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KD62V12
Kohler KD62V12 User Manual
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Repair
Charge air sys
tem
11
Screw (M10)
22
Clamp
Fig. 152: T
ask overview - Without engine by-pass flap
23
Compensator
Fig. 153: T
ask overview - With engine by-pass flap
24
O-ring
27
Screw (M10)
25
E
ngine by-pass flap
28
Screw (M10)
26
Flange join
t
29
Compensator
142
© 2022 by Kohler Co. All righ
ts reserved.
KD62V12 33525088601_8_1 EN_US
2022-09
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 ISO 16016
6
Other applicable documents
7
General information
8
Manual structure
8
Task layout
8
Additional identifications
9
Contents
11
1 Product description
17
1.1 Technical description
17
1.1.1 Conventions
19
1.1.2 Engine or component identification
20
1.2 Function description
28
1.2.1 Fuel system
28
1.2.2 Cooling system
30
1.2.3 Charge air system
31
1.2.4 Charge air diagram (engine with EATS)
32
2 Safety
34
2.1 Identification of the warnings
34
2.1.1 Warnings
34
2.1.2 Additional rules and directives
34
2.2 Target audience
35
2.2.1 Responsibility of machinery owner
35
2.2.2 Recommended occupations according to International standards
35
2.2.3 Unauthorized personnel - servicing
36
2.3 Intended use
36
2.4 Limitation of liability
37
2.5 Safety instructions
38
2.5.1 General safety instructions
38
2.5.2 Safety while commissioning
38
2.5.3 Safety when starting
39
2.6 Preventing injuries
41
2.6.1 Preventing bruising
41
2.6.2 Preventing burns
41
2.6.3 Preventing fires and explosion hazards
42
2.6.4 Preventing intoxication and poisoning hazards
43
2.6.5 Preventing electrical hazards
43
2.6.6 Preventing noise hazards
43
2.6.7 Preventing vibrations hazards
44
2.6.8 Preventing electro-magnetic hazards
44
2.6.9 Preventing falling risks
44
2.7 Personal Protective Equipment (PPE)
44
2.8 Accessible areas
46
2.8.1 Engine ready for use or in operation
46
2.8.2 Engine in commissioning — test run
47
2.8.3 Emergency stop
47
2.8.4 Signage recommendations
48
2.9 Prevent property damage
49
2.9.1 Safety instructions for engine control unit (ECU)
49
2.9.2 Alarm conditions
49
2.9.3 Safety instructions for the fuel system
50
2.9.4 Cleanliness standards and safety
51
2.10 Disposal and environment protection
52
3 Repair
54
3.1 Prevent property damage
54
3.2 Preparatory maintenance activities
55
3.3 Post maintenance activities
56
3.3.1 Spray painting
56
3.4 Covers
58
3.4.1 Vibration damper cover removal and installation
58
3.4.2 Battery charging alternator & PTO cover removal and installation
60
3.4.3 Cylinder head cover removal and installation
64
3.5 Rocker arms
68
3.5.1 Rocker arms - Valve clearance set (SL 204)
68
3.5.2 Inlet and outlet rocker arms removal and installation
75
3.5.3 Rocker arms housing removal and installation
81
3.6 Cylinder head
89
3.6.1 Removing and installing cylinder head
89
3.7 Driving gear
97
3.7.1 Power unit
97
3.7.2 Torsional vibration damper removal and installation - SL2-1340
99
3.8 Fuel system
109
3.8.1 Fuel return and venting pipes removal and installation
109
3.8.2 High pressure pipes removal and installation
112
3.8.3 Fuel supply pipes removal and installation
120
3.8.4 Injector removal and installation (SL 205)
121
3.8.5 Fuel filters removal and installation
130
3.8.6 Leakage fuel block removal and installation
132
3.8.7 Fuel pump HP and LP removal and installation (SL 209)
133
3.9 Charge air system
139
3.9.1 Air intake line removal and installation
139
3.9.2 Charge air line removal and installation
140
3.9.3 Charge air cooler removal and installation (SL 220)
149
3.10 Exhaust gas system
154
3.10.1 Admission pipes to turbocharger removal and installation
154
3.10.2 Exhaust pipes to turbocharger removal and installation
