Kohler KD27V12 Service And Repair Manual

Hide thumbs Also See for KD27V12:

Operation and maintenance manual (112 pages)

Operation and maintenance manual (118 pages)

Table Of Contents

100

101

102

103

104

105

106

107

108

109

110

111

112

113

114

115

116

117

118

119

120

121

122

123

124

125

126

127

128

129

130

131

132

133

134

135

136

137

138

page of 138

/ 138
Contents
Table of Contents
Bookmarks

Table of Contents

Quick Links

Download this manual

Service and Repair Manual

(Translation of the original Service and Repair Manual)

Diesel engine

KD27V12

from serial number 2016 16 0001

33525087701_1_1

12-2016

Table of Contents

Need help?

Do you have a question about the KD27V12 and is the answer not in the manual?

Questions and answers

Summary of Contents for Kohler KD27V12

Page 1 Service and Repair Manual (Translation of the original Service and Repair Manual) Diesel engine KD27V12 from serial number 2016 16 0001 33525087701_1_1 12-2016...
Page 2 California Proposition 65 Engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. California Proposition 65 This product contains and/or emits chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Page 3 The Operating Manual facilitates the operator's familiarization with the diesel engine and prevents faults through incorrect operation. Kohler Co. will not allow any warranty claims that arise due to incorrect operation, insufficient maintenance, use of unapproved operating fluids or non-compliance with safety regulations.
Page 4 (65) 6264-6455 Bangalore, India TEL.: (91) 80 3366208 (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Agency Tokyo, Japan TEL.: (813) 3440-4515 Fax: (813) 3440-2727 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 7: Table Of Contents
General engine data......................2-28 Fuel scheme ..........................2-33 Lubricant scheme .......................... 2-34 Coolant scheme..........................2-36 2.6.1 Overall system - engine with accessory cooler ............... 2-36 Engine electrics ..........................2-38 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 5 KD27V12...
Page 8 Fitting and removing the rail ......................5-74 Fitting and removing the pressure adapter and injector ..............5-75 5.5.1 Removing ........................5-78 5.5.2 Fitting..........................5-81 Fitting and removing the high pressure pump ................5-84 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 9 10.1.4 Standard torques for cutting ring flange joints............. 10-122 10.1.5 Standard torques for Triple Lock flange joints............. 10-123 10.1.6 Standard torques for VSTI screw plugs............... 10-124 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 7 KD27V12...
Page 10 10.2 Detergents, plumbing lacquers and greases ................10-125 10.3 Tools ............................10-126 10.3.1 Special tools ........................ 10-126 10.3.2 Special tools with order number .................. 10-128 10.4 Terms used (glossary) ....................... 10-132 10.5 Abbreviations used ........................10-133 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 11: Safety
The work on engines, equipment as well as mechanical and electronic equipment includes: • Operating the machine and facilities • Performance of scheduled maintenance work • Assembly, installation, assessment, adjustment, testing and maintenance © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 9 KD27V12...
Page 12: Unauthorized Personnel
Taking readings from charts, meters and gages at established intervals, troubleshooting and performing correc- tive action as necessary • Completing and maintaining station records, logs and reports, and communicating with other plant personnel to assess the equipment operating status © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 13: Intended Use
The employment of personnel who do not satisfy the requirements in accordance with Target audience, page • Alterations and conversions of the Diesel engine that have been carried out without the consent of Kohler Co. • Operating and auxiliary materials that have not been approved by Kohler Co. •...
Page 14: General Safety Instructions
Make sure that the workplace is well lit. • Only perform assembly work if the diesel engine has been secured. • Ensure that the diesel engine is not started by unauthorized persons. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 15: Preventing Personal Injuries
Fasten and secure individual parts and larger assemblies carefully with suitable lifting gear during their replace- ment. • Use Kohler lifting gear in accordance with the repair instructions. • Observe the regulations on the lifting points. For additional information see 2-47.
Page 16: Electrical Energy
1-9. However, if a technician has to approach an unprotected engine for troubleshooting work he must wear hearing protection suitable for the noise level. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 17: Personal Protective Equipment
