User guide and maintenance manual

KOHLER

Engine

KD83V16
From serial number 2019740015

12868237
33521030601_1_1
01/02/2019
Operation and Maintenance Manual
Original Instructions

Diesel engine
KD83V16
From serial number 2019740015

EN_US
33521030601_1_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

© 2019 by Kohler Co. All rights reserved. KD83V16 33521030601_1_1 EN_US

2 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 China

(EMEA) East China Regional Office, Shanghai
Kohler EMEA Headquarters Phone: (86) 21 6288 0500
Netherlands B.V. Fax: (86) 21 6288 0550
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific India, Bangladesh, Sri Lanka
Kohler Asia Pacific Headquarters India Regional Office
Singapore, Republic of Singapore Bangalore, India
Phone: (65) 6264-6422 Phone: (91) 80 3366208
Fax: (65) 6264-6455 (91) 80 3366231
Fax: (91) 80 3315972
China Japan, Korea
North China Regional Office, Beijing North Asia Regional Office
Phone: (86) 10 6518 7950 Tokyo, Japan
(86) 10 6518 7951 Phone: (813) 3440-4515
(86) 10 6518 7952 Fax: (813) 3440-2727
Fax: (86) 10 6518 7955

To order special tools, please refer to the cross reference list in the appendix.

KD83V16 33521030601_1_1 EN_US © 2019 by Kohler Co. All rights reserved.

2019-02 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 SOUTHWEST BRANCH OFFICES

WEST SDMO TOULOUSE SOUTH AFRICA
SDMO BREST Tel.: +33 (0) 5 61 24 75 75 SDMO SOUTH AFRICA
Tel.: +33 (0) 2 98 41 13 48 Fax: +33 (0) 5 61 24 75 79 Tel.: +27 (0) 8 32 33 55 61
Fax: +33 (0) 2 98 41 13 57 Fax: +33 (0) 1 72 27 61 51
MID-WEST SUBSIDIARIES ALGERIA
SDMO CHOLET GERMANY SDMO ALGIERS
Tel.: +33 (0) 2 41 75 96 70 SDMO GMBH Tel.: +213 (0) 21 68 12 12
Fax: +33 (0) 2 41 75 96 71 Tel.: +49 (0) 63 32 97 15 00 Fax: +213 (0) 21 68 14 14
Fax: +49 (0) 63 32 97 15 11
PARIS/NORTH & NORMANDY LATIN AMERICA & CARRIBEAN DUBAI
SDMO ARRAS Tel.: +1 (305) 863 0012 SDMO MIDDLE EAST
Tel.: +33 (0) 3 21 73 38 26 Fax: +1 (954) 432 8330 Tel.: +971 4 458 70 20
Fax: +33 (0) 3 21 73 14 59 Fax: +971 4 458 69 85
SDMO GENNEVILLIERS
BELGIUM EGYPT
Tel.: +33 (0) 1 41 88 38 00
SDMO NV/SA SDMO KAIRO
Fax: +33 (0) 1 41 88 38 37
Tel.: +32 36 46 04 15 Tel./Fax: +20 (2) 22 67 12 78
Fax: +32 36 46 06 25
EAST BRAZIL KENYA
SDMO METZ KOHLER MAQUIGERAL SDMO NAIROBI
Tel.: +33 (0) 3 87 37 88 50 Tel.: +55 (11) 37 89 60 00 Tel./Fax: +25 (47) 07 60 54
Fax: +33 (0) 3 87 37 88 59 00
SOUTH ESAT SPAIN RUSSIA
SDMO AIX-EN-PROVENCE SDMO INDUSTRIES IBERICA SDMO MOSCOW
Tel.: +33 (0) 4 42 52 51 60 Tel.: +34 (9) 35 86 34 00 Tel./Fax: +7 495 665 16 98
Fax: +33 (0) 4 42 52 51 61 Tel./Fax: +34 (9) 35 80 31 36
SDMO VALENCE
UK TOGO
Tel.: +33 (0) 4 75 81 31 00
SDMO ENERGY LTD. SDMO WEST AFRICA
Fax: +33 (0) 4 75 81 31 10
Tel.: +44 (0) 16 06 83 81 20 Tel.: +228 22 22 65 65
Fax: +44 (0) 16 06 83 78 63
TURKEY
SDMO ISTANBUL
Tel.: +90 53 07 35 09 10

Please consult the cross-reference list in the appendix when ordering special tools.

© 2019 by Kohler Co. All rights reserved. KD83V16 33521030601_1_1 EN_US

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 Revision history

Version Author Modification Date

00 MUA First 3.01 engine 25th of July 2019
version
01 MUA First 3.02 engine 22th of February 2019
version

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 Operation and Maintenance Manual

© 2019 by Kohler Co. All rights reserved. KD83V16 33521030601_1_1 EN_US

6 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
u For any information concerning the machinery in which the engine is mounted, refer to the
instructions of the generator set.
u For 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.

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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.

© 2019 by Kohler Co. All rights reserved. KD83V16 33521030601_1_1 EN_US

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 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

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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

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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

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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 80
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 84
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 88
5.5 Preparatory maintenance activities 90
5.6 Daily or monthly maintenance activities 91
5.6.1 Visual inspection — SL000 91
5.6.2 Observation of the engine while running — SL007 94
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 103
5.7.5 Replacing centrifuge paper filter — SL102 104
5.7.6 Changing Diesel engine oil — SL101/SL121 107
5.8 Cooling system 111

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Operation and Maintenance Manual Contents

5.8.1 Coolant sampling — SL120 111

5.8.2 Checking coolant level — SL001 111
5.8.3 Inspecting low temperature circuit (charge air cooler) — SL002 112
5.8.4 Checking relieve bores — water/coolant pump — SL003 113
5.8.5 Coolant drain points — SL116 114
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

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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

© 2019 by Kohler Co. All rights reserved. KD83V16 33521030601_1_1 EN_US

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KD83V16 33521030601_1_1 EN_US © 2019 by Kohler Co. All rights reserved.

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 Operation and Maintenance Manual

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 1 Product description

1.1 Technical description

1.1.1 Design overview

Fig. 1: Diesel engine / view from the flywheel side

CS Engine rear (flywheel side) 6 Charge air cooler
1 Engine brackets (x4) 7 Battery charging alternator
2 Flywheel 8 Oil dipstick
3 Fuel filter 9 Oil centrifuge assembly
4 Crankcase ventilation filter housing 10 High pressure fuel pump (x2)
5 Turbocharger assembly (x4)

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Product description Operation and Maintenance Manual
Technical description

Fig. 2: Diesel engine / view from the damper side

CCS Engine front (vibration damper side) 5 Exhaust gas connection (x4)
1 Water pump high temperature 6 Lifting lug (x4)
2 Thermostat housing high temperature 7 Oil cooler (x2)
3 Water pump low temperature 8 Oil filter cartridge
4 Thermostat housing low temperature

Fig. 3: Diesel engine / view from the damper side

CCS Engine front (vibration damper side) 12 Cylinder head cover
9 Vibration damper cover 13 Charge air pipe
10 Engine control unit - ECU (x2) 14 Starter (x2)
11 Straight air intake (x4) 15 Oil pan

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Operation and Maintenance Manual Product description
Technical description

Design
Water-cooled 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 V16 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. Actuated through steel
camshaft via cam follower, push rod and rocker arm.
Driven by gear train 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
– Air conditioning compressor (depending on application)
– Air compressor (depending on application)

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 application)

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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

Fig. 4: Sampling point on engine left side

1 Sampling point
The oil sampling point is located on the engine left side.

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.

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Operation and Maintenance Manual Product description
Technical description

Electronic Control System

Information
To connect the interfaces, refer to the "Electrical Installation Guideline" of your engine application
and generation.
The information on the engine control unit nameplate corresponds to the delivery status.
Depending on software updates in the field, it may be the case that this information is no longer up
to date.
The real information can be viewed in the device display or read out with the diagnosis and service
tool KODIA.

The engine control system consists of an programmable engine control unit.

The ECU controls the actuators and reads values from the sensors to ensure optimal engine
performance.
The ECU is programmed according to configuration and application. Mappable parameters among
others are:
– Ignition timing,
– Maximal RPM,
– Cooling temperature correction,
– Transient fueling,
– Closed loop lambda,
– Waste gate control, ...
The diagnosis and service tool KODIA provides several functions including:
– General information,
– Status overview,
– Configuration adjustement,
– Error list information,
– Process data list,
– Oscilloscope,
– Direct triggering,
– Main values display,
– CRS visualization and operation,
– Long-term error memory,
– Fault Reactions.

Engine electronic sensors

The engine sensors are interfaces for external monitoring such as:
– charge air pressure,
– fuel pressure,
– rail pressure,
– oil pressure,
– coolant temperature,
– charge air temperature,
– engine speed and position.
and actuators for control functions:
– starters,
– volume control valve,
– pressure control valve,
– injectors.
The individual functions and error messages are described in the instructions manual of the manu-
facturer’s machinery.

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Product description Operation and Maintenance Manual
Technical description

1.1.2 Cylinder designation, direction of rotation

Principle according to ISO 1204
Cylinder 1 is located on flywheel side. Direction of rotation as shown on the flywheel side.

Fig. 5: Cylinder designation - direction of rotation according to ISO 1204

A1-A8 Series of cylinders – Bank A - Exhaust valves
B1-B8 Series of cylinders – Bank B + Inlet valves
CS Engine rear (coupling/flywheel side) L Left engine side
CCS Engine front (counter-coupling/damper R Right engine side
side)
DoR Direction of rotation

1.1.3 Nameplates

Type designation

Designation Description
K D 83 V 16 - 5 A F C Engine type description
K Engine manufacturer
D Fuel type (D=Diesel)
83 Total displacement in liter
V Cylinder configuration
16 Number of cylinders
5 Frequency. 5=50Hz; 6=60Hz

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Operation and Maintenance Manual Product description
Technical description

Designation Description
K D 83 V 16 - 5 A F C Engine type description
A Power level. A=power level designation,
where A= the lowest power level, B=next
higher power level, C=next higher power
level…
F Emissions or fuel optimization. F=Fuel Opti-
mized, E=Emissions Optimized
C Application. C=COP; P=Prime; S=Stand by;
D=Data center

Tab. 1: Engine type description

Emission control information label

The emission control information label is attached on the crankcase.

Fig. 6: Engine nameplate

1 Engine main values 4 Notes regarding emissions exemptions,
fuel and application types
2 USA regulations references 5 Country of assembly
3 QR code area

Fig. 7: Engine nameplate location

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Product description Operation and Maintenance Manual
Technical description

Engine serial number

The engine serial number is stamped into the engine nameplate.

Designation Description
2016 73 0001 Engine serial number
2016 Year of manufacture
73 Engine type code (73= KD62V12) (74=
KD83V16)
0001 Incremential production number

Tab. 2: Engine serial number

Fig. 8: Serial number on nameplate

1 Serial number

Engine control nameplates

Fig. 9: Example of engine control unit nameplates

1 Software nameplate 2 Hardware nameplate

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Technical description

Fig. 10: Software nameplate

1 Product designation 6 Engine serial number
2 Product type 7 Engine control unit ID number
3 Engine designation 8 Certification ID number
4 QR Code 9 Data set ID number
5 Delivery date

Fig. 11: Hardware nameplate

1 Product designation 5 Serial number
2 Engine control unit ID number 6 Supplier number
3 Hardware version 7 QR Code
4 Delivery date

Information
u The information on the engine control unit nameplate corresponds to the delivery status (ex:
works Kohler Co.). Depending on software updates in the field, it may be the case that this infor-
mation is no longer up to date.
u The real information can be viewed in the device display or read out with the KOHLER diag-
nosis and service tool KODIA.

1.1.4 Diesel engine accessory equipment

Information
For more information about the accessories attached on auxiliary drives and their respective range
of use of engine, contact your nearest authorized Kohler service representative.

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Technical description

Air Conditioning (A/C) compressor (depending on application)

The engine is optionally equipped with an A/C compressor which can be directly mounted on the
Diesel engine counter coupling side and powered via a V-ribbed belt.

Battery charging alternator

The engine is equipped with a battery charging alternator: 28V / 140A.

Fig. 12: Battery charging alternator

Retrofitting preheating devices

Information
For the connections dimensions provided, contact your nearest authorized Kohler service repre-
sentative.

The interfaces for retrofitting preheating devices such as coolant, fuel and Diesel engine oil have
already been integrated.

Battery charging alternator cover

Technical solution
The battery charging alternator cover is a protective device fitted directly behind the battery
charging alternator. It ensures a global protection to the alternator environment while the engine is
running.

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Operation and Maintenance Manual Product description
Technical description

Fig. 13: Task overview

1 Pin 6 Nut (M8)
2 Distance sleeve 7 Lock washer
3 Vibration damper 8 Captive screw (M8)
4 Pin 9 Cover - front side
5 Cover - back side

Features

– Protection device ensuring isolation of moving parts

– Adapted fastening points
– Captive screws technology to avoid fastener loss
– Ease of (dis)-assembly, free of maintenance
– Additional solution to fulfill the machine compliance with the applicable regulations.

Vibration damper cover

Information
The design of the cover depends on the application.

Technical solution
The vibration damper cover is a protective device fitted directly onto the front end of the engine. It
ensures a overall protection to the vibration damper environment while the engine is running.

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Product description Operation and Maintenance Manual
Technical description

Fig. 14: Details of vibration damper cover

1 Cover 2 Screw (M10)

Features

– Protection device ensuring isolation of moving parts

– Adapted fastening points
– Captive screws technology to avoid fastener loss
– Ease of (dis)-assembly, free of maintenance
– Additional solution to fulfill the machine compliance with the applicable regulations.

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Operation and Maintenance Manual Product description
Technical data

1.2 Technical data

1.2.1 Diesel engine

Designation Unit Value

Cylinder configuration V-Diesel engine
Number of cylinders 16
Firing order A1–B7–A2–B5– A4–B3–A6–B1– A8–
B2–A7–B4– A5–B6–A3–B8
Bore mm 175
inch 6.889
Stroke mm 215
inch 8.464
Displacement liter 83
Compression ratio 16
Direction of rotation of the diesel engine Counterclockwise
(seen from flywheel)
Power specificationas per ISO3046-1
Rated power see nameplate
Rated speed see nameplate
Emission limit stage see nameplate

Tab. 3: General technical data table — Diesel engine

1.2.2 Cylinder head

Designation Unit Value

Inlet valve clearance, cold mm 0,5
inch 0.0196
Outlet valve clearance, cold mm 1
inch 0.0393

Tab. 4: Technical data table — Cylinder head

1.2.3 Coolant thermostat

Designation Unit Values

Low Temperature Opening start °C 45
(LT) Thermostat
°F 113
Completely open °C 57
°F 134.6

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Product description Operation and Maintenance Manual
Technical data

Designation Unit Values

High Temperature Opening start °C 71
(HT) Thermostat
°F 159.8
Completely open °C 81
°F 177.8

Tab. 5: Technical data table – Coolant thermostat

1.2.4 Battery charging alternator

Designation Unit Value

Voltage V 28
Current A 140

Tab. 6: Technical data table — Battery charging alternator

1.2.5 Starter

Designation Unit Value

Voltage V 24
Output per start system kW 9

Tab. 7: Technical data table — Starter

1.2.6 Flywheel housing

Designation Unit Value

Connection SAE 00

Tab. 8: Technical data table - Flywheel housing

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 2 Safety

2.1 Identification of the warnings

2.1.1 Warnings

This is the safety alert symbol. It is used to alert you to potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid
possible injuries or death.

Tab. 9: Example of warning

The safety alert symbol always appears in connection with one of the signal words:
– DANGER
– WARNING
– CAUTION

DANGER Indicates a hazardous situation that, if not avoided, will

result in death or serious injury.

WARNING Indicates a hazardous situation that, if not avoided, could

result in death or serious injury.

CAUTION Indicates a hazardous situation that, if not avoided, could

result in minor or moderate injury.

NOTICE Used to address practices not related to personal injury.

Tab. 10: Warning signs

2.1.2 Additional identifications

Note Indicates helpful advices and tips.

Precondition Identifies a condition that must be fulfilled in order to be

able to carry out the actions subsequently described.
Action Identifies an action which has to be carried out.

Result Identifies the result of an action.

Listing Identifies a listing.

Torque value Identifies special tightening torque or specification.

Tab. 11: Additional symbols

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Safety Operation and Maintenance Manual
Identification of the warnings

2.1.3 Additional rules and directives

Follow these instructions and observe any additional or local rules and directives!
Additional points that should be noted are:
– the safety regulations which apply on site,
– the guidelines provided by professional associations.

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Target audience

2.2 Target audience

2.2.1 Responsibility of machinery owner

Information
The machinery owner is responsible for:
u Checking the knowledge and skills of the personnel.
u Establish the required additional, refresher and further training.
u Establish the responsibilities and authorizations.
u Apply the ILO – “C138 - Minimum Age Convention, 1973” with a minimum age for admission to
employment of 14 years.
u Supply the required tools and spare parts.

Information
u The Customer Service training center departments of the Kohler Co. provides several training
programs.
u Please contact your nearest authorized Kohler service representative for queries.

2.2.2 International standard classification of occupations

In accordance with the international standard classification of occupations (ISCO-08) of the Interna-
tional Labor Office (ILO), the following unit groups are listed as references to define the target
groups, occupations and joint tasks.

2.2.3 Occupational references

The occupations listed perform the following work in accordance with the "General safety instruc-
tions" chapter:
– The main tasks described in this manual or these instructions,
– The tasks identified as requirements to prepare the main tasks.

2.2.4 For the SL1 maintenance of power generation engines: Mainte-

nance Technician
In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group 7233 / ISCED-97
level 2)
The work on engines, equipment as well as mechanical and electronic equipment includes:
– Operating the machine and facilities.
– Performance of scheduled maintenance work.
– Assembly, installation, assessment, adjustment, testing and maintenance.
– Location of defects.
– Recording the repair and maintenance work performed.

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Safety Operation and Maintenance Manual
Target audience

2.2.5 For the SL2 maintenance of power generation engines: Techni-

cian
In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group 7233 / ISCED-97
on at least one level, from 3 to 4).
The work on engines, equipment as well as mechanical and electronic equipment includes:
– Operating the machine and facilities.
– Performance of scheduled maintenance work.
– Assembly, installation, assessment, adjustment, testing and maintenance.
– Location of defects.
– Dismantling and reassembly of the machine as well as the mechanical and electronic equip-
ment.
– Ensuring compliance with standards and specifications.
– Recording the repair and maintenance work performed.

2.2.6 For the SL3 maintenance of power generation engines: Mechan-

ical Technician
In relation to ILO – Power Plant or Industrial Machinery Mechanics – unit group 7233 / ISCED-97
on at least one level, from 3 to 4).
The work on engines, equipment as well as mechanical and electronic equipment includes:
– Operating the machine and facilities.
– Performance of scheduled maintenance work.
– Assembly, installation, assessment, adjustment, testing and maintenance.
– Location of defects.
– Dismantling and reassembly of the machine as well as the mechanical and electronic equip-
ment.
– Replacement of complete engines or components.
– Repairs to mechanical, hydraulic and electronic equipment.
– Examination and testing of new machines and equipment.
– Ensuring compliance with standards and specifications.
– Recording the repair and maintenance work performed.

2.2.7 For the operation of power generation engines: Operator

In relation to ILO – Power Production Plant Operators – unit group 3131 / ISCED-97 on at least one
level, from 2 to 4).
Power production plant operators operate, monitor and maintain switchboards and related equip-
ment in electrical control centers which control the production and distribution of electrical or other
power in transmission networks. The work includes:
– 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.
– Communicating with systems operators to regulate and coordinate transmission loads,
frequency and line voltages.
– Taking readings from charts, meters and gages at established intervals, troubleshooting and
performing corrective action as necessary.
– Completing and maintaining station records, logs and reports, and communicating with other
plant personnel to assess the equipment operating status.
– Cleaning and maintaining equipment such as generators, pumps or compressors in order to
prevent defects or damage to the equipment.

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Intended use

2.2.8 Unauthorized personnel - servicing

All other persons, including operators, supervisors and trainees, are classified as "unauthorized
personnel" for maintenance work.
They are not allowed to service the engine or access the engine compartment or engine cover.

For the operating of power production engines: Operator

With reference to ILO - Power Production Plant Operators - Unit group 3131 / ISCED-97 at least
one level, from 2 to 4) Power production plant operators operate, monitor and maintain switch-
boards and related equipment in electrical control centres which control the production and distribu-
tion of electrical power-generating stations. Tasks include:
– Operating, monitoring and inspecting power plants.
– Operating and controlling power-generating systems and equipment.
– Controlling start-up and shut-down of power plant equipment.
– Controlling switching operations, regulating coolant levels.
– Communicating with systems operators to regulate and coordinate transmission loads,
frequency and line voltages.
– Taking readings from charts, meters and gauges at established intervals, troubleshooting and
performing corrective action as necessary.
– Completing and maintaining station records, logs and reports, and communicating with other
plant personnel to assess equipment operating status.
– Cleaning and maintaining equipment such as generators, pumps and compressors in order to
prevent equipment failure or deterioration.

2.3 Intended use

– Power supply to the equipment (electric generator) and to equipment auxiliaries as specified by
customer.
– The Diesel engines produced by Kohler Co. are partly completed machinery according to
Machinery Directive 2006/42/EC Article 2 g (EU only). They are intended for installation in
machineries.
– Engines that are used in conjunction with alternators as emergency power generator must be
firmly connected to the ground of the operation site. To reduce the vibrations generated, appro-
priate mounting shall be utilized. This mounting must be released by Kohler Co.
– The engines may only be operated in faultless condition.
– Operate the Diesel engine in closed rooms only with adequate ventilation. If additional fresh air
is needed, open the doors and windows.
– The conditions prescribed by the manufacturer of the machinery in which the engine has been
installed are also part of intended use.
– The engine must only be installed by personnel who have been trained and familiarized here-
with and are aware of the dangers.
– Unauthorized changes on the engine or its components voids the liability of Kohler Co. for any
resulting property damage or personal injury. Likewise, interference with the injection and
control system must influence the power and exhaust gas parameters of the engine, meaning
that compliance with statutory environmental requirements is no longer assured.
Any other use above and beyond this is considered to be improper use. In this case, Kohler Co. is
not liable for any damages. The risk is placed solely on the user.

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Safety Operation and Maintenance Manual
Limitation of liability

2.4 Limitation of liability

The use of an engine under conditions or for purposes not intended by Kohler Co., but which can
happen, induced by the engine in combination with, or as a result of, common human behavior, is
considered as reasonably foreseeable misuse. Including, but not limited to:
– Drive of not specified machinery.
– Overload of the engine.
– Use of different applications and conditions rather than specified.
– Improper use of fuels, lubricants, starting aids and coolants,.
– Use of the engine manipulated overspeeds controls.
– Modifications of the engine mounting and suspensions.
– Lifting the engine using unforeseen lifting points.
– Continued use of the engine in emergency mode.
– Operating the engine with open engine cover.
– 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 Co. is not liable for any damages. The risk is borne solely by the user.

NOTICE
Risk of engine failure!
Non-compliant installation according to installation plan and torque tightening values will lead to
engine main failure (leakage in the charge air circuit, parts ejection, and others).
Mount any component according to:
u For the KOHLER application, the “Operation and Maintenance Manual” and its "Service and
Repair Manual".
u For non KOHLER components, refer to the “Instructions” or “Assembly Instructions” from the
supplier.

