Format: PDF (Printable Document)
File Language: English
File Pages: 104
File Size: 12.43 MB (Speed Download Link)
Brand: Kohler
Model: TAD1240GE, TAD1241GE-VE TAD1242GE-VE, TWD1240VE
Book No: tp6764
Type of Document: Workshop Manual
$ 40
These Kohler TAD/TWD 1240-series generator engines usually live in tough spots—backup power at plants, rental units on construction sites, or prime power in remote yards. This workshop manual is what I’d pull when we’re doing a deep engine job, not just filters and belts. It walks you through teardown, inspection, and reassembly so you can, for example, trace a hard-start issue back through fuel, timing, and compression without guessing or tearing things apart twice.
Applications & Use Cases
FAQ
Q: Can I keep this manual on a tablet in the field?
A: Yes, it’s practical to use digitally; you can zoom diagrams and search terms while working next to the unit.
Q: Is it worth printing sections of this manual?
A: Many techs print the specific procedures they’re doing that day to keep on the bench, then discard or update as the job changes.
Safety Note
Always lock out the generator set and verify it cannot start automatically before opening or working on the engine.
GROUP 20 GENERAL INFORMATION
Safety Information ………………………………………… 2
General Information ………………………………………. 5
General repair instructions ……………………………. 6
GROUP 22 LUBRICATING SYSTEM
General ……………………………………………………….. 8
Special tools ………………………………………………… 9
Design and Operation
Lubrication system ……………………………………… 10
Repair instructions
Working with chemicals, fuel and
lubricating oil ……………………………………………… 12
Oil filter, changing ……………………………………….. 12
Oil sump gasket, changing …………………………… 13
Oil filter bypass valve, replacing ……………………. 14
Safety valve, changing …………………………………. 15
Reducing valve, changing…………………………….. 15
Piston cooling valve, changing ……………………… 16
Bypass filter (turbocharger) bypass valve,
changing ……………………………………………………. 17
Bypass valve (pressure valve) oil cooler,
changing ……………………………………………………. 17
Piston cooling nozzle, changing ……………………. 18
Oil pump, changing ……………………………………… 19
Oil pressure, checking …………………………………. 21
Engine oil, changing ……………………………………. 22
Oil cooler element, changing ………………………… 22
Oil cooler element, leakage test ……………………. 26
GROUP 23 FUEL SYSTEM
General ……………………………………………………… 28
Instructions for working with electronic
fuel injection ………………………………………………. 28
Special tools ………………………………………………. 29
Design and Operation
Unit injectors, overview ………………………………… 31
Unit injectors, working phases ………………………. 32
Repair instructions
Control module (EDC III), changing……………….. 34
Fuel system, draining ………………………………….. 36
Fuel filter, changing …………………………………….. 37
Fuel pump, changing …………………………………… 38
Fuel pump, rebuilding ………………………………….. 39
Fuel system, bleeding ………………………………….. 41
Bypass valve, changing ……………………………….. 42
Fuel pressure, checking ………………………………. 43
Unit injectors, changing ……………………………….. 44
Draining condensate water …………………………… 48
Fuel pre-filter with water monitor, changing …….. 48
Copper sleeve for unit injector, change ………….. 49
GROUP 25 INTAKE AND EXHAUST SYSTEMS
General ……………………………………………………… 55
Design and Operation
Turbocharger ……………………………………………… 56
Repair instructions
Working with chemicals, fuel and
lubricating oil ……………………………………………… 57
Intake manifold (gasket), changing ………………… 57
Exhaust manifold gasket, changing ……………….. 63
Turbocharger, changing ……………………………….. 66
Pressure drop indicator, checking …………………. 69
GROUP 26 COOLING SYSTEM
General ……………………………………………………… 70
Special tools ………………………………………………. 71
Design and Operation
Cooling system (TAD) ………………………………….. 72
Cooling system (TWD) ………………………………… 73
Charge air cooler ………………………………………… 74
Repair instructions
Cooling system, draining ……………………………… 75
Cooling system, filling ………………………………….. 75
Coolant pump, changing ………………………………. 76
Coolant filter, changing ………………………………… 79
Piston thermostat, changing …………………………. 80
Piston thermostat, functional check ……………….. 81
Drive belts, changing …………………………………… 82
Cooling system, cleaning …………………………….. 85
Charge air cooler, changing (TAD) ………………… 86
Charge air cooler, changing (TWD) ……………….. 87
Charge air cooler, leakage test (TAD)…………….. 90
Charge air cooler, cleaning …………………………… 91
Radiator core, changing ………………………………. 92
Cooling system, leakage testing ……………………. 96
Auxiliary cooling pump, overhaul (TWD) ………… 98
