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Kohler KD62V12 User manual

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Service and Repair Manual
Service Level 2
(Original Service and Repair Manual)
Diesel engine
KD62V12
From serial number 2020730163
EN_US
33525088601_8_1
09-2022
For United States only
WARNING: This product can expose you to chemicals,
including carbon monoxide and benzene, which are known
to the State of California to cause cancer and birth defects
or other reproductive harm.
For more information, go to www.p65warnings.ca.gov/
WARNING: Breathing diesel engine exhaust exposes you
to chemicals known to the State of California to cause
cancer and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated
area.
- If in an enclosed area, vent the exhaust to the outside.
- Do not modify or tamper with the exhaust system.
- Do not idle the engine except as necessary.
For more information, go to www.p65warnings.ca.gov/diesel
2
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09
Revision history
Version Author Modification Date
05 TB12 - Technical documentation According to development and
improvement
2018-07
06 TB12 - Technical documentation First 3.02 engine version
According to development and
improvement
2019-02
07 TB12 - Technical documentation According to development and
improvement
2021-07
08 TB12 - Technical documentation HVO introduction
According to development and
improvement
2022-09
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
3
4
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09
Preface
About this document
This repair and service manual is dedicated for the mechanics and the workshop personnel of
the Kohler Co. dealers and subsidiaries.
This repair manual provides information regarding the assembly, disassembly, and adjustment
tasks for KOHLER Diesel engines.
Information
Information for the United States
Failing to follow these instructions when installing a certified engine in a piece of nonroad
equipment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as
described in the Clean Air Act.
If you install the engine in a way that makes the engine's emission control information label
hard to read during normal engine maintenance, you must place a duplicate label on the equip‐
ment, as described in 40 CFR 1068.105.
Some sections of this manual do not apply to all engines.
Some illustrations in this repair and service manual show details and implements that may be
different from your engine and machinery.
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 repair and service manual.
If you require further explanations or information, please contact your nearest authorized
Kohler service representative. See “Service Assistance” section.
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
maintenance 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.
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
5
Preface
About this document
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 main‐
tenance 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 opera‐
tion, 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
guarantees, 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 ISO 16016
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 damage.
All rights reserved in the event of the grant of a patent, utility model, or design.
6
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09
Preface
Other applicable documents
Other applicable documents
Document Application
Operation and Maintenance Manual Operator's manual for the engine operation
KoDIA Operation Manual Description of KoDIA, diagnosis software
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
7
Preface
General information
General information
Manual structure
Information
Read and understand this manual before performing any service or maintenance procedures on
any component.
The procedures described in this manual are based on the following structure:
1. Product description (For more information see: 1 Product description, page 17.)
2. Safety (For more information see: 2 Safety, page 34.)
3. Repair (For more information see: 3 Repair, page 54.)
4. Tools and devices (For more information see: 4 Tools and devices, page 258.)
5. Appendix (For more information see: 5 Appendix, page 266.)
Task layout
Information
Before any intervention, read the complete task procedure.
Each task in this manual has the following structure:
8
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09
Preface
General information
Task layout description
1. Chapter heading
2. Previous tasks with details of the chapter
3. Specific safety instructions which complete the general safety instructions
4. Special tools, consumables, and equipment which are needed to fulfill the task
5. One or more overviews of the assembly with list of components
6. Instructions to remove and install the components, with additional directives
7. Specific values spreadsheet to check the nominal and tolerances values of critical compo‐
nents and data recording sheet, if required, to inform the engine manufacturer
8. Tightening sequence table if required
9. Tightening specifications table for specific fastener
Additional identifications
Note Indicates helpful advice and tips.
Precondition Identifies a condition that must be fulfilled in order to
be able to carry out the actions subsequently
described.
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
9
Preface
General information
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.
Additional symbols
10
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09