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Safety instructions

2.5 Safety instructions

2.5.1 General safety instructions

DANGER
Failure to follow safety and hazard instructions will result in death or serious injury.
Death or serious injury by failure to follow safety and hazard prevention instructions.
u Follow and enforce the safety instructions according this operator and maintenance manual, the
application set manual and local regulations.

The machinery owner must apply following requirements:

– Before receiving the engine, the responsibilities and the definition of the safe conditions have to
be established by the machinery owner.
– Only trained and instructed operators expressly authorized to do so must install, operate, main-
tain or repair the engine and the machinery.
– Only allow operators who have been trained, instructed or are present for training purposes, to
work on the engine or the machinery under constant supervision of an experienced supervisor.
Organization commitments for the machinery owner:
– The Operation and Maintenance Manual of the engine has to be at the operator's disposal until
the commissioning of the machinery. Afterwards the Operator and Maintenance Manual has to
be a part of operator's manual of the manufacturer of the machinery.
– Familiarize yourself with the Operation and Maintenance Manual of the machinery before
commissioning the machine.
– Develop, document, implement, and enforce a safety and health program, adapted to the
machinery and its environment, and comply with the local regulations or at least with the Inter-
national Labour Organization Standards.
– Make sure that operators are conscious of safety and hazards involved in their work and that
they regularly check the Operation and Maintenance Manual of the machinery. This is especially
to be repeated for the operators which occasionally operate the machinery.

NOTICE
Risk of engine failure by use of non-compliant operating fluids!
Use of non-compliant operating fluids will lead to engine main failure.
u Use only operating fluids tested and approved by Kohler Co.

NOTICE
Risk of engine failure by use of non-original spare parts!
The use of original spare parts guarantees the compliance with the technical requirements estab-
lished by Kohler Co.
u Use only original spare parts approved by Kohler Co.

2.5.2 Safety while commissioning

Before initial operation, the owner must check that the installation complies with local regulations
and instructions of the manufacturer of the application set.
Always ensure that:
– All installation, maintenance, and repair work are fulfilled.
– All loose parts and tools have been fixed or removed, especially safety devices.
– Each operator has been properly trained, and applies the local safety measures.

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Safety instructions

After start-up of the application set, make sure that all control, display, and warning devices are
working.

2.5.3 Safety when starting

DANGER
Entanglement, trapping, ejection of parts or impact hazards!
Fatal or serious injuries.
u The engine shall not be started until the drive train has been connected to the flywheel.
u Ensure the integrity of the machine and the engine before starting.
u All openings must be closed and the safe conditions established by the manufacturer of the
machinery must be fulfilled.
u Standing in the vicinity of the engine while starting or operating the manufacturer’s machinery is
forbidden.

DANGER
Crushing, ejection of parts or high-pressure fluid ejection hazards!
Fatal or serious injuries.
u Standing in the vicinity of the engine while starting or operating the machinery of the manufac-
turer is forbidden.
u Wear proper personal protective equipment.

WARNING
Health damaging effects by hot or cold work environment!
Damages and/or injuries by temperature in the engine compartment.
u The manufacturer of the machinery shall define the appropriate ventilation of the engine
compartment.
u The manufacturer of the machinery shall define the appropriate insulation of the exhaust pipe
and the engine compartment.
u Wear proper personal protective equipment.
u Wait until the environment of the engine and the engine itself have cooled down.

WARNING
Hearing loss or other physiological disorders (e.g. loss of balance, loss of awareness)!
Risks of injuries due to high sound level.
u Wear proper personal protective equipment in the vicinity of the engine.
u Noise reduction systems adapted to the machinery should be designed by the manufacturer, to
comply with the local regulations.

WARNING
Loss of stability, hazards generated by vibration!
Fatal or serious injuries.
u Standing in the vicinity of the engine while starting or operating the manufacturer’s machinery is
forbidden.

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Safety instructions

WARNING
Hazards generated by materials and substances processed, used or exhausted by machinery for
example.
Fatal or serious injuries.
u The machinery’s manufacturer shall design and implement an adapted extraction system.
u Wear proper personal protective equipment.

DANGER
Ejection of parts due to moving parts!
Fatal or serious injuries.
u Standing in the vicinity of the engine while starting or operating the manufacturer’s machinery is
forbidden.
u Starter activation for service without engine start, e.g. for fuel injection system, must not operate
longer than a maximum of 3 cycles lasting 30 seconds each, and with a minimum of 30 seconds
between each starter activation.
u Wear proper personal protective equipment.

NOTICE
Engine failure by non-compliant starting procedure.
u Unless otherwise instructed, start the engine according to the instructions in the instructions
manual of the machinery.
u Ensure that the Diesel engine is started after all display units and control devices have been
checked.
u Ensure that the engine is only running in an enclosed space and sufficient ventilation is avail-
able.
u Ensure that all devices used to ensure evacuation of stagnant air and ensure air supply are
functional.

WARNING
Ejection of parts and impact hazards by missing guards on rotating or drive sytem.
On starting and while operation, accessing to the engine could cause serious injury or death by
ejection of parts and impact on human body.
u The manufacturer of the machinery shall observe and enforce the country-specific regulations
regarding prevention of injuries and risks.
u The manufacturer of the machinery shall define the appropriate guards according to the
country-specific regulations regarding ergonomics-related hazards, for the entire life-cycle of the
machinery.
u Standing in the vicinity of the engine while starting or operating the machinery is forbidden.
u Wear proper personal protective equipment.

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Safety Operation and Maintenance Manual
Preventing injuries

2.6 Preventing injuries

2.6.1 Preventing bruising

WARNING
Moving parts will cause severe injuries!
Objects getting in contact with moving parts will be catapulted or destroyed, cause injuries and/or
damage the engine.
u When the engine is running, avoid any contact with moving parts.

2.6.2 Preventing burns

WARNING
Burns by hot engine near operating temperature.
Injuries by contact with hot surfaces!
The ECU is hot while operating the engine.
u Avoid any contact with the engine, parts carrying hot coolant or oil, the exhaust system, the
turbocharger, the heat protection, the battery, the covers and the ECU.
u After the temperature has cooled down to a level it can be touched, proceed with the tasks on
the engine.

WARNING
Burns by hot operating fluids under pressure!
Injuries by high pressure hot fluid ejection.
u Only check operating fluids level after the operating fluids temperature has cooled down to a
level it can be touched.
u Carefully open the lid in order to first reduce the excessive pressure.

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Preventing injuries

2.6.3 Preventing fires and explosion hazards

DANGER
Fire or explosion by flammable and explosive lubricants and fuels.
Lethal or heavy injuries.
u Keep all caps and valves closed near the operating temperature.
u Avoid any contact of flammable and explosive operating fluids, gases or combustible materials
with any hot surface or ignition source.
u Keep the engine clean and free from accumulation of dust and flammable liquids.
u Keep the insulation free of operating fluids contamination.
u Never release operating fluids while operating the engine.
u Check the electrical system. Immediately rectify all errors, such as loose connections and frayed
cables.
u During refueling, switch off any additionally installed heater (optional).
u Lock out and tag out the engine prior to accessing to engine.
u Ensure a good ventilation while refueling or prior to accessing to the engine.
u Regularly check all lines, hoses and screw connections for leaks and damages. Immediately
rectify the leaks and replace the damaged parts.
u Smoking and open flames are forbidden in the vicinity of the engine.
u Always start the engine according to the instructions in the instructions manual of the machi-
nery.

DANGER
Fire or explosion by ignition of the air/gas mixture in the air intake, initiated by electrostatic charging
from insulated mounting!
Lethal or heavy injuries.
u Ground every component potentially electrically insulated from the engine, especially the turbo-
charger.

Information
According to local regulations, the manufacturer of the specific application is responsible to design
adapted fire protection system.

Information
Engines provided by Kohler Co. are not intended to be used in potentially explosive atmospheres
according to Directive 2014/34/EC.

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Safety Operation and Maintenance Manual
Preventing injuries

2.6.4 Preventing intoxication and poisoning hazards

WARNING
Lethal or heavy injury due to operating fluids!
Exhaust gases emissions increase the likelihood of cancers.
Operating fluids generate intoxicating gases and emanations.
u Ensure a good ventilation while running or refueling the engine.
u In case of doubt, apply any means to ensure evacuation of personnel and stale air, ensure air
supply and ventilation.
u Respect the local health and safety regulations, the material safety data sheets (MSDS) and the
instructions manual of the manufacturer’s machinery.
u Avoid any contact with additives, operating fluids, gases, battery acid and fumes and acid
condensate in charge air or exhaust system, especially by inhalation.
u Regularly check the exhaust gas circuit and turbochargers.
u Immediately rectify the errors and replace the damaged parts. Safety instructions of the fluids
have to be considered.

2.6.5 Preventing electrical hazards

WARNING
Powered engine could cause electrical shocks.
Lethal or heavy injury due to contact with live conductor.
u Access to live parts shall only be possible with voluntary action.
u Proceed to lock out and tag out prior to accessing to the engine.
u Respect the voltage indication of the engine’s technical data sheet.
u Check the grounding connection to avoid any risk of electrical arc.
u Observe the local safety regulations that apply to the machinery.

2.6.6 Preventing noise hazards

CAUTION
Increased hazards by drowned warning sounds and high sound pressure level!
Injury due to high sound level.
u Wear proper personal protective equipment where applicable.
u Noise reduction systems adapted to the machinery must be designed by the manufacturer, to
comply with the local regulations.
u In case of abnormal noises, rectify it immediately.

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Personal Protective Equipment (PPE)

2.6.7 Preventing vibrations hazards

CAUTION
Vibration acceleration, intensity, frequency and exposure time could harm personnel and cause
property damages.
Injury by vascular, neuro-sensory or musculoskeletal disorders.
u The manufacturer of the machinery must design adapted dampering to comply with the local
legislation.
u In case of vibration's abnormal noises, identifiy and rectify immediately.

2.6.8 Preventing electro-magnetic hazards

WARNING
Electromagnetic field and pulse generated by the engine starting and speed variations could lead
to electromagnetic hazards.
Lethal or heavy injury by exposure to electromagnetic fields
u The manufacturer must ensure the conformity of its machinery to the current Electromagnetic
Compatibility (EMC) Directive.
u Observe the safety regulations that apply to the machinery.
u Avoid any electromagnetic sensitive devices in the vicinity of the engine, especially artificially
health assist devices.

2.6.9 Preventing falling risks

CAUTION
Accessing to the engine top or leakages could lead to falling hazards!
Injury by slipping and falling.
u Climbing on the engine is prohibited.
u Perform visual inspections for leaks or damages.
u In case of leakage, correct deficiencies discovered immediately, clean and dry the operating
fluids contaminated area.
u The manufacturer of the machinery must provide adapted stairs and gangways to work in safe
conditions.

2.7 Personal Protective Equipment (PPE)

WARNING
Serious injury hazards by non-wearing of personal protective equipment!
Missing, non-adapted, altered or misuse of personal protected equipment may accentuate the
severity of injuries.
u The manufacturer of the machinery shall define the safe conditions, including the personal
protective equipment to wear before starting to work on the engine.
u The manufacturer of the machinery shall forbid any accessories and loose clothing.

Following personal protective equipment is necessary:

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Safety Operation and Maintenance Manual
Personal Protective Equipment (PPE)

Sign
Description
(ISO 7010)
Protective work wear
Protection against splinters and chemical splashes.
Must be worn in the direct vicinity of the engine
Safety helmet
Protection against falling/flying objects and against knocks to the head.
Must be worn in the direct vicinity of the engine
Safety shoes
Protect feet against falling objects and from getting caught in. Additional protec-
tion against slipping.
Must be worn in the direct vicinity of the engine
Safety gloves
Protection against hot elements and chemicals.
Must be worn when handling hot parts, chemicals, operating fluids.
Hearing protection
Protection against noise.
Must be worn in the direct vicinity of the engine
Safety goggles
Protection against flying splinters and chemical splashes.
Must be worn when handling operating materials and during mechanical opera-
tions.

Tab. 12: Personal protective equipments

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Operation and Maintenance Manual Safety
Accessible areas

2.8 Accessible areas

Before first start-up, the manufacturer of the machinery shall respect and enforce following safety
and health instructions:

DANGER
Entanglement, trapping, ejection of parts or impact hazards!
Fatal or serious injuries.
u The engine shall not be started until the drive train has been connected to the flywheel.
u Ensure the integrity of the machine and the engine before starting.
u All openings must be closed and the safe conditions established by the manufacturer of the
machinery must be fulfilled.
u Standing in the vicinity of the engine while starting or operating the manufacturer’s machinery is
forbidden.

2.8.1 Engine ready for use or in operation

Fig. 32: Engine areas in operation — view from above and flywheel side

It is forbidden to access to following areas:

– A – Engine front (damper side)
– B – Engine sides
– C – Engine rear (flywheel side)
– D – Above the engine
– E – Below the engine

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Accessible areas

2.8.2 Engine in commissioning — test-run

Fig. 33: Engine areas during commissioning/test run — view from above and coupling side

Following areas are accessible for commissioning and test run tasks:
– A – Counter coupling side (damper side)
– B – Engine sides
– C – Coupling side (flywheel side)
– D – Above the engine

It is forbidden to access to following areas:

– E - Below the engine.

2.8.3 Emergency stop

Information
The machinery owner is responsible to mark the hazardous areas and the fail-safe devices.
The emergency stops must withstand the operational conditions, kept visible and legible during the
entire life cycle.
Additional emergency stops and measures according to project standards and local regulations
and standards are possible.

The emergency buttons and signals, as the acknowledge buttons are described in the generator
set manual.

NOTICE
Property damages by misuse of emergency stops!
Misusing the emergency stops to stop the engine could lead to property damages
u Initiate an emergency stop only in emergency situations.

Initiating an emergency stop::

u Press the emergency button.
After an emergency stop:
u Remedy to the emergency situation.
u Acknowledge the emergency buttons and signals.

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Accessible areas

2.8.4 Signage recommendations

Information
The machinery owner is responsible to mark the hazardous areas and the fail-safe devices.
The signs must withstand the ambient conditions, be kept visible and legible during the entire life
cycle.
Additional signs and measures according to project standards and local regulations and standards
are possible. For example: the signs for the United States market shall comply with ANSI Z535.4.

Following warning signs must be clearly visible and mounted in the accessible areas.

Sign
Description
(ISO 7010)
ISO 7010/W012 – Warning sign - Electrical voltage Lethal or heavy injury due to
electrical shocks
(For more information see: 2.6.5 Preventing electrical hazards, page 42)
ISO 7010/W017 – Warning sign - Hot surface Severe injuries due to hot surfaces!
(For more information see: 2.6.2 Preventing burns, page 40)

ISO 7010/W025 – Warning sign - Counter rotating rollers Severe injuries due to
drawing-in movement!
(For more information see: 2.6.1 Preventing bruising, page 40)
ISO 7010/P007 - Prohibition sign - No access with cardiac pacemaker or
implanted defibrillators Lethal or heavy injury due to electromagnetic fields!
(For more information see: 2.6.8 Preventing electro-magnetic hazards, page 43)
ISO 7010/M002 – Mandatory sign - Refer to instruction manual Observe instruc-
tions
In order to ensure that all residual risks are known by the personnel, the system
documentation must be read and understood. Make sure that all residual risks
according to the risk assessment are reflected in the system documentation.
Provide documentation to the personnel according to the "Target audience".

Tab. 13: Engine area signs requirement

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Prevent property damages

2.9 Prevent property damages

2.9.1 Safety instructions for engine control unit (ECU)

NOTICE
Improper installation or misuse of the engine leads to ECU damages!
Property damages due to non-compliant installation or operation.
u Ensure the connection to power supply before starting the engine.
u It is prohibited to disconnect the electrical power supply during operation.
u Ensure the connection of the ECU before starting the engine.
u Using a rapid charging device to start the engine is prohibited. Only jump start with separate
batteries is allowed.
u Electrical welding in the vicinity of the engine is forbidden, especially near the ECU.
u Switch off the electrical system before connecting or disconnecting the ECU. Apply to the
prescribed tightening torque to tighten the fixing screws of the interface plugs. The manufacturer
of the machinery has to provide an electrical disconnect.
u Reversing the polarity of supply voltage results in the ECU destruction.
u Apply to the prescribed torque to tighten the connections to the injection system.
u Extreme engine compartment temperatures will damage the ECU. Please refer to the technical
data sheet for temperatures values.
u Use suitable test cables to ensure the measures at plug connectors.
u Connecting the sensors or actuators individually to or between external voltage sources for
testing purposes is prohibited. Risk of destruction or malfunction of the engine. Connect the
sensors or actuators to the ECU.
u Mount and fix the mating connectors to protect the ECU against dust and moisture. When the
mating connectors are dismounted, ensure protection of the ECU against dust and moisture by
protective covers.
u Using mobile phones and wireless devices in the vicinity of the engine is prohibited. Risk of
malfunction of the ECU and the engine.

2.9.2 Alarm conditions

CAUTION
Property damages and/or injuries due to neglect of fault codes.
Neglecting the fault code may lead to engine failure (for example, overspeed) and injuries (for
example, ejection of parts) by hazards from linked sequences.
The engine is equipped with an electronic control unit which monitors the engine and itself (self-
diagnosis). After assessment of an identified fault, the following actions are automatically initiated:
u Issue of a fault message with a fault code.
u In combination with the machinery diagnosis system, the fault code is shown via a display.
u Switch over to appropriate backup/emergency functions for further, restricted operation of the
engine (for example, constant limp-home speed).
u Get faults immediately repaired.

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Prevent property damages

Information
The machinery owner is responsible to implement, and enforce emergency procedures to be
followed in the event of accident or breakdown, according the messages and codes displayed.
The ECU generates the signals and error codes for the engine.
The messages and codes are displayed on the generator set display.
If a blockage is likely to occur, the operating method to be followed so as to enable the machinery
to be safely unblocked.
See the generator set manual for more details.

2.9.3 Safety instructions for the fuel system

DANGER
Lethal or heavy injury due to flammable fluids under high pressure
When the engine is running, the fuel lines are under a constant pressure of up to
2000 bar (29,007.40 psi).
Fuel escaping under pressure can penetrate the skin and lead to severe injuries, vaporize and
explode when an ignition source is present.
u Never release the screws on the fuel circuit, especially between the high pressure pump and
the injector when the engine is running.
u Before starting any task on the fuel system, ensure the build-up pressure in the circuit has been
released, and the temperature of the engine has cooled down.
u Keep the engine away from heat, sparks, open flame, or any other ignition source.

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Prevent property damages

2.9.4 Cleanliness standards and safety

NOTICE
Property damages due to neglect of cleanliness standards!
Modern components, especially the injection system, consist of high precision parts that are
subject to extreme loading.
Dirt particles of 0.02 mm (0.00“ in) or greater can result in component outages. Due to this high
precision engineering, maintain a high standard of cleanliness for all tasks.
Before and while performing any task, observe the following precautions:
u Ensure a clean area, free of stirred up dust by air movements.
u Perform visual inspections for leaks or damages.
u Before starting any task on the closed fuel system, clean the engine and its compartment with
lint free tissue.
u Ensure waterproof covers are on the electrical components.
u Do not direct steam jet at electrical components or their covers.
u Clean and dry the area around the still closed fuel system with compressed air.
u Remove loose dirt particles such as paint chips and insulation material with suitable equipment.
u Cover the areas of the engine compartment which could produce dirt particles with a new and
clean covering film.
u Before beginning the dismantling work, wash hands and put on fresh personal protective equip-
ment.
u Clean tools and working materials.
u Perform work on components at a suitably equipped workplace.
u Use only undamaged tools.
u After opening the fuel system, the use of compressed air for cleaning is prohibited.
u Remove any loose dirt during installation work with suitable equipment.
u Remove any paint chips before loosening or tightening any connections.
u Use only lint-free cleaning tissues.
u Use particle and fiber-free materials.
u Immediately seal the opened connection with sealing caps.
u Keep the sealing material in dust-free packaging until use and dispose of it after single use.
u Place the components into a clean, sealed container.
u Never use contaminated cleaning or testing fluids.
u Remove new components from the original packaging immediately before use.
u Use the original packaging of the new parts to ship removed parts.

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Disposal and environment protection

2.10 Disposal and environment protection

CAUTION
Environmental and health hazards by incorrect disposal.
Incorrect waste disposal leads to environment and water supply pollution and injuries by hazards
from linked sequences.
u Observe the country-specific regulations regarding environmental protection when disposing of
scrap materials.
u Before disposing or recycling waste products, ask for the correct method at the responsible
environmental or recycling center.
u When handling waste, lubricants and fuel make sure that none is disposed into the environ-
ment.
u Collect and dispose waste, lubricants and fuel in separate, suitable, properly designated
containers.
u Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is
prohibited.
u Dispose all scrap materials only at official locations in an environment-friendly manner.

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 3 Transportation - Storage

Information
The machinery owner is responsible for the lifting, handling and storing of the engine.
The storage concrete foundation shall have a sufficient load capacity.
Refer to the chapter “Dimensions and weight”. (For more information see: 3.2 Dimensions and
weight, page 54) .

3.1 Safe handling

DANGER
Death by crushing hazards
Lifting and handling heavy loads will lead to death by crushing hazards.
u Use only adapted transport and lifting devices.
u Lift and handle the packed engine according to the markings on the packaging.
u After engine unpacking, separate the engine from its stand.
u Use only the dedicated lifting points to lift only the engine.
u Before handling or lifting the load, fix or remove any loose part.
u Avoid friction between components of the engine and suspension devices by putting protection
between them.
u Avoid any abrupt movement to avoid the load to swing.
u Before handling or lifting the load, warn all employees in the immediate vicinity.
u Before readjusting the lifting devices, warn all employees in the immediate vicinity.
u Only readjust the lifting devices when the load is on the floor and the suspension devices are
tension-free. Pay attention to the center of gravity.
u Respect a safety distance while handling and never pass under the load.
u While moving the load, keep a constant attention on the load and the other employees.
u While moving the load warn everyone to keep a safety distance and forbid anyone to pass
under the load.

Information
Several adapted lifting devices are available.
Follow the instructions manual of the hoisting beam, handling devices and the local safety regula-
tions.
For further information, please contact your nearest authorized Kohler service representative.

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Dimensions and weight

3.2 Dimensions and weight

Information
The manufacturer of the machinery is responsible for the lifting, handling and storing of the engine.
For the latest engine dimensions and weights, refer to the “Installation Drawing”. (For more infor-
mation see: 8 Appendix, page 145) .

WARNING
Crushing, impact, shearing, part ejection hazards by load movement or lifting devices failure.
Guiding the moving load by hand could cause serious injury or death by crushing or shearing.
Lifting the entire machinery could cause serious injury or death by crushing, impact or parts ejec-
tion.
Falling load could cause serious injury or death by crushing, impact or parts ejection.
Failure of lifting devices could cause serious injury or death by ejection of parts, crushing and
impact.
u It is forbidden to guide the load by hand.
u It is forbidden to lift complete machinery set by use of dedicated lifting points on the engine.
u Use only adapted lifting devices in good shape.
u Check and replace the lifting devices according local regulations.
u Respect a safety distance while lifting and moving the load.
u It is forbidden to pass under the load.

NOTICE
Falling/hanging lifting devices on the engine.
Falling/hanging lifting devices could result in property damages by impacts or tearing.
u Check and replace the lifting devices according local regulations.
u Move the lifting devices near the engine cautiously.

