Kohler KD27V12 Generator Set

Tools: Allen key, Feeler gage, Torque wrench, Turning device [10123791]

1. Fit the turning device [10123791].
2. Turn crankshaft until cylinder 1 is in TDC position (cylinder 6 valves overlap).
3. Set/check inlet valves 1-4-8-9.
4. Set/check outlet valves 1-2-3-9-11-12.
5. If play does not agree, unscrew lock nut and correct the setting.
6. Tighten the lock nut with 45 Nm, holding the adjusting screw with the Allen key.
7. Check the setting again.
8. Turn the crankshaft 310° in direction of rotation; set/check inlet valves 2-3-10-11-12 and outlet valves 5-6-7-10.
9. Turn the crankshaft 230° (TDC +540°); set/check inlet valves 5-6-7 and outlet valves 4-8.
10. Install cylinder head cover with inspected, undamaged seals.
11. Remove the turning device.

1. Remove the thermostat.
2. Check the engraved start of opening.
3. Compare to technical data: start of opening 82°C, fully open 90°C, stroke with full opening 15 mm.

⚠ Damage through leaks.

⚠ Check the software version as soon as the electric power supply is switched on after a change of engine control unit.

1. Make sure that the electric power supply from the battery is disconnected.
2. Install the engine control unit mechanically.
3. Replace the vibration damper when replacing the engine control unit.
4. Connect the fuel lines to the engine control unit.
5. Turn the fuel supply back on on the device side.
6. Carefully connect the plug connectors A700A.X1, A700B.X2, A700C.X3 and A700D.X4.
7. Perform a visual check of connections and seals for leaks.
8. Connect the power supply between the battery and engine control unit.
9. Check that the correct software is installed with a new engine control unit; carry out a software update if necessary.
10. Start the engine and check its correct function.

⚠ Hot cooler fluid! Injuries, burns!

⚠ Coolant can cause injuries to the eyes and allergic skin reactions!

Tools: Drain hose [12690422], Drain hose [12690423]

1. Place a reservoir beneath the Diesel engine.
2. Carefully loosen the sealing plug on the equalizing reservoir until the overpressure is released, then open it.
3. Open the protecting cap of the drain valves.
4. Screw drain hose [12690422 or 12690423] on the drain valves one after the other.
5. When the coolant has drained, unscrew the drain hose from the drain valves.
6. Screw the protecting caps back into place.

Tools: KODIA diagnostic program

1. Stop the engine and carry out the following checks.
2. Check the oil level.
3. Check the coolant level.
4. Perform a visual check for any leaks in the lines.
5. Check the error messages in the KODIA diagnostic program.
6. Check for error messages on the device side.
7. Top off all fluids if necessary.

⚠ The lifting device may be torn out and the engine can fall down.

⚠ Observe a maximum deviation of 10° between the perpendicular and the engine axis.

1. Fit/remove ring bolt and lifting hook.
2. Tighten hex screws with the specified torques.
3. Use washer and socket head screws as shown.

⚠ Oil contamination through incorrect seal installation.

⚠ The seal may be distorted by incorrect handling.

1. Check seal for damage (deformation, visible cracks).
2. Replace the seal if damaged.
3. Open the cable bushing slightly by hand.
4. Apply Optimol White T in the closure area and on the cable bushing.
5. Insert the cable in the cable bushing.
6. Apply Optimol White T to the contact surface to the cylinder head cover.
7. Place the strand in the bushing and in the guide.
8. Place the fastening inserts in the screw head.
9. Tighten the strands on the injector (1.2 +0.2/0 Nm).
10. Align the positions of the seal to the bore of the cylinder head.
11. Visual check of the position of the seal; replace distorted seals.
12. Fit the cylinder head cover so the seal does not move from the positioning.

⚠ Access to the maintenance zones must be secured against accidental starting before entering the safety zones.

1. Disconnect electrical power supply and secure against reactivation.
2. Label cut-off point.
3. Complete installation, maintenance and repair activities.
4. Make sure that all foreign bodies have been removed.
5. Make sure all protective devices are installed and working properly.
6. Make sure no external persons stand in the danger zones.
7. Remove the label from the electrical power supply.
8. Establish the electrical power supply.

⚠ An unexpected start of the engine can cause severe injury or death.

⚠ Continuous actuation damages the starter.

⚠ Make sure the oil pressure builds up immediately after the engine is started.

Tools: KODIA diagnostic program

1. Pay attention to the safety instructions in the chapter "Safety".
2. Switch on the electrical power supply (battery voltage).
3. Check that there are no error messages with the KODIA diagnostic program.
4. Press the starter for a maximum of 30 seconds.
5. If the engine does not start, wait at least two minutes then press the starter again for a maximum of 30 seconds.
6. Wait at least five minutes before every subsequent attempt.
7. If the engine still does not start, check all connections and operating materials; troubleshoot with KODIA.

⚠ If the angle has not been set correctly, the Diesel engine does not develop its full rated power.

Tools: Turning device [10123791], Torque angle gage [10023839]

1. Fit the turning device [10123791].
2. Ensure that the 1st cylinder is in ignition TDC.
3. Position the shaft's oil feed bore horizontally.
4. Replace the O-rings, oil and insert into the grooves.
5. Install both HP pumps starting from the bottom at a 45° angle without twisting the shaft.
6. Remove the protective caps from the fuel feed and return lines.
7. Replace O-rings and screw connection.
8. Connect connecting lines.
9. Remove the inlet manifold.
10. Remove the HP pumps' drive cover and remove the gear.
11. Fit the torque angle gage [10023839] with attachment on the gear.
12. Rotate the gear 135° clockwise, measured at the torque angle gage.
13. Remove the torque angle gage with attachment.
14. Fit the gear and tighten hex screws.
15. Replace gasket, fit the HP pumps' drive cover and tighten hex screws.

⚠ Leaks in the pressure adapter - the pressure adapter must be replaced after every removal.

⚠ Leaks in the HP connections - the box nut must be replaced after every removal.

Tools: Centering aid [10153847]

1. Fit a new O-ring onto the injector and grease with NBU 30.
2. Replace gasket (symmetrical, no set installation side).
3. Insert the injector with fitted support lug into the cylinder head and align.
4. Press the injector into the cylinder head by hand.
5. Insert the centering aid [10153847] into the bore of the pressure adapter.
6. Exert a slight pressure on the end face to center the injector bore.
7. Fit the spherical washer, oil the socket head screw and tighten (5 Nm).
8. Remove the centering aid.
9. Grease a new O-ring for the pressure adapter with NBU 30.
10. Install the pressure adapter so the centering lugs are flush with the recesses in the cylinder head.
11. Tighten the box nut (5 Nm) then the socket head screw (28 Nm) then the box nut (35 Nm).
12. Connect cable to injector.

Tools: Special tool [0528470]

1. Degrease the contact surfaces between the viscous damper and the parts behind this.
2. Fit the viscous damper carefully without moving the parts behind it.
3. Degrease the contact surfaces between the pulley and the parts behind this.
4. Fit the pulley carefully without moving the parts behind it.
5. Grease the new hexalobular screws with engine oil.
6. Fit the hexalobular screws 1, 2, 5, 6, 7, 8 and tighten hand tight.
7. Remove the mounting bolts [0528470].
8. Fit the remaining hexalobular screws and tighten hand tight.
9. Tighten all hexalobular screws according to the tightening instruction.