Page 1 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...
Page 2 - 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 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 3 2019-02 According to development and improvement TB12 - Technical documentation According to development and 2021-07 improvement TB12 - Technical documentation HVO introduction 2022-09 According to development and improvement © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 5 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.
Page 6 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.
Page 7 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 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 8 (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: © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 9 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. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 10 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 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 11 2.5.2 Safety while commissioning 2.5.3 Safety when starting Preventing injuries 2.6.1 Preventing bruising 2.6.2 Preventing burns 2.6.3 Preventing fires and explosion hazards 2.6.4 Preventing intoxication and poisoning hazards © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 12 Inlet and outlet rocker arms removal and installation 3.5.3 Rocker arms housing removal and installation Cylinder head 3.6.1 Removing and installing cylinder head Driving gear 3.7.1 Power unit © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 13 3.12.4 Thermostat LT and housing removal and installation (SL 217) 3.12.5 Coolant pump HT removal and installation (SL 216) 3.12.6 Coolant pump LT removal and installation (SL 215) 3.12.7 Fan drive (option) 3.13 Electrical system © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 14 5.3.13 Standard torques for pipe clamps according to DIN 3015 Abbreviations - Acronyms Unit conversion tables 5.5.1 Length conversion factors 5.5.2 Mass conversion factors 5.5.3 Pressure conversion factors © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 15 5.5.15 Power conversion factors 5.5.16 Moment of inertia and torque conversion factors 5.5.17 Fuel consumption conversion factors 5.5.18 Flow conversion factors 5.5.19 Temperature conversion factors 5.5.20 Density conversion factors Prefix © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 17 DE Driving end Exhaust gas turbocharger assembly Engine brackets Charge air cooler Flywheel Battery charging alternator Fuel filter Oil dipstick Crankcase breather system filter housing High-pressure fuel pump © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 18 Fig. 3: Diesel engine / view from the free end Free end Cylinder head cover Torsional vibration damper cover Charge air pipe Engine control unit Starter Straight air intake Oil pan © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 19 Exhaust valves B1-Bn Series of cylinders – Bank B Intake valves Driving end Left engine side Free end Right engine side Direction of rotation Firing sequence: A1-B2-A2-B4-A4-B6-A6-B5-A5-B3-A3- B1 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 20 Tab. 1: Engine type description Diesel engine nameplate Fig. 5: Engine nameplate Engine main values QR code area USA regulations references Notes regarding emissions exemptions, fuel, and application types © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 21 Year of manufacture Engine type code (73= KD62V12) (74= KD83V16) (75= KD103V20) 0001 Incremental production number Tab. 2: Engine serial number Fig. 7: Serial number on nameplate Serial number © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 22 Fig. 9: Software nameplate Product designation Engine serial number Product type Engine control unit ID number Engine designation Certification ID number QR Code Data set ID number Delivery date © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 23 Kohler Co.). Depending on software updates in the field, it may be the case that this information is no longer up to date. u The real information can be viewed in the device display or read out with the KOHLER diag‐ nosis and service tool KODIA.
Page 24 Matching of the connecting rod and connecting rod bearing cap is identified by connecting rod number. Turbocharger identification Fig. 13: Turbocharger nameplate The turbocharger company nameplate is mounted on the turbocharger. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 25 The oil cooler company nameplate is mounted on the oil cooler. Injector identification Fig. 15: Injection number location The injector identification number is stamped on the side of the injector. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 26 Product description Technical description High-pressure pumps identification Fig. 16: High pressure pump nameplate Fig. 17: High pressure pump number The high pressure pump number is stamped on the pump. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 27 The charge air cooler company nameplate is mounted on the charge air cooler. Thermostat opening point value Fig. 19: Thermostat markings The opening point value of the thermostat is engraved on the thermostat. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 28 Smoking and open flames are forbidden in the vicinity of the engine. u Always start the engine according to the instructions in the instructions manual of the machinery. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 29 PCV 1 tion Bank B (Leakage) Low pressure pump Y728 and Y727 – Fuel pump Fuel cooler (optional) PCV 2 See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 30 Sensors list B708 – Coolant temperature S710 – HT Coolant Min level after engine alert B718 – Coolant temperature S711 – LT Coolant Min level before cooler alert © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 31 B749 - Air intake tempera‐ Bxx1 - Atmospheric pressure ature on cylinder Bx ture - A side (on ECU 2-HD) (optional) See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 32 1.2.4 Charge air diagram (engine with EATS) Fig. 23: Charge air diagram Exhaust gas Oil vapor For odd number of turbo‐ chargers only Fresh air Depending on engine config‐ CR Customer responsibility uration © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 33 B781 - Air intake pressure B703 - Charged air pressure switch - B side (clogging) A after charge air cooler Engine type Number of turbochargers Tab. 4: Blowby connections © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 34 Follow these instructions and observe any additional or local rules and directives. Note the following points: – Safety regulations applicable on site – Guidelines provided by professional associations © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 35 1 to 3 years following completion of secondary education (ISCED-97 Level 5b). In some cases, extensive relevant work experience and prolonged on-the-job training may substitute for the formal education. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 36 – The engines must only be installed by personnel who have been trained and familiarized herewith and are aware of the dangers. – Unauthorized changes on the engines or their components void the liability of Kohler Co. for any resulting property damage or personal injury.
Page 37 Safety Limitation of liability Any other use above and beyond this is considered to be improper use. In this case, Kohler Co. is not liable for any damage. The risk is borne solely by the user. 2.4 Limitation of liability The use of an engine under conditions or for purposes not intended by Kohler Co., but which...
Page 38 Risk of engine failure by use of non-compliant operating fluids! Use of non-compliant operating fluids will lead to engine main failure. u Use only operating fluids tested and approved by Kohler Co. NOTICE Risk of engine failure by use of non-original spare parts! The use of original spare parts guarantees the compliance with the technical requirements established by Kohler Co.