Fig. 39: Dimensions and weight of engine

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Dimensions and weight

Information
u RFOB stands for “Rear Face of Block”.

Designation Ref. Dimensions

Overall length x width x height 3117 mm
(10‘ 3“ ft-in) x
1639 mm
(5‘ 5“ ft-in) x
2137 mm
(7‘ ft-in)
From RFOB to center of gravity X1 1282 mm
4‘ 2“ ft-in
From RFOB to lifting point - right side X2 594 mm
1‘ 11“ ft-in
From RFOB to lifting point - left side X3 545 mm
1‘ 9“ ft-in
Distance between engine lifting points - right side X4 1300 mm
4‘ 3“ ft-in
Distance between engine lifting points - left side X5 1040 mm
3‘ 5“ ft-in
Axis to center of gravity Y1 299.5 mm
1‘ ft-in
Axis to lifting point Y2 729 mm
2‘ 5“ ft-in
From center of gravity to lifting point Z1 645 mm
2‘ 1“ ft-in
Distance between engine lifting points Z2 1290 mm
4‘ 3“ ft-in
Maximal weight P 11300 kg
24,912 lb
Maximal angles of lifting devices — side view α1–α2 15°
Maximal angles of lifting devices — front view β1–β2 15°

Tab. 14: Dimensions and weight of engine - values

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Transport

3.3 Transport

3.3.1 Safe transportation

Information
The generator set owner is responsible for the transportation and storage of the engine. The
storage concrete foundation shall have a sufficient load capacity.

DANGER
Crushing hazards!
Will cause serious injury or death.
Lifting heavy loads can lead to death by crushing hazards.
u Use only adapted transport and lifting devices.
u Lift and handle the packed engine according to the markings on the packaging.
u After engine unpacking, separate the engine from its stand.
u Use only the dedicated lifting points to lift only the engine.
u Before handling or lifting the load, fix or remove any loose part.
u Avoid friction between components of the engine and suspension devices by putting protection
between them.
u Avoid any abrupt movement to avoid the load swinging.
u Before lifting the load, warn all employees in the immediate vicinity.
u Fix or remove any loose part on the engine.
u Before readjust the lifting devices, warn all employees in the immediate vicinity.
u Only readjust the lifting devices when the load is on the floor and the suspension devices are
tension-free. Pay attention to the center of gravity.
u Respect a safe distance while lifting and never pass under the load.
u While moving the load, keep a constant attention on the load and the other employees
u While moving the load warn everyone to keep a safe distance and forbid anyone to pass under
the load.

Information
u Several adapted lifting devices are available. Follow the operator's manual of the hoisting beam,
lifting devices and the local safety regulations. For further information, please contact your
nearest authorized Kohler service representative.

3.3.2 Transport fastening

Information
u For transportation, the engine should be deposited on adapted stands.
u Kohler Co. provides one wooden stand with engine. For transportation and storage use the
provided stand.

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Transport

Fig. 40: Example of wood stand on undercarriage

Fig. 41: Example of transportation fixing

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Transport

Fig. 42: Example of waterproof packaging

3.3.3 Transport devices

Fig. 43: Examples of fixing the lifting devices on the engine

1 Engine 3 Lifting beam
2 Lifting hook 4 Lifting point

3.3.4 Transport conditions

Transport conditions should comply with the following minimum requirements:
Land transport:
In a freight wagon or a closed lorry.

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Transport

Sea and river transport:

In the hatch of the boat with the measures to prevent the penetration of water.
Air transport:
In a closed air freight container.

Information
For further information, please contact your nearest authorized Kohler service representative.

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Storage

3.4 Storage

3.4.1 Storage conditions

Information
Respect the preservation and storage conditions according to “ISO 6749–1984” standards.
The storage is part of the scope of the application set owner.
In any doubt, please contact your nearest authorized Kohler service representative.

Storage conditions should meet the following minimum requirements:

In temperate or cool areas:
In a closed and unheated warehouse
In coastal area, in an air-conditioned warehouse.
In dry tropical climatic areas:
– In a closed and unheated warehouse.
– In coastal area, in an air-conditioned warehouse.
In humid tropic zones:
– In a closed and air-conditioned warehouse.

Information
The relative humidity of the air in a closed and air-conditioned warehouse should not exceed 70%.

3.4.2 Storage site foundation requirements

Information
The storage site foundation is part of the scope of the generator set owner.
The generator set owner shall measure the foundation performances before storing the engine.
(For more information see: 3.2 Dimensions and weight, page 54) .

Information
Kohler Co. provides one wooden stand with engine. For transportation and storage use the
provided stand.
Steel stands are available for long term storage.
For further information, please contact your nearest authorized Kohler service representative.

3.4.3 Storage up to 12 months

The Diesel engine is kept from the date of shipment in its original packaging. Storage in a closed,
dry and ventilated area ensures a conservation and storage life of 12 months.

3.4.4 Storage over 12 months

For storage longer than 12 months, please contact your nearest authorized Kohler service repre-
sentative.

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Unpacking/Depreservation

3.5 Unpacking/Depreservation

3.5.1 Unpacking

CAUTION
Environmental and health hazards by incorrect disposal.
Incorrect waste disposal leads to environment and water supply pollution and injuries by hazards
from linked sequences.
u Observe the country-specific regulations regarding environmental protection when disposing of
scrap materials.
u Before disposing or recycling waste products, ask for the correct method at the responsible
environmental or recycling center.
u When handling waste, lubricants and fuel make sure that none is disposed into the environ-
ment.
u Collect and dispose waste, lubricants and fuel in separate, suitable, properly designated
containers.
u Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is
prohibited.
u Dispose all scrap materials only at official locations in an environment-friendly manner.

CAUTION
Cutting or severing hazards by contact with sharpen surfaces, tools or materials!
Could cause minor or moderate injury.
u Wear proper personal protective equipment.

q The engine is stored close to the installation site

Unpack and depreserve the engine or delivered components shortly before the use or the installa-
tion.
u Cut and remove the packing tape.
u Open the packaging film and release the engine or component.
u Perform a visual check for damages or deformations.
u Check for corrosions which impair function and strength.
u Check for abrasions, breaks or dislocation of components, connections and systems.
u Perform a visual check of lines and hoses for damages (chafe marks, cuts, tears), embrittlement
of the outer layer (crack formation in the material), any deformations (swollen, crushes), non-
compliant bends, delamination, blister formation.
u Check for damages or deformations to the fittings.
u Check for dislocation from the fittings.
u Leave all opening seals until connection

Troubleshooting
By damages
u Register the date of unpacking
u Please contact your nearest authorized Kohler service representative.

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Unpacking/Depreservation

3.5.2 Depreservation

Information
u The Diesel engine and components delivered are immediately ready for use and do not require
depreservation.
u In an environment-friendly manner, reuse the packaging to send back the engine or other
components.

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Suspension of activity

3.6 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 Co.
The Diesel engine is installed.
u Fill with operating fluids until it reaches the maximum level. (For more information see:
5.11.2 Filling volume, page 121) .

Information
u The Diesel engine and components delivered are immediately ready for use and do not require
depreservation.
u In an environment-friendly manner, reuse the packaging to send back the engine or other
components.

u Clean the engine and remove the existing rust.

u Spray or apply on unpainted bare parts or surfaces, corrosion inhibitor “Rustilio DWX 30”.

Information
u Do not spray the corrosion inhibitor on electrical connections.

u Follow the procedure for the suspension of activity in the generator set manual.
For starting after 12 months of suspension of activity,
u Follow starting procedure (For more information see: 4.2.9 Initial starting/test run/after out of
service period, page 69) .

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Preservation, packaging

3.7 Preservation, packaging

3.7.1 Preservation
After dismantling of the machinery and dismounting of the engine.
u Preserve, pack and store according to following standards:
– ISO 6749:1987-10 - Earth-moving machinery. Preservation and storage.
– EN ISO 780:1999-04 - Packaging - Pictorial marking for the handling of goods

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 4 Control and operation

4.1 Filling lubricants and operating fluids

– Charge air is connected

– Exhaust system is connected
– Electrical power supply is ready
– Fuel and cooling supplies are connected

4.1.1 Engine oil

Engine oil must correspond to the released specifications (For more information see: 5.11 Lubri-
cants and operating fluids, page 120) .

4.1.2 Coolant
Coolant and water must correspond to the released specifications (For more information see:
5.11 Lubricants and operating fluids, page 120) .

4.1.3 Fuel
Fuels must correspond to the released specifications. (For more information see: 5.11 Lubricants
and operating fluids, page 120) .

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Starting the engine

4.2 Starting the engine

– Operating fluids levels are correct.

DANGER
Hazards by entanglement, rotating or moving and ejected parts!
Impacts by ejected parts will cause serious injury or death.
Before starting:
u Keep all persons away from all hazardous areas.
u Secure external parts against unexpected movements.
u Remove any loose parts or tools.
u Put all protective devices into their protective position. If equipped, close the housing.
u While starting or operating the application set, standing in the vicinity of the engine is forbidden.

NOTICE
Risk of property damages by continuous actuation
Actuate continuously the starter could lead to property damages (starter, engine)
u Run the starter for a maximum of 30 seconds.
u Wait for at least two minutes after the first attempt at starting before trying again.
u Wait for at least five minutes after every subsequent attempt before trying again.
u ECU software can prevent the starting procedure as protection against over-heating depending
on the start time and start attempts.

NOTICE
Risk of property damages by inadequate lubrication
Inadequate lubrication could lead to property damages.
u The oil pressure has to build up immediately after the diesel engine is started,
If all of the safety instructions in the “Safety” chapter have been taken into account:
u Switch on the electrical power supply.
The equipment may not report any errors relating to the Diesel engine.
u Press the starter for a maximum of 30 seconds.

4.2.1 Final check

Before starting the engine, carry out the following checks and top off with operating materials if
necessary:
u Check the oil level.
u Check the coolant level.
Once the engine has started, carry out the following checks:
u Perform a visual check for any leaks in the lines.
u Check for KODIA error messages.
u Check for error messages on the generator set.

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Starting the engine

4.2.2 Starting in cold temperatures

WARNING
Hazards by use of starting aids containing ether!
Using starting aids containing ether could cause serious injury or death by inhalation of toxic gazes.
u Do not use starting aids containing ether.

The KOHLER generators are equipped with a preheating system.

Fig. 44: Precautions at cold temperatures

The following precautions improve the starting performance at low temperatures. Precautions:
u Check battery charging.
u Recharge battery if required.
u Use Diesel fuel with sufficient flow properties.

4.2.3 Monitoring the running engine

DANGER
Hazards by rotating or moving and ejected parts!
Impacts by ejected parts will cause serious injury or death.
Before monitoring or accessing the engine covers, housing or compartement:
u Switch off the engine. (For more information see: Shutting down the Diesel engine, page 69) .
u Make sure all parts are stopped.
u Secure all parts against unexpected movements.

Engine is under load at rated speed

To ensure Diesel engine performance and endurance, fulfill the following tasks when operating the
machinery:
u Check for leaks.
u Check for unusual noises and vibrations

Troubleshooting
In case of any abnomalies
u Report and rectify immediately by authorized personnel

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Starting the engine

4.2.4 Exhaust
(For more information see: 6.2 Faults - Cause - Remedy, page 136) .
u Check exhaust gas color.

Troubleshooting
In case of any abnomalies
u Report and rectify immediately by authorized personnel.

4.2.5 Drainage
(For more information see: 6.2 Faults - Cause - Remedy, page 136) .
u Check presence of any blocking elements in draining pipes.

Troubleshooting
In case of any abnomalies
u Report and rectify immediately by authorized personnel.

4.2.6 Air filter

(For more information see: 6.2 Faults - Cause - Remedy, page 136) .
u Check charging air temperature.

Troubleshooting
In case of any abnomalies
u Report and rectify immediately by authorized personnel.

4.2.7 Engine and coolant pumps — Charge air cooler

u Check drain holes.

Troubleshooting
In case of any abnomalies
u In case of any abnomalies, contact your nearest authorized Kohler service representative.

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Starting the engine

4.2.8 Stopping the Diesel engine

Shutting down the Diesel engine

NOTICE
Property damages by shutting down the loaded engine!
Shutting down the loaded engine could damage the engine!
The exhaust gas turbocharger continues running for some time without oil supply.
u Do not shut down the loaded engine.
u Reduce load on engine to zero.
u Let the engine idle for 10 to 15 seconds.
u Shut down the engine according to the application set manual.

Emergency stop
The emergency buttons and signals, as the acknowledge buttons are described in the the applica-
tion set manual.

NOTICE
Property damages by misuse of emergency stops!
Misusing the emergency stops to stop the engine could lead to property damages
u Initiate an emergency stop only in emergency situations.

Initiating an emergency stop:

u Press the emergency button.
After an emergency stop:
u Remedy to the emergency situation.
u Acknowledge the emergency buttons and signals.

4.2.9 Initial starting/test run/after out of service period

Preparation of initial starting

For initial starting or after a suspension of activity, perform the following tasks:
u Replace Diesel engine oil. Refer to chapter Maintenance.
u Replace oil filters. Refer to chapter Maintenance.
u Perform a general visual inspection. Refer to chapter Maintenance.
u Check coolant level. Refer to chapter Maintenance.
u Drain off water and sediment of fuel tank. Refer to Operation and Maintenance Manual.
u Check water separator of fuel prefilter and bleed water if necessary. Refer to Operation and
Maintenance Manual.
u Check visually the starter, battery charging alternator.
u Check belt, and replace if necessary. Refer to chapter Maintenance.
u Vent the fuel system. Refer to Operation and Maintenance Manual of generator set.

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Control and operation Operation and Maintenance Manual
Dismantling

4.3 Dismantling

The dismantling must be carried out or supervised by a trained and qualified staff.
Prepare the dismantling as follows:
u According local regulations, clarify the means and quality of the dismantling process.
u Disconnect the electrical power supply.
u Remove any electronic control or electrical connections.
u Drain all fluids.
u Remove any coolant, lubricants and fuel connections.
u Collect and dispose of waste, coolant, lubricants and fuel.
u Disassemble the component or engine according to general mechanics procedures.

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Operation and Maintenance Manual Control and operation
Components disposal

4.4 Components disposal

CAUTION
Environmental and health hazards by incorrect disposal.
Incorrect waste disposal leads to environment and water supply pollution and injuries by hazards
from linked sequences.
u Observe the country-specific regulations regarding environmental protection when disposing of
scrap materials.
u Before disposing or recycling waste products, ask for the correct method at the responsible
environmental or recycling center.
u When handling waste, lubricants and fuel make sure that none is disposed into the environ-
ment.
u Collect and dispose waste, lubricants and fuel in separate, suitable, properly designated
containers.
u Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is
prohibited.
u Dispose all scrap materials only at official locations in an environment-friendly manner.

Dispose of the components for recycling according to the categories as follows:

– Steel and iron.
– Aluminum.
– Non-ferrous metal.
– Insulating material.
– Cables and wires.
– Electrical waste.
– Plastics.
– Lubricants and greases.
– Fuels
– Coolant
– Paint residues.
– Cleaning agents and rags

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Control and operation Operation and Maintenance Manual
Packaging material disposal

4.5 Packaging material disposal

Information
Use the original packaging of the new parts to ship removed parts.

Recover packaging material as follows:

– Wood, impregnated wood.
– Packaging foils.
– Board.
– Tinplate.
– Adhesive tape.
– Contaminated packaging materials.

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 5 Maintenance

5.1 Inspection and maintenance schedule

General information
Shorten the maintenance intervals according to the operating conditions, for example:
– Dusty environment
– Oil quality
– Fuel quality
Always make sure lubricants, fuel, other liquids and replaced parts are disposed of in a safe and
environmentally acceptable manner. The environmental regulations applicable in the country of use
must be adhered to.

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Maintenance Operation and Maintenance Manual
Maintenance plan use

5.2 Maintenance plan use

The time intervals during which a component can remain in operation between two servicing are
divided into:
– Time limit is the duration in hours of service.
– 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.

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Operation and Maintenance Manual Maintenance
Generator set ratings

5.3 Generator set ratings

The following generator set ratings are defined by the standard ISO 8528-1:2005.
The classifications according to ISO 8528-1: 2005 are intended to help to improve the under-
standing between manufacturer and customer.

5.3.1 Continuous Operating Power (COP)

Continuous power is defined as being the maximum power which the generating set is capable of
delivering continuously whilst supplying a constant electrical load when operated for an unlimited
number of hours per year under the agreed operating conditions with the maintenance intervals
and procedures being carried out as prescribed by the manufacturer.

5.3.2 Prime Power (PRP)

Prime power is defined as being the maximum power which a generating set is capable of deliv-
ering continuously whilst supplying a variable electrical load when operated for an unlimited
number of hours per year under the agreed operating conditions with the maintenance intervals
and procedures being carried out as prescribed by the manufacturer.

5.3.3 Emergency Standby Power (ESP)

Emergency standby power is defined as the maximum power available during a variable electrical
power sequence, under the stated operating conditions, for which a generating set is capable of
delivering in the event of a utility power outage or under test conditions for up to 200 h of operation
per year with the maintenance intervals and procedures being carried out as prescribed by the
manufacturers.

5.3.4 Time between overhaul (TBO)

The designation of the average duration until the Diesel engine is revised.

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Maintenance Operation and Maintenance Manual
Service level definition

5.4 Service level definition

Preventive Maintenance Corrective Maintenance

Level 2 — Advanced Troubleshooting and
Level 1 — Basic Maintenance Level 3 — Main Overhaul
Maintenance repair
Daily checks, inspection and Maintenance tasks Operations for which the Repair services such as
maintenance tasks which can involving partial disas- procedures entail expert exchange of components
be carried out in intervals sembly of the engine in knowledge of a specific needed to correct failures
between operation without situ (mid-life service). For technique or technology or malfunctions including
dismantling parts from example: change of pump, and/or use of specialized parts and labor
engine. For example: oil and injectors, heads. support equipment.
fuel refilling
By customer or authorized By authorized Kohler By authorized Kohler By authorized Kohler
Kohler service representative service representative service representative service representative

Tab. 15: Service level definition

The descriptions of the maintenance activities are given in the following documents:
– Level 1 in this Operating and Maintenance Manual
– Level 2 and 3 in the Repair and Service Manual

5.4.1 Daily or monthly maintenance activities (Level 1) - Version:

2018/07-2

Service
Schedule
Type
Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit

Component Task description

Replacement
Overhaul
(year)

Visual inspection of the engine for overall condition.

Record and report any abnormality found (leaks,
Before
SL000 Engine operation Daily X damages, loose components, unusual noise, etc.).
start
(For more information see: 5.6.1 Visual inspection —
SL000, page 91) .
Check engine oil, fuel and coolant levels.
Before
SL001 Daily X (For more information see: 5.7.3 Checking the engine
start
oil level — SL001, page 101) .
Inspect low temperature circuit (intercooler) vent
system.
Before
SL002 Daily X Check dewatering bores on air intake manifold. (For
start
more information see: 5.8.3 Inspecting low tempera-
ture circuit (charge air cooler) — SL002, page 112) .
Check relieve bores - water/coolant pump. (For more
Before
SL003 Daily X information see: 5.8.4 Checking relieve bores —
start
water/coolant pump — SL003, page 113) .

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Operation and Maintenance Manual Maintenance
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Drain off water from fuel prefilter. If applicable, see
Before supplier's manual. (For more information see:
SL004 Daily X
start 5.9.1 Draining off water from fuel prefilter — SL004,
page 117)
Check differential pressure gauge of fuel prefilter /
Before indicator for check monitoring (if installed). (For more
SL005 Daily X
start information see: 5.9.5 Checking differential pressure
— fuel prefilter — SL005, page 118)
Inspect service indicator of air filter / dismount and
Before visual check- depending of environment. Customer
SL006 Daily X
start set. (For more information see: 5.10.1 Check service
indicator on air filter — SL006, page 119)
Observe engine operation. Record and report any
abnormality found (faulty parameters, unusual noise,
Before
SL007 Daily X vibration, exhaust gas color, etc.). (For more informa-
start
tion see: 5.6.2 Observation of the engine while
running — SL007, page 94)
Test run (if parameters are in the setting range) at
Month more than a 1/3 load and at least until steady-state
SL008 X
ly temperature is reached (monthly). (For more informa-
tion see: 5.6.7 Test run — SL008, page 99) .

Tab. 16: Daily maintenance activities — Engine operation -Version : 2018/07-2

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Maintenance Operation and Maintenance Manual
Service level definition

5.4.2 Service level 1 — Engine Service, TBO 4000 hrs for ESP —
Engine Operation - Version: 2018/07-2

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)

Collect and send oil sample for analysis every 100

hours on ESP or 250 h (in PRP and COP applica-
tions). If the results are not within the requested
SL100 Oil sampling 100 1Y X parameters repeat analysis at shorter intervals. In
case of use of high sulfure rate (>0,5%). No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Check coolant quality. (For more information see:
SL120 Coolant sampling - 2Y X
5.8.1 Coolant sampling — SL120, page 111) .
Engine oil replacement (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
Oil filters and oil filters for cooling jet replacement.
Recommended : (For more information see: 5.7.4 Changing oil filters
First 250 service — SL101, page 103) .
SL122 250 1Y X X
hours for a new or It is recommended to check the engine oil character-
overhauled engine istics at the same time. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Perform all check before starting and perform a test
run. (For more information see: 5.6.7 Test run —
SL008, page 99) .
Without centrifuge
Engine oil filters Replace filters. Clean the seal area before removal
standard - main the old filter to prevent oil contamination. (For more
SL101 250 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube Oil "Cate- 250 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube Oil "Cate- 500 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
With Centrifuge

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Operation and Maintenance Manual Maintenance
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Engine oil filters Replace filters. Clean the seal area before removal
standard - main the old filter to prevent oil contamination. (For more
SL101 500 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Replace the paper (sleeve) for sludge at each oil
change. Measure and record thickness of the sludge
Centrifugal oil filter - accumulated on paper if above limits. Reduce lube oil
SL102 500 2Y X
paper filter interval if the sludge accumulated is above limits.
(For more information see: 5.7.5 Replacing centrifuge
paper filter — SL102, page 104) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube oil "Cate- 500 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube oil "Cate- 1000 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .

Replace main fuel filter cartridge. (For more informa-

SL105 Fuel main filter 1000 2Y X tion see: 5.9.3 Replacing main filter - SL105,
page 117) .
Replace primary fuel filter cartridge.
Recommended:
SL106 1000 2Y X See the operator and maintenance manual of your
Fuel prefilters
application.
Replace the air filter and clean air ducting between
Recommended: Air air filter and compressor.
SL108 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Inspect conditions of drive belt and fit new one if
necessary. (For more information see: 5.6.4 Checking
SL109 Alternator belt 1000 2Y X X drive belt — SL109, page 96) . Check belt tension.
(For more information see: 5.6.5 Replacing V-ribbed
belt — SL 109, page 97) .
Visual inspection of the tensioner. Replacement if
Alternator belt
SL110 1000 18Y X necessary. (For more information see: 5.6.6
tensioner
Replacing tensioning device — SL110, page 98) .

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Maintenance Operation and Maintenance Manual
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Replace coolant (at least every 4 years for coolant
formulated with Glysantin G48).
Respect fluids and lubricants specifications.
Coolant drain points
SL116 — 4Y X Note: for coolant formulated with Glysantin G40, the
(Glysantin G48)
extension up to 8000h/6Y is possible after analysis.
(For more information see: 5.8.5 Coolant drain points
— SL116, page 114) .

