Kohler KD27V12 Manuals

Manuals and User Guides for Kohler KD27V12. We have 3 Kohler KD27V12 manuals available for free PDF download: Service And Repair Manual, Operation And Maintenance Manual

Kohler KD27V12 Service And Repair Manual (138 pages)

Brand: Kohler | Category: Engine | Size: 17 MB

Table of Contents
7
Safety
11
Safety Instructions
11
Target Audience
11
International Standard Classification of Occupations
11
Occupational References
11
Unauthorized Personnel
12
Intended Use
13
Limitation of Liability
13
General Safety Instructions
14
Preventing Personal Injuries
15
Risk of Burns
15
Fires and Explosions
15
Poisoning
15
Electrical Energy
16
Danger Due to Noise
16
Personal Protective Equipment
17
Operating and Maintenance Areas
18
Secure and Release the Diesel Engine against Unexpected Starting
20
Emergency Stop
21
Signage
21
Preventing Material Damages
22
General Information
23
Layout of These Instructions
23
User Guidance
25
Engine Illustrations and Engine Parts
26
Signs
29
Safety Signs
29
Notice Signs
30
General Engine Data
30
Fuel Scheme
35
Lubricant Scheme
36
Coolant Scheme
38
Overall System - Engine with Accessory Cooler
38
Engine Electrics
40
Overview of Sensors and Actuators
40
Function of Battery Charging Alternator
41
Starter Function
44
Breakdown of Cable Names Acc. to Wiring Diagram
46
Arrangement of Channels in the Crankcase and Cylinder Head
48
Transport Stand and Fastening Pieces
49
Lifting Device and Fastening Pieces
49
Fitting and Removing Fastening Pieces
50
Transporting the Diesel Engine
52
Fastening During Transport
53
Steel Transport Stand
54
Wooden Transport Stand
55
Starting the Engine
56
Final Check
57
Cylinder Head, Engine Control Unit and Valves
59
Fitting and Removing the Cylinder Head Cover
59
Checking and Setting the Valve Clearance
61
Power Unit
65
Fitting and Removing Crankshaft Add-On Parts
65
Fuel and Injection System
67
Safety Instructions for Work on the Fuel and Injection System
67
Preventing Personal Injuries
67
Preventing Material Damages
67
Fitting and Removing the Fuel Lines
68
Fuel Lines - Suction Pressure and Low Pressure
68
Fuel Lines - Return and Permanent Ventilation
70
Fitting and Removing the Injection Line
72
Removing
74
Fitting
75
Fitting and Removing the Rail
76
Fitting and Removing the Pressure Adapter and Injector
77
Removing
80
Fitting
83
Fitting and Removing the High Pressure Pump
86
Removing the HP Pump
87
Fitting the HP Pump
88
Charge Air and Exhaust Gas System
91
Fitting and Removing the Inlet Manifold
91
Fitting and Removing the Charge Air Line
92
Disassembling and Assembling the Charge Air Line
93
Fitting and Removing the Connecting Line
94
Fitting and Removing the Air Intake Pipe
95
Fitting and Removing the Exhaust Gas Stub
96
Fitting and Removing the Charge Air Control Unit (Only 1800 Rpm)
97
Fitting and Removing the Exhaust Gas Turbocharger
99
Lubrication System
101
Fitting and Removing the Crankcase Ventilation Piping
101
Cooling System
103
Fitting and Removing the Vent Line
103
Fitting and Removing the Coolant Pump
105
Fitting and Removing the Thermostat Housing
106
Checking the Thermostat
108
Electrical System
111
Fitting and Removing the Battery Charging Alternator
111
Connecting the Battery Charging Alternator
112
Fitting and Removing the Starter
113
Fitting and Removing the Engine Control Unit Including Add-On
115
Removal Instructions Engine Control Unit
116
Installation Instructions Engine Control Unit
116
10 Appendix
117
Standard Torques
117
Standard Torques for Screw Connections
117
Standard Torques for Screw Plugs and Hollow Screws
119
Standard Torques for Flange Joints
120
Standard Torques for Cutting Ring Flange Joints
124
Standard Torques for Triple Lock Flange Joints
125
Standard Torques for VSTI Screw Plugs
126
Detergents, Plumbing Lacquers and Greases
127
Tools
128
Special Tools
128
Special Tools with Order Number
130
Terms Used (Glossary)
134
Abbreviations Used
135

Kohler KD27V12 Operation And Maintenance Manual (118 pages)

