Kohler KD27V12 Diesel Engine Service and Repair Manual (33525087701)

Format: PDF (Printable Document)

File Language: English

File Pages: 146

File Size: 19.39 MB (Speed Download Link)

Brand: Kohler

Model: KD27V12 Diesel Engine

Book No: 33525087701

Type of Document: Service and Repair Manual

Categories: Kohler PDF, PDF

$ 40

Kohler KD27V12 Diesel Engine Service and Repair Manual (33525087701)

These KD27V12 engines usually sit in generators, pumps, or industrial equipment that run long hours in dusty or cramped plant rooms. This manual is what I keep handy when I’m tearing into one for a hard-start complaint or an overheating issue and need to trace the problem without guessing. It walks you through how the engine is put together, so when you strip it down you know what to inspect, what to measure, and how to reassemble it so it fires right up and runs clean.

Applications & Use Cases

Plan a full teardown and rebuild, so parts come off in order and go back aligned and sealed correctly.
Trace fuel or air issues during hard-start or smoking complaints by following the proper inspection sequence.
Verify wear limits on internal components while the engine is open, before you decide what to replace.
Route hoses, wiring, and linkages correctly after major repairs, avoiding chafing and misadjusted controls.
Bleed and test the fuel system after filter or component changes to clear air and confirm proper operation.

FAQ

Q: Can I use this manual on a tablet in the field?

A: Yes, it works well digitally; you can zoom in on diagrams and use search to jump to the procedure you need.

Q: Is it worth printing sections of this manual?

A: For messy jobs, printing just the relevant pages keeps your device clean and lets you mark notes as you work.

Safety Note

Always lock out the machine and follow the manual’s safety instructions before opening or cranking the engine.

📘 Show Index

Kohler KD27V12 Diesel Engine Index:

