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Kohler KD83V16 Service And Repair Manual

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Service and Repair Manual
Original Instructions
Diesel engine
KD83V16
From serial number 2021740003
EN_US
33525088901_2_1
07-2021

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Summary of Contents for Kohler KD83V16

  • Page 1 Service and Repair Manual Original Instructions Diesel engine KD83V16 From serial number 2021740003 EN_US 33525088901_2_1 07-2021...

  • Page 2: For United States Only

    - 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 3: Revision History

    First 3.01 engine version 2018-07 Technical documen- tation TB12 - First 3.02 engine version 2019-02 Technical Spelling mistakes documen- tation TB12 - According to development and improvement 2021-07 Technical documen- tation © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 4 Service and Repair Manual © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 5: About This Document

    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: Liability And Warranty

    Kohler Co. will cancel any obligations entered into by Kohler Co. and/or its dealers, such as guar- antees, service contracts etc., without advance notice if any parts other than original KOHLER parts or spare parts purchased from Kohler Co.

  • Page 7: Other Applicable Documents

    Service and Repair Manual 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 8: General Information

    Prior to any intervention, read the complete task procedure through to the end. Various symbols are used and explained in chapter (For more information see: 2.1.2 Additional identifications, page 38.) Each task in this manual have the following structure: © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 9 Specific values spreadsheet to check the nominal and tolerances values of critical components and data recording sheet, if required, to inform the engine manufacturer. Tightening sequence table if required Tightening specifications table for specific fastener © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 10 Preface Service and Repair Manual General information © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 11 Occupational references 2.2.4 Unauthorized personnel - servicing Intended use Limitation of liability Safety instructions 2.5.1 General safety instructions 2.5.2 Safety while commissioning 2.5.3 Safety when starting Preventing injuries © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 12 3.3.2 Inlet and outlet rocker arms removal and installation 3.3.3 Rocker arms housing removal and installation Cylinder head (SL 224) 3.4.1 Cylinder head removal and installation Driving gear © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 13 3.10.5 Thermostat LT and housing removal and installation (SL 217) 3.10.6 Coolant pump HT removal and installation (SL 216) 3.10.7 Coolant pump LT removal and installation (SL 215) 3.10.8 Fan drive (option) 3.11 Electrical system © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 14 5.3.11 Assembling pipes with DKO connectors (EL, ET, EW, GZ, GZR, RED) 5.3.12 Standard torques for collar clamps Abbreviations - Acronyms Unit conversion tables 5.5.1 Length conversion factors 5.5.2 Mass conversion factors 5.5.3 Pressure conversion factors © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 15 Power conversion factors 5.5.6 Moment of inertia and torque conversion factors 5.5.7 Fuel consumption conversion factors 5.5.8 Flow conversion factors 5.5.9 Temperature conversion factors 5.5.10 Density conversion factors Prefix © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 16 Contents Service and Repair Manual © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 17: Product Description

    CS Engine rear (flywheel side) Charge air cooler Engine brackets (x4) Battery charging alternator Flywheel Oil dipstick Fuel filter Oil centrifuge assembly Crankcase breather system filter High pressure fuel pump Turbocharger assembly © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 18: Cylinder Designation, Direction Of Rotation

    Oil pan 1.1.1 Cylinder designation, direction of rotation Principle according to ISO 1204 Cylinder 1 is located on flywheel side. Direction of rotation as shown on the flywheel side. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 19: Firing Order

    Cylinder B6 is located on the engine right opposite the flywheel side. The rotational direction is on the left-hand side as viewed towards the flywheel. Fig. 5: Cylinder valves order © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 20: Emission Control Information Label

    E=Emissions Optimized C Application. C=COP; P=Prime; S=Stand by; D=Data center Tab. 2: Engine type description Emission control information label The emission control information label is attached on the crankcase. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 21: Engine Serial Number

    Description 2016 0001 Engine serial number 2016 Year of manufacture Engine type code (73= KD62V12) (74= KD83V16) (75= KD103V20) 0001 Incremential production number Tab. 3: Engine serial number © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 22 Fig. 10: 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 23 The information on the engine control unit nameplate corresponds to the delivery status (ex: works Kohler Co.). Depending on software updates in the field, it may be the case that this infor- mation is no longer up to date.

  • Page 24: Turbocharger Identification

    Matching of the connecting rod and connecting rod bearing cap is identified by connecting rod number. Turbocharger identification Fig. 14: Turbocharger nameplate The turbocharger company nameplate is mounted on the turbocharger. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 25 The oil cooler company nameplate is mounted on the oil cooler. Injector identification Fig. 16: Injection number location The injector identification number is stamped on the side of the injector. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 26 Service and Repair Manual Technical description High-pressure pumps identification Fig. 17: High pressure pump nameplate Fig. 18: High pressure pump number The high pressure pump number is stamped on the pump. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 27 The charge air cooler company nameplate is mounted on the charge air cooler. Thermostat opening point value Fig. 20: Thermostat markings The opening point value of the thermostat is engraved on the thermostat. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 28: Technical Data

    Product description Service and Repair Manual Technical data 1.2 Technical data Information Refer also to the “Technical data sheet”. (For more information see: 5 Appendix, page 272.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 29: Function Description

    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 machi- nery. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 30: Fuel Diagram

