2Thermostat housing high temperature3Water pump low temperature4Thermostat housing low temperature5Exhaust gas connection (x3)678Lifting lug (x4)Oil coolerOil filter cartridge (lubrication system)Fig. 3: Diesel engine / view from the vibration damper sideCCS Engine front (vibration damper side)12Cylinder head coverSee next page for continuation of the image legend 2019 by Kohler Co. All rights reserved.18KD62V12 33521030301 6 1 EN US2019-02

Operation and Maintenance ManualProduct descriptionTechnical description91011Vibration damper coverEngine control unit - ECUAir intake (x4)131415Charge air pipeStarter (x2)Oil panDesignWater-cooled V12 Diesel engine with common rail (CR), exhaust gas turbo charging and air towater charge air cooling.CharacteristicsA robust basic design and generous dimensioning form the basis for high operational safety and along service life. Low fuel consumption and exhaust gas emissions by optimized combustionprocess adapted to the emission requirements. Minimized maintenance obtained by optimizedengine components and accessories lead to higher availability and increased efficiency.Driving gearThe V12 Diesel engine has a quench tempered steel crankshaft with inductively hardened pins andfillets. 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 stagesupport and cooling ductHousingRigid, laterally drawn down crankcase upper section with optimized structure and an oil pan aslower section. Four–valve single cylinder heads with flow optimized ports as well as replaceablevalve seats and valve guide. Br

Operation and Maintenance Manual Original Instructions Diesel engine KD62V12 From serial number 2019730018 EN_US 33521030301_6_1 02-2019a. Operation and Maintenance Manual ... Service Assistance For professional advice on generator set power requirements and conscientious service, please