• Wear safety goggles during mechanical operations. (For example when using compressed air) Hearing protection Protection against noise • Wear hearing protection near running engines. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 15 KD27V12...
Page 18: Operating And Maintenance Areas
142878 Item Description Safety zone, unit carrier side Safety zone next to engine Safety zone, flywheel side Safety zone, above engine Safety zone, below engine © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 19 Maintenance areas Fig. 2 Safety zones during maintenance and repairs 142877 Item Description Safety zone, unit carrier side Safety zone next to engine Safety zone, flywheel side © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 17 KD27V12...
Page 20: Secure And Release The Diesel Engine Against Unexpected Starting
• Make sure that no external persons stand or walk in the danger zones. • Remove the label from the electrical power supply. • Establish the electrical power supply. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 21: Emergency Stop
The preceding required signs must be able to withstand the ambient conditions. The end user must ensure that these are kept visible and legible over the entire life cycle. Additional warnings or adaptations to product standards (ISO 8528-13) are possible. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 1 - 19...
Page 22: Preventing Material Damages
Make sure the engine is switched off before disconnecting the electrical power supply. • Use suitable test leads for measurements at plug connections. • Protect the engine control unit against dust and water if no mating plug has been connected. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 23: General Information
Various icons are used in the images and texts in these instructions. The icons are explained on the following pages. Interactive cross-references and links are identified by blue text. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 21 KD27V12...
Page 25: User Guidance
10-115. The information in this data sheet does not release the user from their duty to conduct their own assessments and checks. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 23...
Page 26: Engine Illustrations And Engine Parts
Charge air connecting line to charge air cooler Coolant connection to coolant cooling Exhaust gas stub Battery charging alternator Intake stack Fuel filter Exhaust gas turbocharger Crankcase breather Exhaust manifold Fan drive Cylinder head cover © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 27 Overview of flywheel side 143152 Oil cooler Fastening point for hand drive Oil filter Flywheel Oil filler inlet Flywheel housing Oil dipstick Flywheel sensor Oil drain © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 25 KD27V12...
Page 28 Service and Repair Manual Engine illustrations and engine parts Gear train Fig. 4 Gear train 143354 Clock wheel Gear Gear - camshaft Flywheel Gear Gear - crankshaft HP pump drive Oil pump © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 29: Signs
Please refer to 2-47 for safety instructions and the procedure. Keep the hang tag together with the device documentation if it is not used. Fig. 5 Raise the diesel engine hang tag © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 27 KD27V12...
Page 30: Notice Signs
27 l (1648 cubic inch) = V12 V-engine No. of cylinders: Engine type plate Fig. 7 Engine type plate The engine type plate is attached to the left side of the crankcase, Fig. 8. CODE © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 31 ENGINE POWER (kW/min.-1 ) CONFIGURATION POWER CATEGORY The engine serial number is stamped into the crankcase Fig. 10 Engine serial number on crankcase joint face to the cylinder heads © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 29 KD27V12...
Page 32 The notch in the flywheel must be flush with the tip of the plate in the flywheel housing (arrows). Injector code Fig. 13 Injector code The injector code is attached in the area marked by the ar- row. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 33 The HP pump type plate is attached to the HP pump hous- ing. Exhaust gas turbocharger type plate Fig. 15 Exhaust gas turbocharger type plate The exhaust gas turbocharger type plate is attached to the compressor housing. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 31 KD27V12...
Page 34 ECU ID: 12345678 Certﬁcation ID: 12345678 Dataset ID: 12345678 DD.MM.YYYY Thermostat start of opening Fig. 17 Thermostat The thermostat opening is engraved in the area marked by the arrow. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 35: Fuel Scheme
High pressure sensor Common rail Fuel fine filter Injectors Distributor block Integrated pressure limiting valve (PCV) Engine control unit Throttle Device side Fuel air cooler (optional) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 33 KD27V12...
Page 36: Lubricant Scheme