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 31 Prelubricating pump Support bearing Flywheel Oil sampling Bypass valve for cold start Gear box Intermediate gears HP Pump Turbochargers Flywheel See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 32 Venting HT Coolant pump LT Elbow B Venting LT Mechanical thermostat ECU 2-HD Engine oil cooler Manual venting point See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 33 Sensors list B708 – Coolant temperature S710 – HT Coolant Min level after engine alert B718 – Coolant temperature S711 – LT Coolant Min level before cooler alert © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 34 - A side (on ECU 2-HD) B7811 - Exhaust gas temper- B7923 - Crankcase pressure ature before turbocharger 1&2 See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 35 Aggregate support Turbocharger Venting point Charge air cooler - B side Air filter - A side Engine A bank See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 36 B781 - Air intake pressure B703 - Charged air pressure switch - B side (clogging) A after charge air cooler Engine type Number of turbochargers Tab. 5: Blowby connections © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 37 Service and Repair Manual Product description Function description © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 38: Identification Of The Warnings

    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. Tab. 8: Additional symbols © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 39: Additional Rules And Directives

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 40: Target Audience

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 41: For The Sl3 Maintenance Of Power Generation Engines: Mechan- Ical Technician

    – The engines must only be installed by personnel who have been trained and familiarized here- with 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 42: 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.

  • Page 43: General Safety Instructions

    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 estab- lished by Kohler Co.

  • Page 44: Safety When Starting

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 45 Standing in the vicinity of the engine while starting or operating the machinery is forbidden. u Wear proper personal protective equipment. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 46: Preventing Injuries

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 47: Preventing Fires And Explosion Hazards

    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 atmospheres according to Directive 2014/34/EC. © 2021 by Kohler Co. All rights reserved.

  • Page 48: Preventing Intoxication And Poisoning Hazards

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 49: Personal Protective Equipment (Ppe)

    The manufacturer of the machinery shall forbid any accessories and loose clothing. Following personal protective equipment is necessary: © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 50 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 operations. Tab. 9: Personal protective equipments © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 51: Engine Ready For Use Or In Operation

    – A – Engine front (damper side) – B – Engine sides – C – Engine rear (flywheel side) – D – Above the engine – E – Below the engine © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 52: Engine In Commissioning - Test-Run

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 53: Signage Recommendations

    Make sure that all residual risks according to the risk assessment are reflected in the system documentation. Provide documentation to the personnel according to the "Target audience". Tab. 10: Engine area signs requirement © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 54: Safety Instructions For Engine Control Unit (Ecu)

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 55: Safety Instructions For The Fuel System

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 56: Cleanliness Standards And Safety

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 57: Disposal And Environment Protection

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 58 (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 59 Not applicable. Special tools Not applicable. Consumables and equipment Not applicable. Overview Fig. 51: Task overview Screw (M8) Cover Protection plate Screw (M12) Removal u Remove screws 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 60: Installation

    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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 61: Specific Safety Instructions

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 62 Cover - front side Cover - back side Removal Fig. 54: Removing cover - front part u Remove screws 8 and lock washers 7. u Remove cover - front side 9. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 63 Remove nuts 6, vibration dampers 3, distance sleeves 2 and pins 1, 4. u Remove cover - back side 5 Installation Fig. 56: Installing pins u Screw pins 1, 4 on aggregate support and PTO bracket. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 64 Screw cover with nuts 6. Fig. 58: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 65 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse and marking, page 274.) 3.2.3 Cylinder head cover removal and installation Previous tasks Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 66 After the temperature has cooled down to a level it can be touched, proceed with the tasks on the engine. u Shut down the engine. u Secure the area according to local lockout/tagout procedure. Special tools Not applicable. Consumables and equipment Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 67 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 68 Repair Service and Repair Manual Covers Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 69: Rocker Arms

    After the temperature has cooled down to a level it can be touched, proceed with the tasks on the engine. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 70 A1-A8 Series of cylinders Exhaust valves B1-B8 Series of cylinders Inlet valves Engine rear (flywheel side) Left engine side Engine front (damper side) Right engine side Direction of rotation © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 71 A4, A6 B1, B3 Tab. 14: Reference table for the flywheel positioning Set the valve clearance u Rotate crankshaft in direction of rotation with turning device to index 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 72 (For more information see: Checking valve clearance, page 74.) (For more information see: Setting valve clearance, page 74.) Step 6 u Pass flywheel groove index 5. Step 7 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 73 Overlap TDC** A8 B2 A7 B4 A5 B6 A3 B8 A1 B7 A2 B5 A4 B3 A6 B1 * Ignition order ** Opposite cylinder (overlap) Tab. 15: Valve set order u Set cylinder to overlap TDC position. u Adjust valve clearance of ignition TDC cylinder. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 74: Checking Valve Clearance

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 75 +100 µm (3.94 th) clearance 19.69 th Exhaust 1 mm +100 µm (3.94 th) valve/ clear- 0.04 in ance Tab. 16: Tolerance values Tightening specifications Fig. 69: Rocker arms locknuts © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 76 Special tool Designation Turning device. (For more information see: Use the turning device, page 270.) Tab. 18: Special tools Consumables and equipment – Engine oil – Rags – Cleaner © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 77 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 78 Remove inlet rocker arm assembly 5 and exhaust rocker arm assembly 8. Fig. 74: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 79 Remove valve bridges 3 and pushrods 2 from swing followers 1. Installation Information Put matching cylinder in firing TDC position. Fig. 76: Preparing inlet and exhaust shafts u Inspect presence of plug in inlet shaft and exhaust shaft. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 80 Fig. 78: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 81: Tightening Specifications

