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KD62V12
Kohler KD62V12 Service And Repair Manual
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Repair
Service and Repair Manual
Charge air system
1
1
Screw (M10)
22
Clamp
Fig. 161: T
ask overview - Without EA
TS
23
Compensator
Fig. 162: T
ask overview - With EA
TS
24
O-ring
27
Screw (M10)
25
Flap with actuator
28
Screw (M10)
26
Flange joint
29
Compensator
142
© 2021 by Kohler Co. All rights reserved.
KD62V12 33525088601_7_1 EN_US
2021-07
141
143
Table of Contents
Service and Repair Manual
1
For United States only
2
Revision history
3
Preface
5
About this document
5
Spare parts
5
Fuels, lubricants and coolants
5
Liability and warranty
6
Modifications, conditions, copyright
6
Copyright - Proprietary notice ISO16016
6
Other applicable documents
7
General information
8
Manual structure
8
Task layout
8
Contents
11
1 Product description
17
1.1 Technical description
17
1.1.1 Cylinder designation, direction of rotation
19
1.1.2 Engine or component identification
20
1.2 Technical data
29
1.3 Function description
30
1.3.1 Fuel system
30
1.3.2 Lubricating system
32
1.3.3 Cooling system
33
1.3.4 Charge air system
35
1.3.5 Charge air diagram (engine with EATS)
36
2 Safety
38
2.1 Identification of the warnings
38
2.1.1 Warnings
38
2.1.2 Additional identifications
38
2.1.3 Additional rules and directives
39
2.2 Target audience
40
2.2.1 Responsibility of machinery owner
40
2.2.2 International standard classification of occupations
40
2.2.3 Occupational references
40
2.2.4 Unauthorized personnel - servicing
41
2.3 Intended use
41
2.4 Limitation of liability
42
2.5 Safety instructions
43
2.5.1 General safety instructions
43
2.5.2 Safety while commissioning
43
2.5.3 Safety when starting
44
2.6 Preventing injuries
46
2.6.1 Preventing bruising
46
2.6.2 Preventing burns
46
2.6.3 Preventing fires and explosion hazards
47
2.6.4 Preventing intoxication and poisoning hazards
48
2.6.5 Preventing electrical hazards
48
2.6.6 Preventing noise hazards
48
2.6.7 Preventing vibrations hazards
49
2.6.8 Preventing electro-magnetic hazards
49
2.6.9 Preventing falling risks
49
2.7 Personal Protective Equipment (PPE)
49
2.8 Accessible areas
51
2.8.1 Engine ready for use or in operation
51
2.8.2 Engine in commissioning — test-run
52
2.8.3 Emergency stop
52
2.8.4 Signage recommendations
53
2.9 Prevent property damage
54
2.9.1 Safety instructions for engine control unit (ECU)
54
2.9.2 Alarm conditions
54
2.9.3 Safety instructions for the fuel system
55
2.9.4 Cleanliness standards and safety
56
2.10 Disposal and environment protection
57
3 Repair
58
3.1 Prevent property damage
58
3.2 Covers
59
3.2.1 Vibration damper cover removal and installation
59
3.2.2 Battery charging alternator & PTO cover removal and installation
61
3.2.3 Cylinder head cover removal and installation
65
3.3 Rocker arms
69
3.3.1 Rocker arms - Valve clearance set (SL 204)
69
3.3.2 Inlet and outlet rocker arms removal and installation
76
3.3.3 Rocker arms housing removal and installation
82
3.4 Cylinder head (SL 224)
90
3.4.1 Cylinder head removal and installation
90
3.5 Driving gear
97
3.5.1 Power unit
97
3.5.2 Torsional vibration damper removal and installation - SL2-1340
99
3.6 Fuel system
106
3.6.1 Fuel return and venting pipes removal and installation
106
3.6.2 High pressure pipes removal and installation
109
3.6.3 Fuel supply pipes removal and installation
117
3.6.4 Injector removal and installation (SL 205)
118
3.6.5 Fuel filters removal and installation
127
3.6.6 Leakage fuel block removal and installation