Oil pressure sensor Oil pump Camshaft Anti-drain valve Piston cooling Pressure limiting valve (cold start) Con rod Pressure limiting valve Rocker arm bracket Oil cooler Turbocharger Pressure limiting valve Oil module © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 37 Cylinder head Crankcase breather Camshaft bearing Oil intake Exhaust gas turbocharger Pressure limiting valve (cold start) Crankshaft bearing Oil pump Cylinder head cooling Pressure limiting valve © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 35 KD27V12...
Page 38: Coolant Scheme
Thermostat housing with two thermostats Oil cooler Coolant manifold Temperature sensor Restriction in coolant manifold Central water return Baffle Heated coolant Temperature sensor Cooled coolant Water cooler Ventilation Coolant ventilation © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 39 Cooled coolant Permanent ventilation Return from cylinder head Coolant manifold Cylinder head Feed to cylinder head Feed from water cooler Return from water cooler Water pump © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 37 KD27V12...
Page 40: Engine Electrics
Overview of sensors and actuators (with operating materials designation) B702 B708 B713 B701 B751 B709 Y737 Y731 Y738 Y732 Y739 Y733 Y740 Y734 Y741 Y735 Y742 Y736 Y707 Y705 Y704 Y708 Y703 B704 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 41: Function Of Battery Charging Alternator
Field controller ..........DF controls the strength of the magnetic field. Alternating current ........... The actual speed can be determined from the frequency of the alternating current signal. This function is not used. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 39...
Page 42 Maxi. permissible voltage drop between battery charging alternator and battery 0.5 V, at 140 A. • Use a short cable if possible. • All cable contacts are free from grease and varnish. Protect against oxidation. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 43 Option 2 ............The exciting current is limited by the resistor. Voltage monitoring is the feedback that excitation is taking place. Battery charging alternator Ignition Battery + Earth © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 41 KD27V12...
Page 44: Starter Function
24V DC 24V DC 143315 Item Description Starter relay Piston Holding coil Pull-in coil Pinion Slider Gearbox with overspeed clutch Starter stator winding Starter rotor winding Collector Starter crown gear © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 45 (1). • No more current flows to the holding coil (3). • The pinion (5) is withdrawn from the starter gear ring (11). 143317 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 43 KD27V12...
Page 46: Breakdown Of Cable Names Acc. To Wiring Diagram
Definition of the type of element in question Reference in the wiring diagram Connector Reference identifier acc. to standard: Control unit, assemblies Sensor Heater Fuse Generator (battery charging alternator) Relay © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 47 Source - acc. to wiring diagram Target - connector Source - connector Target - pin on connector Source - pin on connector Crimp contact Target (operating materials description) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 45 KD27V12...
Page 48: Arrangement Of Channels In The Crankcase And Cylinder Head
Arrangement of channels in the crankcase and cylinder head 140653 Air intake pipe side Push rod Exhaust pipe side Oil feed (pressure oil) Cylinder head screw Combustion chamber Coolant return Straight pin Coolant feed Oil return © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 49: Transport Stand And Fastening Pieces
Pay attention to the safety instructions / warnings in the operating instructions for the hoisting beam. • Observe any national and international guidelines on lifting heavy loads. Fig. 34 Lifting device max.10° max.10° max.6° max.6° 142532 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 47 KD27V12...
Page 50: Fitting And Removing Fastening Pieces
Tolerance for maximum deviation from the horizontal 2.10.1 Fitting and removing fastening pieces Fig. 35 Fastening pieces 142870 Item Description Work instructions Ring bolt Lifting hook Hex screw M12x80, 10.9 ......... see tightening instructions © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 51 Hex screw M12-10.9 Fig. 36 Lifting hook Lubricant Plumbing lacquer Component contact surfac- degreased Can the screws be reused? Step Torque 104 ±20 Nm (76.7 ±14.7 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 49 KD27V12...
Page 52: Transporting The Diesel Engine
DANGER Instability during transportation of the Diesel engine. Mortal danger. • Use the original transport stands used during the delivery by Kohler Co. • Secure the transport stand with mounted engine against slipping and toppling over during transporta- tion. DANGER Protective atmosphere against damage by oxidation inside the protective film.
Page 53: Fastening During Transport