    Screw and fit rocker arms with screws 7 in inlet shaft, exhaust shaft and fitting sleeves 4. Specific values (For more information see: 3.3.1 Rocker arms - Valve clearance set (SL 204), page 69.) Tightening specifications Fig. 80: Rocker arms screws © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 82 (For more information see: 3.6.2 High pressure pipes removal and installation, page 113.) Specific safety instructions – Set cylinders to ignition TDC position. Special tools Special tool Designation Coolant connector pipe tool Tab. 20: Special tools © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 83 – Cleaner Overview Fig. 82: Task overview Positioning pin Seal (x4) Screw (M8) Coolant pipe HT Closing cover Locking ring Seal Rocker arm housing Fitting sleeve (x5) Seal © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 84 Repair Service and Repair Manual Rocker arms Removal Fig. 83: Sliding locking ring u Slide locking ring 8. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 85 Slide pipes out of rocker arm housing. Fig. 85: Removing rocker arm housing u Lift rocker arm housing 9. u Move rocker arm housing and coolant pipe HT to remove the assembly. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 86 Remove seals 4, 6 from closing cover and coolant pipe HT. u Remove fitting sleeves 5. Installation Fig. 87: Preparing rocker arm housing u Grease coolant pipe. u Insert fitting sleeves 5. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 87 Put seals 6 and locking ring 8 on coolant pipe HT 7. u Insert coolant pipe HT 7 in rocker arm housing. Fig. 90: Inserting pins and seal © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 88 Insert positioning pins 1 in rocker arm housing. Fig. 91: Placing tool Information Tighten screws from inlet and outlet rocker arms. u Place tool on pipe. u Insert pipe into rocker arm housing. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 89 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 90 Spare battery pack for electric torque multiplier only No illustration Battery charger 110V for electric torque multiplier only No illustration Battery charger 230V for electric torque multiplier only © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 91 – Castrol Optimol paste white T – Rags – Cleaner Overview Fig. 94: Task overview Cylinder head Flame ring O-ring set Bolt (M30) Seal carrier Washer Cylinder head gasket (soft metal) Locating pin © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 92 Lift and push cylinder head up and down to dismantle it. u Remove cylinder head. u Remove cylinder head gasket 4. u Remove flame ring 5. Installation Fig. 96: Installing cylinder head gasket and flame ring © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 93 Mount seal carrier 3 with O-rings 2. u Grease O-rings 2. Fig. 98: Installing cylinder head u Mount lifting device on cylinder head. u Mount cylinder head. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 94 Lubricate bolts 6 and washers 7 with Castrol Optimol paste white T. u Insert and tighten the bolts. Fig. 100: Mounting lifting lug u Mount lifting lug 10 with extended length bolts 9. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 95 If cylinder heads are connected with a lifting lug bracket, both need to be taken off and replaced. Information Vent coolant circuit at the end of installation. Specific values Not applicable. Tightening specifications Fig. 101: Cylinder head tightening sequence Fig. 102: Cylinder head bolts © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 96 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 97 Not applicable. Special tools Special tool Designation Turning device. (For more information see: Use the turning device, page 270.) Tab. 23: Special tool Consumables and equipment – Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 98 Turn engine until piston is in BDC (Bottom Dead Center) position. u Check inside of liner by endoscope. u Note findings on data sheet. u Repeat procedure for each cylinder. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 99 3.5.2 Torsional vibration damper removal and installation - SL2-1340 Previous tasks q Remove the protection plate of the torsional vibration damper. (For more information see: 3.2.1 Vibration damper cover removal and installation, page 59.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 100 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. 25: Special tools Consumables and equipment – Rags – Cleaner © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 101 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 269.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 102 Remove bolts 4 and disk 3. Fig. 111: Lifting thread location u Install lifting device on the lifting thread. u Remove screws 2. u Remove torsional vibration damper 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 103 Install locking device with screws (M16) to lock crankshaft. Fig. 113: Lifting thread location u Install lifting device on the lifting thread. u Lift torsional vibration damper 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 104 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. 114: Bolts sequence © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 105 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. Special tools Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 106: Sample Collection

    Fig. 116: Task overview Upper sample opening Lower sample opening Sample collection Fig. 117: Collecting silicon oil sample u Rotate the crankshaft until sample openings 1, 2 are located vertically. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 107 (For more information see: Tightening specifications, page 108.) u Remove the sample container from the lower sample opening 3. Information Make sure that silicon oil does not leak from the sample container. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 108 Screw plug 1 15 Nm 11 ft-lb Tab. 27: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 109 Service and Repair Manual Repair Driving gear O = Engine oil XX = Loctite 243 YY = Loctite 577 **Refer to screws reuse rules. Otherwise, refer to standard tightening torques. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 110: Fuel System