Tab. 17: Service level 1 — ESP — Basic maintenance - Version : 2018/07-2

5.4.3 Service level 2— Engine Service, TBO 4000 hrs for ESP —
Advanced maintenance - Version: 2018/07-2

Service
Schedule
Type
Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit

Component Task description

Replacement
Overhaul
(year)

Replace the air filter and clean air ducting between

Recommended: Air air filter and compressor.
SL201 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Clearence check and adjustment.
First inspection at 1000 h, second at 1500 h.
SL204 Valves clearance 2000 2Y X
Proceed in the same way after cylinder head repair
work.
SL205 Fuel injectors - 8Y X Replacement
Done at the time the injectors are replaced. Use a
Combustion cham-
SL206 — 4Y X boroscope to identify condition of combustion
bers
chamber (piston crown, liner hatches, fire deck, etc.)
HP Fuel pump and Inspect for leaks. Replace pump if necessary.
SL209 — 8Y X
LP Fuel pump
Cold Start Oil Replacement
SL212 Cooler by-pass - 18Y X
Valve

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Operation and Maintenance Manual Maintenance
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Check overall condition (compressor blades, leaks,
connections, housings, etc.) every 4000 hrs.
SL213 Turbochargers - 18Y X
Replace the turbocharger at the indicated service
interval.
SL215 LT Water pump — 18Y X Replacement
SL216 HT Water pump — 18Y X Replacement
Coolant thermo- Replacement
SL217 — 18Y X
stats
Auxiliary Belt Drive Replacement
SL218 — 18Y X
- PTO
Replace all rubber hose connections on the engine:
SL219 Rubber sleeves — 18Y X e.g. coolant hoses for ECU cooling, hose connections
for crankcase ventilation
Clean component according supplier requirements.
SL220 Charged Air Cooler — 18Y X Check visually for leaks. If shown, identify reason.
Replace component if needed.
SL221 Oil Cooler — 18Y X Inspect the oil cooler
Recommended: Inspect the starter (winding insulation, relay, condition
SL222 — 18Y X
Starter of the gear teeth, etc..)
Battery charging Replace battery charging alternator
SL223 — 18Y X
alternator
SL224 Cylinder Heads — 18Y X Replace cylinder heads.

Tab. 18: Service level 2 — ESP — Advanced maintenance - Version : 2018/07-2

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Maintenance Operation and Maintenance Manual
Service level definition

5.4.4 Service level 1 — Engine Service, TBO 15000 hrs for PRP —
Engine Operation - Version: 2018/07-2

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)

Collect and send oil sample for analysis every 100

hours on ESP or 250 h (in PRP and COP applica-
tions). If the results are not within the requested
SL100 Oil sampling 250 1Y X parameters repeat analysis at shorter intervals. In
case of use of high sulfure rate (>0,5%). No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Check coolant quality. (For more information see:
SL120 Coolant sampling - 2Y X
5.8.1 Coolant sampling — SL120, page 111) .
Engine oil replacement (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
Oil filters and oil filters for cooling jet replacement.
Recommended : (For more information see: 5.7.4 Changing oil filters
First 250 service — SL101, page 103) .
SL122 250 1Y X X
hours for a new or It is recommended to check the engine oil character-
overhauled engine istics at the same time. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Perform all check before starting and perform a test
run. (For more information see: 5.6.7 Test run —
SL008, page 99) .
Without centrifuge
Engine oil filters Replace filters. Clean the seal area before removal
standard - main the old filter to prevent oil contamination. (For more
SL101 250 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube oil "Cate- 250 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube oil "Cate- 500 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
With Centrifuge

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Operation and Maintenance Manual Maintenance
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Engine oil filters Replace filters. Clean the seal area before removal
standard - main the old filter to prevent oil contamination. (For more
SL101 500 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Replace the paper (sleeve) for sludge at each oil
change. Measure and record thickness of the sludge
Centrifugal oil filter - accumulated on paper if above limits. Reduce lube oil
SL102 500 2Y X
paper filter interval if the sludge accumulated is above limits.
(For more information see: 5.7.5 Replacing centrifuge
paper filter — SL102, page 104) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube oil "Cate- 500 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube oil "Cate- 1000 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .

Replace main fuel filter cartridge. (For more informa-

SL105 Fuel main filter 1000 2Y X tion see: 5.9.3 Replacing main filter - SL105,
page 117) .
Replace primary fuel filter cartridge.
Recommended:
SL106 1000 2Y X See the operator and maintenance manual of your
Fuel prefilters
application.
Replace the air filter and clean air ducting between
Recommended: Air air filter and compressor.
SL108 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Inspect conditions of drive belt and fit new one if
necessary. (For more information see: 5.6.4 Checking
SL109 Alternator belt 1500 2Y X X drive belt — SL109, page 96) . Check belt tension.
(For more information see: 5.6.5 Replacing V-ribbed
belt — SL 109, page 97) .
Visual inspection of the tensioner. Replacement if
Alternator belt
SL110 4000 18Y X necessary. (For more information see: 5.6.6
tensioner
Replacing tensioning device — SL110, page 98) .

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Maintenance Operation and Maintenance Manual
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Replace coolant (at least every 4 years for coolant
formulated with Glysantin G48).
Respect fluids and lubricants specifications.
Coolant drain points
SL116 6000 4Y X Note: for coolant formulated with Glysantin G40, the
(Glysantin G48)
extension up to 8000h/6Y is possible after analysis.
(For more information see: 5.8.5 Coolant drain points
— SL116, page 114) .

Tab. 19: Service level 1 — PRP — Basic maintenance - Version : 2018/07-2

5.4.5 Service level 2— Engine Service, TBO 15000 hrs for PRP —
Advanced maintenance - Version: 2018/07-2

Service
Schedule
Type
Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit

Component Task description

Replacement
Overhaul
(year)

Replace the air filter and clean air ducting between

Recommended: Air air filter and compressor.
SL201 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Clearence check and adjustment.
First inspection at 1000 h, second at 1500 h.
SL204 Valves clearance 2000 2Y X
Proceed in the same way after cylinder head repair
work.
SL205 Fuel injectors 7500 8Y X Replacement
Done at the time the injectors are replaced. Use a
Combustion cham-
SL206 7500 8Y X boroscope to identify condition of combustion
bers
chamber (piston crown, liner hatches, fire deck, etc.)
HP Fuel pump and Inspect for leaks. Replace pump if necessary.
SL209 — 8Y X
LP Fuel pump
Cold Start Oil Replacement
SL212 Cooler by-pass 7500 18Y X
Valve

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Operation and Maintenance Manual Maintenance
Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Visual check condition on compressor side (blades,
leaks, connections, housings, etc.) every 4000 hrs.
SL213 Turbochargers 7500 18Y X
Replace the turbocharger at the indicated service
interval.
SL215 LT Water pump 7500 18Y X Replacement
SL216 HT Water pump 7500 18Y X Replacement
Coolant thermo- Replacement
SL217 7500 18Y X
stats
Auxiliary Belt Drive Replacement
SL218 7500 18Y X
- PTO
Replace all rubber hose connections on the engine:
SL219 Rubber sleeves 7500 18Y X e.g. coolant hoses for ECU cooling, hose connections
for crankcase ventilation
Clean component according supplier requirements.
SL220 Charged Air Cooler 7500 18Y X Check visually for leaks. If shown, identify reason.
Replace component if needed.
SL221 Oil Cooler 7500 18Y X Inspect the oil cooler
Recommended: Inspect the starter (winding insulation, relay, condition
SL222 7500 18Y X
Starter of the gear teeth, etc..)
Battery charging Replace battery charging alternator
SL223 7500 18Y X
alternator
SL224 Cylinder Heads 7500 18Y X Replace cylinder heads.

Tab. 20: Service level 2 — PRP — Advanced maintenance - Version : 2018/07-2

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Maintenance Operation and Maintenance Manual
Service level definition

5.4.6 Service level 1 — Engine Service, TBO 24000 hrs for COP —
Engine Operation - Version: 2018/07-2

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)

Collect and send oil sample for analysis every 100

hours on ESP or 250 h (in PRP and COP applica-
tions). If the results are not within the requested
SL100 Oil sampling 250 1Y X parameters repeat analysis at shorter intervals. In
case of use of high sulfure rate (>0,5%). No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Check coolant quality. (For more information see:
SL120 Coolant sampling - 2Y X
5.8.1 Coolant sampling — SL120, page 111) .
Engine oil replacement (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
Oil filters and oil filters for cooling jet replacement.
Recommended : (For more information see: 5.7.4 Changing oil filters
First 250 service — SL101, page 103) .
SL122 250 1Y X X
hours for a new or It is recommended to check the engine oil character-
overhauled engine istics at the same time. (For more information see:
5.7.1 Oil sampling and analyze — SL100, page 100) .
Perform all check before starting and perform a test
run. (For more information see: 5.6.7 Test run —
SL008, page 99) .
Without centrifuge
Engine oil filters Replace filters. Clean the seal area before removal
standard - main the old filter to prevent oil contamination. (For more
SL101 250 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube oil "Cate- 250 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube oil "Cate- 500 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .
With Centrifuge

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Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Engine oil filters Replace filters. Clean the seal area before removal
standard - Main the old filter to prevent oil contamination. (For more
SL101 500 2Y X
bearing with lube oil information see: 5.7.6 Changing Diesel engine oil —
"Category 3" SL101/SL121, page 107) .
Replace the paper (sleeve) for sludge at each oil
change. Measure and record thickness of the sludge
Centrifugal oil filter - accumulated on paper if above limits. Reduce lube oil
SL102 500 2Y X
paper filter interval if the sludge accumulated is above limits.
(For more information see: 5.7.5 Replacing centrifuge
paper filter — SL102, page 104) .
Engine oil change Oil Change Maximum Interval. Note : Replace Diesel
with lube oil "Cate- 500 2Y X engine oil at least every 2 years. Final lube oil interval
gory 2" (2) depends on exchange interval factor according to
lube oil category and fuel sulfur rate. 0<fuel sulfur
rate<0.5%: the factor is 1 (no change on the lube oil
change interval). 0.5<fuel Sulfur rate<1%: the factor
SL121
Engine oil change is 1/2 (reduce by 2 times the lube oil change interval
with lube oil "Cate- 1000 2Y X and use only lube oil category 2 or 3). 1<fuel sulfur
gory 3" (2) rate <1.5%: requires additional approval. No oil Cate-
gory 1 in case of K175. (For more information see:
5.7.6 Changing Diesel engine oil — SL101/SL121,
page 107) .

Replace main fuel filter cartridge. (For more informa-

SL105 Fuel main filter 1000 2Y X tion see: 5.9.3 Replacing main filter - SL105,
page 117) .
Replace primary fuel filter cartridge.
Recommended:
SL106 1000 2Y X See the operator and maintenance manual of your
Fuel prefilters
application.
Replace the air filter and clean air ducting between
Recommended: Air air filter and compressor.
SL108 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Inspect conditions of drive belt and fit new one if
necessary. (For more information see: 5.6.4 Checking
SL109 Alternator belt 1500 2Y X X drive belt — SL109, page 96) . Check belt tension.
(For more information see: 5.6.5 Replacing V-ribbed
belt — SL 109, page 97) .
Visual inspection of the tensioner. Replacement if
Alternator belt
SL110 4000 18Y X necessary. (For more information see: 5.6.6
tensioner
Replacing tensioning device — SL110, page 98) .

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Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Replace coolant (at least every 4 years for coolant
formulated with Glysantin G48).
Respect fluids and lubricants specifications.
Coolant drain points
SL116 6000 4Y X Note: for coolant formulated with Glysantin G40, the
(Glysantin G48)
extension up to 8000h/6Y is possible after analysis.
(For more information see: 5.8.5 Coolant drain points
— SL116, page 114) .

Tab. 21: Service level 1 — COP — Basic maintenance - Version : 2018/07-2

5.4.7 Service level 2— Engine Service, TBO 24000 hrs for COP —
Advanced maintenance - Version: 2018/07-2

Service
Schedule
Type
Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit

Component Task description

Replacement
Overhaul
(year)

Replace the air filter and clean air ducting between

Recommended: Air air filter and compressor.
SL201 3000 2Y X
filters + Air ducting See the operator and maintenance manual of your
application.
Clearence check and adjustment.
First inspection at 1000 h, second at 1500 h.
SL204 Valves clearance 2000 2Y X
Proceed in the same way after cylinder head repair
work.
SL205 Fuel injectors 8000 8Y X Replacement
Done at the time the injectors are replaced. Use a
Combustion cham-
SL206 8000 8Y X boroscope to identify condition of combustion
bers
chamber (piston crown, liner hatches, fire deck, etc.)
HP Fuel pump and Inspect for leaks. Replace pump if necessary.
SL209 — 8Y X
LP Fuel pump
Cold Start Oil Replacement
SL212 Cooler by-pass 12000 18Y X
Valve

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Service level definition

Service
Schedule
Type

Repair/Adjustment
Task identification

Inspection/Clean
Time limit (hrs)

Calendar limit
Component Task description

Replacement
Overhaul
(year)
Visual check condition on compressor side (blades,
leaks, connections, housings, etc.) every 4000 hrs.
No dismantling of the turbocharger only the air
SL213 Turbochargers 12000 18Y X
ducting.
Replace the turbocharger at the indicated service
interval.
SL215 LT Water pump 12000 18Y X Replacement
SL216 HT Water pump 12000 18Y X Replacement
Coolant thermo- Replacement
SL217 12000 18Y X
stats
Auxiliary Belt Drive Replacement
SL218 12000 18Y X
- PTO
Replace all rubber hose connections on the engine:
SL219 Rubber sleeves 12000 18Y X e.g. coolant hoses for ECU cooling, hose connections
for crankcase ventilation
Clean component according supplier requirements.
SL220 Charged Air Cooler 12000 18Y X Check visually for leaks. If shown, identify reason.
Replace component if needed.
SL221 Oil Cooler 12000 18Y X Inspect the oil cooler
Recommended: Inspect the starter (winding insulation, relay, condition
SL222 12000 18Y X
Starter of the gear teeth, etc..)
Battery charging Replace battery charging alternator
SL223 12000 18Y X
alternator
SL224 Cylinder Heads 12000 18Y X Replace cylinder heads.

Tab. 22: Service level 2 — COP — Advanced maintenance - Version : 2018/07-2

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5.5 Preparatory maintenance activities

DANGER
Hazards by entanglement, rotating or moving and ejected parts!
Impacts by ejected parts will cause serious injury or death.
Before monitoring or accessing to the engine covers, housing or compartement:
u Switch off the engine. (For more information see: Shutting down the Diesel engine, page 69) .
u Make sure all parts are stopped.
u Secure all parts against unexpected movements.

Information
The application set owner shall develop, document, implement, and enforce Lockout/Tagout proce-
dures.

Ensure the engine maintenance conditions as follows:

u Secure the area according local lockout/tagout procedures.
u Turn off battery main switch.
u If present, remove main switch key.
u Let the engine cool down at ambient temperature.
u Position the engine horizontally.

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5.6 Daily or monthly maintenance activities

5.6.1 Visual inspection — SL000

A visual inspection of the engine, ducts, and hoses shall be carried out in order to:
– Search for possible leaks.
– Eliminate the risk of contamination.
– Search for loose components.
– Prevent all engine damages.
The lines and hoses must be free of:
– Damage to the outer layer down as far as the insert (for example, chafe marks, cuts, and tears).
– Embrittlement of the outer layer (crack formation in the material).
– Deformation that doesn't match the natural shape of the hose or line, for example: delamination,
blister formation. Take into account depressurized and pressurized conditions of the hose or
line, as well as bends.
– Leaks.
– Failure to comply with the installation requirements.
– Damage or deformation to the fitting that reduces the strength of the fitting or of the connection
between the hose and the fitting.
– Dislocation of the hose from the fitting.
– Corrosion on the fitting that impairs function and strength.
Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory mainte-
nance activities, page 90) .
u Inspect all the points shown in the pictures below.
u Identify and report any failure. Let perform any repair work by the competent personnel.

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Fig. 45: Visual inspection of engine (1)

1 Crankshaft flange — Shaft seal 4 Injection system
2 Crankcase ventilation 5 Oil centrifuge
3 Turbochargers

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Fig. 46: Visual inspection of engine (2)

6 Damper — Shaft seal 11 Oil coolers
7 Water pump low temperature 12 Spin-on oil filters
8 Thermostat low temperature 13 Thermostat high temperature
9 Engine control unit (ECU) 14 Water pump high temperature
10 Charge air cooler

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Fig. 47: Visual inspection of engine (3)

15 Rubber sleeve 16 Compensator

Fig. 48: Visual inspection of engine (4)

17 Oil return (Turbocharger — Crankcase) 18 Exhaust line

5.6.2 Observation of the engine while running — SL007

By use of the “Faults — Cause — Remedy” (For more information see: 6.2 Faults - Cause -
Remedy, page 136) :

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u Observe the engine while running.

u Identify and report any failure. Let perform any repair work by the competent personnel.

5.6.3 Removal of the battery charging alternator cover

Fig. 49: Battery charging alternator cover details

1 Screw (M8) 3 Cover
2 Lock washer
Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory mainte-
nance activities, page 90) .
u Unscrew and remove screws 1.
u Remove cover 3 with screws and lock washers 2.

Information
Perform assembly in reverse sequence.

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5.6.4 Checking drive belt — SL109

Fig. 50: Drive belt alternator

1 V-ribbed belt

WARNING
Crushing hazards! During the assembly of auxiliaries, fingers can be crushed between tensioner
and bracket.
Could cause serious injury or death.
u Wear proper personal protective equipment.
u Use assembly and lifting devices.

Damage to the V-ribbed belt are:

– Rip breaks
– Rubber nodules in the belt base
– Deposits of dirt and / or stones
– Ribs detached from belt base
– Traverse cracks on the back
– Traverse cracks in several ribs

Fig. 51: Damage to the V-ribbed belt

The belt attachment is self-tensioning and maintenance-free.

The belt drive is located at the engine damper side.

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In case of wear, have the belt replaced immediately by the competent personnel.

5.6.5 Replacing V-ribbed belt — SL 109

Make sure that:
– 1x new V-ribbed belt is provided.
– 1x new tensioning device is available.
– 1x ratchet wrench (1/2-inch square drive) with lever is available.
The battery charging alternator cover is dismounted. (For more information see: 5.6.3 Removal of
the battery charging alternator cover, page 95) .

V-ribbed belt removal

Fig. 52: Removing V-ribbed belt

u Mount ratchet wrench with lever to the corresponding tensioning device.

u Pivot back tensioning device 1 against the spring force to the limit stop.
u Insert guiding pin (8 mm/0.315 inch diameter) to block the tensioning device.
u Remove V-ribbed belt 2.
u Remove guiding pin.
u Release and remove ratchet wrench.
w The tensioning device is released.

Install V-ribbed belt

u Install ratchet wrench on tensioning device 1.
u Pivot back the tensioning device against the spring force to the limit stop.
u Insert 8 mm/0.315 inch guiding pin to block the tensioning device.
u Install V-ribbed belt 2.
u Hold ratchet wrench, remove guiding pin.

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u Release and remove ratchet wrench.

w The tensioning device is released.

Fig. 53: Checking V-ribbed belt tension — Measurement area (left)

1 Sensor 2 Belt section
u Check tension with adequate tool. The measured frequency value must be 165 Hz (Min149 Hz -
Max 182 Hz).
In case of air conditioning compressor installed, proceed in the same way.

Information
Mount the battery charging alternator cover in reverse sequence. (For more information see:
5.6.3 Removal of the battery charging alternator cover, page 95)

5.6.6 Replacing tensioning device — SL110

q The battery charging alternator cover is dismounted. (For more information see: 5.6.3 Removal
of the battery charging alternator cover, page 95) .
q The V-ribbed belt is removed. (For more information see: 5.6.5 Replacing V-ribbed belt — SL
109, page 97) .

Fig. 54: Replacing tensioning device

1 Nut (M10) 3 Washer
2 Tensioning device 4 Screw (M10)

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Tensioning device removal

u Remove screw (M10) 4 with washer 3 and nut (M10) 1.
u Remove tensioning device 2.

Tensioning device installation

u Mount tensioning device with screw (M10) 4, washer 2 and nut (M10) 1.
u Tighten screw (M10) 4 and nut (M10) 1 to 40 Nm.

Information
Mount the battery charging alternator cover in reverse sequence. (For more information see:
5.6.3 Removal of the battery charging alternator cover, page 95) .

5.6.7 Test run — SL008

See the generator set manual for more details.

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5.7 Lubricating system

5.7.1 Oil sampling and analyze — SL100

WARNING
Hazards by hot engine oil!
Serious injuries or death by burns or skin penetrating oil.
u Avoid skin contact with the engine oil.
u Wear proper personal protective equipment.

Fig. 55: Sampling point on engine left side

1 Sampling point

Information
The oil quality is to be ensured by regular analyzes.
For more informations, refer to the generator set manual.

Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory mainte-
nance activities, page 90) .
u Take oil sample from the sampling point.
u Ensure analyses according to generator set operator and maintenance manual.

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5.7.2 Checking prelubricating pump (optional) — SL103

Fig. 56: Prelubricating pump

u Check for abnormal noise when operating.

u Check pump for leaks.
u Control pump functions.
u Identify and report any failure. Let perform any repair work by the competent personnel.

5.7.3 Checking the engine oil level — SL001

q Engine stopped since at least 8 hours.
q Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90) .
The location of the dipstick and the oil filler neck vary according to Diesel engine type. On the
engine, the dipstick is located on the right side of the engine. The oil filler neck is located on the oil
pan on the right side, the flywheel housing or on the cylinder head.

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Fig. 57: Example of oil dipstick — oil filler neck

1 Dipstick 2 Oil filler neck
u Pull out Dipstick 1, wipe with clean cloth and re-insert as far as it goes.
u Pull the oil dipstick again and determine the oil level.
w The oil level must be between the “min.” and “max.” marks on the dipstick.

Information
Depending on application, some dipsticks have markings ("stopped" / "started").
Check the oil level on the "stopped" side.

If the oil level is too low:

u Remove oil filling cap.
u Replenish oil via the Oil filler neck 2.
u Do not replenish Diesel engine with oil over the “max.” mark.

Information
Depending on application, some dipsticks have markings ("stopped" / "started").
Check the oil level on the "stopped" side.

u Clean filling cap and close the filler neck.

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5.7.4 Changing oil filters — SL101

q Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90) .

Fig. 58: Spin-on oil filters

1 Spin-on oil filter 3 Seal
2 Filter head
Spin-on oil filter removal
u Clean sealing area.
u Open spin-on oil filter 1 with filter wrench.
u Remove filter.
u Repeat procedure for all filters.
Spin-on oil filter installation
u Clean sealing area.
u Lubricate filter seal 3 with engine oil.
u Screw spin-on oil filter 1 in filter head 2 until it contacts base.
u Tighten filter by hand by 1/2 turn.
u Operate prelubricating pump to vent the filters.
u In the absence of prelubricating pump, disconnect TDC sensor (flywheel) and start engine until
oil pressure shows up.
u Reconnect TDC sensor.
u Check for leaks and damages.
u Retighten if necessary.