Make sure that cranes or fork-lift trucks are designed for the weight to be lifted. • If a crane is used: Use the Kohler Co. hoisting beam, see 2-47. • Make sure that there are no persons within the danger zones during loading and unloading.
Page 54: Steel Transport Stand
Instability during transportation of the Diesel engine. Mortal danger. • The Diesel engine must be securely bolted to the transport stand. Information Return the steel transport stand to Kohler Co. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 55: Wooden Transport Stand
Mortal danger. • The Diesel engine must be securely bolted to the transport stand. Information Wooden transport stands do not have to be returned to Kohler Co. Keep for later use. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016...
Page 56: Starting The Engine
If the engine does not start after repeated attempts: make sure that all of the connections are correct and that there are sufficient operating materials. Troubleshooting with the KODIA diagnostic program. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 57: Final Check
Perform a visual check for any leaks in the lines. • Check the error messages in the KODIA diagnostic program. • Check for error messages on the device side. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 2 - 55 KD27V12...
Page 59: Cylinder Head, Engine Control Unit And Valves
Tighten cable to injector, Nm see tightening instructions. • Fix cable bushing with knobs (4) to the two socket head screws of the rocker arm bracket. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 3 - 57 KD27V12...
Page 60 Apply the tightening torque shown in the tightening instructions! Hexagon nut M4 (5) Lubricant Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque 1.2 +0.2/0 Nm (0.88 +0.15/0 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 61: Checking And Setting The Valve Clearance
Checking and setting the valve clearance Previous work: Remarks Cylinder head cover removed ......3-57 Fig. 42 Valve setting 143333 Item Description Allen key Torque wrench Feeler gage Special tool © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 3 - 59 KD27V12...
Page 62 5 - 6 - 7 - 10 TDC +540° 5 - 6 - 7 4 - 8 Setting position "TDC" • Fit the turning device [10123791]. Fig. 44 Turning device © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 63 Check the setting again. • After checking and/or setting all valves, install cylinder head cover with inspected, undamaged seals. • Remove the turning device, see Fig. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 3 - 61 KD27V12...
Page 65: Power Unit
Damage to the camshaft gasket. • Two mounting bolts, use special tool [0528470]. • When removing the viscous damper make sure that the parts behind this do not move too. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 4 - 63 KD27V12...
Page 66 Remove the special tools [0528470] Fig. 47 Pos. 3, 4. • Fit the remaining hexalobular screws and tighten hand tight. • Tighten all of the hexalobular screws according to the tightening instruction. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 67: Fuel And Injection System
Pay attention to the utmost cleanliness when working on removed components. • Use fresh cleaning fluids. • If removed components have to be sent anywhere: always use the original packing of the "new" part. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 65 KD27V12...
Page 68: Fitting And Removing The Fuel Lines
Fuel line before fuel fine filter Fuel line after fuel fine filter Connection between fuel fine filter and engine control unit Connection between engine control unit and feed pump © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 69 Connection between engine control unit and feed pump Fuel supply Information Vent the fuel system after installing the relevant fuel line, see Operation and Maintenance Manual. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 67 KD27V12...
Page 70: Fuel Lines - Return And Permanent Ventilation
Hollow screw 10-3 ..........Replace sealing ring Clamp Fuel return line Banjo bolt 10-6 ..........Replace sealing ring Fuel return line Hollow screw 10-6 ..........Replace sealing ring Fuel return line © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 71 Hollow screw ........... Replace sealing ring Spacer Fuel return line Information Vent the fuel system after installing the relevant fuel line, see Operation and Maintenance Manual. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 69 KD27V12...
Page 72: Fitting And Removing The Injection Line
Nm, see tightening instruction High pressure rail Clamp Hex screw M8x45 8.8 Marking on box nut .......... see tightening instructions Box nut, width A/F 17 ........Nm, see tightening instruction © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 73 30 Nm (22 ft lb) Hex screws M8x16-8.8 (3) Lubricant Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque hand tight 23 Nm (17 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 71 KD27V12...