    3.6.1 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 111 Service and Repair Manual Repair Fuel system Overview Fig. 119: Fuel return and venting pipes Fig. 120: Fuel pump pipes © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 112 Leakage-fuel detection block to leakage- fuel distributor block Sensor A Connection leakage fuel HP pump (A bank) Leakage indication high-pressure system Leakage-fuel distributor block Removal u Remove fuel return and venting pipes. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 113 (For more information see: 5.3 Standard tightening torques, page 274.) 3.6.2 High pressure pipes removal and installation Previous tasks q Release the pressure of the HP fuel system using Kodia tool. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 114 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 115 Fuel pipe Fuel pipe Retaining plate Screw (M10) Clamp Distributor block Fig. 124: Task overview Screw (M10) Clamp Clamp Screw (M10) Clamp Plate Holder Clamp Screw (M8) Clamp Clamp © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 116 Fig. 126: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 117 Remove screws 12. u Remove clamps 13, 14. Fig. 128: Removing high pressure piping u Remove fuel pipes 19, 20, 21, 22, 23 with flange joints 24. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 118 Install fuel pipes 19, 20, 21, 22, 23 with flange joints 24. Fig. 130: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 119 (For more information see: Tightening specifications, page 119.) Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 120 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 121 Consumables and equipment – Rags – Cleaner Overview Fig. 133: Low pressure circuit piping Removal u Remove fuel supply pipes. Information Close all open connections with original plugs. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 122 Keep the engine away from heat, sparks, open flame, or any other ignition source. NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 123 – Engine oil – Castrol Optimol Paste White T Overview Fig. 135: Task overview Injector sleeve Screw (M12) Retaining plate Injector clamp Screw (M12) Collet Injector Adaptor High-pressure pipe © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 124 Disconnect HT sensor on both ends if installed. u Remove both adaptors from rocker arm housing. Fig. 137: Removing high-pressure pipe u Take off high-pressure pipe 5 from adaptor 9. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 125 Remove retaining plate 2 with screws 3. u Close all open connections with the matching plugs (available as replacement parts). Fig. 139: Removing clamp u Remove clamp 7 by opening screw 6. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 126 Remove injector 4 with extracting tool. Installation Fig. 141: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 127 Fig. 143: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 128 Tighten screw 6 to torque. (For more information see: Tightening specifications, page 129.) u Tighten high-pressure pipe 5 to torque. (For more information see: Tightening specifications, page 129.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 129 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 274.) Fig. 147: Injector © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 130 1 70 Nm 52 ft-lb Tab. 31: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 131 – Cleaner – Bucket for fuel Overview Fig. 149: Task overview Screw (M8) Flange joint Protection guard Flange joint See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 132 Fig. 150: Fuel filter screws Torque Angle (°) Screw specifications ± 5% ± 5° 201AA EN 1665 M10x1.5x30-8.8-FLZN 1 25 Nm 18 ft-lb Tab. 32: Tightening specifications table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 133 – Rags – Cleaner – Bucket for fuel Overview Fig. 151: Task overview Fuel return block Screw (M8) Screw (M10) Screw (M8) Retaining plate Break leakage detection block © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 134 Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Special tool Designation HP Fuel Pump Lifting Device © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 135 HP Fuel pump with LP pump Removal u Remove a first screw 3 and a second one diametrically opposed. u Place guiding rods in place of the two screws. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 136 Install new O-ring. Information Lubricate HP connection o-ring with Castrol Optimol paste white T. Lubricate shaft teeth and o-rings with engine oil. Fig. 156: Fuel pump O-rings © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 137 Tighten screws to torque following the given order. (For more information see: Tightening speci- fications, page 138.) u Install HP pump piping. u Perform the venting on the fuel circuit. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 138 44 ft-lb 2 120 Nm 89 ft-lb 171AB 22L M26x1.5 1 140 Nm 103 ft-lb 212AA 22L M26x1.5 1 140 Nm 103 ft-lb Tab. 34: Tightening specifications table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 139 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 140 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) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 141 Previous tasks Not applicable. Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 142 Screw (M10) Compensator Nut (M10) End cover Compensator Screw (M10) Pipe Screw (M10) Clamp Screw (M12) Screw (M12) Distance sleeve See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 143 Fig. 162: Task overview Distance sleeve Screw (M12) Screw (M10) Pipe Pipe Screw plug Removal Fig. 163: Removing charge air lines u Remove screws 3, 10 with nuts 1, 4. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 144 Remove compensator 5 with seals 2. u Remove screws 20 with distance sleeves 19 and nuts 1. u Remove screws 3, 22. u Remove pipe 21 with seals 2. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 145 Screw assembly to charge air cooler with screws 11 and seal 2. u Screw clamps 7, 18 with screws 8, 16, locking plates 9 and distance sleeves 17. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US...
  • Page 146 Fig. 166: Installing clamps u Pretighten both screws 8 simultaneously to ensure Δ = Δ after tightening. Information Bend locking plates 9 after assembly. u Tighten screws 8 to torque. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 147 Screw clamps 7, 18 with screws 8, 16, locking plates 9 and distance sleeves 17. Information Bend locking plates 9 after assembly. u Tighten screws 8 to torque. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 148 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse and marking, page 274.) Charge air line removal and installation (EATS configuration) Previous tasks Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 149 Seal Screw (M10) Screw (M10) Screw (M10) Nut (M10) Screw (M10) Compensator Compensator Pipe Screw (M10) Clamp Distance sleeve See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 150 Fig. 170: Task overview O-ring Screw (M10) O-ring Screw (M10) Flap with actuator Compensator Flange joint Fig. 171: Task overview Distance sleeve Screw (M10) Screw (M10) Pipe Pipe Screw plug © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 151 Remove compensator 5, and seals 2. u Remove screws 10, and nuts 4. u Remove pipe 6. u Remove screws 11. u Remove compensator 5, and seals 2. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 152 Remove compensator 5, and seals 2. u Remove screws 10, and nuts 4. u Remove pipe 28. u Remove screws 11. u Remove compensator 5, and seals 2. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 153 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 154 Assemble pipe 6 with compensators 5, and seals 2 using screws 10, and nuts 4. u Install assembly to charge air cooler with screws 11 and seal 2. u Install assembly to turbocharger with screws 3, seal 2, and nuts 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 155 Fig. 177: Installing clamps u Pretighten both screws 8 simultaneously to ensure Δ = Δ after tightening. Information Bend locking plates 9 after assembly. u Tighten screws 8 to torque. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 156 Install assembly to turbocharger with screws 3, seal 2, and nuts 1. u Install clamps 7, 16 with screws 8, 14, distance sleeves 15, and locking plates 9. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US...
  • Page 157 Bend locking plates 9 after assembly. u Tighten screws 8 to torque. u Tighten all screws to torque, making sure that compensators are aligned evenly. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 158 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 159: Exhaust Gas System

