Kohler KD62V12 User manual

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

Contents
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
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
11

Contents
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
12
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09

Contents
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
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
13

Contents
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
14
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09

Contents
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
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
15

Contents
16
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09

1 Product description
1.1 Technical description
Fig. 1: Diesel engine / view from the driving end
DE Driving end 5Exhaust gas turbocharger assembly
1Engine brackets 6Charge air cooler
2Flywheel 7Battery charging alternator
3Fuel filter 8Oil dipstick
4Crankcase breather system filter housing 9High-pressure fuel pump
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
17

Product description
Technical description
Fig. 2: Diesel engine / view from the free end
FE Free end 14 Exhaust gas connection
10 High-temperature coolant pump 15 Lifting lug
11 High-temperature thermostat housing 16 Oil cooler
12 Low-temperature coolant pump 17 Oil filter
13 Low-temperature thermostat housing
Fig. 3: Diesel engine / view from the free end
FE Free end 21 Cylinder head cover
18 Torsional vibration damper cover 22 Charge air pipe
19 Engine control unit 23 Starter
20 Straight air intake 24 Oil pan
18
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09

Product description
Technical description
1.1.1 Conventions
Cylinder designation, direction of rotation, firing sequence
In this manual, all locations and directions shown on the diesel engine are compliant with ISO
1204 in its English version.
Cylinder A1 and cylinder B1 are located on the driving end of the diesel engine. Direction of rota‐
tion is counterclockwise, as seen from the driving end of the diesel engine.
Fig. 4: Cylinder designation - direction of rotation according to ISO 1204
A1-An Series of cylinders – Bank A XExhaust valves
B1-Bn Series of cylinders – Bank B IIntake valves
DE Driving end LLeft engine side
FE Free end RRight engine side
DoR Direction of rotation
Firing sequence: A1-B2-A2-B4-A4-B6-A6-B5-A5-B3-A3- B1
KD62V12 33525088601_8_1 EN_US
2022-09
© 2022 by Kohler Co. All rights reserved.
19

Product description
Technical description
1.1.2 Engine or component identification
Type designation
Designation Description
K D 62 V 12 - 5 A F C Engine type description
K Engine manufacturer
D Fuel type (D=Diesel)
62 Total displacement in liter
V Cylinder configuration
12 Number of cylinders
5 Frequency. 5=50Hz; 6=60Hz
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
Diesel engine nameplate
Fig. 5: Engine nameplate
1Engine main values 3QR code area
2USA regulations references 4Notes regarding emissions exemptions,
fuel, and application types
20
© 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US
2022-09