Page 74: Removing
Replace box nuts that already have two punch marks. • Release the box nut and remove the injection line. • Affix a protective cap immediately on all open connec- tions. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 75: Fitting
Tighten the box nut (1) to the final torque with a wrench Fig. 53 Final torque t [10020852] (width A/F 17 mm) or t [10289118] (width A/F 19 mm), see tightening instruction 2nd step. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 73 KD27V12...
Page 76: Fitting And Removing The Rail
Injection lines removed........5-70 Fig. 54 Rail Item Description Work instructions High pressure rail Hex screw M8x45 8.8 Information The bevels in the rails must be aligned according to the arrows. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 77: Fitting And Removing The Pressure Adapter And Injector
Fig. 55 Pressure adapter and injector Item Description Work instructions Socket head screw M8x55-10.9 Spherical washer Support lug O-ring Injector Gasket Pressure adapter O-ring Box nut M24x1.5 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 75 KD27V12...
Page 78 Lubricant Engine oil Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque 1. (B) 5 Nm (3.7 ft lb) 2. (D) 35 Nm (26 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 79 Hexagon nut M4 (5) Lubricant Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque 1,2 + 0.2/0 Nm (0.88 +0.15/0 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 77 KD27V12...
Page 80: Removing
(11) [0524072] on the pressure adapter if the pressure adapter sits tight. • Pull the pressure adapter (7) out of the cylinder head. Fig. 60 Close bore • Close bore immediately with the appropriate protective cap. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 81 NOTICE Damage to the nozzle crown. • Remove the gasket carefully. Information Replace the injector sleeve if the gasket is stuck. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 79 KD27V12...
Page 82 Remove the gasket (6) from the injector. • Close the injector immediately with protective caps. Fig. 64 Protective caps for the injector • Cover the bore in cylinder head for the injector. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 83: Fitting
Insert the injector (5) with fitted support lug (3) into the Fig. 66 Injector with support lug cylinder head and align. • Press the injector into the cylinder head by hand. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 81 KD27V12...
Page 84 Fitting the pressure adapter • Install the pressure adapter (7) in such a way that the centering lugs on the pressure adapter are flush with the recesses in the cylinder head (arrows). © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 85 Tightening 2nd Step instruction 2nd step. • Tighten the box nut (9), see tightening instruction 2nd step. • Connect cable to injector, see installation and tighten- ing instructions. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 83 KD27V12...
Page 86: Fitting And Removing The High Pressure Pump
5-86 Top HP pump ........... Basic setting oil bore horizontal, J see, 5-86 Socket head screw M10x25-10.9 ..... tighten, 0 see tightening instruction. Pay atten- tion to the sequence. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 87: Removing The Hp Pump
Close opened lines immediately with protective caps. • Close openings in the HP pump immediately with protective caps. • The warranty will be forfeited if the assembly instructions are ignored. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 85 KD27V12...
Page 88: Fitting The Hp Pump
(Fig. 75). • Remove the protective caps from the fuel feed and return lines. • Replace O-rings (1) and (7) • Replace screw connection (2) • Connect connecting lines © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 89 Fig. 79 Gear rotation Diesel engine’s 135°, measured at the torque angle gage [10023839]. 135° • Remove the torque angle gage [10023839] with attach- ment. 143292 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 5 - 87 KD27V12...
Page 90 Fuel and injection system Service and Repair Manual Fitting and removing the high pressure pump • Fit the gear (1) Fig. 80 Insert intermediate gear • Fit the HP pumps' drive cover. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 91: Charge Air And Exhaust Gas System
NBU 30 Inlet manifold attachment O-ring 12x2 ............. grease with NBU 30 Cover Screw plug M30x1.5 Hex screw M6x50 8.8 Hex screw M6x16 8.8 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 6 - 89 KD27V12...
Page 92: Fitting And Removing The Charge Air Line
Fitting and removing the charge air line 143405 Item Description Work instructions Hex screw M8x100 8.8 Hex screw M8x200 8.8 Clamp O-ring 132.94x3.53 .......... replace, grease with NBU 30 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 93: Disassembling And Assembling The Charge Air Line
Item Description Work instructions Clamp O-ring 78x3 ............. replace, grease with NBU 30 Pipe socket left Hose clamp Rubber sleeve Charge air line Pipe socket right © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 6 - 91 KD27V12...