Revision history
1 Safety
- 1.1 Safety instructions
- 1.2 Target audience
  - 1.2.1 International standard classification of occupations
  - 1.2.2 Occupational references
    - For the Service Level 1 maintenance of power generation engines: Maintenance Technician
    - For the Service Level 2 maintenance of power generation engines: Technician
    - For the Service Level 3 maintenance of power generation engines: Mechanical Technician
  - 1.2.3 Unauthorized personnel
    - For the operation of power generation engines: Operator
- 1.3 Intended use
- 1.4 Foreseeable misuse
- 1.5 General safety instructions
- 1.6 Preventing personal injuries
  - 1.6.1 Bruises
  - 1.6.2 Risk of burns
  - 1.6.3 Fires and explosions
  - 1.6.4 Poisoning
  - 1.6.5 Electrical energy
  - 1.6.6 Danger due to noise
- 1.7 Personal protective equipment
- 1.8 Operating and maintenance areas
  - Safety instructions
  - Operating areas
  - Maintenance areas
  - 1.8.1 Secure the Diesel engine against unexpected starting and recommission
    - Procedure:
  - 1.8.2 Emergency stop
  - 1.8.3 Signage
- 1.9 Preventing material damages
2 General information
- 2.1 Layout of these instructions
  - 2.1.1 User guidance
- 2.2 Engine illustrations and engine parts
  - View of power unit support side
  - View of flywheel side
  - Gear train
- 2.3 Signage
  - 2.3.1 Safety signs
    - Raise the Diesel engine hang tag
  - 2.3.2 Notice signs
    - Hang tag engine without engine oil
  - 2.3.3 General engine data
    - Engine type designation
    - Emission control information label
    - Engine serial number
    - HP pump nameplate
    - Exhaust gas turbocharger nameplate
    - Engine control unit nameplates
    - Thermostat start of opening
- 2.4 Fuel scheme
- 2.5 Lubricant scheme
- 2.6 Coolant scheme
  - 2.6.1 Overall system – engine with accessory cooler
- 2.7 Engine electrics
  - 2.7.1 Overview of sensors and actuators
  - 2.7.2 Function of battery charging alternator
    - Excitation for battery charging alternator
  - 2.7.3 Starter function
    - Starting the Diesel engine
  - 2.7.4 Breakdown of cable names acc. to wiring diagram
- 2.8 Arrangement of channels in the crankcase and cylinder head
- 2.9 Transport stand and fastening pieces
- 2.10 Lifting device and fastening pieces
  - 2.10.1 Fitting and removing fastening pieces
    - Tightening instructions for lifting device
- 2.11 Transporting the Diesel engine
  - 2.11.1 Fastening during transport
  - 2.11.2 Steel transport stand
  - 2.11.3 Wooden transport stand
- 2.12 Starting the engine
  - 2.12.1 Final check
3 Cylinder head and valves
- 3.1 Fitting and removing the cylinder head cover
  - 3.1.1 Cylinder head cover with crankcase breather (optional)
    - Tightening instructions for wiring harness at injector
  - 3.1.2 Fitting the seal for the cylinder head cover
    - Procedure
- 3.2 Checking and setting the valve clearance
  - Setting position “TDC”
  - Setting position “TDC +310°”
  - Setting position “TDC +540°”
4 Power unit
- 4.1 Fitting and removing the crankshaft add-on parts
  - Tightening instructions for the crankshaft add-on parts
  - Procedure for removing the viscous damper
  - Procedure for fitting the viscous damper
5 Fuel and injection system
- 5.1 Safety instructions for work on the fuel and injection system
  - 5.1.1 Preventing personal injuries
  - 5.1.2 Preventing material damages
- 5.2 Fitting and removing the fuel lines
  - 5.2.1 Fuel lines – suction pressure and low pressure
  - 5.2.2 Fuel lines – return and permanent ventilation
- 5.3 Fitting and removing pressure lines
  - Tightening instructions for injection lines
  - 5.3.1 Removing
  - 5.3.2 Fitting
- 5.4 Fitting and removing the rail
- 5.5 Fitting and removing the pressure adapter and injector
  - 5.5.1 Removing
  - 5.5.2 Fitting
    - Tightening instructions for injector and pressure adapter
- 5.6 Fitting and removing the high pressure pump
  - Tightening instructions for the HP pump
  - 5.6.1 Removing the HP pump
  - 5.6.2 Fitting the HP pump
6 Belt drive
- 6.1 Fitting and removing the belt tensioning device and pulley
  - 6.1.1 Fitting and removing the fan drive belt
    - Tightening instructions for the belt tensioning device
  - 6.1.2 Belt tensioning device with automatic belt tensioning
    - Tightening instructions for the belt tensioning device
7 Charge air and exhaust gas system
- 7.1 Fitting and removing the intake stack before the compressor
- 7.2 Fitting and removing the charge air line
  - 7.2.1 Disassembling and assembling the charge air line
- 7.3 Fitting and removing the connecting line
- 7.4 Fitting and removing the air intake pipe
- 7.5 Fitting and removing the exhaust gas stub
- 7.6 Fitting and removing the charge air control unit (only 1800 rpm)
- 7.7 Fitting and removing the exhaust gas turbocharger
  - Tightening instructions turbocharger and flange on turbocharger
8 Lubrication system
- 8.1 Fitting and removing the crankcase breather piping
9 Cooling system
- 9.1 Draining the coolant
  - Procedure
- 9.2 Fitting and removing the vent line
- 9.3 Fitting and removing the coolant pump
- 9.4 Fitting and removing the thermostat housing
  - Fitting the thermostat
  - 9.4.1 Checking the thermostat
10 Electrical system
- 10.1 Fitting and removing the battery charging alternator
  - 10.1.1 Connecting the battery charging alternator
- 10.2 Fitting and removing the starter
  - Tightening instructions starter
- 10.3 Fitting and removing the engine control unit including add-on
  - 10.3.1 Removal instructions engine control unit
  - 10.3.2 Installation instructions engine control unit
    - Tightening instructions engine control unit add-on
11 Appendix
- 11.1 Standard torques
  - 11.1.1 Standard torques for screw connections
  - 11.1.2 Standard torques for screw plugs and hollow screws
  - 11.1.3 Standard torques for flange joints
    - Metric flange joints, series L (light) acc. to Fig. 121
    - Metric flange joints, series S (heavy) acc. to Fig. 121
    - Imperial flange joints, series L (light) acc. to Fig. 121
    - Imperial flange joints, series S (heavy) acc. to Fig. 121
    - Metric flange joints, series L (light) for aluminum acc. to Fig. 121
  - 11.1.4 Standard torques for cutting ring flange joints
  - 11.1.5 Standard torques for Triple Lock flange joints
  - 11.1.6 Standard torques for VSTI screw plugs
- 11.2 Detergents, threadlocks and greases
- 11.3 Tools
  - 11.3.1 Special tools
    - Lifting device
  - 11.3.2 Special tools with order number
- 11.4 Terms used (glossary)
- 11.5 Abbreviations used