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5.7.5 Replacing centrifuge paper filter — SL102

WARNING
Hazards by hot engine oil!
Serious injuries or death by burns or skin penetrating oil.
u Avoid skin contact with the engine oil.
u Wear proper personal protective equipment.

Ensure that:
q Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90)
q Original KOHLER oil filters with the seals are provided.
q A suitable drainage container is available.
q The required quantity of approved oil is provided. (For more information see: 5.11 Lubricants
and operating fluids, page 120)
The oil centrifuge is equipped with a stop valve which stops the oil inlet.
The oil centrifuge is attached to the engine on the right side.

Replacing centrifuge paper filter

Fig. 59: Oil centrifuge

1 Centrifuge base 5 Rotor cylinder
2 V-clamp 6 Paper filter
3 Rotor 7 Rotor base
4 Cover 8 Rotor cover

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Fig. 60: Opening the centrifuge

u Unclamp and remove V-clamp 2.

u Open screw on top of cover 4.
u Remove cover 4.

Fig. 61: Opening the rotor

u Unscrew and remove the nut of rotor cover 8.

u Lift carefully the rotator cylinder 5 so that the mud remains in the cylinder.
u 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 (1.77“ in). Other-
wise:
u Reduce maintenance intervals and operate oil analysis.

u Clean all components of oil centrifuge.

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u Replace rotor cover 8 seals in cover 4.

Fig. 62: Deflector disk and seals on rotor base and bearing tube

u Lift and clean the deflector disk 9.

u Clean bearing tube 10 and rotor base 7.
u Replace seals of rotor base 7 and bearing tube 10.
u Insert deflector disk 9.

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.

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Fig. 65: Assembling rotor

u Assemble rotor cylinder 5 on rotor base 7.

u Mount rotor cover 8 and tighten nut to 40 Nm (30 ft-lb).

Fig. 66: Assembling the centrifuge

u Place rotor 3 in centrifuge base 1.

u Install cover 4 and tighten nut to 7 Nm (5 ft-lb).
u Check seal of V-clamp 2. Replace if necessary.
u Install and tighten V-clamp 2 to 7 Nm (5 ft-lb).
u Start and run engine for three minutes.
u Check engine oil level. (For more information see: 5.7.3 Checking the engine oil level — SL001,
page 101)

5.7.6 Changing Diesel engine oil — SL101/SL121

WARNING
Hazards by hot engine oil!
Serious injuries or death by burns or skin penetrating oil.
u Avoid skin contact with the engine oil.
u Wear proper personal protective equipment.

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Ensure that:
q Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90)
q A container with the required capacity is ready.
q Original KOHLER oil filters with the seals are provided.
q A suitable drainage container is available.
q The required quantity of approved oil is provided. (For more information see: 5.11 Lubricants
and operating fluids, page 120)
The engine has several outlet bores to drain off lubricants and operating fluids.
The oil filter modules are attached to the engine on the right side.

Draining off Diesel engine oil

Fig. 67: Oil drain point - engine rear side

1 Oil drain aggregate support. Engine right 3 Oil drain on oil pan (main)
side
See next page for continuation of the image legend

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2 Oil drain aggregate support. Engine left

side

Fig. 68: Oil drain - engine left side

1 Oil drain on oil cooler
On each drain-off point:
u Unscrew and remove plug or open valve.
u Let the oil flow into the container.
u Wait until no more oil drips.
u Clean the drain-hole, plug or valve and the surrounding area with a clean rag.
u Check washer condition.

Troubleshooting
If washer is worn or broken:
u Replace washer.

u Refit the plug or close the valve.

u Tighten plug according standard torque.

Filling Diesel engine oil

q Engine oil drained.
q Filters replaced.
q Draining plugs and valves closed.

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Fig. 69: Filling engine oil — right side

1 Dipstick 2 Filler neck
u Remove oil filling cap.
u Fill with oil via filler neck 2 until between “min.” and “max.” marks on the dipstick 1.

Information
Depending on application, some dipsticks have markings ("stopped" / "started").
Check the oil level on the "stopped" side.

u Clean oil filling cap, place on the filler neck and tighten by hand.
u Start the engine.
u Check oil pressure (engine oil pressure display unit) and check oil filter for leaks.
u Shut down the engine.
u After 2 to 3 minutes, check oil level on the dipstick. (For more information see: 5.7.3 Checking
the engine oil level — SL001, page 101)

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5.8 Cooling system

5.8.1 Coolant sampling — SL120

See the generator set manual for more details.

5.8.2 Checking coolant level — SL001

DANGER
Hazards by ejection of hot operating fluids or filler cap!
Hot fluid spray from a pressurized cooling system will cause death or serious injuries by burns.
Filler cap ejected by operating fluid under pressure will cause death or serious injuries by impact.
u Only perform maintenance and inspection work on the cooling system when the engine has
cooled down to ambient temperature.
u Wear proper personal protective equipment.
u Remove the filler cap when it is cold or cooled enough to be touched with bare hands.
u Loosen the filler cap to first stop to relieve pressure.
u Wait until pressure drop.
u Remove the filler cap.

Fig. 70: Risk of burns while checking coolant level

See the generator set manual for more details.

u Check the glycol concentration of the coolant with a refractometer.
In case of incorrect mixture:
u Check the quantities of water / anti-freeze mixture.
In case of correct mixture:
u Fill up with approved engine coolant inhibitors. (For more information see: 5.11.5 Diesel engine
coolant, page 129)
u Fill up with KOHLER coolant in other cases.
u Respect the level marks on the level indicator window.

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5.8.3 Inspecting low temperature circuit (charge air cooler) — SL002

Fig. 71: Low Temperature circuit drain holes

At drain holes 1:
u Check for fluid leakage.
If water escapes from one of these holes:
u The leakage of condensation water is not a determining factor. Let the condensation water flows
out.
If air escapes from one of these holes:
u Air leakage is normal.
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.

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5.8.4 Checking relieve bores — water/coolant pump — SL003

Fig. 72: Relieve bores on water pumps

1 Water pump high temperature 2 Water pump low temperature

DANGER
Hazards by ejection of hot operating fluids or filler cap!
Hot fluid spray from a pressurized cooling system will lead to lethal or heavy injuries by burns.
Filler cap ejected by operating fluid under pressure will lead to lethal or heavy injuries by impact.
u Only perform maintenance and inspection work on the cooling system when the engine has
cooled down to ambient temperature.
u Wear proper personal protective equipment.

Ensure that:
q Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90) .
u Check relieve bores of water pump high temperature 1 and water pump low temperature 2 for
leakage on oil or water side.
In case of oil or water leakage:
u Let replace the pump by the competent personnel.

Information
Slight drops are not critical.

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5.8.5 Coolant drain points — SL116

DANGER
Hazards by ejection of hot operating fluids or filler cap!
Hot fluid spray from a pressurized cooling system will cause death or serious injuries by burns.
Filler cap ejected by operating fluid under pressure will cause death or serious injuries by impact.
u Only perform maintenance and inspection work on the cooling system when the engine has
cooled down to ambient temperature.
u Wear proper personal protective equipment.

Ensure that:
q Preparatory maintenance activities are fulfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90)
q A container with the required capacity is ready.
q A suitable drainage container is available.
q The required quantity of approved coolant is provided. (For more information see: 5.11 Lubri-
cants and operating fluids, page 120)

Fig. 73: Coolant drain points

u Drain coolant system at the deepest point. Refer to the application set manual.

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Fig. 74: LT thermostat and HT thermostat venting connections

Fig. 75: Bleeding point on engine HT coolant pump

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Fig. 76: Venting connection on flywheel housing

Fig. 77: Venting connections on vent tube assembly

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5.9 Fuel system

DANGER
Fire or explosion by flammable and explosive lubricants and fuels.
Lethal or heavy injuries.
u Keep all caps and valves closed near the operating temperature.
u Avoid any contact of flammable and explosive operating fluids, gases or combustible materials
with any hot surface or ignition source.
u Keep the engine clean and free from accumulation of dust and flammable liquids.
u Keep the insulation free of operating fluids contamination.
u Never release operating fluids while operating the engine.
u Check the electrical system. Immediately rectify all errors, such as loose connections and frayed
cables.
u During refueling, switch off any additionally installed heater (optional).
u Lock out and tag out the engine prior to accessing to engine.
u Ensure a good ventilation while refueling or prior to accessing to the engine.
u Regularly check all lines, hoses and screw connections for leaks and damages. Immediately
rectify the leaks and replace the damaged parts.
u Smoking and open flames are forbidden in the vicinity of the engine.
u Always start the engine according to the instructions in the instructions manual of the machi-
nery.

5.9.1 Draining off water from fuel prefilter — SL004

Refer to the generator set manual for more details.

5.9.2 Drain off water and sediment of fuel tank

Refer to the Operation and Maintenance Manual of the application set for more details.

5.9.3 Replacing main filter - SL105

The main filter is located on the flywheel side, on the right side of the engine.

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Fig. 78: Fuel filters

1 Fuel filter 2 Filter head
Ensure that:
q Preparatory maintenance activities are fullfilled. (For more information see: 5.5 Preparatory
maintenance activities, page 90) .
q A container with the required capacity is ready.
q Original KOHLER main fuel filters are available.
q A suitable drainage container is available.
q A fuel filter ribbon spanner is available.
Fuel filter removal
u Remove dust from sealing area.
u Open fuel filter 1 with filter ribbon spanner.
u Remove filter.
u Repeat procedure for all filters.
Fuel filter installation
u Remove dust from sealing area.
u Lubricate filter seal with engine oil.
u Screw fuel filter 1 in filter head 2 until it contacts base.
u Tighten filter by hand by 3/4 to 1 turn.
u Check for leaks and damages.
u Retighten if necessary.

5.9.4 Bleeding the fuel system

Refer to the generator set manual for more details.

5.9.5 Checking differential pressure — fuel prefilter — SL005

Refer to the generator set manual for more details.

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Air system

5.10 Air system

5.10.1 Check service indicator on air filter — SL006

Refer to the generator set manual for more details.

5.10.2 Replace crankcase breather — SL107

Fig. 79: Crankcase ventilation

1 Screw (M8) 6 Hose
2 Filter element 7 Hose
3 Clamp 8 Hose
4 Hose 9 Hose
5 Clamp

Removal
u Loosen clamps 3, 5.
u Remove hoses 4, 6, 7, 8, 9.
u Remove screws 1.
u Remove filter element 2.

Installation
u Screw filter element 2 with screws 1.
u Install hoses 4, 6, 7, 8, 9 with clamps 3, 5 on filter element 2.

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5.11 Lubricants and operating fluids

5.11.1 Handling lubricants and operating fluids

Information
u Only fuel and lubricants 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 and lubricants other than fuel and lubricants approved by Kohler Co. are used.

The conscientious observance of the regulations for handling lubricants and operating fluids
increases the reliability and service life of the engine.
It is particularly important that the stated replacement intervals and lubricant qualities are adhered
to.
u Lubricate the machine within the specified time intervals.
u Change the oils within the specified time intervals.
u Observe environmental regulations and rules for handling lubricants and operating fluids.

Environmental protection measures

CAUTION
Environmental and health hazards by incorrect disposal.
Incorrect waste disposal leads to environment and water supply pollution and injuries by hazards
from linked sequences.
u Observe the country-specific regulations regarding environmental protection when disposing of
scrap materials.
u Before disposing or recycling waste products, ask for the correct method at the responsible
environmental or recycling center.
u When handling waste, lubricants and fuel make sure that none is disposed into the environ-
ment.
u Collect and dispose waste, lubricants and fuel in separate, suitable, properly designated
containers.
u Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is
prohibited.
u Dispose all scrap materials only at official locations in an environment-friendly manner.

Disposal of scrap materials

Concerning scrap materials and hazardous waste, such as:
– Oils, lubricants, refrigerants from air conditioning systems
– Coolant
– Fuels
– Filters, oil filter cartridges, etc.

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5.11.2 Filling volume

Information
The following values are indicative. Refer to the technical data sheet of your engine for the latest
values. For further information, please contact your nearest authorized Kohler service representa-
tive.

Description Unit Value

Engine Oil - maximal volume l 335
gal 88.5
Engine Oil - minimal volume l 272
gal 71.9
Coolant - Filling volume in the Diesel engine — high and low l 375
temperature circuits gal 99

5.11.3 Diesel fuels

Diesel fuels requirements

Authorized diesel fuels based on DIN EN 590 and ASTM D975

Maximum sulfur content 5000 ppm
Lubricating ability at 60 °C (140 °F) 460 μm
Minimum cetane number 45

Tab. 23: Standard diesel fuels

Approved Diesel fuels

Following fuel names and summary of definitions are approved.
Restrictions or impacts on the maintenance schedule are indicated.

ASTM D975 N°1 and N°2

Fuel Name Detail Restriction

ASTM D975 1D on road N°1 => S15 Maximal HFRR < 460μm
diesel
N°1 => S500 Maximal HFRR < 460μm without EATS
N°1 => S5000 Maximal HFRR < 460μm without EATS
ASTM D975 2D N°1 => S15 Maximal HFRR < 460μm
N°1 => S500 Maximal HFRR < 460μm without EATS
N°1 => S5000 Maximal HFRR < 460μm without EATS
ASTM D975 4D N°4 Maximal HFRR < 460μm without EATS

Tab. 24: ASTM D975 approved fuels

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EN590 road and non-road Diesel fuels

Information
It is recommended to add a polishing primary fuel filtering system on the storage tank for standby
application due the bio content.
For further information, please contact your nearest authorized Kohler service representative.

Fuel Name Detail Restriction

EN590 Road Diesel Fuel CSR Maximal 10% biodiesel
4.0.05
EN590 Non Road Diesel Fuel Maximal 10% biodiesel
CSR 4.1.03

Tab. 25: EN590 approved Diesel fuels

BS 2869 British specification

Information
It is recommended to add a polishing primary fuel filtering system on the storage tank for standby
application due the bio content.
For further information, please contact your nearest authorized Kohler service representative.

Fuel Name Detail Restriction

BS 2869 2010 classA2 Non Road Diesel Gasoil Maximal 10% biodiesel
10 ppm

Tab. 26: Approved BS 2869 Diesel fuels

Heating oil or domestic fuel

Information
Heating oil or domestic fuel can impact the engine performances (power lost, higher consumption,
etc..).
Maintenance schedule must be revised according to the fuel quality of these non-standard fuels.
For further information, please contact your nearest authorized Kohler service representative.

Fuel Name Detail Restriction

Heating oil / domestic CSR 4.4.06 DIN 51603 Not feasible without EATS and reinforce fuel
fuel primary filtering system.
We recommend to add a water separator
between the main storage tank and the daily
tank.

Tab. 27: Approved heating oils or domestic fuels

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Military Fuel

Information
Military fuels can impact the engine performances (power lost, higher consumption, etc..).
Maintenance schedule must be revised according to the fuel quality of these non-standard fuels.
For further information, please contact your nearest authorized Kohler service representative.

Type Detail Restriction

NATO F-54 Road Same as EN590 CSR HFRR < 460μm.
Diesel fuel 4.0.05
XF-10 Heating oil Same as Heating oil HFRR < 460μm.
CSR 4.4.06 Without EATS.
XF-51 Non Road fuel Same as EN590 non HFRR < 460μm.
road fuel CSR 4.1.02 Maximal 10% biodiesel
=> CSR 4.1.03
NATO F-35 JET A1 (03/2015) HFRR < 460μm.
ASTMD 1655-15 Kero- Without EATS.
sene grade cut of fuel With additive S-1750.
suitable for most turbine (With up to 1:200 two stroke oil 0-1177
engine aircraft. German Military approach for COP due to
Produced to a stringent starting and soot issues).
internationally agreed F35 has to be updated to F34 and with Addi-
standard. tive S-1750.
Widely available outside
the U.S.
NATO F-34 (JP8) JET A1 (03/2015) HFRR < 460μm.
MIL-DTL- 83133 ASTMD 1655-15 Without EATS.
DEF STAN 91-87 + Additive => S-1747 With additive S-1750.
for oxidation stability Not suitable for standby applications.
and lubricity. Suitable for PRP or COP application due to
+ Additive => S-1745 cold start issue
for freezing point.
Jet A-1 specification
fuel containing military
fuel additive package:
static dissipater additive
(SDA), corrosion inhib-
itor/ lubricity improver
(CI/LI), and fuel system
icing inhibitor (FSII) and
may contain antioxidant
(AO) and metal deacti-
vators (MDA).
Single fuel on the
battlefield used by the
Army and Air Force per
AR 70-12.

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Type Detail Restriction

NATO F-63 or XF-63 NATO F34 or F35 or HFRR < 460μm.
F44 + additive => Without EATS.
S-1750 for cetane index With additive S-1750.
and lubricity.

Tab. 28: Approved military fuels

Bio Diesel EN12214 and ASTM D6751-12

Information
The maximal Biodiesel content is 10%.
If larger quantities or pure Biodiesel is used, the engine has to be modified to use with biofuels.

Type Detail Restriction

Bio Fuel EN 12214 Bio Fuel < 10%. Without EATS.
A fuel build from a We recommend to improve storage condition
blend with a mix up to in order to stabilize the fuel (avoid oxidation,
10% of Biodiesel EN batteries and corrosion).
12214 and EN 590 or We recommend to add a water separator fuel
heating fuel. filtering process between the main storage
tank and the daily tank.
Bio Fuel ASTM D6751 Bio Fuel < 10%. Without EATS.
A fuel build from a We recommend to improve storage condition
blend with a mix up to in order to stabilize the fuel (avoid oxidation,
10% of Biodiesel ASTM batteries and corrosion).
D6751 and ASTM D975 We recommend to add a water separator fuel
or heating fuel. filtering process between the main storage
tank and the daily tank.

Tab. 29: Approved bio Diesel fuels

Alternative fuel

Information
Alternative fuels can impact the engine performances (power lost, higher consumption, etc..).
Maintenance schedule must be revised according to the fuel quality of these non-standard fuels.
For further information, please contact your nearest authorized Kohler service representative.

Type Detail Restriction

GTL fuel DIN 15940
CEN TS 15940

Tab. 30: Approved alternative fuels

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Approved fuel additives

Information
Additives are not permitted except fuel biocides such as Grotamar 81 and 71 von Schülke & Mayr
GmbH.

Diesel fuel at low temperatures (winter operation)

Diesel fuel produces paraffin crystals at low ambient temperatures. These crystals increase the
flow resistance in the fuel filter to such an extent that an adequate fuel supply to the diesel engine
is no longer guaranteed.

NOTICE
Risk of property damages!
Incorrect fuel damages the engine. Admixture of paraffin, normal petrol or other substances will
cause damage to the injection system. Leaks due to precipitated paraffins.
u Do not admix paraffin, normal petrol or other additives to the diesel fuel.
u Use a start-up aid (for example fuel filter heating system).
u Use special diesel fuels with adequate flow properties.

5.11.4 Diesel engine lubricants

Engine oil requirements

Quality level
The approved engine oils are divided into the following Quality Categories:

– Oil category 2: Standard quality / Synthetic multigrade oils

– Oil category 2.1: Standard quality / Synthetic multigrade oils dedicated for engines with
Exhaust After Treatment system (low SAPS lube oils)
– Oil category 3: Highest quality / Synthetic Multigrade oils
– Oil category 3.1: Highest quality / Synthetic multigrade oils dedicated for engines with Exhaust
After Treatment system (low SAPS lube oils)
Low SAPS lube oils are dedicated for fuel which content < 15 mg/kg (15ppm) => lube oils with a
low sulfur and phosphor content and an ash-forming additive content of ≤1%
Do not use Lube oil category 2.1 and 3.1 with a sulfur rate over 15 mg/kg (15 ppm).

NOTICE
Property damages by additives mismatching with engine oil
Use of additional engine oil additives may damage the engine
u Additional engine oil additives are not allowed.

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Quality categories performances

Oil category Minimum standards Recommended Base oil. All have to Base oil. All
viscosity be compliant to high have to be
classes power turbo charged compliant to
engines high power
turbo
charged
engines
Oil category 1 Not allowed
Oil category 2 ACEA E4 or ACEA SAE 5W-40; SAE Synthetic (Group 2 1
E7 or API CI-4 Plus 10W-40; SAE and/or 3 Base oils)
or DHD-1 or JASO 15W-40 with
DH-1 preheating
system
Oil category ACEA E6 or ACEA SAE 5W-40; SAE Synthetic (Group 2 1
2.1 E9 or API CJ-4 or 10W-40; SAE and/or 3 Base oils)
JASO DH-2 15W-40 with
preheating
system
Oil category 3 ACEA E4-16 or both SAE 5W-40; SAE Synthetic (Group 3 2
(standard ACEA E4 and ACEA 10W-40 and/or 4), VI > 155,
today) E7 and long live additives
Oil category ACEA E6-12 or both SAE 5W-40; SAE Synthetic, VI > 155, 2
3.1 (standard ACEA E6 and ACEA 10W-40 and long live additive
today) E9 or API CK-4

Tab. 31: Quality categories performances according oil categories

Lube Oil Category 3 minimum requirements

Parameter Unit Value Engine oil Value Engine oil Method

without exhaust with exhaust after
after treatment treatment
Visual appearance clear clear Visual
Viscosity at min. Temp. mm2/s 3500 3500 DIN 51562
Viscosity at operation mm2/s 10.0 - 16,0 10.0 - 16,0 DIN 51562
temp.
VI-Index > 145 > 155 i.A. DIN ISO 2909
Height Temp. High cP 3.5 - 4.3 3.5 - 4.3 CEC L-36-A-90
Shear
Ignition point °C > 220 > 220 DIN ISO 2592
Total base number mg KOH/g > 12 >9 DIN ISO 3771
Shear stability % 10% 10% ASTM D6278
NOACK (1h at 250°C) % 10% 10% CEC-L-040-93
Ash (Sulphur) max. g/100g 1.9 0.95 DIN 51575
Ash (Sulphur) max. g/100g 1.9 0.6 DIN 51575

Tab. 32: Oil category 3 characteristic requirements

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Selecting the engine oil

Fuel sulfur content influence
The following table is intended to help select the right engine oil based on the total base number
(TBN) and according to the sulfur rate.
This measurement value is important for reducing combustion gases that are influenced by the
sulfur content in the fuel.
Ensure that the index of basicity TBN (Total Base Number) is >8 mg mgKOH/g and the soot
(SiO) is <3%
The following measures must be taken in the case of diesel fuels with a sulfur content
above 0.5%:
– Use an engine oil with a total base number (TBN) of more than 10 mgKOH/g in case of high
sulphur rate (0.5 < Sulfur ratio % <1).
– Shorten the oil drain intervals according to chapter “Oil change interval”.
– Confirm oil change interval by oil analyzes.

Information
u 0,5% of sulfur = 5000 ppm and 1% of sulfur = 10000 ppm

Fig. 81: TBN curves according to sulphur rate

1 TBN - Index of basicity 4 Recommended Index of basicity
(mgKOH/g)
2 Sulfur content part per million 5 Minimum Index of basicity (mgKOH/g)
3 Engine oil must be changed as soon as
possible

Viscosity grade

Information
u Monograde lube oils are prohibited.

Following viscosity classes are permitted

– 5W40
– 10W40
– 15W40 with coolant preheating system
The selection of lubricant viscosity is based on the SAE classification (Society of Automotive Engi-
neers).

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Excessive viscosity can result in starting difficulties. If the viscosity is too low, this can compromise
the lubricating efficiency.