    Replace all sealings. Special tools Not applicable. Consumables and equipment – Rags – Cleaner Overview Fig. 181: Task overview Terminal flange See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 160 Install screw plugs 3 in straight air intake connections 2, 7. Specific values Not applicable. Tightening specifications Fig. 182: Admission pipes Torque Angle (°) Screw specifications ± 5% ± 5° 221AA EN 1664 M10x1,5-10.9-FLZN 35 Nm 26 ft-lb © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 161 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 162 Position clamp segments 6 and hand tighten nuts 7. u Position supports 3 with distance sleeves 2. u Tighten nuts 7 to torque. u Tighten screws 1 to torque. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 163 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 164 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 165 Exhaust gas turbocharger Screw plug Nut (M10) Distance sleeve Seal Retaining plate Orifice plate Screw (M12) Fig. 186: Task overview Screw (M8) Compensator Cover O-ring O-ring Compensator Compensator © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 166 Remove compensators 14, 15, 17. u Remove cover 12. Fig. 188: Removing elbows u Remove screws 10, and distance sleeves 8. u Remove retaining plates 9. u Remove exhaust elbow 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 167 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 168 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 169 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 170 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 171 O-ring Seal Turbocharger Compensator Screw plug Distance sleeve Screw (M10) Removal Fig. 193: Removing turbocharger u Remove screws 1 and washers 2. u Open and loosen V-clamp 9. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 172 Mount compensator 6 with seal 5 on turbocharger 4, 12. u Tighten screws 8 with applied distance sleeves 7 to torque. u Insert o-rings 10, 11 in turbocharger bracket. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 173 Install turbocharger cooling lines. (For more information see: 3.10.3 Turbocharger cooling lines removal and installation, page 211.) Information Vent coolant circuit at the end of installation. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 174 *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 YY = Loctite 577 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 175 Consumables and equipment – Rags – Cleaner Overview Fig. 197: Task overview Flange joint Flange joint Pipe O-ring Clamp Pipe See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 176 Service and Repair Manual Exhaust gas system Plate Screw (M10) Screw (M8) Orifice Screw (M8) O-ring Distribution block Fig. 198: Task overview O-ring O-ring Flange Pipe Screw (M8) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 177 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 178 Assemble o-rings 17 on pipe 18 and place both flanges 15. u Insert o-rings 14 in bothflanges 15. u Position assembly with screws 16 between both turbocharger brackets on oil supply connection. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 179 Install plate 4 and clamps 3 with screws 5. u Tighten screws 5 to torque. Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 180 175.) Specific safety instructions Not applicable. Special tools Not applicable. Consumables and equipment – Rags – Cleaner Overview Fig. 203: Task overview - 60 Hz engine without EATS © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 181 Holder Fig. 205: Task overview Screw plug Seal Turbocharger bracket Oil return pipe Fitting O-ring Screw (M16) Screw (M8) See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 182 Remove holders 3, 6. u Remove screws 4. u Remove holder 5. u Remove screws 8, 9. u Remove holder 7. u Remove screws 4, 10. u Remove holder 11. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 183 Remove oil return pipe 19 with seal 18 and o-ring 20. u Repeat procedure for all oil return pipes 19. u Remove screws 16. u Remove bracket 17. u Repeat procedure for all brackets 17. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 184 Insert o-rings 20 on the oil return pipes 19. u Position turbocharger brackets 13 on the rocker arm housings with screws 15. u Tighten screws 15 to torque. u Install screw plugs 12, 22. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 185 (For more information see: 3.8.3 Exhaust gas turbocharger removal and installation (SL 213), page 170.) q Remove turbocharger bracket. (For more information see: 3.8.5 Turbocharger brackets removal and installation, page 180.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 186 Consumables and equipment – Hot temperature grease – Rags Overview Fig. 210: Task overview Compensator V-clamp Seal Removal u Loosen V-clamps 3. u Remove compensators 1 with seals 2. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 187 274.) Exhaust pipes removal and installation Previous tasks q Remove turbocharger. (For more information see: 3.8.3 Exhaust gas turbocharger removal and installation (SL 213), page 170.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 188 Outlet manifold Plug Screw (M10) Outlet manifold Seal Outlet manifold V-clamp Outlet manifold Compensator Plug Outlet manifold Sealing ring See next page for continuation of the image legend © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 189 Place outlet manifolds 2 with seals 1 and screws 3. u Tighten plugs 9, 11, 15, V-clamps 5 and screws 3 to torque. Specific values Not applicable. Tightening specifications Fig. 213: Exhaust pipe screws tightening sequence © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 190 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 191: Lubricating System