129
3.6.7 Fuel pump HP and LP removal and installation (SL 250)
130
3.6.8 Gearbox - Fuel pump removal and installation
135
3.7 Charge air system
139
3.7.1 Air intake line removal and installation
139
3.7.2 Charge air line removal and installation
140
3.7.3 Charge air cooler removal and installation (SL 220)
149
3.8 Exhaust gas system
154
3.8.1 Admission pipes to turbocharger removal and installation
154
3.8.2 Exhaust pipes to turbocharger removal and installation
156
3.8.3 Turbocharger removal and installation (SL 233)
165
3.8.4 Oil supply – turbocharger removal and installation
170
3.8.5 Turbocharger brackets removal and installation
175
3.8.6 Exhaust pipes and compensators (SL 214)
180
3.9 Lubricating system
187
3.9.1 Crankcase breather system rubber hoses (SL 219)
187
3.9.2 Oil centrifuge removal and installation (depending on application)
189
3.9.3 Spin-on oil filters removal and installation
192
3.9.4 Prelubricating pump removal and installation (depending on application)
193
3.10 Cooling system
197
3.10.1 Venting line removal and installation
197
3.10.2 Turbocharger cooling lines removal and installation
203
3.10.3 Thermostat HT and housing removal and installation (SL 217)
215
3.10.4 Thermostat LT and housing removal and installation (SL 217)
217
3.10.5 Coolant pump HT removal and installation (SL 216)
220
3.10.6 Coolant pump LT removal and installation (SL 215)
222
3.10.7 Fan drive (option)
225
3.11 Electrical system
231
3.11.1 Power take-off (PTO) and battery charging alternator removal and installation (SL 223)
231
3.11.2 Starter removal and installation (SL 260)
238
3.12 Exhaust aftertreatment system
244
3.12.1 Diesel exhaust fluid injector removal and installation (SL2-5330)
244
3.12.2 Diesel exhaust fluid pump removal and installation (SL2-5340)
250
4 Tools and devices
256
4.1 Tools
256
4.1.1 Special tools
256
4.1.2 Turning device
259
5 Appendix
262
5.1 Technical design documents
262
5.2 Cleaning agents, thread-locking adhesives and greases
263
5.2.1 Cleaning agents and thread-locking adhesives
263
5.2.2 Greases
263
5.3 Standard tightening torques
264
5.3.1 Lubricant and threadlocker application rules
264
5.3.2 Screws pre-tightening, reuse and marking
264
5.3.3 Standard torques for hexagonal / socket / flange screws and hexagonal / flange nuts
267
5.3.4 Standard torques for internal drive pipe plug with conical thread
268
5.3.5 Standard torques for screws according to DIN 7643, DIN 910, DIN 908
268
5.3.6 Standard torques for flange joints
270
5.3.7 Assembling pipes with cutting rings
276
5.3.8 Standard torques for triple lock flange joints
277
5.3.9 Standard torques for VSTI screw plugs for steel
278
5.3.10 Standard torques for VSTI screw plugs for aluminium
279
5.3.11 Assembling pipes with DKO connectors (EL, ET, EW, GZ, GZR, RED)
281
5.3.12 Standard torques for collar clamps
282
5.4 Abbreviations - Acronyms
283
5.5 Unit conversion tables
285
5.5.1 Length conversion factors
285
5.5.2 Mass conversion factors
285
5.5.3 Pressure conversion factors
285
5.5.4 Volume conversion factors
285
5.5.5 Power conversion factors
286
5.5.6 Moment of inertia and torque conversion factors
286
5.5.7 Fuel consumption conversion factors
286
5.5.8 Flow conversion factors
286
5.5.9 Temperature conversion factors
286
5.5.10 Density conversion factors
286
5.6 Prefix
288
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Kohler KD62V12 Specifications
General
Brand
Kohler
Model
KD62V12
Category
Engine
Language
English
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