Kohler KD62V12 Generator Set

⚠ Hot surfaces - wait until engine has cooled

⚠ Risk of injuries if valve springs are under stress

Tools: Turning device, Feeler gauge, Allen key, Wrench

1. Remove cylinder head covers and install turning device.
2. Rotate crankshaft with turning device to index 1.
3. Verify scavenging TDC on A1; if not, turn 360 degrees and verify again.
4. Rotate to index 2; set clearance for cylinders A5, A6, B5.
5. Rotate to index 4; set clearance for cylinders A3, B1, B3.
6. Rotate to index 2 second time (2+360); set A1, A2, B2.
7. Rotate to index 4 second time (4+360); set A4, B4, B6.
8. Insert feeler gauge between rocker ball cap and valve bridge to check clearance.
9. Loosen locknut and turn adjusting screw with Allen key until gauge shows slight resistance.
10. Tighten locknut while holding set screw; re-check and mark cylinder.
11. Repeat for rocker arm exhaust.

Tools: Endoscope, Turning device

1. Remove cylinder head covers and injectors.
2. Place endoscope in injector hole on top of cylinder head.
3. Turn engine until piston is in BDC position.
4. Check inside of liner by endoscope.
5. Note findings on data sheet.
6. Repeat procedure for each cylinder.

⚠ Dismount immediately the turning device and mount the cover on the flywheel housing before operating the engine

⚠ Risk of injuries by ejected tools or turning device parts

Tools: Turning device, Wrench

1. Unscrew screws 4.
2. Remove cover 3.
3. Position turning device 2.
4. Mount and tighten screws 1 according standard torque values.

⚠ Fire or explosion by flammable and explosive lubricants and fuels

1. Ensure fuel supply is closed and fuel pipes and sensors disconnected.
2. Remove flange joints.
3. Remove screws.
4. Remove fuel filters.
5. Installation: install fuel filters with screws.
6. Tighten screws to torque.
7. Install flange joints.

⚠ Risk of crushing, shearing, cutting or severing by use of the turning device

⚠ Check for spring function of the turning device; if faulty replace with new

Tools: Manual wrench tool

1. Engage a manual wrench tool to turn the wheel from the turning device which drives the flywheel gear rim.
2. Turn the engine flywheel to the required position.
3. Disengage the manual wrench each time you stop to turn.
4. At the end of the setting dismount the turning device and mount the cover on the flywheel housing.
5. Tighten the turning device cover bolts according standard torque values.

⚠ Replace all sealings

⚠ Vent coolant circuit at the end of installation

1. Remove venting line and drain LT coolant water.
2. Remove screws.
3. Remove charge air cooler.
4. Installation: insert O-ring in charge air cooler.
5. Insert pipes in aggregate support.
6. Position charge air cooler.
7. Screw charge air cooler with screws and distance sleeve.
8. Vent coolant circuit at the end of installation.

⚠ Replace all sealings

⚠ Vent coolant circuit at the end of installation

Tools: Lifting tool with steel bar, Socket, Torque spanner, T-bar, Marker

1. Drain HT/LT coolant; remove turbocharger, brackets, rocker arm housings, exhaust and admission pipes, rocker arms, retaining plate and oil supply.
2. Unscrew bolts 6.
3. Mount lifting device on cylinder head.
4. Lift and push cylinder head up and down to dismantle it; remove cylinder head.
5. Installation: mount cylinder head gasket on liner and flame ring in liner.
6. Mount locating pins and seal carrier with O-rings; grease O-rings.
7. Mount lifting device and mount cylinder head.
8. Grease and insert bolts with washers; tighten.
9. Mount lifting lug with extended length bolts; grease and tighten.

⚠ Risk of injuries by contact with hot surfaces

⚠ Replace all sealings

1. Disconnect machinery exhaust system.
2. Remove screws with distance sleeves.
3. Remove supports.
4. Remove nuts with clamp segments.
5. Remove exhaust elbow.
6. Installation: install screw plugs with washers into exhaust elbows and tighten.
7. Position exhaust elbow with seal in turbocharger outlet.
8. Position clamp segments and hand tighten nuts.
9. Position supports with distance sleeves.
10. Tighten nuts to torque; tighten screws to torque.

⚠ Replace all sealings

⚠ Release HP fuel pressure before any task

Tools: HP Fuel Pump Lifting Device, Guiding rod M12 (x2)

1. Close fuel supply and release HP fuel side pressure using KODIA tool.
2. Remove fuel piping connected to HP fuel pump.
3. Remove a first screw and a second diametrically opposed.
4. Place guiding rods in place of the two screws and remove remaining screws.
5. Install fuel pump lifting device and remove fuel pumps.
6. Remove guiding rods.
7. Installation: install new O-ring and place guiding rods.
8. Use lifting device to position fuel pumps into gearbox; place screw.
9. Remove guiding rods, place remaining screws and remove lifting tools.
10. Tighten screws following the given order and install HP pump piping.
11. Perform venting on the fuel circuit.

⚠ Lethal or heavy injury due to flammable fluids under high pressure (up to 2000 bar)

⚠ Replace all sealings

⚠ Never release fuel circuit screws while engine is running

Tools: Injector extractor, Plugs for piping

1. Remove cylinder head covers.
2. Remove electrical contacts from injector.
3. Take off high pressure pipe from adaptor.
4. Remove retaining plate with screws and close all open connections with plugs.
5. Open screw and remove clamp.
6. Extract injector with injector extractor.
7. Clean carbon from injector seat; lubricate sleeve and injector O-rings.
8. Position injector with connection upwards into sleeve; introduce clamp and screw; screw collet 90 degrees back.
9. Position retaining plate with screws.
10. Lubricate threads and O-rings of high pressure pipe, adaptor and injector.
11. Push injector in cylinder head and check alignment of fuel pipe and distributor block.
12. Tighten following the tightening sequence.

⚠ Vent coolant circuit at the end of installation

Tools: Guiding rod M12x600 - Oil cooler (x2)

1. Drain HT coolant water.
2. Remove two top outer screws.
3. Mount guiding rods.
4. Remove screws with sleeves.
5. Remove oil cooler.
6. Installation: position guiding rods.
7. Insert O-rings on oil cooler.
8. Position oil cooler on oil cooler casing.
9. Tighten by hand screws with sleeves.
10. Remove guiding rods, mount remaining screws and tighten all screws to torque.
11. Vent coolant circuit at the end.

⚠ Lethal or heavy injury due to electrical shocks

⚠ Replace all sealings

Tools: Pin for belt tensioner (x1), Frequency meter, Belt tension frequency meter

1. Remove battery charging alternator cover.
2. Use 1/2 inch toggle in tensioning device; pivot back against spring force to limit stop.
3. Use a guiding rod to lock the tensioning device; remove V-belt; remove guiding rod.
4. Remove screws and battery charging alternator; remove sleeve.
5. Remove screws and auxiliary PTO; remove O-rings.
6. Remove screws, washer and nut; remove tensioning device.
7. Remove plate with pin and distance sleeve.
8. Remove screw and roller; remove screws with washers; remove screw and distance sleeve; remove plate.
9. Installation: grease O-rings, insert in auxiliary PTO and mount with screws.
10. Insert sleeve into bracket; position battery charging alternator and screw.
11. Install roller, plate, tensioning device and holders; tighten to torque.
12. Mount V-belt, remove guiding rod, tension V-belt and check tension.