    Wait until the engine has cooled down. Special tools Not applicable. Consumables and equipment Not applicable. Overview Fig. 215: Task overview Clamp Clamp Hose Hose Screw (M8) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 192 Service and Repair Manual Lubricating system Removal Fig. 216: Removing hoses u Remove screw 3. u Remove clamp 4. u Loosen clamps 1. u Remove hoses 2, 5. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 193 (For more information see: 5.3.2 Screws pre-tightening, reuse and marking, page 274.) 3.9.2 Oil centrifuge removal and installation (depending on application) Previous tasks q Drain engine oil. Specific safety instructions Not applicable. Special tools Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 194 Remove screws 4 from pipe 14. u Disconnect pipe 14 with flange joints 15, 16. u Remove screws 9, 10. u Remove screws 12. u Remove holders 11. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 195 Connect flange joints 15, 16 to pipe 14. u Install cover plate 5 with o-ring 6 and screws 4. Specific values Not applicable. Tightening specifications Fig. 219: Oil centrifuge screws © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 196 3.9.3 Spin-on oil filters removal and installation Previous tasks Not applicable. Specific safety instructions Not applicable. Special tools Not applicable. Consumables and equipment – Cleaner – Rags – Optimol © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 197 Tighten filter by hand by 1/2 turn. Specific values Not applicable. Tightening specifications Refer to standard tightening torques. (For more information see: 5.3 Standard tightening torques, page 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 198 Consumables and equipment – Rags Overview Fig. 221: Task overview Screw (M8) Return valve Clamp Oil line Prelubricating pump O-ring Screw (M10) Relay Distance sleeve Screw (M12) Oil line Holder © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 199 Install return valve 8. u Tighten return valve 8. u Hand-tighten oil line 9. u Tighten screws 1. u Tighten oil lines 9, 12 nuts. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 200 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 201: Cooling System

    Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment – Rags – Cleaner Overview Fig. 223: Task overview HT collector Pipe Pipe Cover © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 202 Move clamp 7 to the middle of the pipe 3. u Push pipe 3 towards the left housing. u Remove rocker arm housing. u Remove pipe 3. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 203 Remove pipe 2. Fig. 227: Removing collector u Remove screws 6. u Remove collector 1. Installation Fig. 228: Installing collector u Insert o-ring 5 in HT collector 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 204 Insert pipe 3 from the left into the rocker arm housing. u After housing is installed, push pipe to the right until clamp 7 can be placed in its groove. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US...
  • Page 205 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 206 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 207 Repair Cooling system Fig. 233: Task overview Screw (M8) Holder Screw (M6) Holder Clamp Holder Nut (M6) Holder Holder Holder Distance sleeve Fig. 234: Task overview Venting line © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 208 Fig. 236: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 209 Fig. 237: Removing venting lines u Remove venting pipes 1, 3, 7, 9, 10, 11. u Remove screws 5. u Remove distributor block 6. Installation Fig. 238: Installing venting lines © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 210 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 211 (For more information see: 3.10.2 Venting line removal and installation, page 205.) Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 212 Aggregate support connector Pipe Screw (M10) Pipe Pipe Distance sleeve Retaining plate Screw (M8) Pipe Screw (M8) Fitting Screw (M8) Pipe Retaining plate Pipe Flange joint Retaining plate T connector © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 213 T connector O-ring Fitting Aggregate support connector Fitting Screw (M10) 90° connector Pipe T connector Screw (M8) Pipe Retaining plate Flange joint Pipe Adaptor Retaining plate Pipe Pipe © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 214 Unscrew connection nuts of pipes 6, 7, 15, 21, 23, 25, 26. u Remove fittings 24. u Remove screws 10, 11 and distance sleeve 8. u Remove retaining plate 12. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 215 Unscrew connection nuts of pipes 33, 36, 40, 43, 45. u Remove pipes 33, 36, 40, 43, 45. u Remove aggregate support connector 38. u Disconnect fittings, flange joints, and connectors. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 216 Mount pipes 33, 40, 43, 45 with T connectors 14, 28, 32. u Install 90° connectors 31 and fittings 30 on pipe assembly 33, 40, 43, 45. u Install plates 2 and clamps 3 with screws 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 217 Install retaining plate 27 with screws 1, plate 2 and clamp 3. u Install plates 2 and clamps 3 with screws 1, 9. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 218 274.) Turbocharger cooling lines removal and installation (EATS config- uration) Previous tasks q Remove venting lines. (For more information see: 3.10.2 Venting line removal and installation, page 205.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 219 Screw (M8) O-ring Pipe Aggregate support connector Pipe Screw (M10) Distance sleeve Pipe Screw (M8) Retaining plate Screw (M8) Pipe Clamp Fitting Screw (M8) Pipe Retaining plate Pipe © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 220 O-ring Fitting Aggregate support connector 90° connector Screw (M10) T connector Pipe Pipe Screw (M10) Pipe Retaining plate Coupling Pipe Flange joint Retaining plate T connector Pipe Pipe © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 221 Unscrew connection nuts of pipes 6, 7, 15, 21, 23, 25, 26. u Remove fittings 24. u Remove screws 10, 12 and distance sleeve 8. u Remove retaining plate 13. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 222 Unscrew connection nuts of pipes 32, 33, 37, 38, 42 45, 47. u Remove pipes 32, 33, 37, 38, 42 45, 47. u Disconnect fittings, flange joints, and connectors. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 223 Install 90° connectors 30 and fittings 29 on pipe assemblies 32, 42, 45, 47. u Install fittings 28. u Install retaining plates 44, 46 with screws 43. u Install plates 2 and clamps 3 with screws 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 224 Screw retaining plate 13 with screws 10, 12 and distance sleeve 8. u Install retaining plates 22 with screws 5. u Install plates 2, clamps 3, clamp 11 with screws 1, 9. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 225 3.10.4 Thermostat HT and housing removal and installation (SL 217) Previous tasks q Drain HT coolant circuit. Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 226 Screw (M12) Pipe O-ring Screw plug (depending on application) Removal u Remove two screws 4 diametrically opposed. u Place guiding rods in place of the two screws 4. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 227 3.10.5 Thermostat LT and housing removal and installation (SL 217) Previous tasks q Drain LT coolant circuit. q Remove venting line LT charge air cooler. (For more information see: 3.10.2 Venting line removal and installation, page 205.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 228 Replace all sealings. Special tools Special tool Designation Guiding rod M12x230 – Thermostat (x2) Tab. 48: Special tools Consumables and equipment – Vaseline – Rags – Cleaner © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 229 Assemble pipe 8 and flange 7 with o-rings 4, 7. u Insert o-rings 7 on coolant pump inlet. u Position pipe assembly on coolant pump inlet. u Position thermostats 1 in thermostats housing 2. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 230 Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Special tool Designation Guiding rod M12x100 - Coolant pump (x2) Tab. 49: Special tools © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 231 Remove remaining screws 16. u Remove coolant pump HT 9. u Remove screws 5, 15. u Remove coolant pipe 13 with flange 6. u Remove pipe 14 with flange 6. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 232 & PTO cover removal and installation, page 61.) Specific safety instructions NOTICE Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 233 – Rags – Cleaner – Vaseline Overview Fig. 262: Task overview Screw (M12) Flange Branch pipe O-ring O-ring O-ring O-ring O-ring Pipe Coolant pump LT Screw (M10) Screw © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 234 Assemble branch pipe 2 with pipe 5 and flange 7 with o-rings 3, 4, 8. u Position assembly with screws 1, 6 and tighten according to tightening specifications. Information Vent coolant circuit at the end of installation. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 235 59.) Specific safety instructions Not applicable. Special tools Special tool Designation Locking device Tab. 51: Special tools Consumables and equipment – Rags – Cleaner © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 236 Cooling system Overview Fig. 265: Task overview Screw (M16) Screw (M28) Washer Axle Pulley Removal Fig. 266: Locking device u Install locking device with screws (M16) to lock crankshaft. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 237 Remove pulley 3. u Remove screws 4. u Remove axle 5. u Remove locking device. Installation Fig. 268: Locking device u Install locking device with screws (M16) to lock crankshaft. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 238 Observe screws 4 tightening sequence and tightening torque. u Tighten screws 4 to torque. u Install pulley 3 with screws 1, and washers 2. u Tighten screws 1 to torque. Specific values Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 239 Fig. 270: Tightening sequence of pulley axle screws Fig. 271: Screws of fan drive pulley Torque Angle (°) Screw specifications ± 5% ± 5° M16x55 10.9 FLZN 1 275 Nm 203 ft-lb © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 240 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 241: Electrical System