Difficulty factors
Difficulty factors can be:
– Frequent cold starts
– Environmental influences
• Operating temperature
• Dust
• High humidity
• Long standstill times
If there are difficulty factors or difficult usage conditions, the oil change and filter change must:
– be performed according to oil change interval

Oil change interval

The basic change interval is defined in the maintenance tables. The change intervals are defined
as follows:
Basic oil change interval * Factor oil category * Factor sulfur content = change interval

Lubricant oil category Factor oil category

Factor oil category “1/4” => reduces the maintenance interval by 4 times
Factor oil category “1” => no change on the maintenance interval
Lubricant oil category 3 and 3.1 “2” => double the maintenance interval

Tab. 33: Oil category factor definition

Sulfur content in % Factor sulfur content

0 < sulfur content ≤ 0.5 1=> no change on the maintenance
interval
0.5 < sulfur content ≤ 1 limited to lubricant category 2 1/2=> reduces the maintenance interval
and 3 by one half
1 < sulfur content ≤ 1.5 limited to lubricant category 2 1/4=> reduces the maintenance interval
and 3 by one quarter.

Tab. 34: Sulfur content factor definition

Information
u The use of sulfur in the ratio of more than 1% requires an additional approval of the engine
manufacturer.
u Special lubrication oil must be used => TBN > 12 MgKOH/g

Engine oil operating monitoring

Take and analyze oil samples at least once per year and during each oil change and under certain
conditions.
Depending on application and the engine's operating conditions, sampling / analyses should take
place more frequently.

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From the indicated test methods and limit values, it emerges when the result of a single oil sample
analysis is to be viewed as abnormal.
Kohler Co. recommends to perform lube oil analysis of used engine lube oil for the following
parameters (minimum list).
– Viscosity
– Flashpoint
– Soot
– TBN
– Water
– Oxidation
– Ethylene glycol
– Wear elements (Iron, Chromium, Tin, Aluminium, Nickel, Copper, Lead and Molybdenum)
– Contaminants (Silicon, Potassium, Sodium, Lithium, Antimony, Silver, Titanium, Vanadium,
etc…)
– Additives (Calcium, Magnesium, Boron, Zinc, Phosphorus, Barium, Sulfur)
– Diesel fuel rate (dilution)

Engine oil analysis

Analyze oil at regular intervals.
The oil analysis makes it possible:
– to draw conclusions about the oil condition,
– to survey the progress of wear,
– to detect potential damage,
– to take preventative measures,
– to increase the application availability
– with the laboratory report, to optimize the oil change,
– to minimize the environmental pollution by reducing waste oil.
Only authorized specialist personnel must carry out the oil analyzes according to the inspection
and maintenance schedule.
If the operating hours value specified in the inspection and maintenance schedule is not achieved
within 2 years, carry out an oil analysis for the identified oil circuits after 2 years at most.

5.11.5 Diesel engine coolant

Coolant requirements

NOTICE
Mixing different anticorrosion antifreeze agents or prepare unproperly the coolant could alterate the
coolant properties.
Property damages by cavitation, corrosion or overheating.
u Do not combine different products. Drain cooling system if required.
u Do not mix silicate-based and non-silicate based coolants.
u Check the coolant and cooling system according to maintenance spreadsheet.
u Keep the cooling system clean and sealed.

Coolant is a mixture of water with corrosion-inhibiting antifreeze products as additives.

KOHLER engines are tested and approved with SI-OAT-Technology based on Ethylene glycol.
These products are based on BASF Glysantin G40 or G48 coolants.

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Information
Average change intervals (to be validated by coolant analysis):
With Glysantin G48 = 6000 h or 4 years.
With Glysantin G40 = 8000 h or 6 years.

Corrosion inhibiting antifreeze (ready mixed or concentrated)

Corrosion-inhibiting antifreeze products approved by Kohler Co. guarantee adequate protection
against low temperatures, corrosion and cavitation, do not attack seals and hoses and are non-
foaming.
Coolant can be independently blended with the products listed in section “Water” and “anti-freeze
and corrosion protection agent” or as a made up blend.
Kohler Co. recommends to use ready mixed coolant.
Ready mixed coolant limits the risk for the operator while preparing the final coolant by mixing
concentrate coolant and water.
Corrosion inhibitor antifreeze ratio and water quality are determinant factors Coolants containing
unsuitable corrosion-inhibiting antifreeze products or which have not been prepared properly can
cause the failure of components and parts in the coolant circuit as a result of cavitation or corrosion
damage.
In addition, deposits with thermal insulation properties can build up on components that conduct
heat, leading to overheating and ultimately to failure of the engine.
The cooling system only operates reliably under pressure. Keep the cooling system clean and
sealed.
The cooling sealing and operating valves must function correctly. Maintain the required coolant
level.

Corrosion inhibitors

NOTICE
Corrosion inhibitors has to insufficient cavitation protection and lower boiling point limit.
Property damages by cavitation, corrosion or overheating.
u Corrosion inhibitors are forbidden on KOHLER engines.

Fresh water requirements

NOTICE
Using inadequate water could alterate the coolant properties and deposit impurities in the cooling
circuit.
Property damages by cavitation, corrosion or overheating.
u Use recommended water. Drain and flush cooling system if required.

NOTICE
Refilling with inadequate water or coolant mix could lead to precipitation of antifreeze product and
impurities in the cooling circuit.
Property damages by contamination or overheating.
u Use recommended water or coolant mix.
u By precipitation, replace the cooling circuit.

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Kohler Co. recommends to use:

– Fully deionized water
– Corresponding to the 2006 WHO (World Health Organization) guideline for drinking water
By missing water analyses or proven water quality, switch to deionized water or reversed
osmosis water.
Ask for water analyses at the relevant local authorities.
Sea water, brackish water, salt water and industrial waste water are not suitable.

Requirement Value
Water hardness maximum 2.14 mmol/dm3 (214 ppm) with maximum of 12°dH
pH-Value at 20 °C (68 °F) 6,7 to 9,0
Chloride (ions) maximum 100 mg/dm3 (100 ppm)
Sulphate maximum 100 mg/dm3 (100 ppm)
Bacteria and toxic constituents Without
Impurities Clear and free

Tab. 35: Fresh water requirements

Permissible concentration for all coolant types

Kohler Co. recommends a range of concentration of corrosion-inhibiting antifreeze agent from 40%
to 50% all year round.

Information
u KOHLER cooling packages are designed with concentration of corrosion inhibiting antifreeze
agent of 40%.

NOTICE
Property damages by cavitation, corrosion or overheating.
Mixing different anticorrosion antifreeze agents or unproperly prepared coolant could alterate the
coolant properties.
u Do not combine different products. Drain cooling system if required.
u Check the coolant and cooling system according to maintenance spreadsheet.
u Do not mix silicate-based and non-silicate based coolants.
u Keep the cooling system clean and sealed.

Information
If indicated coolant cannot be obtained locally:
u Use coolant which corresponds to the “Coolant specification for KOHLER diesel engines”. For
inquiries, please contact your nearest authorized Kohler service representative.

Coolant monitoring
Carry out periodic coolant analysis to check the used coolant.
Coolant samples should be taken and analyzed at least once per year and under certain condi-
tions, depending on application and the engine's operating conditions, sampling / analysis should
take place more frequently.

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The test methods and limit values reveals the result of a single coolant sample analysis as
abnormal.
Kohler Co. recommends to perform coolant analysis of used coolant for the following minimal
parameters.
Control parameters for the coolant:

Product name
Lab-No
General information
Date of sample
Last fluid exchange
Added fluid during use
Hours of use
Machine operating hours
Analyse Method Unit
Optical appearance
Elements Additives (Ca, Mg, Si, B, P, DIN 51399-1:2012-5 mg/kg
Ba, S, Na, K)
ppm
Elements wear (Fe, Cr, Cu, Sn, Al, Ni, DIN 51399-1:2012-5 mg/kg
Pb, Mo, Mg, Ti, V)
ppm
Contamination (Si, Ca, Mg, Zn, Sn, DIN 51399-1:2012-5 mg/kg
Mo)
ppm
Color Visual
Glycol DIN 51375-1, GC-Headspace, FTIR %
Corrosion Cu EN ISO 2160
Corrosion steel ISO 7120
Bacteria Dipslide test MERK count
Water hardness EN ISO 11885 mmol/l
ppm
Nitrate EN 12014 mg/kg
ppm
Nitrite EN 12014 mg/kg
ppm
Ph-value EN ISO 10523:2012-04
Pour point freezing point ISO 3016, ASTM 5985 °C
°F
* compared to fresh fluid
n.s. - not specified

Tab. 36: Coolant operational monitoring parameters

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Operation and Maintenance Manual Maintenance
Lubricants and operating fluids

Flushing and cleaning specifications for engine coolants circuits

Cleaning agents are not necessary. A mixture of fresh coolant with some biocides is suitable (for
example, Grotan WS).
Kohler Co. recommends following list of biocidal chemicals for cleaning.

Manufacturer Product name Concentration for use Order no.

For coolant systems:
Kluthe Hakutex 111 2% by volume Liquid X00065751
Hakupur 50–706–3 2% by volume Liquid X00055629
Nalco Maxi Clean 2 2% by volume Liquid
For assemblies:
Henkel P3–FD 3 to 5% by weight Powder
Porodox 5 to 10% by Powder
weight
Kluthe Hakutex 60 100% by volume Liquid X00056750
(25kg)
For coolant systems contaminated with bacteria, fungi or yeast (so-called system cleaners):
Schülke & Mayr GmbH Grotan WS Plus 0.15% by volume Liquid X00065326
(10kg)
Grotanol SR1 1% by volume Liquid X00057297
(10kg);
X00057298
(200kg)
Troy Chemical Troyshield 1% by volume Liquid
Company

Tab. 37: Approved cleaning agents

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Lubricants and operating fluids

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 6 Operating faults

6.1 Diagnosis principles

For some engine problems with possible causes and corrective measures see the table Faults -
Causes - Remedy.

Information
Engine faults are displayed by means of a fault code on the device display for diagnostic purposes.
The explanations and remedies are explained in the KODIA manual.

Basic logical steps for diagnosis are as following:

u Know the engine and the associated systems.
u Thoroughly analyze the problem.
u Relate symptoms to current knowledge about the engine and the systems.
u Diagnose problem, starting from the most obvious assumptions.
u Examine closely before starting to take the engine apart.
u Identify the causes and thoroughly perform any repair work.
After correction:
u Check for rectification of the causes.
u Close the incident.
u Run the engine according to Operation and Maintenance Manual.

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Operating faults Operation and Maintenance Manual
Faults - Cause - Remedy

6.2 Faults - Cause - Remedy

Malfunction / error Cause Remedy

Starter does not turn. Main fuse burnt through. Replace fuse.
Battery connections loose or Clean and tighten loose connec-
corroded. tions.
Battery voltage too low. Recharge or replace battery.
Starter circuit broken or contacts Contact your nearest authorized
corroded. Kohler service representative.
Starter defective. Contact your nearest authorized
Kohler service representative.
Starter turns over slowly. 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.
Diesel engine does not start and/or Fuel tank empty. Refuel the engine.
stops immediately.
Fuel filter blocked. Replace fuel filter.
Fuel line, precleaner or sieve in fuel Clean and vent fuel system.
tank blocked.
Fuel system or filter leaking. Seal and vent.
Air in the fuel system. Vent fuel system.
Fuel not cold-resistant. Clean prefilter, replace fuel filter; use
winter fuel.
Exterior temperature too low. Implement measures for winter oper-
ation.
Diesel engine starts badly. Leaks or pressure too low in fuel low Visually control there is no leak;
pressure circuit. Contact your nearest authorized
Kohler service representative to
check engine.
Diesel engine compression too low. Contact your nearest authorized
Kohler service representative.
Fault in electronics. Read out fault memory of motor
control unit. Contact your nearest
authorized Kohler service represen-
tative.

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Operation and Maintenance Manual Operating faults
Faults - Cause - Remedy

Malfunction / error Cause Remedy

Diesel engine shuts down when not Voltage supply interrupted. Contact your nearest authorized
desired. Kohler service representative.
Leaks or pressure too low in fuel low Leak test (visual inspection) ;
pressure circuit. Contact your nearest authorized
Kohler service representative to
check engine.
Fault in electronics. Read out fault memory of motor
control unit, contact your nearest
authorized Kohler service represen-
tative.
Low Diesel engine power (lack of Defect in fuel system (blocked, Visual inspection for leaks, change
power). leaking). filter, contact your nearest author-
ized Kohler service representative.
Charging pressure too low. Loose clips, defective seals and
hoses, air filter contaminated, turbo-
charger has no power.
Charging air temperature too high. Charge air cooler contaminated, low
fan power, ambient too temperature
too high, contact your nearest
authorized Kohler service represen-
tative.
Coolant temperature too high. Check cooler for contamination,
check fan and thermostat, check
coolant level, contact your nearest
authorized Kohler service represen-
tative.
Fuel temperature too high. Contact your nearest authorized
Kohler service representative.
Use at elevation over 1800 m above No remedy. Diesel engine power is
sea level. automatically reduced.
Injection nozzles stuck or do not Contact your nearest authorized
vaporize. Kohler service representative.
Diesel engine compression too low. Contact your nearest authorized
Kohler service representative.
Fault in electronic system. Read out fault logs of engine control
unit, contact your nearest authorized
Kohler service representative.
Diesel engine too hot (according to Coolant quantity low. Check the level.
coolant temperature display).
Cooler contaminated or scaled. Clean or descale.
Thermostat failure. Check, replace if necessary, contact
your nearest authorized Kohler
service representative.
Coolant temperature thermocouple Check, replace if necessary, contact
failure. your nearest authorized Kohler
service representative.

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Operating faults Operation and Maintenance Manual
Faults - Cause - Remedy

Malfunction / error Cause Remedy

Black smoke from Diesel engine. Injection nozzles stuck or inefficient. Contact your nearest authorized
Kohler service representative.
Turbocharger failure (charge pres- Contact your nearest authorized
sure too low). Kohler service representative.
Engine overloaded. Contact your nearest authorized
Kohler service representative.
Exhaust gases blue. Oil level in the Diesel engine too Adjust oil level.
high.
Lubricant reaches the combustion Contact your nearest authorized
chamber and is burned. Kohler service representative.
Compressor-side seal on the Contact your nearest authorized
exhaust gas turbocharger defective. Kohler service representative.
Crankcase ventilation defective. Check, if necessary replace.
Exhaust gases white. Injection starts too late. Contact your nearest authorized
Kohler service representative.
Operating temperature not reached. Warm up the engine until operating
temperature is reached.
Water in fuel system. Check fuel system and drain
prefilter.
Charge air cooler leaking. Contact your nearest authorized
Kohler service representative.
Diesel engine rattles. Combustion faults. Contact your nearest authorized
Kohler service representative.
Diesel engine knocks. Wrong Valve clearance. Set valve clearance.
Injection nozzles damaged or Contact your nearest authorized
carbonized. Kohler service representative.
Bearing damage. Contact your nearest authorized
Kohler service representative.
Piston rings worn or broken, pistons Contact your nearest authorized
eroded. Kohler service representative.
Abnormal noises. Leaks in the suction and exhaust Seal leaks, replace seal if necessary.
lines cause whistling noise.
Turbine or compressor wheel Contact your nearest authorized
rubbing against the housing; foreign Kohler service representative.
bodies in the compressor or turbine;
seized up bearings of rotating parts.

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Operation and Maintenance Manual Operating faults
Faults - Cause - Remedy

Malfunction / error Cause Remedy

Lubricant oil pressure too low. Oil level in the oil pan too low. Fill oil to prescribed mark.
Bad viscosity (oil diluted by Diesel Drain off oil, fill with prescribed oil.
fuel).
Pressure transducer failure. Check oil pressure and replace
damaged oil pressure transducer;
contact your nearest authorized
Kohler service representative.
End control valve does not work Contact your nearest authorized
properly or dirt in the end control Kohler service representative.
valve.
Bearing play too great due to wear Contact your nearest authorized
or bearing damage. Kohler service representative.
Lubricant oil in the cooling system. Oil cooler or oil cooler plate leaking. Contact your nearest authorized
Kohler service representative.
Cooling water in the lubricant oil. Cylinder liners seals leaking. Contact your nearest authorized
Kohler service representative.
Oil cooler or oil cooler plate leaking. Contact your nearest authorized
Kohler service representative.
Charge air temperature too high. Coolant concentration incorrect. Check concentration using test kit.
Charge air cooler contaminated. Contact your nearest authorized
Kohler service representative.
Air intake temperature too high. Check fans, air supply and ventila-
tion.
Charge air pressure too low. Air filter clogged. Check air filter service indicator.
Charge air cooler contaminated. Contact your nearest authorized
Kohler service representative.
Turbocharger exhaust defect. Contact your nearest authorized
Kohler service representative.
Coolant leaks on charge air cooler. Leaking, breaking. Contact your nearest authorized
Kohler service representative.

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Faults - Cause - Remedy

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 7 Tools and devices

7.1 Tools

7.1.1 Special tools

Special tool Designation Qty Ident KOHLER Ident

number
Turning device 1 11133437 230611637

Flywheel lock 1 11343230 230612868

Guiding rod M30x2 - Cylinder head 2 11133371 230610035

Guiding rod M28x2 - Damper 2 11133372 230610036

Guiding rod M24x2 - Intermediate gear 2 11133373 230610037

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Tools and devices Operation and Maintenance Manual
Tools

Special tool Designation Qty Ident KOHLER Ident

number
Guiding rod M22x2 - Flywheel 2 11133374 230612869

Guiding rod M20 - Oil filter 2 11133375 230610038

Guiding rod M16 - Oil cooler support 2 11133376 230610039

Guiding rod M12 - Oil cooler 2 11133377 230610040

Guiding rod M10 - Exhaust line 2 11133379 230610041

Guiding rod M12 Water pump 2 12427300 230610042

Guiding rod M12 Thermostat 2 12465862 230611638

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Operation and Maintenance Manual Tools and devices
Tools

Special tool Designation Qty Ident KOHLER Ident

number
Pin for belt tensioner 1 12217125 230611639

Frequency meter 1 12693396 230612870

Injector Extraction Tool 1 12226280 230611925

HP Fuel Pump Lifting Device 1 12226441 230612457

Power unit handling device 1 12588884 230612871

Injector Connector Torque Screwdriver 1 12691409 230612675

Sampling Tube for each liquid sampling 1 7002475 230612676
Handling bar 1 11344345 230612677
Electric Torque Multiplier 1 12226986 230612678
Torque Reaction Arm for Electric Torque 1 12226968 230612679
Multiplier
Manual Torque Multiplier 1 12227994 230612680
Torque Reaction Arm for Manual Torque 1 12227989 230612681
Multiplier
Spare Battery pack 1 12226992 230612682
Battery Charger 110V 1 12226970 230612683
Battery Charger 230V 1 12226972 230612684
Adapter 1 11343096 230612685

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Tools and devices Operation and Maintenance Manual
Tools

Special tool Designation Qty Ident KOHLER Ident

number
Coolant Connector Pipe Tool 1 11343242 230612686

Tab. 38: Special tools

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 8 Appendix

8.1 Technical design documents

Information
The technical design documents are specific to the delivered engine.
Using those documents for other engines is forbidden.
For inquiry, please contact your nearest authorized Kohler service representative.

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Appendix Operation and Maintenance Manual
Error code

8.2 Error code

Information
Error code list extracted from ECU software version 21.12.10 and dataset revision 9.
The following error code table is indicative. Refer to the technical data sheet of your engine for the
latest software version.
For further information, please contact your nearest authorized Kohler service representative.

Abbreviations:
– SPN - Suspect Parameter Number
– FMI - Failure mode identification

SPN FMI Designation

107 11 Air filter - Blocked / Clogged
516101 31 Air filter pressure switch - Supply voltage out of range
516428 31 Air pressure sensors - Plausibility error
108 31 Ambient pressure sensor - Supply voltage out of range
171 5 Ambient temperature sensor - Open circuit
171 3 Ambient temperature sensor - Short circuit to battery
171 4 Ambient temperature sensor - Short circuit to ground
171 31 Ambient temperature sensor - Supply voltage out of range
1176 1 Boost pressure - Pressure too high
1176 0 Boost pressure - Pressure too low
636 2 Camshaft position - Plausibility error
636 14 Camshaft position sensor - Ground error
636 5 Camshaft position sensor - Open circuit
636 3 Camshaft position sensor - Short circuit to battery
636 3 Camshaft position sensor - Short circuit to battery or open circuit
636 4 Camshaft position sensor - Short circuit to ground
636 31 Camshaft position sensor - Supply voltage out of range
157 0 Common rail - Critical overpressure
1239 2 Common rail - Leakage
157 15 Common rail - Overpressure warning
516117 11 Common rail - PCV opened due to overpressure
1075 2 Common rail - Plausibility error
516118 11 Common rail - Plausibility error of VCV current
516121 11 Common rail - Pressure remains above the set point
516122 11 Common rail - Pressure remains below the set point
516123 11 Common rail - Start pressure too low

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Operation and Maintenance Manual Appendix
Error code

SPN FMI Designation

1349 0 Common rail 2 - Critical overpressure
1240 2 Common rail 2 - Leakage
1349 15 Common rail 2 - Overpressure warning
516124 11 Common rail 2 - PCV opened due to overpressure
516125 11 Common rail 2 - Plausibility error of VCV current
516128 11 Common rail 2 - Pressure remains above the set point
516129 11 Common rail 2 - Pressure remains below the set point
516130 11 Common rail 2 - Start pressure too low
1239 0 Common rail leakage 1 - Fuel leak
1239 11 Common rail leakage 1 - Out of range
1239 31 Common rail leakage 1 - Supply voltage out of range
1240 0 Common rail leakage 2 - Fuel leak
1240 11 Common rail leakage 2 - Out of range
1240 31 Common rail leakage 2 - Supply voltage out of range
516131 11 Common rail pressure sensor - No signal variation
157 3 Common rail pressure sensor - Short circuit to battery or open
circuit
157 4 Common rail pressure sensor - Short circuit to ground
157 31 Common rail pressure sensor - Supply voltage out of range
516133 11 Common rail pressure sensor 2 - No signal variation
1349 3 Common rail pressure sensor 2 - Short circuit to battery or open
circuit
1349 4 Common rail pressure sensor 2 - Short circuit to ground
1349 31 Common rail pressure sensor 2 - Supply voltage out of range
2430 11 Coolant level sensor - Out of range
2430 3 Coolant level sensor - Short circuit to battery
2430 4 Coolant level sensor - Short circuit to ground or open circuit
2430 31 Coolant level sensor - Supply voltage out of range
6303 11 Coolant level sensor 2 - Out of range
6303 3 Coolant level sensor 2 - Short circuit to battery
6303 4 Coolant level sensor 2 - Short circuit to ground or open circuit
6303 31 Coolant level sensor 2 - Supply voltage out of range
6209 0 Coolant temperature at intercooler - Critical overtemperature
6209 15 Coolant temperature at intercooler - Overtemperature warning
110 5 Coolant temperature sensor - Open circuit
110 3 Coolant temperature sensor - Short circuit to battery
110 4 Coolant temperature sensor - Short circuit to ground
110 31 Coolant temperature sensor - Supply voltage out of range

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Appendix Operation and Maintenance Manual
Error code