Brand: Kohler | Category: Engine | Size: 5 MB

ESP Fuel Optimized - Service Level
2
ESP Emission Optimized - Service Level
2
PRP Fuel Optimized - Service Level
2
PRP Emission Optimized - Service Level
2
COP Fuel Optimized - Service Level
2
COP Emission Optimized - Service Level
2
Table of Contents
5
Service
9
Product Description
11
Technical Description
11
Design Overview
11
Cylinder Designation, Direction of Rotation
14
Explanation of the Type Designation
14
Engine Serial Number
15
Technical Data
17
Diesel Engine
17
Cylinder Head
17
Coolant Thermostat
17
Alternator to Charge the Battery
18
Starter
18
Flywheel Housing
18
Safety
19
Identification of the Warnings
19
Target Audience
20
International Standard Classification of Occupations
20
Occupational References
20
Unauthorized Personnel
21
Intended Use
21
Limitation of Liability
22
General Safety Instructions
22
Preventing Personal Injuries
23
Bruises
23
Burns and Scalding
24
Fires and Explosions
24
Poisoning
24
High-Pressure Injection (Liquids at High Pressure Can Squirt Out)
24
Electrical Energy
25
Danger Due to Noise
25
Personal Protective Equipment
25
Operating Areas and Maintenance Areas
26
Safety Instructions
26
Operating Areas
27
Maintenance Areas
27
Secure and Release the Diesel Engine against Unexpected Starting
28
Emergency Stop
29
Signage
29
Prevent Material Damages
30
Handling, Operation
31
Start-Up Procedure
31
Filling the Operating Fluids
31
Starting the Engine
31
Vent Fuel System
33
Breakdowns
35
Errors - Cause - Remedy
35
Operating Fluids and Maintenance
41
Fill Quantities
41
Lubricants and Operating Materials
41
Lubricants and Operating Materials
42
Diesel Fuels
42
Engine Oils
43
Coolant
45
Maintenance
47
Maintenance Schedule
47
Daily Maintenance Work
48
Maintenance Schedule - ESP Fuel Optimized
49
ESP Fuel Optimized - Service Level
49
Maintenance Schedule - ESP Emission Optimized
51
ESP Emission Optimized - Service Level
51
Maintenance Schedule - PRP Fuel Optimized
53
PRP Fuel Optimized - Service Level
53
Maintenance Schedule - PRP Emission Optimized
55
PRP Emission Optimized - Service Level
55
Maintenance Schedule - COP Fuel Optimized
57
COP Fuel Optimized - Service Level
57
Maintenance Schedule - COP Emission Optimized
59
COP Emission Optimized - Service Level
59
Special Tools for Maintenance Activities
61
Preparatory Maintenance Activities
62
Daily Maintenance Work
63
Perform Visual Inspection (Leaks, Damage, Loose Components)
63
Checking the Engine Oil Level
66
Check Coolant Level
68
Check/Drain Water Trap on the Fuel Prefilter
68
Check Differential Pressure Gage
68
Check the Air Filter Display
68
Observe the Engine Operation
69
Test Run (Perform Monthly)
69
Maintenance Activities
70
Take Oil Sample and Perform Oil Analysis
70
Replace Fuel Fine Filter
71
Changing the Fuel Prefilter
73
Change Diesel Engine Oil and Oil Filter
73
Changing the Oil Filter
75
Take Coolant Sample and Perform Coolant Analysis
77
Change Air Filter Main Element
77
Check State of Fan Drive Belt Drive and Replace if Necessary
77
Changing the Crankcase Breather V-Ribbed Belt
79
Checking and Replacing the Belt Drive for the Water Pump and Alternator to Charge the Battery
83
Change the Oil Separator Filter Insert of the Crankcase Breather
87
Replacing the Coolant
90
Draining the Coolant
90
Filling the Coolant
91
Transport and Storage
93
Fastening During Transport
94
Wooden Transport Stand
96
Steel Transport Stand
97
Suspension Device
98
Storage
101
Storage for up to 6 Months
101
Storage for over 6 and up to 24 Months
101
Standard Torques
103
Standard Torques for Screw Connections
103
Standard Torques for Screw Plugs and Hollow Screws
104
Standard Torques for Flange Joints
105
Metric Flange Joints, Series L (Light) for Aluminum
108
Standard Torques for Cutting Ring Flange Joints
109
Standard Torques for Triple Lok® Flange Joints
109
Standard Torques for VSTI Screw Plugs
110
Special Tool
111
Terms Used (Glossary)
112
Abbreviations Used
113
Index
115

Kohler KD27V12 Operation And Maintenance Manual (112 pages)

Brand: Kohler | Category: Engine | Size: 4 MB

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Service Assistance

1 Product Description

2 Safety

3 Handling, Operation

4 Operating Faults

5 Operating Fluids and Maintenance

6 Transport and Storage

Index

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