Page 94: Fitting And Removing The Connecting Line
Sensors on connecting line electrically discon- nected OMM = Operation and Maintenance Manual Fig. 84 Connecting line 143176 Item Description Work instructions Hex screw M8x40 10.9 Gasket ............. Replace Connecting line © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 95: Fitting And Removing The Air Intake Pipe
Pos. 6, 7, 14 removed Fig. 85 Air intake pipe 143177 Item Description Work instructions Gasket Hex screw M10x25 10.9 Hex screw M10x100 10.9 Air intake right Air intake left © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 6 - 93 KD27V12...
Page 96: Fitting And Removing The Exhaust Gas Stub
Replace Stud screw M10x35, high-temperature resistant Grease with copper paste Clamp .............. Only for 1800 rpm machines Hex screw M8x25, high-temperature resistant Only for 1500 rpm machines Exhaust manifold © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 97: Fitting And Removing The Charge Air Control Unit (Only 1800 Rpm)
Charge air control unit 143182 Item Description Work instructions Hose clamp Clamp Screw connection Hose clamp Rubber sleeve Pipe Clamp Clamp Clamp Pipe Clamp Screw connection Hose clamp © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 6 - 95 KD27V12...
Page 98 Charge air and exhaust gas system Service and Repair Manual Fitting and removing the charge air control unit (only 1800 rpm) Item Description Work instructions Proportional valve Rubber sleeve Rubber sleeve © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 99: Fitting And Removing The Exhaust Gas Turbocharger
Hollow screw 12-3 Clamp Lube oil line Screw connection Nut ..............Tightening instructions, see 6-98 Washer ............Repair instructions, see 6-98 Stud screw ............Grease with copper paste © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 6 - 97 KD27V12...
Page 100 Fig. 90 Spherical hexagon nut Lubricant Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque 20 Nm (14.8 ft lb) 44 +3/0 Nm (32 +2.2/0 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 101: Lubrication System
Clamp Spacer Hex screw M8x30 8.8 Hose clamp Rubber sleeve Hose nipple with O-ring Hex screw M8x60 8.8 Spacer Pipe Spacer Crankcase breather Hex screw Belt © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 7 - 99 KD27V12...
Page 103: Cooling System
Vent line Screw connection Hex screw M8x60 8.8, spacer, clamp Vent line Hollow screw ........... Replace sealing rings Vent line Hollow screw ........... Replace sealing rings Bracket © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 8 - 101 KD27V12...
Page 104 Service and Repair Manual Fitting and removing the vent line Item Description Work instructions Hex screw M8x20 8.8, spacer, clamp Banjo bolt Sealing ring ............. Replace Vent line Vent line Vent line © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 105: Fitting And Removing The Coolant Pump
Belt drives removed ......... OMM OMM = Operation and Maintenance Manual Fig. 93 Coolant pump 143219 Item Description Work instructions Hex screw M10x30 8.8 Water pump © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 8 - 103 KD27V12...
Page 106: Fitting And Removing The Thermostat Housing
NBU 30 Thermostat O-ring .............. replace, grease with NBU 30 O-ring .............. replace, grease with NBU 30 Thermostat housing O-ring .............. replace, grease with NBU 30 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 107 Fitting the thermostat Item Description Work instructions Optical alignment ..........Has to point upwards. Thermostat Mechanical alignment ........Align according to the grooves in the power unit support. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 8 - 105 KD27V12...
Page 108: Checking The Thermostat
82 °C (179.6 °F) which it starts to open Temperature at 90 °C (194 °F) which it is fully open  15 mm (0.6 in) Stroke (A) with full opening © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 111: Electrical System
Fitting the battery charging alternator 143202 Item Description Work instructions Hex screw M10x30 8.8 Hex screw M10x120 8.8 Bracket Hex screw M10x40 8.8 Battery charging alternator © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 9 - 109 KD27V12...
Page 112: Connecting The Battery Charging Alternator
(B-) Earth connection 5.1 ±0.9 Nm (3.8 ±0.7 ft lb) Fig. 98 is not used (D+) Diagnosis connection, 2 +0.3/-0.4 Nm (8.8 +0.22/-0.3 ft lb) (B+) Battery voltage, 11 ±2 Nm (8.1 ±0.15 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 113: Fitting And Removing The Starter
Electrical power supply interrupted ....1-18 Starter cable disconnected Fig. 99 Starter 143203 Item Description Work instructions Hex screw M12x35 10.9 ........Tightening instructions, see 9-112 Starter © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 9 - 111 KD27V12...