    Special tools Special tool Designation Pin for belt tensioner (x1) Frequency meter Tab. 53: Special tools Consumables and equipment – Vaseline – Rags – Belt tension frequency meter © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 242 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 243 Remove belt 13. u Remove guiding rod. Fig. 275: Removing battery charging alternator u Remove screws 4, 18. u Remove battery charging alternator 1. u Remove distance sleeve 20. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 244 Remove screws 7. u Remove auxiliary PTO 12. u Remove o-rings 10, 11. Fig. 277: Removing tensioning device u Remove screw 14. u Remove tensioning device 15. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 245 Installation Fig. 279: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 246 Fig. 281: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 247 Install belt 13 on the PTO pulley. u Remove the guiding rod. u Use 1/2” toggle in tensioning device 15 to tension belt 13. u Check belt 13 tension. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 248 **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse and marking, page 274.) 3.11.2 Starter removal and installation (SL 260) Previous tasks Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 249 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 250 30 Nm (22 ft-lb) Tab. 55: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 251 – Not applicable. Special tools – Not applicable. Consumables and equipment – Not applicable. Overview Fig. 287: Task overview Starter Screw (M16) Removal u Disconnect starter electrical connections. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 252 *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 YY = Loctite 577 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 253 Service and Repair Manual Repair Electrical system **Refer to screws reuse rules. (For more information see: 5.3.2 Screws pre-tightening, reuse and marking, page 274.) ***± 25% Accuracy is accepted. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 254: Exhaust Aftertreatment System