Page 39 Vibrations generated by the engine could result in death or serious injuries. u Standing in the vicinity of the engine while starting or operating the equipment is forbidden. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 40 Standing in the vicinity of the engine while starting or operating the machinery is forbidden. u Wear proper personal protective equipment. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 41 Check operating fluid levels only once the temperature has cooled down enough so that surfaces can be touched with bare hands. u Carefully open the cover in order to first reduce the excessive pressure. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 42 According to local regulations, the manufacturer of the specific application is responsible to design adapted fire protection system. Information Engines provided by Kohler Co. are not intended to be used in potentially explosive atmos‐ pheres according to Directive 2014/34/EC. © 2022 by Kohler Co. All rights reserved.
Page 43 Noise reduction systems adapted to the machinery must be designed by the manufacturer, to comply with the local regulations. u In case of abnormal noises, rectify it immediately. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 44 The manufacturer of the machinery shall define the safe conditions, including the personal protective equipment to wear before starting to work on the engine. u The manufacturer of the machinery shall forbid any accessories and loose clothing. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 45 Must be worn in the direct vicinity of the engine Safety goggles Protection against flying objects and chemical splashes Must be worn when handling operating materials and during mechanical opera‐ tions Tab. 7: Personal protective equipment © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 46 Fig. 35: Areas in operation — view from above and driving end Access to the following areas is forbidden: Engine free end Above the engine Engine sides Below the engine Engine driving end © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 47 Initiating an emergency stop: u Press the emergency stop button. After an emergency stop: u Remedy to the emergency situation. u Acknowledge the emergency stop button and signals. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 48 Provide documentation to the personnel according to the “Target audience”. Tab. 8: Engine area signs requirement © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 49 Switch over to appropriate backup/emergency functions for additional, restricted operation of the engine (for example, constant limp-home speed). u Make sure that the faults are immediately repaired. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 50 Before starting any task on the fuel system, ensure the build-up pressure in the circuit has been released, and the temperature of the engine has cooled down. u Keep the engine away from heat, sparks, open flame, or any other ignition source. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 51 Never use contaminated cleaning or testing fluids. u Remove new components from the original packaging immediately before use. u Use the original packaging of the new parts to ship removed parts. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 52 Use adapted leak-proof containers to drain lubricants and fuel. Use of food or drink containers is prohibited. u Dispose all scrap materials only at official locations in an environment-friendly manner. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 54 (leakage in the charge air circuit, parts ejection, and others). Mount any component according to: u For the KOHLER application, the “Operation and Maintenance Manual” and its "Service and Repair Manual". u For non KOHLER components, refer to the “Instructions” or “Assembly Instructions” from the supplier.
Page 55 Secure the area according to local lockout/tagout procedures. u Turn off battery main switch. u If present, remove main switch key. u Let the engine cool down to ambient temperature. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 56 Make sure that the spray paint can is at ambient temperature. q Make sure that all areas not to be painted are masked. Consumables and equipment – Spray paint can - black color (12692707) – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 57 Turn the spray can upside down and bleed the valve after finishing the paint work. Information In optimal conditions (20 °C (68 °F), 65% of humidity), the paint is completely dry after 24 hours. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 58 Not applicable. Special tools Not applicable. Consumables and equipment Not applicable. Overview Fig. 41: Task overview Screw (M8) Cover Protection plate Screw (M12) Removal u Remove screws 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 59 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 60 Check the grounding connection to avoid any risk of electrical arc. u Observe the local safety regulations that apply to the machinery. Special tools Not applicable. Consumables and equipment – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 61 Cover - front side Cover - back side Removal Fig. 44: Removing cover - front part u Remove screws 8 and lock washers 7. u Remove cover - front side 9. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 62 Remove nuts 6, vibration dampers 3, distance sleeves 2 and pins 1, 4. u Remove cover - back side 5 Installation Fig. 46: Installing pins u Screw pins 1, 4 on aggregate support and PTO bracket. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 63 Screw cover with nuts 6. Fig. 48: Installing cover u Mount cover 9 on pins 1, 4. u Fix cover 9 with lock washers 7 and screws 8. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 64 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) 3.4.3 Cylinder head cover removal and installation Previous tasks Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 65 Before servicing the engine, let it cool down until surface temperature allows you to touch it with bare hand. u Wear proper personal protective equipment. Special tools Not applicable. Consumables and equipment Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 66 Mount a new seal 3 on cylinder head cover 1. u Position screws 2 into the bores of the cylinder head cover 1. u Position cylinder head cover 1 on rocker arm housing. u Tighten screws 2. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 67 Repair Covers Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 69 Exhaust valves B1-B6 Series of cylinders – Bank B Inlet valves Driving End (engine rear) Left engine side Free End (engine front) Right engine side Direction of rotation © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 70 B4, B6 Tab. 12: Reference table for the flywheel positioning Set the valve clearance Step 1 u Rotate crankshaft in direction of rotation with turning device to index 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 71 73.) (For more information see: Setting valve clearance, page 73.) Step 6 u Pass flywheel groove index 5. Step 7 u Pass flywheel groove index 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 72 Overlap TDC** * Ignition order ** Opposite cylinder (overlap) Tab. 13: Valve set order u Set cylinder to overlap TDC position. u Adjust valve clearance of ignition TDC cylinder. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 73 Repeat procedure for next valve. u Mark cylinder when the operation is completed. u Repeat entire procedure for exhaust rocker arm 5. Specific values Use feeler gauge to set valve clearance. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 74 +100 µm (3.94 th) clearance 19.69 th Exhaust 1 mm +100 µm (3.94 th) valve/ clear‐ 0.04 in ance Tab. 14: Tolerance values Tightening specifications Fig. 59: Rocker arms locknuts © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 75 Special tool Designation Turning device. (For more information see: Use the turning device, page 263.) Tab. 16: Special tools Consumables and equipment – Engine oil – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 76 Inlet rocker arm Rocker arm housing Removal WARNING The valve springs must not be under stress. Risk of injuries. u Turn crankshaft to firing TDC position using turning device. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 77 Remove inlet rocker arm assembly 5 and exhaust rocker arm assembly 8. Fig. 64: Removing shafts from rocker arms u Remove inlet shaft 6 from inlet rocker arm 5. u Remove exhaust shaft 9 from exhaust rocker arm 8. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 78 Remove valve bridges 3 and pushrods 2 from swing followers 1. Installation Information Put matching cylinder in firing TDC position. Fig. 66: Preparing inlet and exhaust shafts u Inspect presence of plug in inlet shaft and exhaust shaft. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 79 Fig. 68: Installing pushrods and valve bridges u Insert pushrods 2 into cylinder head and fit it with swing followers 1. u Insert valve bridges 3 into inlet and exhaust valves. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 80 Screw and fit rocker arms with screws 7 in inlet shaft, exhaust shaft and fitting sleeves 4. Specific values (For more information see: 3.5.1 Rocker arms - Valve clearance set (SL 204), page 68.) Tightening specifications Fig. 70: Rocker arms screws © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 81 (For more information see: 3.8.2 High pressure pipes removal and installation, page 112.) Specific safety instructions – Set cylinders to ignition TDC position. Special tools Special tool Designation Coolant connector pipe tool Tab. 18: Special tools © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 82 – Cleaner Overview Fig. 72: Task overview Positioning pin Seal (x4) Screw (M8) Coolant pipe HT Closing cover Locking ring Seal Rocker arm housing Fitting sleeve (x5) Seal © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 84 Slide pipes out of rocker arm housing. Fig. 75: Removing rocker arm housing u Lift rocker arm housing 9. u Move rocker arm housing and coolant pipe HT to remove the assembly. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 85 Remove seals 4, 6 from closing cover and coolant pipe HT. u Remove fitting sleeves 5. Installation Fig. 77: Preparing rocker arm housing u Grease coolant pipe. u Insert fitting sleeves 5. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 86 Put seals 6 and locking ring 8 on coolant pipe HT 7. u Insert coolant pipe HT 7 in rocker arm housing. Fig. 80: Inserting pins and seal © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 87 Insert positioning pins 1 in rocker arm housing. Fig. 81: Placing tool Information Tighten screws from inlet and outlet rocker arms. u Place tool on pipe. u Insert pipe into rocker arm housing. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 88 Vent cooling system at the end of installation. Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 89 (For more information see: 4.1.1 Special tools, page 258.) Consumables and equipment Make sure that the following consumables and equipment are available: – Vaseline – Castrol Optimol paste white T – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 90 O-ring set Bolt (M30) Multichannel gasket Washer Cylinder head gasket (soft metal) Locating pin Removal Fig. 84: Lifting the cylinder head u Unscrew bolts 6 with washers 7. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 91 Remove flame ring 5. Installation Fig. 85: Installing cylinder head gasket and flame ring u Mount flame ring 5 in liner. u Mount cylinder head gasket 4 on liner. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 92 Grease o-rings 2. u Mount multichannel gasket 3 with o-rings 2. Fig. 87: Installing cylinder head u Mount lifting device on cylinder head. u Mount cylinder head on engine block. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 93 Insert and tighten the bolts 6 by hand. u Tighten all bolts 6 with the torque wrench according to the specifications. (For more infor‐ mation see: Tightening specifications, page 95.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 94 If cylinder heads 1 are connected with a lifting lug bracket, both cylinder heads 1 need to be removed. Information Bleed coolant circuit at the end of installation. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 95 Tab. 19: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 96 Repair Cylinder head YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 97 Make sure that the following tools are available: – Turning device (For more information see: 4.1.1 Special tools, page 258.) Consumables and equipment Not applicable Overview Fig. 94: Task overview Exhaust side Admission side © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 98 10° Scratch traces Complete length 290° Dirt traces Center 2 cm 170° 200° Traces 80% of height Honing pattern visible Tab. 20: Example of note on endoscopy results © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 99 In case of shock or damage, always replace the torsional vibration damper. Special tools Special tool Designation Guiding rod M28 – Damper (x2) Locking device Tab. 21: Special tools Consumables and equipment – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 100 Using the turning device, rotate the torsional vibration damper so that the lifting thread is located at the top. (For more information see: 4.1.2 Turning device, page 261.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 101 Remove bolts 4 and disk 3. Fig. 101: Lifting thread location u Install lifting device on the lifting thread. u Remove screws 2. u Remove torsional vibration damper 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 102 Install locking device with screws (M16) to lock crankshaft. Fig. 103: Lifting thread location u Install lifting device on the lifting thread. u Lift torsional vibration damper 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 103 Tighten screws 2 to torque. u Position disk 3 and bolts 4. u Tighten bolts 4 to torque. u Remove locking device. Specific values Not applicable. Tightening specifications Fig. 104: Bolts sequence © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 104 The area around the sample openings is clean and free from engine oil and dirt. q Torsional vibration damper cover is removed. Specific safety instructions Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 105 – Sampling kit for silicon oil collection (sampling instructions, form, sample container, sample plugs, padded return envelope) Overview Fig. 106: Task overview Upper sample opening Lower sample opening © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 106 Remove the cap from the other end of the sample container. Information Place the sample container cap in a safe place. u Make sure that silicon oil flows from the torsional vibration damper into the sample container. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 107 Fill in the sample form delivered with the sampling kit. u Place the sample container and form into the padded envelope and send them for analysis. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 108 (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) Otherwise, refer to standard tightening torques. (For more information see: 5.3 Standard tight‐ ening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 109 3.8.1 Fuel return and venting pipes removal and installation Previous tasks q Close fuel supply. Specific safety instructions Not applicable. Special tools Not applicable. Consumables and equipment – Rags – Cleaner – Bucket for fuel © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 111 Connection from fuel return block to distributor block Fuel connection from high pressure Connection from permanent venting on system fuel filters Removal u Remove fuel return and venting pipes. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 112 (For more information see: 5.3 Standard tightening torques, page 268.) 3.8.2 High pressure pipes removal and installation Previous tasks q Release the pressure of the HP fuel system using KoDIA tool. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 113 Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools – Plugs for piping Consumables and equipment – Rags – Cleaner – Bucket for fuel © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 114 Fuel pipe Fuel pipe Retaining plate Screw (M10) Clamp Distributor block Fig. 114: Task overview Screw (M10) Clamp Clamp Screw (M10) Clamp Plate Holder Clamp Screw (M8) Clamp Clamp © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 115 Fig. 116: Removing high pressure piping u Remove screw 1 with retaining plate 6 and clamp 7. u Remove screw 3. u Remove distributor block 4. u Remove fuel pipes 2, 5. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 116 Remove screws 12. u Remove clamps 13, 14. Fig. 118: Removing high pressure piping u Remove fuel pipes 19, 20, 21, 22, 23 with flange joints 24. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 117 Install fuel pipes 19, 20, 21, 22, 23 with flange joints 24. Fig. 120: Installing clamps u Install clamps 13, 14 with screws 12. u Install clamps 9, 10, 17, 18,plate 16 and holder 11 with screws 8, 15. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 118 (For more information see: Tightening specifica‐ tions, page 118.) Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 119 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 120 Consumables and equipment – Rags – Cleaner Overview Fig. 123: Low pressure circuit piping Removal u Remove fuel supply pipes. Information Close all open connections with original plugs. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 121 Keep the engine away from heat, sparks, open flame, or any other ignition source. NOTICE Risk of property damage by reuse of sealing. Leaks by faulty seal. u Replace all sealings. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 122 – Engine oil – Castrol Optimol Paste White T Overview Fig. 125: Task overview Injector sleeve Screw (M12) Retaining plate Injector clamp Screw (M12) Collet Injector Adaptor High-pressure pipe © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 123 Disconnect HT sensor on both ends if installed. u Remove both adaptors from rocker arm housing. Fig. 127: Removing high-pressure pipe u Take off high-pressure pipe 5 from adaptor 9. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 124 Remove retaining plate 2 with screws 3. u Close all open connections with the matching plugs (available as replacement parts). Fig. 129: Removing clamp u Remove clamp 7 by opening screw 6. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 125 Remove injector 4 with extracting tool. Installation Fig. 131: Lubricating injector O-rings u Clean carbon from injector seat surface on injector sleeve. u Lubricate injector 4 O-rings with Castrol Optimol Paste White T. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 126 Fig. 133: Positioning injector and clamp Information Injectors can be mounted in two positions. Note that only one position is correct. Make sure the clamp is centered between valve springs. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 127 Pre-tighten high-pressure pipe 5 to torque. (For more information see: Tightening specifica‐ tions, page 128.) u Tighten high-pressure pipe 5 to torque. (For more information see: Tightening specifications, page 128.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 128 Put all parts in place and tighten by hand before following the sequence. Information Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) Fig. 137: Injector © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 129 *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 YY = Loctite 577 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 130 Consumables and equipment – Rags – Cleaner – Bucket for fuel Overview Fig. 139: Task overview Fuel filter Flange joint Flange joint Flange joint Flange joint Screw (M10) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 131 ± 5° 201AA EN 1665 M10x1.5x30-8.8-FLZN 1 25 Nm 18 ft-lb Tab. 28: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 132 – Rags – Cleaner – Bucket for fuel Overview Fig. 141: Task overview Fuel return block Distributor block Screw (M10) Screw plug Retaining plate Screw (M8) Screw (M8) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 133 Remove fuel pipings connected to HP fuel pump. Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 134 HP Fuel Pump Lifting Device Guiding rod M12 (x2) Tab. 29: Special tools Consumables and equipment – Vaseline – Oil – Castrol Optimol paste white T – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 135 Removal u Remove a first screw 3 and a second one diametrically opposed. u Place guiding rods in place of the two screws. u Remove remaining screws 3. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 136 Information Lubricate HP connection o-ring with Castrol Optimol paste white T. Lubricate shaft teeth and o-rings with engine oil. Fig. 146: Fuel pump O-rings u Place guiding rods. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 137 137.) u Install HP pump piping. u Perform the venting on the fuel circuit. Specific values Not applicable. Tightening specifications Fig. 148: Fuel pump tightening sequence © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 138 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 139 Charge air pipe – end segment (B bank) Screw (M10) O-ring Screw plug Pipe Connection piece Charge air pipe – middle segment (B O-ring bank) Gasket Screw plug Screw (M10) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 140 Previous tasks Not applicable. Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leaks by faulty seal. u Replace all sealings. Special tools Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 141 Screw (M10) Pipe Screw plug Clamp Screw (M10) Locking plate Screw (M10) Screw (M12) Screw (M10) Screw (M10) Distance sleeve See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 142 Fig. 152: Task overview - Without engine by-pass flap Compensator Fig. 153: Task overview - With engine by-pass flap O-ring Screw (M10) Engine by-pass flap Screw (M10) Flange joint Compensator © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 143 Remove compensator 3 with seals 2. u Remove screws 4, 11 with nuts 1. u Remove compensator 12 with seals 2. Fig. 155: Removing charge air lines © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 144 Remove screws 11. u Remove compensator 3 with seal 2. Fig. 156: Removing compensator - Without engine by-pass flap u Remove screws 11. u Remove compensator 23 with seals 2. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 145 Information At first, install the whole line without tightening the screws. Tighten all screws to torque at the end of installation, making sure that compensators are aligned evenly. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 146 Screw clamps 7, 22 with screws 9, 20, locking plates 8, and distance sleeves 21. Fig. 159: Installing clamps u Pretighten both screws 9 simultaneously to ensure Δ = Δ after tightening. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 147 Screw assembly to exhaust gas turbocharger with screws 16, distance sleeves 18, seal 2, and nuts 1. u Install screw plug 17. u Tighten screws 16 to torque. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 148 Fig. 162: Installing engine by-pass flap and compensator - With engine by-pass flap u Install engine by-pass flap 25 and compensator 29 with screws 27, 28 and o-rings 24. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 149 (For more information see: 3.12.1 Venting line removal and installation, page 200.) q Drain LT coolant circuit until level is lower than the base of the charge air coolers. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 150 Information Several adapted lifting devices are available. Follow the instructions manual of the hoisting beam, handling devices and the local safety regulations. For further information, please contact your nearest authorized Kohler service representative. Consumables and equipment – Vaseline – Rags ©...