156
3.10.3 Turbocharger removal and installation (SL 213)
166
3.10.4 Oil supply – turbocharger removal and installation
171
3.10.5 Turbocharger brackets removal and installation
176
3.10.6 Exhaust pipes and compensators (SL 214)
181
3.11 Lubricating system
188
3.11.1 Crankcase breather system rubber hoses (SL 219)
188
3.11.2 Oil centrifuge removal and installation (depending on application)
190
3.11.3 Spin-on oil filters removal and installation
193
3.11.4 Oil cooler by-pass valve (SL 212)
194
3.11.5 Prelubricating pump removal and installation (option)
196
3.12 Cooling system
200
3.12.1 Venting line removal and installation
200
3.12.2 Turbocharger cooling lines removal and installation
206
3.12.3 Thermostat HT and housing removal and installation (SL 217)
218
3.12.4 Thermostat LT and housing removal and installation (SL 217)
220
3.12.5 Coolant pump HT removal and installation (SL 216)
222
3.12.6 Coolant pump LT removal and installation (SL 215)
225
3.12.7 Fan drive (option)
227
3.13 Electrical system
233
3.13.1 Power take-off (PTO) and battery charging alternator removal and installation (SL 218, SL 223)
233
3.13.2 Starter removal and installation (SL 260)
240
3.14 Exhaust gas aftertreatment system (depending on configuration)
246
3.14.1 Removing and installing diesel exhaust fluid injector (SL2-5330)
246
3.14.2 Diesel exhaust fluid pump removal and installation (SL2-5340)
252
4 Tools and devices
258
4.1 Tools
258
4.1.1 Special tools
258
4.1.2 Turning device
261
5 Appendix
266
5.1 Technical design documents
266
5.2 Cleaning agents, thread-locking adhesives and greases
267
5.2.1 Cleaning agents, thread-locking adhesives and greases
267
5.3 Standard tightening torques
268
5.3.1 Lubricant and threadlocker application rules
268
5.3.2 Screws pre-tightening, reuse, and marking
268
5.3.3 Standard torques for hexagonal / socket / flange screws and hexagonal / flange nuts
271
5.3.4 Standard torques for internal drive pipe plug with conical thread
272
5.3.5 Standard torques for screws according to DIN 7643, DIN 910, DIN 908
272
5.3.6 Standard torques for flange joints
274
5.3.7 Assembling pipes with cutting rings
280
5.3.8 Standard torques for triple lock flange joints
281
5.3.9 Standard torques for VSTI screw plugs for steel and iron cast part
282
5.3.10 Standard torques for VSTI screw plugs for aluminium
283
5.3.11 Assembling pipes with DKO connectors (EL, ET, EW, GZ, GZR, RED)
285
5.3.12 Standard torques for collar clamps
286
5.3.13 Standard torques for pipe clamps according to DIN 3015
287
5.4 Abbreviations - Acronyms
288
5.5 Unit conversion tables
290
5.5.1 Length conversion factors
290
5.5.2 Mass conversion factors
290
5.5.3 Pressure conversion factors
290
5.5.4 Volume conversion factors
290
5.5.5 Power conversion factors
291
5.5.6 Moment of inertia and torque conversion factors
291
5.5.7 Factors of fuel consumption conversion
291
5.5.8 Flow conversion factors
291
5.5.9 Temperature conversion factors
291
5.5.10 Density conversion factors
291
5.5.11 Length conversion factors
292
5.5.12 Mass conversion factors
292
5.5.13 Pressure conversion factors
292
5.5.14 Volume conversion factors
292
5.5.15 Power conversion factors
293
5.5.16 Moment of inertia and torque conversion factors
293
5.5.17 Fuel consumption conversion factors
293
5.5.18 Flow conversion factors
293
5.5.19 Temperature conversion factors
293
5.5.20 Density conversion factors
293
5.6 Prefix
295
Other manuals for Kohler KD62V12
Operation And Maintenance Manual
210 pages
Service And Repair Manual
290 pages
4
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Kohler KD62V12 Specifications
General
Brand
Kohler
Model
KD62V12
Category
Engine
Language
English
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