    Risk of property damage by reuse of sealing. Leakage by faulty seal. u Replace all sealings. Special tools Not applicable. Consumables and equipment – High temperature grease – Rags – Cleaner © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 255 Disconnect the diesel exhaust fluid return line from the injector. u Disconnect the electrical connector from the injector. Information Make sure that dust cannot go into the system. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 256 Fig. 292: Removing injector assembly u Remove the injector 3, and the retaining plate 10 together as an assembly. Information Make sure the screws remain in place on the reactor. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 257 Clean the sealing surface on the reactor. Information The sealing surface between injector and reactor must be clean to avoid gas leakage. u Apply high temperature grease on the screws. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 258 Make sure that the gasket 7 remains in place during installation. Make sure that the injector inlet port faces 3 downwards and overlaps the slot in the retaining plate 10. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 259 Connect the diesel exhaust fluid inlet line. u Connect the diesel exhaust fluid return line. u Connect the electrical connector. u Run the system for 30 min to confirm leak-free operation. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 260 Pay attention to the center of gravity and the total weight. u Ensure the load against slipping and toppling. Special tools Not applicable. Consumables and equipment Not applicable. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 261 Screw (M10) 10-pin connector Lifting hook 48-pin connector Connection (M26/M22) Removal Fig. 299: Securing pump u Using the lifting hooks 3, secure the pump 1 to a crane. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 262 It is forbidden to handle the connector locking device 8 on the pump side. Only use the lock on the harness side to disconnect the 10-pin connector 6. u Disconnect the connectors 4, 5 of the diesel exhaust fluid lines. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 263 Remove the pump 1. Installation Fig. 303: Installing pump u Install the pump 1 with screws 2. u Tighten the screws 2 to 33 ±3 ±2 Nm (24 ft-lb). © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 264 Tighten the fastening screws of the 48-pin connector 7 to 4 ±0.5 ±0 Nm (3 ft-lb). Fig. 305: Connector locking device - handling forbidden u Connect the 10-pin connector 6 to the pump 1. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 265 Run the system for 30 min 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 274.) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 266: Tools And Devices

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 267 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 268 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 269 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 270 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. Use the turning device q The turning device is mounted on the engine.
  • Page 271 Remove turning device 2. u Position cover 3. u Mount and tighten screws 4 according to standard torques values. Information For queries, please contact your nearest authorized Kohler service representative. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 272: Technical Design Documents

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US...

  • Page 273: Cleaning Agents, Thread-Locking Adhesives And Greases

    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. 60: Greases © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 274: Standard Tightening Torques

    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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 275 For every maintenance task, when a sequence is specified, achieve step 1 for all the sequence before starting step 2. Fig. 330: Standard sequence for 4, 5 and six screws. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 276 Except components listed below, and otherwise noted, u Marking on screws or nuts to track their reuse is not required. Fig. 331: Examples of markings on screws and HP pipe nut. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 277 100 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 278 – Hexagon head screw plugs with collar - Cylindrical thread according to DIN 910 – Internal drive screw plugs with collar - Cylindrical thread according to DIN 908 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 279 240 Nm M 65 x 2 620 Nm 52 ft-lb 177 ft-lb 457 ft-lb Tab. 65: Tightening torques for screws according to DIN 7643, DIN 910, DIN 908 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 280: Standard Torques For Flange Joints

    540 Nm 260 Nm 214 ft-lb 465 ft-lb 398 ft-lb 192 ft-lb Tab. 66: Standard torques for metric thread unions L series, for steel – see figure above © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 281 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). © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 282 G 1/2A 65 Nm 150 Nm 115 Nm 48 ft-lb 111 ft-lb 85 ft-lb G 1/2A 65 Nm 130 Nm 115 Nm 48 ft-lb 96 ft-lb 85 ft-lb © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 283 432 Nm 208 Nm 171 ft-lb 372 ft-lb 319 ft-lb 153 ft-lb Tab. 70: Standard torques for metric thread unions L series, for aluminium – see figure above © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 284 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). © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 285 G 1/2A 52 Nm 120 Nm 92 Nm 38 ft-lb 89 ft-lb 68 ft-lb G 1/2A 52 Nm 104 Nm 92 Nm 38 ft-lb 77 ft-lb 68 ft-lb © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 286 Fig. 347: Cutting ring lubrication Information Tolerances of the indicated tightening torques: 10 %. Always lubricate the thread before tightening these parts (engine oil). Fig. 348: Cutting ring tightening © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 287: Standard Torques For Triple Lock Flange Joints

    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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 288 Tolerances of the indicated tightening torques: 10 %. Always lubricate the thread before tightening these parts (engine oil). Fig. 350: VSTI screw plugs with ED seal (left), with o-ring (right) © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 289 Tab. 76: 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. © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 290 127 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 291 Tighten the nut a further 90°. 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 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 292 5 ft-lb 25 mm 12 Nm 0.98 in 9 ft-lb 30 mm 30 Nm 1.18 in 22 ft-lb Tab. 79: Tightening torques for collar clamps according to DIN 3017-3 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 293: Abbreviations - Acronyms

    Personal Protective Equipment Power Take-Off Repair and Service Manual SAPS Sulphated Ash, Phosphorus and Sulfur Safe Work Procedure Top Dead Center Volume Control Valve Tab. 80: Abbreviations table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 294 American National Standards Institute German standard European standard European Union International Labor Organisation ISCED International Standard Classification of Education Society of Automotive Engineers World Health Organization Tab. 81: Acronyms table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...

  • Page 295: Unit Conversion Tables

    Tab. 84: Pressure conversion factors table 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. 85: Volume conversion factors table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 296 °C K = C + 273.15 Tab. 90: Temperature conversion factors table 5.5.10 Density conversion factors Convert from Multiply by Kg/m lb/US gallon 0.00834 Kg/m lb/imperial gallon 0.01002 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 297 Service and Repair Manual Appendix Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 91: Density conversion factors table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 298 Appendix Service and Repair Manual Prefix 5.6 Prefix Name Symbol Factor tera giga mega kilo milli μ micro nano Tab. 92: Common prefix multipliers table © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 299 Service and Repair Manual Appendix Prefix © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07...
  • Page 300 33525088901_2_1 EN_US 2021-07 LHID12868252 © 2021 by Kohler Co. All rights reserved.

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