Page 151 Remove screws 1, 2. u Remove charge air coolers 4. Installation u Insert o-ring 5 in charge air coolers 4. u Insert pipes 6 in aggregate support. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 152 1 60 Nm 44 ft-lb Tab. 32: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 153 Charge air system XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 154 NOTICE Risk of property damage by reuse of sealing. Leaks by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 155 Install straight air intake connections 2, 7 with nuts 1. u Install flanges 5, 8 with o-rings 6 and screws 4. u Install plugs 3 in straight air intake connections 2, 7. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 156 (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) 3.10.2 Exhaust pipes to turbocharger removal and installation Previous tasks q Disconnect application set exhaust system. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 157 Replace all sealings. Special tools Not applicable. Overview Fig. 169: Task overview Screw (M12) Nut (M10) Distance sleeve Turbocharger Support Turbocharger Exhaust elbow Screw plug Seal Washer Clamp segment © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 158 Position supports 3 with distance sleeves 2. u Tighten nuts 7 to torque. u Tighten screws 1 to torque. Specific values Not applicable. Tightening specifications Fig. 170: Exhaust pipes © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 159 After the temperature has cooled down to a level it can be touched, proceed with the tasks on the engine. NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 160 Fig. 171: Task overview Exhaust elbow Washer Exhaust gas turbocharger Screw plug Nut (M10) Distance sleeve Seal Retaining plate See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 161 Exhaust gas system Orifice plate Screw (M12) Fig. 172: Task overview Screw (M8) Compensator Cover O-ring O-ring Compensator Compensator Removal Fig. 173: Removing compensators u Remove screws 11. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 162 Remove compensators 14, 15, 17. u Remove cover 12. Fig. 174: Removing elbows u Remove screws 10, and distance sleeves 8. u Remove retaining plates 9. u Remove exhaust elbow 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 163 Install exhaust elbow 1, and seal 15 on turbocharger outlet. u Install retaining plates 9 with screws 10, and distance sleeves 8. u Tighten screws 10 to torque. u Repeat procedure for each exhaust elbow. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 164 Install compensators 14, 17 with screws 11, and o-rings 13. u Install compensator 15 with screws 11, and o-rings 13, 16. u Tighten screws 11 to torque. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 165 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 166 Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment – Hot temperature grease – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 167 Screw plug Distance sleeve Screw (M10) Removal Fig. 179: Removing turbocharger u Remove screws 1 and washers 2. u Open and loosen V-clamp 9. u Lift the turbocharger. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 168 Tighten screws 8 with applied distance sleeves 7 to torque. u Insert o-rings 10, 11 in turbocharger bracket. u Position V-clamp 9 on exhaust pipe outlets. u Lift the turbocharger. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 169 Install turbocharger cooling lines. (For more information see: 3.12.2 Turbocharger cooling lines removal and installation, page 206.) Information Vent coolant circuit at the end of installation. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 170 *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 YY = Loctite 577 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 171 Make sure that the following consumables and equipment are available: – Rags – Cleaner Overview Fig. 183: Task overview Flange joint Flange joint Pipe O-ring See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 172 Repair Exhaust gas system Clamp Pipe Plate Screw (M8) Screw (M8) Orifice Screw (M8) O-ring Distribution block Fig. 184: Task overview O-ring O-ring Flange Pipe Screw (M8) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 173 Remove screws 11. u Remove pipe 10, orifice 12, and o-ring 13. u Remove screws 6. u Remove distribution block 7 and o-ring 9. u Remove flange joints 1, 8. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 174 Assemble o-rings 17 on pipe 18 and place both flanges 15. u Insert o-rings 14 in both flanges 15. u Position assembly with screws 16 between both turbocharger brackets on oil supply connec‐ tion. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 175 Install plate 4 and clamps 3 with screws 5. u Tighten screws 5. Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 176 Fig. 189: Task overview Turbocharger bracket Bracket Washer Seal Screw (M16) Oil return pipe Holder O-ring Screw plug Screw (M8) Flange joint Screw plug Screw (M16) Cover Screw (M10) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 177 Fig. 190: Task overview Screw (M12) Screw (M12) Screw (M12) Holder Holder Removal Fig. 191: Removing holders u Remove screws 16, 17. u Remove holders 18. u Remove screws 19. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 178 Exhaust gas system u Remove holder 20. Fig. 192: Removing turbocharger brackets u Remove screws 7. u Lift off turbocharger bracket 1. u Remove screws 8. u Remove brackets 9. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 179 Fig. 193: Removing oil return pipes u Remove screws 13. u Remove oil return pipes 11. u Remove cover 15. Installation u Install brackets 9 with screws 8 on turbocharger bracket 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 180 Tighten screws 13 to torque. Fig. 195: Installing turbocharger brackets u Install screw plugs 5, 14 and flange joint 6. u Screw turbocharger brackets 1 with screws 7 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 181 (For more information see: 3.10.3 Turbocharger removal and installa‐ tion (SL 213), page 166.) q Remove turbocharger bracket. (For more information see: 3.10.5 Turbocharger brackets removal and installation, page 176.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 182 Not applicable. Consumables – Hot temperature grease – Rags Overview Fig. 197: Task overview Compensator V-clamp Seal Removal u Loosen V-clamps 3. u Remove compensators 1 with seals 2. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 183 268.) Exhaust pipes removal and installation Previous tasks q Remove exhaust gas turbocharger. (For more information see: 3.10.3 Turbocharger removal and installation (SL 213), page 166.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 184 – Hot temperature grease – Rags Overview Fig. 199: Task overview Seal Plug Outlet manifold Outlet manifold Screw (M10) Outlet manifold Seal V-clamp Sealing ring Compensator Plug Outlet manifold Sealing ring © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 185 Place outlet manifolds 2, 13 with seals 1 and screws 3. u Tighten plugs 6, 8, V-clamps 11, and screws 3 to torque. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 186 Fig. 200: Exhaust pipe screws tightening sequence Fig. 201: Exhaust pipe screws and plugs Torque Angle (°) Screw specifications ± 5% ± 5° 410AA DRW 10123168 M10x1.5x80-C3J 1 20 Nm 15 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 187 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 188 Wait until the engine has cooled down. Special tools Not applicable. Consumables and equipment Not applicable. Overview Fig. 202: Task overview Clamp Screw (M8) Hose Screw (M12) Clamp Hose © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 189 Installation Fig. 204: Installing hoses u Install hoses 2, 6 with clamps 1. u Install clamp 3 with screws 4, 5 on hose 6. u Tighten clamps 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 190 3.11.2 Oil centrifuge removal and installation (depending on application) Previous tasks q Drain engine oil. Specific safety instructions Not applicable. Special tools Not applicable. Consumables and equipment – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 191 Remove oil centrifuge base 7 from oil centrifuge 1. u Remove screws 16. u Remove flange 17 with pipe 19. Installation u Install o-rings 20 on pipe 19. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 192 *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 YY = Loctite 577 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 193 Spin-on oil filter Seal Filter head Removal u Clean sealing area. u Open spin-on oil filter 1 with filter wrench. u Remove filter. u Repeat procedure for all filters. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 194 Leaks by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment Make sure that the following consumables and equipment are available: – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 195 Remove by-pass valve 1. Installation u Insert by-pass valve 1. u Tighten by-pass valve to torque. Specific values Not applicable. Tightening specifications Fig. 209: Oil cooler by pass valve © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 196 268.) 3.11.5 Prelubricating pump removal and installation (option) Previous tasks q Drain engine oil. Specific safety instructions Not applicable. Special tools Not applicable. Consumables and equipment – Rags © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 197 Remove screws 4, distance sleeves 5 and nuts 6. u Remove holders 7. Installation Information Do not install relay 11 on the engine. u Install holders 7 with screws 4, distance sleeves 5 and nuts 6. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 199 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 200 Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment – Rags – Cleaner – Loctite 243 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 201 Venting LT charge air cooler Flange joint Flange joint Venting LT charge air cooler Venting HT thermostat T connector Venting LT turbocharger Screw (M10) Venting HT collecting pipe Distribution block © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 202 Repair Cooling system Fig. 213: Task overview Screw (M8) Holder Screw (M6) Holder Clamp Holder Nut (M6) Holder Holder Holder Distance sleeve Fig. 214: Task overview Venting line © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 203 Fig. 216: Removing venting lines u Remove clamps 14 with screws 13, and nuts 15. u Remove holders 16, 18, 19, 20, 21, 22 with screws 5, 12, and distance sleeve 17. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 204 Fig. 217: Removing venting lines u Remove venting pipes 1, 3, 7, 9, 10, 11. u Remove screws 5. u Remove distributor block 6. Installation Fig. 218: Installing venting lines © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 205 Install clamps 14 and holders 16, 18, 19, 20, 21, 22 with screws 5, 12, 13, distance sleeve 17 and nuts 15. Information Use Loctite 243 only for screw 13 in holder 19. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 206 (For more information see: 3.12.1 Venting line removal and installation, page 200.) Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 207 Distance sleeve Pipe Screw (M8) Retaining plate Screw (M8) Fitting Retaining plate Fitting Screw (M8) Retaining plate Flange joint Screw (M8) T connector Pipe Pipe Pipe Screw (M10) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 208 Aggregate support connector T connector 40 Screw (M10) Pipe Retaining plate Screw (M10) Plug Pipe Removal Turbocharger coolant supply Fig. 223: Removing pipes u Remove screws 1, 7, 19. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 209 Remove aggregate support connector 39. u Unscrew connection nuts of pipes 33, 36, 37, 43. u Remove pipes 33, 36, 37, 43. u Disconnect fittings, flange joints and connectors. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 210 Install plugs 35 with nuts 34 on T connectors 12, 29 and flange joint 11. u Install retaining plate 41 with screws 42. u Install plates 2 with clamps 3 and screws 1. u Tighten screws 1 to torque. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 211 Install plates 2 and clamps 3 with screws 1, 7. u Tighten screws 1 to torque. u Screw retaining plates 21, 24 with screws 8, 25. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 212 (For more information see: 3.12.1 Venting line removal and installation, page 200.) Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 213 Aggregate support connector Pipe Screw (M10) Pipe Screw (M8) Distance sleeve Retaining plate Screw (M8) Pipe Screw (M8) Fitting Clamp Retaining plate Screw (M8) Fitting Retaining plate Pipe Adaptor © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 214 Plug Pipe Coupling Retaining plate Flange joint Pipe T connector Screw (M10) Pipe 48 T connector Pipe Removal Fig. 230: Removing pipes u Remove screws 1, 9, 21. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 215 Remove retaining plates 45. u Remove screws 16, 41 u Remove aggregate support connector 40. u Loosen connection nuts of pipes 32, 33, 37, 38, 42, 46. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 216 Install fittings 28. u Install plug 43 and nut 44. u Install retaining plates 45 with screws 47. u Install plates 2 and clamps 3 with screws 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 217 Install plate 2 and clamps 3 with screws 21. u Install retaining plate 25 with screws 5. u Install plates 2 and clamps 3 with screws 1. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 218 3.12.3 Thermostat HT and housing removal and installation (SL 217) Previous tasks q HT coolant circuit drained. Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 219 Screw (M10) Thermostat housing O-ring Screw (M12) Pipe O-ring Removal u Remove two screws 4 diametrically opposed. u Place guiding rods in place of the two screws 4. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 220 Make sure that the following preconditions are met: q LT coolant circuit is drained. q Venting line LT charge air cooler is removed. (For more information see: 3.12.1 Venting line removal and installation, page 200.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 221 Make sure that the following consumables and equipment are available: – Vaseline – Rags – Cleaner Overview Fig. 237: Task overview LT thermostat Flange Thermostat housing Screw (M10) Screw (M12) O-ring O-ring Pipe © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 222 (For more information see: 5.3 Standard tightening torques, page 268.) 3.12.5 Coolant pump HT removal and installation (SL 216) Previous tasks q Drain HT coolant circuit. q Remove machinery HT cooling system piping. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 223 Tab. 45: Special tools Consumables and equipment – Rags – Cleaner – Vaseline Overview Fig. 239: Task overview Screw (M12) O-ring See next page for continuation of the image legend © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 224 Position assembly with screws 1, 5 and tighten according to tightening specifications. u Install test point fitting 8 on coolant pump. Information Vent coolant circuit at the end of installation. Specific values Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 225 Make sure that the following special tools are available: – Guiding rod M12x100 - coolant pump (x2) Consumables and equipment Make sure that the following consumables and equipment are available: – Rags – Cleaner – Vaseline © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 226 Branch pipe O-ring O-ring O-ring O-ring O-ring Pipe Coolant pump LT Screw (M10) Screw Fig. 241: Task overview O-ring O-ring Flange Elbow pipe O-ring Screw (M12) Screw (M10) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 227 3.12.7 Fan drive (option) Previous tasks q Remove vibration damper cover. (For more information see: 3.4.1 Vibration damper cover removal and installation, page 58.) Specific safety instructions Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 228 Special tool Designation Locking device Tab. 46: Special tools Consumables and equipment – Rags – Cleaner Overview Fig. 243: Task overview Screw (M16) Screw (M28) Washer Axle Pulley © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 229 Fig. 245: Removal of fan drive pulley u Remove screws 1, and washers 2. u Remove pulley 3. u Remove screws 4. u Remove axle 5. u Remove locking device. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 230 Install locking device with screws (M16) to lock crankshaft. Fig. 247: Installation of fan drive pulley u Install axle 5 with screws 4. Information Observe screws 4 tightening sequence and tightening torque. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 231 Install pulley 3 with screws 1, and washers 2. u Tighten screws 1 to torque. Specific values Not applicable. Tightening specifications Fig. 248: Tightening sequence of pulley axle screws Fig. 249: Screws of fan drive pulley © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 232 O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 233 Special tools Special tool Designation Pin for belt tensioner (x1) Frequency meter Tab. 48: Special tools Consumables and equipment – Vaseline – Rags – Belt tension frequency meter © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 234 Screw (M10) Screw (M10) Tensioning device Retaining plate Screw (M10) Washer Washer Screw (M12) Screw (M10) Screw (M8) Screw (M12) Roller Distance sleeve (EATS only) O-ring Sleeve O-ring © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 235 Remove belt 13. u Remove guiding rod. Fig. 253: Removing battery charging alternator u Remove screws 4, 18. u Remove battery charging alternator 1. u Remove distance sleeve 20. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 236 Remove screws 7. u Remove auxiliary PTO 12. u Remove o-rings 10, 11. Fig. 255: Removing tensioning device u Remove screw 14. u Remove tensioning device 15. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 237 Installation Fig. 257: Installing auxiliary PTO u Grease o-rings 10, 11. u Insert o-rings 10, 11 in auxiliary PTO 12. u Install auxiliary PTO 12 with screws 7. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 238 Fig. 259: Installing roller u Install roller 9 on plate 5. u Install plate 5 with screws 7, 8, 16 and washers 6, 17. u Tighten roller 9 to torque. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 239 Install belt 13 on the PTO pulley. u Remove the guiding rod. u Use the ratchet wrench in tensioning device 15 to tension belt 13. u Check belt 13 tension. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 240 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) 3.13.2 Starter removal and installation (SL 260) Previous tasks Not applicable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 241 Unplug wiring harness connection 3. u Remove nut from ground connection 1. u Disconnect ground cable 6. u Remove nut from power supply 5. u Disconnect power supply cable. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 242 30 Nm (22 ft-lb) Tab. 50: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 243 – Not applicable. Special tools – Not applicable. Consumables and equipment – Not applicable. Overview Fig. 265: Task overview Starter Screw (M16) Removal u Disconnect starter electrical connections. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 244 ± 5% ± 5° 450AA ISO 4762 M16x2x35-10.9-FLZN 1 180 Nm (133 ft-lb) 1 9.5 Nm 7 ft-lb 1 1.6 Nm 1 ft-lb Tab. 51: Tightening specifications table © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 245 (For more information see: 5.3.2 Screws pre-tightening, reuse, and marking, page 268.) ***± 25% Accuracy is accepted. For more information about sensors location, refer to the “Electrical Wiring Diagram” manual. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 246 Replace all sealings. Special tools Not applicable. Consumables and equipment Make sure that the following consumables and equipment are available: – High temperature grease – Rags – Cleaner © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 247 Nut (M8) Information The design of the diesel exhaust fluid injector and its installation method may vary depending on application. Contact your nearest authorized Kohler service representative for up-to-date information about the installation method. Removal Information Always make sure that dust is prevented from going into the system.
Page 248 Remove injector 7, and mounting plates 4, 8 together as an assembly. Information Prevent top screw 2 from falling down. u Remove screws 2. u Remove front mounting plate 8 from injector assembly. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 249 Assemble injector 7, and back mounting plate 4 with v-clamp 5. Information Make sure that gasket 6 is located between back mounting plate 4 and injector 7. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 250 Apply high temperature grease to the threads of screws 2. u Install top screw 2 on front mounting plate with nut 10, and washer 9. u Install new gasket 3 at the back of injector assembly. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 251 If the feeler gauge can be inserted between dosing cover 1 and back mounting plate 4, loosen nuts 10, then push the injector assembly further while retightening nuts 10. u Tighten nuts 10 to 17 Nm (13 ft-lb)-20 Nm (15 ft-lb). © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 252 3.14.2 Diesel exhaust fluid pump removal and installation (SL2-5340) Previous tasks Make sure that the following preconditions are met: q Engine is switched off. q Exhaust gas aftertreatment system is drained. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 253 Not applicable. Consumables and equipment Not applicable. Overview Fig. 275: Task overview Diesel exhaust fluid pump Connection (M26) Screw (M10) 10-pin connector Lifting hook 48-pin connector Connection (M22) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 254 Repair Exhaust gas aftertreatment system (depending on configuration) Removal Fig. 276: Securing pump u Using lifting hooks 3, secure pump 1 to a crane. Fig. 277: Disconnecting connectors © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 255 Disconnect 48-pin connector 7. u Disconnect connectors 4, 5 of the diesel exhaust fluid lines. Fig. 279: Removing screws u Remove screws 2. u Remove pump 1. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 256 Nm (26 ft-lb). ±5 ±4 u Connect 48-pin connector 7 to pump 1. u Tighten the fastening screws of 48-pin connector 7 to 4 Nm (3 ft-lb). ±0.5 ±0 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 257 Run the system for 30 minutes to confirm successful priming and leak-free operation. Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 268.) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 258 230611637 Locking device 11343230 230612868 Guiding rod M30x2 - Cylinder head 11133371 230610035 Guiding rod M28x2 - Damper 11133372 230610036 Guiding rod M24x2 - Intermediate gear 11133373 230610037 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 259 Guiding rod M12 - Oil cooler 11133377 230610040 Guiding rod M10 - Exhaust line 11133379 230610041 Guiding rod M12 coolant pump 12427300 230610042 Guiding rod M12 Thermostat 12465862 230611638 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 260 230612680 Torque Reaction Arm for Manual Torque 12227989 230612681 Multiplier Spare Battery pack 12226992 230612682 Battery Charger 110V 12226970 230612683 Battery Charger 230V 12226972 230612684 Adapter 11343096 230612685 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 261 Using the turning device can lead to injuries to personnel working on the engine! u Before using the turning device, prevent the personnel in the vicinity of the engine and get confirmed they stand in a secure area. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 262 Remove cover 3. u Position turning device 2. u Mount and tighten screws 1 according to standard torques values. Information For queries, please contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 263 To dismount the turning device: u Unscrew screws 1. u Remove turning device 2. u Position cover 3. u Mount and tighten screws 4 according to standard torques values. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 264 Tools and devices Tools Information For queries, please contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 266 Information The technical design documents are specific to the delivered engine. Using those documents for other engines is forbidden. For inquiry, please contact your nearest authorized Kohler service representative. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US...