Page 114 24 ±4 Nm (18 ±0.3 ft lb) Hex collar nut M6 Fig. 102 Electrical connection Lubricant Plumbing lacquer Component contact surfac- Can the screws be reused? Step Torque 4 +0.6/-0.3 Nm (3 +0.44/-022 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 115: Fitting And Removing The Engine Control Unit Including Add-On
Screw M8x30x12.6 Washer Fastening clip Rubber buffer Engine control unit Engine control unit add-on Hex screw M8x20 8.8 Hex screw M10x20 8.8 Hex screw M8x50 8.8 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 9 - 113 KD27V12...
Page 116: Removal Instructions Engine Control Unit
Tightening instructions engine control unit add-on Hex screw M8-8.8 Fig. 104 Engine control unit fastening Lubricant Plumbing lacquer Loctite 243 Component contact surfac- Can the screws be reused? Step Torque 10 Nm(7.4 ft lb) © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 KD27V12...
Page 117: 10 Appendix
3300 / 2430 3900 / 2880 M 16 195 / 140 280 / 210 330 / 240 M 39 3000 / 2210 4300 / 3170 5100 / 3770 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 115 KD27V12...
Page 119: Standard Torques For Screw Plugs And Hollow Screws
M 64 x 2 M 30 x 2 M 65 x 2 M 33 x 2 Information Oil the thread and sealing surfaces with engine oil. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 117 KD27V12...
Page 120: Standard Torques For Flange Joints
Tightening torques apply for mating material: steel. Tolerance for the tightening torques specified in the table: + 10 %. Oil the screw-in thread with engine oil before screwing in. © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016...
Page 124: Standard Torques For Cutting Ring Flange Joints
• Secure with screw-on connection. • Screw on box nut up to clearly noticeable increase in force (without wrench extension). • Tighten box nut to aforementioned torque. © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 125: Standard Torques For Triple Lock Flange Joints
Secure with screw-on connection. • Screw on box nut up to clearly noticeable increase in force (without wrench extension). • Tighten box nut to aforementioned torque. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 123 KD27V12...
Page 126: Standard Torques For Vsti Screw Plugs
M 38 X1.5 M 20 x 1.5 M 42 x 2 M 22 x 1.5 M 48 x 2 M 24 x 1.5 M 26 X 1.5 © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 127: Detergents, Plumbing Lacquers And Greases
Greases Name Quantity Source Staburags NBU 30 1.20 kg Klüber Copper paste; 0.85 kg MOTOREX Motorex 14 High temperature spray; 400 ml WEICON Anti Seize ASW © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 125 KD27V12...
Page 128: Tools
Tools 10.3.1 Special tools Lifting device Fig. 106 4-point arrangement 142057 Item Description Remark T-spline end from basic scope 10815480 T-receiving tube Accessory for 4-point suspension 11213360 © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 129 The accessory for the 4-point suspension [11213360] is not Fig. 107 Lifting lugs for 4-point suspension included in the scope of delivery for the lifting device [10815480]. © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 127 KD27V12...
Page 130: Special Tools With Order Number
10123791 230610006 Mounting bolt M8x160 0524059 230610007 Mounting bolt M10x105 0528472 230610008 Mounting bolt M12x85 0524054 230610009 Mounting bolt M12x130 0528471 230610010 Mounting bolt M14x200 0524055 230610011 © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 131 Torque angle gage for 1/2" drive 0524062 230610014 Torque angle gage for 3/4" drive 10023839 230610015 Torx tools 7014716 230610016 Assembly tool for HP lines, width A/F 17 10020852 230610017 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 129 KD27V12...
Page 132 Assembly tool for HP lines, width A/F 22 / 3/8" 11171015 230610019 Dismantling tool 0524072 230610020 Adapter for pressure adapter 12440945 230610021 Dismantling tool for injector 11355589 230610022 142535 11355589 Assembly tool for injector 10153847 230610023 © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 133 Order number Spare tip for assembly tool for injector [10153847] as required 10148425 230610024 Lifting device 10815480 230610025 T-spline end for lifting device [10815480] 11213360 230610026 © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 131 KD27V12...
Page 134: Terms Used (Glossary)
Safety zone Designated area around the engine, access to which in the various operating modes is described in the chapter "Operating and maintenance areas". on page 1-16. © 2016 by Kohler Co. All rights reserved. 10 - 33525087701_1_1 12-2016 KD27V12...
Page 135: Abbreviations Used
Top dead center Pressure control valve Pressure control valve Pump distributor gear Bottom dead center Volume control valve Volume control valve Dosing unit High Pressure Pump © 2016 by Kohler Co. All rights reserved. 33525087701_1_1 12-2016 10 - 133 KD27V12...

Kohler KD27V12 Service And Repair Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Kohler KD27V12

Summary of Contents for Kohler KD27V12

Table of Contents