SPN FMI Designation

101 0 Crankcase pressure - Critical overpressure
101 15 Crankcase pressure - Overpressure warning
101 31 Crankcase pressure - Supply voltage out of range
101 3 Crankcase pressure sensor - Short circuit to battery
101 4 Crankcase pressure sensor - Short circuit to ground or open
circuit
637 2 Crankshaft position - Plausibility error
637 14 Crankshaft position sensor - Ground error
637 5 Crankshaft position sensor - Open circuit
637 3 Crankshaft position sensor - Short circuit to battery
637 3 Crankshaft position sensor - Short circuit to battery or open circuit
637 4 Crankshaft position sensor - Short circuit to ground
637 31 Crankshaft position sensor - Supply voltage out of range
1136 0 ECU - Critical overtemperature
516543 31 ECU - Data recorder was triggered
1136 15 ECU - Overtemperature warning
516495 31 ECU - Runtime reached the maximal time without reset
1136 31 ECU temperature sensor 1 - Supply voltage out of range
516140 31 ECU temperature sensor 2 - Supply voltage out of range
516141 31 ECU temperature sensor 3 - Supply voltage out of range
51644 31 Engine - Starter activated but no engine rotation detected
516356 31 Engine control unit - Communication error to slave injection
control unit
639 5 Engine Control Unit CAN 1 - Open circuit
639 11 Engine Control Unit CAN 1 - Short circuit
625 5 Engine Control Unit CAN 2 - Open circuit
625 11 Engine Control Unit CAN 2 - Short circuit
516148 5 Engine Control Unit CAN 4 - Open circuit
516148 11 Engine Control Unit CAN 4 - Short circuit
110 0 Engine coolant - Critical overtemperature
111 17 Engine coolant - Level low
110 15 Engine coolant - Overtemperature warning
4076 14 Engine coolant 2 - Level low
175 0 Engine oil - Critical overtemperature
100 1 Engine oil - Critical underpressure
175 15 Engine oil - Overtemperature warning
100 2 Engine oil - Plausibility error
100 17 Engine oil - Underpressure warning

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Operation and Maintenance Manual Appendix
Error code

SPN FMI Designation

1180 2 Exhaust boost temperature (CMR sensor) - Communication error
1180 2 Exhaust boost temperature 1 (CMR sensor) - Communication
error
1181 2 Exhaust boost temperature 2 (CMR sensor) - Communication
error
3245 0 Exhaust temperature before turbocharger 1 - Critical overtemper-
ature
1180 15 Exhaust temperature before turbocharger 1 - Overtemperature
warning
3279 0 Exhaust temperature before turbocharger 2 - Critical overtemper-
ature
1181 15 Exhaust temperature before turbocharger 2 - Overtemperature
warning
94 0 Fuel supply - Critical overpressure
174 0 Fuel supply - Critical overtemperature
94 1 Fuel supply - Critical underpressure
174 15 Fuel supply - Overtemperature warning
94 3 Fuel supply pressure sensor - Short circuit to battery
94 4 Fuel supply pressure sensor - Short circuit to ground or open
circuit
94 31 Fuel supply pressure sensor - Supply voltage out of range
174 5 Fuel temperature sensor - Open circuit
174 3 Fuel temperature sensor - Short circuit to battery
174 4 Fuel temperature sensor - Short circuit to ground
174 31 Fuel temperature sensor - Supply voltage out of range
516195 2 Generator Set Controller - Communication error
190 0 Genset - Engine over speed
729 6 Heating flange 1 - Critical high output current
729 11 Heating flange 1 - Electrical error
729 5 Heating flange 1 - Open circuit
729 3 Heating flange 1 - Short circuit to battery high side
516304 3 Heating flange 1 - Short circuit to battery low side
729 4 Heating flange 1 - Short circuit to ground high side
516305 4 Heating flange 1 - Short circuit to ground low side
730 6 Heating flange 2 - Critical high output current
730 11 Heating flange 2 - Electrical error
730 5 Heating flange 2 - Open circuit
730 3 Heating flange 2 - Short circuit to battery high side
516344 3 Heating flange 2 - Short circuit to battery low side
730 4 Heating flange 2 - Short circuit to ground high side

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Appendix Operation and Maintenance Manual
Error code

SPN FMI Designation

516345 4 Heating flange 2 - Short circuit to ground low side
516346 5 Heating flange status input 1 - Open circuit
516346 3 Heating flange status input 1 - Short circuit to battery high side
516347 3 Heating flange status input 1 - Short circuit to battery low side
516346 4 Heating flange status input 1 - Short circuit to ground high side
516347 4 Heating flange status input 1 - Short circuit to ground low side
516348 8 Heating flange status input 2 - Open circuit
516348 3 Heating flange status input 2 - Short circuit to battery high side
516349 3 Heating flange status input 2 - Short circuit to battery low side
516348 4 Heating flange status input 2 - Short circuit to ground high side
516349 4 Heating flange status input 2 - Short circuit to ground low side
516187 31 Ignition digital input - Supply voltage out of range
516509 31 Injection data synchronization - Error during measurement of
voltage-based small quantity injection correction
651 0 Injector 1 - Current Rise time too long
651 8 Injector 1 - No current rise time measured
651 5 Injector 1 - Open circuit
651 3 Injector 1 - Short circuit to battery
651 4 Injector 1 - Short circuit to ground
660 0 Injector 10 - Current Rise time too long
660 8 Injector 10 - No current rise time measured
660 5 Injector 10 - Open circuit
660 3 Injector 10 - Short circuit to battery
660 4 Injector 10 - Short circuit to ground
661 0 Injector 11 - Current Rise time too long
661 8 Injector 11 - No current rise time measured
661 5 Injector 11 - Open circuit
661 3 Injector 11 - Short circuit to battery
661 4 Injector 11 - Short circuit to ground
662 0 Injector 12 - Current Rise time too long
662 8 Injector 12 - No current rise time measured
662 5 Injector 12 - Open circuit
662 3 Injector 12 - Short circuit to battery
662 4 Injector 12 - Short circuit to ground
663 0 Injector 13 - Current Rise time too long
663 8 Injector 13 - No current rise time measured
663 5 Injector 13 - Open circuit
663 3 Injector 13 - Short circuit to battery

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Operation and Maintenance Manual Appendix
Error code

SPN FMI Designation

663 4 Injector 13 - Short circuit to ground
664 0 Injector 14 - Current Rise time too long
664 8 Injector 14 - No current rise time measured
664 5 Injector 14 - Open circuit
664 3 Injector 14 - Short circuit to battery
664 4 Injector 14 - Short circuit to ground
665 0 Injector 15 - Current Rise time too long
665 8 Injector 15 - No current rise time measured
665 5 Injector 15 - Open circuit
665 3 Injector 15 - Short circuit to battery
665 4 Injector 15 - Short circuit to ground
666 0 Injector 16 - Current Rise time too long
666 8 Injector 16 - No current rise time measured
666 5 Injector 16 - Open circuit
666 3 Injector 16 - Short circuit to battery
666 4 Injector 16 - Short circuit to ground
667 0 Injector 17 - Current Rise time too long
667 8 Injector 17 - No current rise time measured
667 5 Injector 17 - Open circuit
667 3 Injector 17 - Short circuit to battery
667 4 Injector 17 - Short circuit to ground
668 0 Injector 18 - Current Rise time too long
669 8 Injector 18 - No current rise time measured
669 5 Injector 18 - Open circuit
669 3 Injector 18 - Short circuit to battery
669 4 Injector 18 - Short circuit to ground
652 0 Injector 19 - Current Rise time too long
652 8 Injector 19 - No current rise time measured
652 5 Injector 19 - Open circuit
652 3 Injector 19 - Short circuit to battery
652 4 Injector 19 - Short circuit to ground
652 0 Injector 2 - Current Rise time too long
652 8 Injector 2 - No current rise time measured
652 5 Injector 2 - Open circuit
652 3 Injector 2 - Short circuit to battery
652 4 Injector 2 - Short circuit to ground
670 0 Injector 20 - Current Rise time too long
670 8 Injector 20 - No current rise time measured

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Appendix Operation and Maintenance Manual
Error code

SPN FMI Designation

670 5 Injector 20 - Open circuit
670 3 Injector 20 - Short circuit to battery
670 4 Injector 20 - Short circuit to ground
653 0 Injector 3 - Current Rise time too long
653 8 Injector 3 - No current rise time measured
653 5 Injector 3 - Open circuit
653 3 Injector 3 - Short circuit to battery
653 4 Injector 3 - Short circuit to ground
654 0 Injector 4 - Current Rise time too long
654 8 Injector 4 - No current rise time measured
654 5 Injector 4 - Open circuit
654 3 Injector 4 - Short circuit to battery
654 4 Injector 4 - Short circuit to ground
655 0 Injector 5 - Current Rise time too long
655 8 Injector 5 - No current rise time measured
655 5 Injector 5 - Open circuit
655 3 Injector 5 - Short circuit to battery
655 4 Injector 5 - Short circuit to ground
656 0 Injector 6 - Current Rise time too long
656 8 Injector 6 - No current rise time measured
656 5 Injector 6 - Open circuit
656 3 Injector 6 - Short circuit to battery
656 4 Injector 6 - Short circuit to ground
657 0 Injector 7 - Current Rise time too long
657 8 Injector 7 - No current rise time measured
657 5 Injector 7 - Open circuit
657 3 Injector 7 - Short circuit to battery
657 4 Injector 7 - Short circuit to ground
658 0 Injector 8 - Current Rise time too long
658 8 Injector 8 - No current rise time measured
658 5 Injector 8 - Open circuit
658 3 Injector 8 - Short circuit to battery
658 4 Injector 8 - Short circuit to ground
659 0 Injector 9 - Current Rise time too long
659 8 Injector 9 - No current rise time measured
659 5 Injector 9 - Open cirscuit
659 3 Injector 9 - Short circuit to battery
659 4 Injector 9 - Short circuit to ground

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Operation and Maintenance Manual Appendix
Error code

SPN FMI Designation

516191 17 Injector supply boost converter - Undervoltage warning
105 5 Intake air temperature sensor - Open circuit
105 3 Intake air temperature sensor - Short circuit to battery
105 4 Intake air temperature sensor - Short circuit to ground
105 31 Intake air temperature sensor - Supply voltage out of range
102 0 Intake manifold - Critical overpressure
1636 0 Intake manifold - Critical overtemperature
102 1 Intake manifold - Critical underpressure
102 15 Intake manifold - Overpressure warning
1636 15 Intake manifold - Overtemperature warning
102 17 Intake manifold - Underpressure warning
102 3 Intake manifold pressure sensor - Short circuit to battery
102 4 Intake manifold pressure sensor - Short circuit to ground or open
circuit
102 31 Intake manifold pressure sensor - Supply voltage out of range
1636 5 Intake manifold temperature sensor - Open circuit
1636 3 Intake manifold temperature sensor - Short circuit to battery
1636 4 Intake manifold temperature sensor - Short circuit to ground
1636 31 Intake manifold temperature sensor - Supply voltage out of range
6209 5 Intercooler coolant temperature sensor - Open circuit
6209 3 Intercooler coolant temperature sensor - Short circuit to battery
6209 4 Intercooler coolant temperature sensor - Short circuit to ground
6209 31 Intercooler coolant temperature sensor - Supply voltage out of
range
516197 2 Master Slave Injection - Communication error
516223 11 Monitoring System - Ecu internal safety error
516226 11 Monitoring System - Injector safety error
100 3 Oil pressure sensor - Short circuit to battery
100 4 Oil pressure sensor - Short circuit to ground or open circuit
100 31 Oil pressure sensor - Supply voltage out of range
175 5 Oil temperature sensor - Open circuit
175 3 Oil temperature sensor - Short circuit to battery
175 4 Oil temperature sensor - Short circuit to ground
175 4 Oil temperature sensor - Short circuit to ground or open circuit
175 31 Oil temperature sensor - Supply voltage out of range
4811 0 Piston cooling pressure 1 - Critical overpressure
4811 1 Piston cooling pressure 1 - Critical underpressure
4811 15 Piston cooling pressure 1 - Overpressure warning

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Error code

SPN FMI Designation

4811 17 Piston cooling pressure 1 - Underpressure warning
4811 3 Piston cooling pressure sensor 1 - Short circuit to battery
4811 4 Piston cooling pressure sensor 1 - Short circuit to ground or open
circuit
4811 31 Piston cooling pressure sensor 1 - Supply voltage out of range
3597 1 Power supply - Critical undervoltage
3597 15 Power supply - Overvoltage warning
3597 17 Power supply - Undervoltage warning
5571 6 Pressure control valve - Critical high output current
5571 0 Pressure control valve - Critical overcurrent
5571 1 Pressure control valve - Critical undercurrent
516209 15 Pressure control valve - Current remains above the set point
516209 17 Pressure control valve - Current remains below the set point
5571 11 Pressure control valve - Electrical error
5571 5 Pressure control valve - Open circuit
516211 11 Pressure control valve - PWM signal - High limit reached
516212 11 Pressure control valve - PWM signal - Plausibility error
516422 11 Pressure control valve - Short circuit load
5571 3 Pressure control valve - Short circuit to battery high side
516331 3 Pressure control valve - Short circuit to battery low side
5571 4 Pressure control valve - Short circuit to ground high side
516331 4 Pressure control valve - Short circuit to ground low side
516215 6 Pressure control valve 2 - Critical high output current
516215 0 Pressure control valve 2 - Critical overcurrent
516215 1 Pressure control valve 2 - Critical undercurrent
516216 11 Pressure control valve 2 - Current remains above the set point
516217 11 Pressure control valve 2 - Current remains below the set point
516337 11 Pressure control valve 2 - Electrical error
516215 5 Pressure control valve 2 - Open circuit
516220 11 Pressure control valve 2 - PWM signal - High limit reached
516221 11 Pressure control valve 2 - PWM signal - Plausibility error
516215 11 Pressure control valve 2 - Short circuit load
516215 3 Pressure control valve 2 - Short circuit to battery high side
516337 3 Pressure control valve 2 - Short circuit to battery low side
516215 4 Pressure control valve 2 - Short circuit to ground high side
516337 4 Pressure control valve 2 - Short circuit to ground low side
516493 31 Slave injection control unit - Emission relevant error
3938 2 Speed adjustment - Plausibility error

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Error code

SPN FMI Designation

3938 3 Speed adjustment (current) - Short circuit to battery
3938 4 Speed adjustment (current) - Short circuit to ground or open
circuit
3938 31 Speed adjustment (current) - Supply voltage out of range
3938 3 Speed adjustment (voltage) - Short circuit to battery
3938 4 Speed adjustment (voltage) - Short circuit to ground or open
circuit
3938 31 Speed adjustment (voltage) - Supply voltage out of range
677 6 Starter - Critical high output current
677 11 Starter - Electrical error
516342 31 Starter - Locked due to overtemperature
677 5 Starter - Open circuit
677 3 Starter - Short circuit to battery high side
516276 3 Starter - Short circuit to battery low side
677 4 Starter - Short circuit to ground high side
516277 4 Starter - Short circuit to ground low side
516369 6 Starter 2 - Critical high output current
516369 11 Starter 2 - Electrical error
516369 31 Starter 2 - Locked due to overtemperature
516369 5 Starter 2 - Open circuit
516369 3 Starter 2 - Short circuit to battery high side
516370 3 Starter 2 - Short circuit to battery low side
516369 4 Starter 2 - Short circuit to ground high side
516371 4 Starter 2 - Short circuit to ground low side
516424 11 Starter digital input - Starter inhibition due to short circuit
516247 31 Starter digital input - Supply voltage out of range
516425 11 Starter digital input 2 - Starter inhibition due to short circuit
516264 31 Starter digital input 2 - Supply voltage out of range
516511 31 Starters - Not connected in the output 1 to ECU
516512 31 Starters - Not connected in the output 2 to ECU
1076 6 Volume control valve - Critical high output current
1076 0 Volume control valve - Critical overcurrent
1076 1 Volume control valve - Critical undercurrent
516251 11 Volume control valve - Current remains above the set point
516252 11 Volume control valve - Current remains below the set point
516330 11 Volume control valve - Electrical error
1076 5 Volume control valve - Open circuit
516253 11 Volume control valve - PWM signal - High limit reached

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Error code

SPN FMI Designation

516254 11 Volume control valve - PWM signal - Plausibility error
1076 11 Volume control valve - Short circuit load
1076 3 Volume control valve - Short circuit to battery high side
516328 3 Volume control valve - Short circuit to battery low side
1076 4 Volume control valve - Short circuit to ground high side
516329 4 Volume control valve - Short circuit to ground low side
516255 6 Volume control valve 2 - Critical high output current
516255 0 Volume control valve 2 - Critical overcurrent
516255 11 Volume control valve 2 - Critical undercurrent
516256 11 Volume control valve 2 - Current remains above the set point
516257 11 Volume control valve 2 - Current remains below the set point
516336 11 Volume control valve 2 - Electrical error
516255 5 Volume control valve 2 - Open circuit
516258 11 Volume control valve 2 - PWM signal - High limit reached
516259 11 Volume control valve 2 - PWM signal - Plausibility error
516255 11 Volume control valve 2 - Short circuit load
516255 3 Volume control valve 2 - Short circuit to battery high side
516336 3 Volume control valve 2 - Short circuit to battery low side
516255 4 Volume control valve 2 - Short circuit to ground high side
516336 4 Volume control valve 2 - Short circuit to ground low side
5386 6 Wastegate valve - Critical high output current
5386 11 Wastegate valve - Electrical error
5386 5 Wastegate valve - Open circuit
516318 31 Wastegate valve - Short circuit load
5386 3 Wastegate valve - Short circuit to battery high side
516266 3 Wastegate valve - Short circuit to battery low side
5386 4 Wastegate valve - Short circuit to ground high side
516266 4 Wastegate valve - Short circuit to ground low side
97 5 P2264-13 Water in fuel sensor - Open circuit
97 11 Water in fuel sensor - Out of range
97 3 Water in fuel sensor - Short circuit to battery
97 4 Water in fuel sensor - Short circuit to ground
97 31 Water in fuel sensor - Supply voltage out of range
97 0 Water in fuel sensor - Water in fuel detected
6301 5 Water in fuel sensor 2 - Open circuit
6301 11 Water in fuel sensor 2 - Out of range
6301 3 Water in fuel sensor 2 - Short circuit to battery
6301 4 Water in fuel sensor 2 - Short circuit to ground

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Error code

SPN FMI Designation

6301 31 Water in fuel sensor 2 - Supply voltage out of range
6301 0 Water in fuel sensor 2 - Water in fuel detected

Tab. 39: Error code table

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Appendix Operation and Maintenance Manual
Cleaning agents, thread-locking adhesives and greases

8.3 Cleaning agents, thread-locking adhesives and

greases

This list includes all thread-locking adhesives and greases required for repair and maintenance
tasks on the engine.
The application is described in the respective job specifications.

Information
Should a thread-locking adhesive be required, first clean, degrease and dry the respective screw
thread and threaded bore.

8.3.1 Cleaning agents and thread-locking adhesives

Designation Designation Amount Supplier

(g / fl-oz)
Omniclean or Loctite 7063 500 / 16.9 Loctite
Loctite 243 250 / 8.4 Loctite
Loctite 270 or Omnifit 200 M 250 / 8.4 Loctite
Loctite 577 250 / 8.4 Loctite
Loctite 648 or Omnifit 230 M 250 / 8.4 Loctite
Loctite 5900 50 / 1.7 Loctite
Loctite 5910 300 / 10.1 Loctite

Tab. 40: Cleaning agents and thread-locking adhesives

Designation Designation Amount Supplier

(g / fl-oz)
Omnivisc 1050 or Loctite 601, Reinzo- 90 / 3.0 Loctite
plast, Hylomar SQ32 /
M
Loctite 480 500 / 16.9 Loctite

Tab. 41: Cleaning agents and thread-locking adhesives

8.3.2 Greases

Designation Amount (g / fl-oz) Supplier

Molykote Longterm 2 Plus 1000 / 33.8 Molykote
Staburags NBU 30 1200 / 40.6 Kübler
Copper Paste; Motorex 14 850 / 28.7 Motorex
Optimol White T 100 / 3.4 Castrol

Tab. 42: Greases

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8.4 Standard tightening torques

8.4.1 Screws pre-tightening, reuse and marking

NOTICE
Property damages by improper pre-tightening, turning angle or reuse of screws or nuts.
Improper pre-tightening, turning angle or reuse of screws or nuts could lead to the rupture of the
screw or nut and lead to property damages by malfunction, ejection, fall or tilting of components.
u Respect following pre-tightening, turning angle, reuse and marking specifications.
u In case of failure or damages, replace any threaded fastener immediately by the authorized
personnel.

Information
The values of the pre-tightening torque and the turning angle are specified in the maintenance
tasks.
Unless otherwise noted, use the standard torque values into the column of screws quality class
"8.8" to tighten screws and bolts.
The screws quality classes "10.9" and "12.9" are always indicated with the "Nm" symbol.

Pre-tightening torque and turning angle

Fig. 100: Pre-tightening marking and angles

u Tighten mounting bolt with the specified pre-tightening torque.

u Mark the specified turning angle on the screw head and on the component 1.

Information
One edge of hexagonal screw corresponds to 60°.

u On the socket key of the torque wrench 2, mark the initial position, aligned with the marking on
the component.
u Use the torque wrench to tighten until the marking of the initial position is aligned with the
marking on the component.
u Repeat process for the other screws, according to standard or described sequence.

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Information
For every maintenance task, when a sequence is specified, achieve step 1 for all the sequence
before starting step 2.

Fig. 101: Standard sequence for 4, 5 and six screws.

Screws reuse

Information
Except components listed below, and otherwise noted,
u Reuse screws as many times as no visible damage appears (thread, coating).
u Replace screws with the same quality class as soon damage appears (thread, coating).

For screws on:

– Main bearing,
– Connecting rod,
– Counterweight,
– Cylinder head,
– Damper,
– Flywheel,
– Camshaft,
– Trunnion mount,
– Engine feets CS and CCS,
– Exhaust screws with copper coating,
u Replace screws and blanking plugs after each dismounting.
On fuel and HP injections pipes:
u Replace connections after first dismouting.
u Change connections after 3 tightenings.
For cutting rings:
u Replace connections after first dismouting.
u Change connections after 3 tightenings.

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Screws marking

Information
Except components listed below, and otherwise noted,
u Marking on screws or nuts to track their reuse is not required.

Fig. 102: Examples of markings on screws and HP pipe nut.

Some nuts and screws are marked to track their reuse. For:
– Fuel and HP injections pipes,
– Cutting rings,
If 2 punchs appears,
u Replace pipe or system after each untightening.
If none or 1 punch appears,
u Add one punch after each untightening.

8.4.2 Standard torques for hexagonal / socket / flange screws

Information
Values apply only to screws with coating and without lubricant.