Page 267 1000 / 33.8 Molykote Staburags NBU 30 1200 / 40.6 Kübler Copper Paste; Motorex 14 850 / 28.7 Motorex Optimol White T 100 / 3.4 Castrol Tab. 55: Greases © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 268 Unless otherwise noted, use the standard torque values into the column of screws quality class “8.8” to tighten screws and bolts. The screws quality classes “10.9” and “12.9” are always indicated with the “Nm” symbol. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 269 For every maintenance task, when a sequence is specified, achieve step 1 for all the sequence before starting step 2. Fig. 307: Standard sequence for four, five, and six screws. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 270 Except components listed below, and otherwise noted, u Marking on screws or nuts to track their reuse is not required. Fig. 308: Examples of markings on screws and HP pipe nut © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 271 100 Nm 110 Nm 52 ft-lb 55 ft-lb 74 ft-lb 81 ft-lb 165 Nm 183 Nm 240 Nm 270 Nm 122 ft-lb 135 ft-lb 177 ft-lb 199 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 272 – Hexagon head screw plugs with collar - Cylindrical thread according to DIN 910 – Internal drive screw plugs with collar - Cylindrical thread according to DIN 908 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 273 240 Nm M 65 x 2 620 Nm 52 ft-lb 177 ft-lb 457 ft-lb Tab. 60: Tightening torques for screws according to DIN 7643, DIN 910, DIN 908 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 274 540 Nm 260 Nm 214 ft-lb 465 ft-lb 398 ft-lb 192 ft-lb Tab. 61: Standard torques for metric thread unions L series, for steel and iron cast part © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 275 According to ISO1179-1 / DIN 3852-T2-Form X / DIN 3852-T3-Form X BSP threading. Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 277 432 Nm 208 Nm 171 ft-lb 372 ft-lb 319 ft-lb 153 ft-lb Tab. 65: Standard torques for metric thread unions L series, for aluminium – see figure above © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 278 According to ISO1179-1 / DIN 3852-T2-Form X / DIN 3852-T3-Form X BSP threading. Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 280 Fig. 324: Cutting ring lubrication Information Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). Fig. 325: Cutting ring tightening © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 281 5/16 1/2-20 20 Nm 40 Nm 15 ft-lb 30 ft-lb 9/16-18 30 Nm 60 Nm 22 ft-lb 44 ft-lb 3/4-16 60 Nm 115 Nm 44 ft-lb 85 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 282 Tolerances of the indicated tightening torques: 10%. Always lubricate the thread before tightening these parts (engine oil). Fig. 327: VSTI screw plugs with ED seal (left), with o-ring (right) © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 283 Tab. 71: VSTI screw plug tightening torques for steel and iron cast parts Do not use hydropneumatic screwdriver. 5.3.10 Standard torques for VSTI screw plugs for aluminium According to DIN EN ISO 6149-2 / ISO 11926-2, metric threading. © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 284 127 ft-lb M33x2 180 Nm 250 Nm 133 ft-lb 184 ft-lb M42x2 290 Nm 265 Nm 214 ft-lb 195 ft-lb M48x2 290 Nm 335 Nm 214 ft-lb 247 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 285 Alternatively, refer to the following table for tightening sequence of the nut: Size Equivalent specification Size Equivalent specification 20 Nm 25 Nm 15 ft-lb 18 ft-lb 30 Nm 40 Nm 22 ft-lb 30 ft-lb © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 286 5 ft-lb 25 mm 12 Nm 0.98 in 9 ft-lb 30 mm 30 Nm 1.18 in 22 ft-lb Tab. 74: Tightening torques for collar clamps according to DIN 3017-3 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 287 148 ft-lb 168 mm (6.61 in)-220 mm (8.66 in) 180 Nm 350 Nm 133 ft-lb 258 ft-lb Tab. 75: Tightening torques for pipe clamps according to DIN 3015 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 288 Top Dead Center Top Dead Center Volume Control Valve Volume Control Valve Tab. 76: Abbreviations table Acronym Designation Translation ANSI American National Standards Institute American National Standards Institute © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 289 International Standard Classification of International Standard Classification of Education Education Society of Automotive Engineers Society of Automative Engineers World Health Organization World Health Organization Tab. 77: Acronyms table © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 290 Tab. 80: Pressure conversion factors 5.5.4 Volume conversion factors Convert from Multiply by 61023.744 35.315 Imperial gallon 219.969 US gallon 264.172 l (liter) 1000 Tab. 81: Volume conversion factors © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 291 F = 9/5*C + 32 °C K = C + 273.15 Tab. 86: Temperature conversion factors 5.5.10 Density conversion factors Convert from Multiply by Kg/m lb/US gallon 0.00834 Kg/m lb/imperial gallon 0.01002 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 292 Tab. 90: Pressure conversion factors table 5.5.14 Volume conversion factors Convert from Multiply by 61023.744 35.315 Imperial gallon 219.969 US gallon 264.172 l (liter) 1000 Tab. 91: Volume conversion factors table © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 293 °C K = C + 273.15 Tab. 96: Temperature conversion factors table 5.5.20 Density conversion factors Convert from Multiply by Kg/m lb/US gallon 0.00834 Kg/m lb/imperial gallon 0.01002 © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 294 Appendix Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 97: Density conversion factors table © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...
Page 295 Appendix Prefix 5.6 Prefix Name Symbol Factor tera giga mega kilo milli micro μ nano Tab. 98: Common prefix multipliers table © 2022 by Kohler Co. All rights reserved. KD62V12 33525088601_8_1 EN_US 2022-09...

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