For hexagonal screws in accordance with:

– ISO 4014
– ISO 4017
For socket screws in accordance with:
– ISO 4762

Thread
diameter Quality class 8.8 Quality class 10.9
(mm)
Hexagonal Socket Flange Hexagonal Socket Flange
screw screw screw screw screw screw

M6 9 Nm 14 Nm
7 ft-lb 10 ft-lb

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Thread
diameter Quality class 8.8 Quality class 10.9
(mm)
M8 22 Nm 33 Nm
16 ft-lb 24 ft-lb
M10 43 Nm 63 Nm
32 ft-lb 46 ft-lb
M12 70 Nm 75 Nm 100 Nm 110 Nm
52 ft-lb 55 ft-lb 74 ft-lb 81 ft-lb
M16 165 Nm 183 Nm 240 Nm 270 Nm
122 ft-lb 135 ft-lb 177 ft-lb 199 ft-lb
M20 320 Nm 358 Nm 470 Nm 525 Nm
236 ft-lb 264 ft-lb 347 ft-lb 387 ft-lb
M24 550 Nm - 800 Nm -
406 ft-lb 590 ft-lb
M30 1100 Nm - 1600 Nm -
811 ft-lb 1,180 ft-lb

Tab. 43: Standard values for shank bolts with coating without lubricant

8.4.3 Standard torques for internal drive pipe plug with conical thread

Fig. 109: Internal drive pipe plug with conical thread DIN 906

Thread Nm ft/lb Thread Nm ft/lb

M6x1 1)
5 3.69 M 16 x 1.5 68 50.15
M8x1 12 8.85 M 18 x 1.5 87 64.17
M 10 x 1 18 13.27 M 20 x 1.5 98 72.28
M 12 x 1.5 30 22.13 M 36 x 1.5 280 206.52
M 14 x 1.5 57 42 M 48 x 1.5 280 206.52

Tab. 44: Standard torques for internal drive pipe plug with conical thread

1)
Special tolerance: +0.5

Information
Tolerances of the indicated tightening torques: 10 %.
Always lubricate the thread before tightening these parts (engine oil).

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8.4.4 Standard torques for locking screws and banjo bolts

With copper sealing ring in accordance with DIN 7603:
For banjo bolts in accordance with DIN 7643.

Fig. 110: DIN 7643

For locking screws in accordance with DIN 910.

Fig. 111: DIN 910

For locking screws in accordance with DIN 908.

Fig. 112: DIN 908

Threads Nm ft/lb Threads Nm ft/lb

M6x1 7 5.16 M 20 x 1.5 47 34.67
M8x1 7.5 5.53 M 22 x 1.5 57 42.04
M 8 x 1.5 7.5 5.53 M 24 x 1.5 68 50.15
M 10 x 1 15 11.06 M 26 x 1.5 75 55.32
M 10 x 1.25 15 11.06 M 27 x 2 87 64.17
M 12 x 1.5 20 14.75 M 30 x 1.5 115 84.82
M 14 x 1.5 27 19.91 M 30 x 2 115 84.82
M 16 x 1.5 37 27.29 M 33 x 2 120 88.51
M 18 x 1.5 40 29.5 M 36 x 1.5 155 114.32
M 36 x 2 155 114.32 M 52 x 1.5 380 280.27
M 38 x 1.5 171 126.12 M 52 x 2 380 280.27
M 39 x 2 215 158.58 M 56 x 2 430 317.15
M 42 x 1.5 240 177.01 M 60 x 2 510 376.16
M 42 x 2 240 177.01 M 64 x 2 570 420.41
M 45 x 1.5 270 199.14 M 65 x 2 620 457.29
M 45 x 2 270 199.14
M 48 x 1.5 300 221.27

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Threads Nm ft/lb Threads Nm ft/lb

M 48 x 2 300 221.27

Tab. 45: Tightening torques for locking screws and banjo bolts

8.4.5 Standard torques for metric flange joints

Fig. 113: 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.

8.4.6 Standard torques for metric thread unions L series (up to 500 bar/
7252 Psi)

Pipe Thread Y Form A with Form B with Form E with flat Form F with O-
diam. X sealing ring sealing edge sealing ring
Nm ft/lb Nm ft/lb Nm ft/lb Nm ft/lb
6 M 10 x 1,0 9 6.64 18 13.28 18 13.28 15 11.06
8 M 12 x 1,5 20 14.75 30 22.13 25 18.44 25 18.44
10 M 14 x 1,5 35 25.81 45 33.19 45 33.19 35 25.81
12 M 16 x 1,5 45 33.19 65 47.94 55 40.57 40 29.5
15 M 18 x 1,5 55 40.57 80 59 70 51.63 45 33.19
18 M 22 x 1,5 65 47.94 140 103.26 125 92.2 60 44.25
22 M 26 x 1,5 90 66.38 190 140.14 180 132.76 100 73.76
28 M 33 x 2,0 150 110.63 340 250.77 310 228.64 160 118.01
35 M 42 x 2,0 240 177.01 500 368.78 450 331.9 210 154.89
42 M 48 x 2,0 290 213.89 630 464.66 540 398.28 260 191.77

Tab. 46: Standard torques for metric thread unions L series, part 1 – see figure above

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Pipe diam. X Thread Y WH TH SWVE

Nm ft/lb Nm ft/lb Nm ft/lb
6 M 10 x 1,0 18 13.28 18 13.28 18 13.28
8 M 12 x 1,5 45 33.19 45 33.19 35 25.81
10 M 14 x 1,5 55 40.57 55 40.57 50 36.88
12 M 16 x 1,5 80 59 80 59 60 44.25
15 M 18 x 1,5 100 73.76 100 73.76 80 59
18 M 22 x 1,5 140 103.26 140 103.26 120 88.51
22 M 26 x 1,5 320 236.02 320 236.02 130 95.88
28 M 33 x 2,0 360 265.52 360 265.52
35 M 42 x 2,0 540 398.28 540 398.28
42 M 48 x 2,0 700 516.29 700 516.29

Tab. 47: Standard torques for metric thread unions L series, part 2 – see figure above

8.4.7 Standard torques for metric thread unions S series (up to 800 bar/
11603 Psi)

Pipe diam. Thread Y Form A with sealing Form B with sealing Form E with flat
X ring edge sealing
Nm ft/lb Nm ft/lb Nm ft/lb
6 M 12 x 1,5 20 14.75 35 25.81 40 29.5
8 M 14 x 1,5 35 25.81 55 40.57 40 29.5
10 M 16 x 1,5 45 33.19 70 51.63 70 51.63
12 M 18 x 1,5 55 40.57 110 81.13 90 66.38
14 M 20 x 1,5 55 40.57 150 110.63 125 92.2
16 M 22 x 1,5 65 47.94 170 125.39 135 99.57
20 M 27 x 2,0 90 66.38 270 199.14 180 132.76
25 M 33 x 2,0 150 110.63 410 302.4 310 228.64
30 M 42 x 2,0 240 177.01 540 398.28 450 331.9
38 M 48 x 2,0 290 213.89 700 516.29 540 398.28

Tab. 48: Standard torques for metric thread union S series, part 1 – see figure above

Pipe diam. X Thread Y WH TH SWVE

Nm ft/lb Nm ft/lb Nm ft/lb
6 M 12 x 1,5 45 33.19 45 33.19 35 25.81
8 M 14 x 1,5 55 40.57 55 40.57 50 36.88
10 M 16 x 1,5 80 59 80 59 60 44.25
12 M 18 x 1,5 100 73.76 100 73.76 80 59
14 M 20 x 1,5 125 92.2 125 92.2 110 81.13
16 M 22 x 1,5 135 99.57 135 99.57 120 88.51

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Pipe diam. X Thread Y WH TH SWVE

Nm ft/lb Nm ft/lb Nm ft/lb
20 M 27 x 2,0 320 236.02 320 236.02 135 99.57
25 M 33 x 2,0 360 265.52 360 265.52
30 M 42 x 2,0 540 398.28 540 398.28
38 M 48 x 2,0 700 516.29 700 516.29

Tab. 49: Standard torques for metric thread union S series, part 2– see figure above

8.4.8 Standard torques for imperial thread unions L series (up to 500
bar/7252 Psi)

Pipe diam. Thread Y Form A with sealing Form B with sealing Form E with flat
X ring edge sealing
Nm ft/lb Nm ft/lb Nm ft/lb
6 G 1/8A 9 6.64 18 13.28 18 13.28
8 G 1/4A 35 25.81 35 25.81 35 25.81
10 G 1/4A 35 25.81 35 25.81 35 25.81
12 G 3/8A 45 33.19 70 51.63 70 51.63
15 G 1/2A 65 47.94 140 103.26 90 66.38
18 G 1/2A 65 47.94 100 73.76 90 66.38
22 G 3/4A 90 66.38 180 132.76 180 132.76
28 G 1A 150 110.63 330 243.4 310 228.64
35 G 1 1/4A 240 177.01 540 398.28 450 331.9
42 G 1 1/2A 290 213.89 630 464.66 540 398.28

Tab. 50: Standard torques for imperial thread unions L series, part 1 – see figure above

Pipe diam. X Thread Y WH TH SWVE

Nm ft/lb Nm ft/lb Nm ft/lb
6 G 1/8A 18 13.28 18 13.28 18 13.28
8 G 1/4A 45 33.19 45 33.19 40 29.5
10 G 1/4A 45 33.19 45 33.19 40 29.5
12 G 3/8A 70 51.63 70 51.63 65 47.94
15 G 1/2A 120 88.51 120 88.51 90 66.38
18 G 1/2A 120 88.51 120 88.51 90 66.38
22 G 3/4A 230 169.64 230 169.64 125 92.2
28 G 1A 320 236.02 320 236.02
35 G 1 1/4A 540 398.28 540 398.28
42 G 1 1/2A 700 516.29 700 516.29

Tab. 51: Standard torques for imperial thread unions L series, part 2 – see figure above

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8.4.9 Standard torques for imperial thread unions S series (up to 800
bar/11603 Psi)

Pipe diam. Thread Y Form A with sealing Form B with sealing Form E with flat
X ring edge sealing
Nm ft/lb Nm ft/lb Nm ft/lb
6 G 1/4A 35 25.81 55 40.57 40 29.5
8 G 1/4A 35 25.81 55 40.57 40 29.5
10 G 3/8A 45 33.19 90 66.38 80 59
12 G 3/8A 45 33.19 90 66.38 80 59
14 G 1/2A 65 47.94 150 110.63 115 84.82
16 G 1/2A 65 47.94 130 95.88 115 84.82
20 G 3/4A 90 66.38 270 199.14 180 132.76
25 G 1A 150 110.63 340 250.77 310 228.64
30 G 1 1/4A 240 177.01 540 398.28 450 331.9
38 G 1 1/2A 290 213.89 700 516.29 540 398.28

Tab. 52: Standard torques for imperial thread union S series, part 1 – see figure above

Pipe diam. X Thread Y WH TH SWVE

Nm ft/lb Nm ft/lb Nm ft/lb
6 G 1/4A 45 33.19 45 33.19 40 29.5
8 G 1/4A 45 33.19 45 33.19 40 29.5
10 G 3/8A 70 51.63 70 51.63 65 47.94
12 G 3/8A 70 51.63 70 51.63 65 47.94
14 G 1/2A 120 88.51 120 88.51 90 66.38
16 G 1/2A 120 88.51 120 88.51 90 66.38
20 G 3/4A 230 169.64 230 169.64 125 92.2
25 G 1A 320 236.02 320 236.02
30 G 1 1/4A 540 398.28 540 398.28
38 G 1 1/2A 700 516.29 700 516.29

Tab. 53: Standard torques for imperial thread union S series, part 2– see figure above

8.4.10 Standard torques for metric thread unions L series (up to 500 bar/
7252 Psi) for aluminum

Pipe diam. X Thread Y Form A with sealing Form B with Form E with flat
ring sealing edge sealing
Nm ft/lb Nm ft/lb Nm ft/lb
6 M 10 x 1,0 15 11.06 12 8.85
8 M 12 x 1,5

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Pipe diam. X Thread Y Form A with sealing Form B with Form E with flat
ring sealing edge sealing
Nm ft/lb Nm ft/lb Nm ft/lb
10 M 14 x 1,5 30 22.13 30 22.13
12 M 16 x 1,5 40 29.5 40 29.5 40 29.5
15 M 18 x 1,5
18 M 22 x 1,5 80 59 80 59
22 M 26 x 1,5 80 59 150 110.63
28 M 33 x 2,0
35 M 42 x 2,0
42 M 48 x 2,0

Tab. 54: Standard torques for metric thread unions L series for aluminium – see figure above

8.4.11 Standard torques for cutting ring flange joints

Fig. 114: Cutting ring flange joints

Series Pipe diam. X Thread Z Nm ft/lb

LL 6 M 10 × 1 14 10.33
L 6 M 12 × 1,5 14 10.33
8 M 14 × 1,5 20 14.75
10 M 16 × 1,5 27–30 19.91 - 22.13
12 M 18 × 1,5 60 44.25
15 M 22 × 1,5 105 77.44
18 M 26 × 1,5 150 110.63
22 M 30 × 2 200 147.51
28 M 36 × 2 250 184.39
35 M 45 × 2 450 331.9
42 M 52 × 2 600 442.54
S 16 M 24 × 1,5 150 110.63
20 M 30 × 2 250 184.39
25 M 36 × 2 450 331.9
30 M 45 × 2 600 442.54
38 M 52 × 2 750 553.17

Tab. 55: Standard torques for cutting ring flange joints

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Fig. 115: Cutting ring lubrication

Information
To assemble pipes with cutting rings, proceed like following:
u Assemble pipe tension free. Mount support clamp after pipe assembling.
u Lubricate the surfaces of the connection, with engine oil. (see: fig. 115, page 169) .

Fig. 116: Cutting ring tightening

Information
u Screw in the nut of the cutting ring nut by hand.
u Hold the wrench as close as possible near to the nut.
u Tighten with a wrench until reaching the resisting point.
u Tighten by 90° maximal. While screwing nut A, preclude connector B to rotate. (see: fig. 116,
page 169) .
u If foreseen, proceed with the mounting of support clamps.

8.4.12 Standard torques for triple lock flange joints

Fig. 117: Triple lock flange joints

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Series Pipe diam. X Thread Z Nm ft/lb Nm ft/lb

mm inch UN/UNF Steel Stainless steel
4 6 1/4 7/17-20 15 11.06 30 22.13
5 8 5/16 1/2-20 20 14.75 40 29.5
6 10 3/8 9/16-18 30 22.13 60 44.25
8 12 1/2 3/4-16 60 44.25 115 84.82
10 14, 15, 5/8 7/8-14 75 55.32 145 106.95
16
12 18, 20 3/4 1 1/16-12 110 81.13 180 132.76
16 22 7/8 1 5/16-12 135 99.57 225 165.95
16 25 1 1 5/16-12 175 129.07 255 188.08
28 1 5/8-12 260 191.77 295 217.58
20 30, 32 1 1/4 1 5/8-12 260 191.77 295 217.58
35 1 7/8-12 340 250.77 345 254.46
24 38 1 1/2 1 7/8-12 340 250.77 345 254.46
28 42 2 1/4-12 380 280.27 400 295.02
32 2 2 1/2-12 450 331.9 470 346.65

Tab. 56: Standard torques for triple lock flange joints

Information
To tighten the screwed socket, proceed like following:
u Hold screwed socket instead.
u Unscrew union nut until noticeable resistance (without wrench extension).
u Tighten union nut according torque above.

8.4.13 Standard torques for VSTI screw plugs

Fig. 118: VSTI screw plugs with ED seal (left), with o-ring (right)

Size Tightening torque Size Tightening torque

1)
VSTI ED VSTI o-ring 1)
VSTI ED VSTI o-ring
M8x1 10 Nm 10 Nm G 1/8 13 Nm -
7 ft-lb 7 ft-lb 10 ft-lb
M10x1 12 Nm 20 Nm G 1/4 30 Nm -
9 ft-lb 15 ft-lb 22 ft-lb
M12x1.5 25 Nm 35 Nm G 3/8 60 Nm -
18 ft-lb 26 ft-lb 44 ft-lb

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Standard tightening torques

Size Tightening torque Size Tightening torque

M14x1.5 35 Nm 45 Nm G 1/2 80 Nm -
26 ft-lb 33 ft-lb 59 ft-lb
M16x1.5 50 Nm 55 Nm G 3/4 140 Nm --
37 ft-lb 41 ft-lb 103 ft-lb
M18x1.5 65 Nm 70 Nm G1 200 Nm -
48 ft-lb 52 ft-lb 148 ft-lb
M20x1.5 75 Nm 80 Nm G 1 1/4 400 Nm -
55 ft-lb 59 ft-lb 295 ft-lb
M22x1.5 90 Nm 100 Nm G 1 1/2 450 Nm -
66 ft-lb 74 ft-lb 332 ft-lb
M24x1.5 90 Nm -
66 ft-lb
M26x1.5 125 Nm - 3/4-16 UNF 70 Nm -
92 ft-lb 52 ft-lb
M30x1.5 240 Nm - 7/8-1/4 UNF 100 Nm -
177 ft-lb 74 ft-lb
M27x2 130 Nm 170 Nm R 3/4" 140 Nm 120 Nm
96 ft-lb 125 ft-lb 103 ft-lb 89 ft-lb
M30x2 - 215 Nm
159 ft-lb
M33x2 225 Nm 310 Nm
166 ft-lb 229 ft-lb
M42x2 360 Nm 330 Nm
266 ft-lb 243 ft-lb
M48x2 360 Nm 420 Nm
266 ft-lb 310 ft-lb
M60x2 - 500 Nm
369 ft-lb

Tab. 57: VSTI screw plug tightening torques for steel and iron cast parts

1)
Do not use hydropneumatic screwdriver.

Size Tightening torque Size Tightening torque

1)
VSTI ED VSTI o-ring 1)
VSTI ED VSTI o-ring
M8x1 8 Nm 8 Nm G 1/8 10 Nm -
6 ft-lb 6 ft-lb 7 ft-lb
M10x1 10 Nm 16 Nm G 1/4 25 Nm -
7 ft-lb 12 ft-lb 18 ft-lb
M12x1.5 20 Nm 28 Nm G 3/8 50 Nm -
15 ft-lb 21 ft-lb 37 ft-lb
M14x1.5 28 Nm 36 Nm G 1/2 65 Nm -
21 ft-lb 27 ft-lb 48 ft-lb
M16x1.5 40 Nm 44 Nm G 3/4 112 Nm --
30 ft-lb 32 ft-lb 83 ft-lb

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Standard tightening torques

Size Tightening torque Size Tightening torque

M18x1.5 52 Nm 56 Nm G1 160 Nm -
38 ft-lb 41 ft-lb 118 ft-lb
M20x1.5 60 Nm 64 Nm G 1 1/4 320 Nm -
44 ft-lb 47 ft-lb 236 ft-lb
M22x1.5 72 Nm 80 Nm G 1 1/2 360 Nm -
53 ft-lb 59 ft-lb 266 ft-lb
M24x1.5 72 Nm -
53 ft-lb
M26x1.5 100 Nm - 3/4-16 UNF 56 Nm -
74 ft-lb 41 ft-lb
M30x1.5 192 Nm - 7/8-1/4 UNF 80 Nm -
142 ft-lb 59 ft-lb
M27x2 105 Nm 135 Nm R 3/4" 112 Nm 96 Nm
77 ft-lb 100 ft-lb 83 ft-lb 71 ft-lb
M30x2 - 172 Nm
127 ft-lb
M33x2 180 Nm 250 Nm
133 ft-lb 184 ft-lb
M42x2 290 Nm 265 Nm
214 ft-lb 195 ft-lb
M48x2 290 Nm 335 Nm
214 ft-lb 247 ft-lb
M60x2 - 400 Nm
295 ft-lb

Tab. 58: VSTI screw plug tightening torques for aluminium parts

1)
Do not use hydropneumatic screwdriver.

Information
Tolerances of the indicated tightening torques: 10 %.
Always lubricate the thread before tightening these parts (engine oil).

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Abbreviations - Acronyms

8.5 Abbreviations - Acronyms

Abbr. Designation
AC Alternating Current
BDC Bottom Dead Center
CAN Controller Area Network
CCS Counter Coupling Side = Damper side
CR Common rail
CRS Common rail system
CS Coupling Side = Flywheel side
DC Diagnosis Code
EATS Engine After Treatment System
ECU Electronic control unit
EMC Electromagnetic Compatibility
ENG Engine
EPDM Ethylene-Propylene - Diene Monomer. Les polyoléfine EPDM sont des élastomères
spéciaux se substituant souvent aux caoutchoucs.
HFFR High Frequency Reciprocating Rig – Measured value for the lubricity of diesel fuels
HP High Pressure
HT High Temperature
JSA Job Safety Analysis
LAN Local Area Network
LED Light Emitting Diode
LOTO Lockout/Tagout
LP Low Pressure
LT Low Temperature
MMC MultiMedia Card (used with digital cameras)
OMM Operation and Maintenance Manual
PCV Pressure control valve
PPE Personal Protective Equipment
PTO Power Take-Off
RSM Repair and Service Manual
SWP Safe Work Procedure
TDC Top Dead Center
VCV Volume control valve

Tab. 59: Abbreviations table

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Abbreviations - Acronyms

Acronym Designation
ANSI American National Standards Institute
DIN German standard
EN European standard
EU European Union
ILO International Labor Organisation
ISCED International Standard Classification of Education
SAE Society of Automotive Engineers
WHO World Health Organization

Tab. 60: Acronyms table

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Operation and Maintenance Manual Appendix
Unit conversion tables

8.6 Unit conversion tables

Use the following tables to convert units used in this guideline. Suitable number of decimals are
used for inaccurate conversion factor.

8.6.1 Length conversion factors

Convert from To Multiply by

mm in 0.0394
mm ft 0.00328

Tab. 61: Length conversion factors table

8.6.2 Mass conversion factors

Convert from To Multiply by

kg lb 2.205
kg oz 35.274

Tab. 62: Mass conversion factors table

8.6.3 Pressure conversion factors

Convert from To Multiply by

kPa psi (lbf/in²) 0.145
kPa lbf/ft² 20.885
kPa inch H2O 4.015
kPa foot H2O 0.335
kPa mm H2O 101.972

Tab. 63: Pressure conversion factors table

8.6.4 Volume conversion factors

Convert from To Multiply by

m3 in3 61023.744
m3 ft3 35.315
m3 Imperial gallon 219.969
m3 US gallon 264.172
m3 l (liter) 1000

Tab. 64: Volume conversion factors table

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Unit conversion tables

8.6.5 Power conversion factors

Convert from To Multiply by

kW hp (metric) 1.360
kW US hp 1.341

Tab. 65: Power conversion factors table

8.6.6 Moment of inertia and torque conversion factors

Convert from To Multiply by

kgm2 lbft2 23.730
kNm lbf ft 737.562

Tab. 66: Moment of inertia and torque conversion factors table

8.6.7 Fuel consumption conversion factors

Convert from To Multiply by

g/kWh g/hph 0.736
g/kWh lb/hph 0.00162

Tab. 67: Fuel consumption conversion factors table

8.6.8 Flow conversion factors

Convert from To Multiply by

m3/h (liquid) US gallon/min 4.403
m3/h (gas) ft3/min 0.586

Tab. 68: Flow conversion factors table

8.6.9 Temperature conversion factors

Convert from To Multiply by

°C °F F = 9/5*C + 32
°C °K K = C + 273.15

Tab. 69: Temperature conversion factors table

8.6.10 Density conversion factors

Convert from To Multiply by

Kg/m 3
lb/US gallon 0.00834
Kg/m3 lb/imperial gallon 0.01002

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Unit conversion tables

Convert from To Multiply by

Kg/m3 lb/ft3 0.0624

Tab. 70: Density conversion factors table

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Appendix Operation and Maintenance Manual
Prefix

8.7 Prefix

Name Symbol Factor

tera T 1012
giga G 109
mega M 106
kilo k 103
milli m 10-3
micro μ 10-6
nano n 10-9

Tab. 71: Common prefix multipliers table

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© 2019 by Kohler Co. All rights reserved.