Page 1 Service and Repair Manual Original Instructions Diesel engine KD83V16 From serial number 2019740015 EN_US 33525088901_1_1 02-2019...
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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 3: Service Assistance
Kohler distributor or dealer. – Visit the KOHLER Co. website at KOHLERPower.com. – Look at the labels and decals on your KOHLER product or review the appropriate literature or documents included with the product. – Call toll free in the US and Canada 1-800-544-2444.
Page 4 For KOHLER-SDMO power generating sets: – Visit the website the site of KOHLER-SDMO at www.kohlersdmo.com. – Pay attention to the labels and stickers on your KOHLER-SDMO product or check the corre- sponding literature or documents included with the product's scope of delivery.
Page 5: Revision History
Revision history Version Author Modification Date First edition (3.01 engine version) July 2018 First 3.02 engine version, of February 2019 Spelling mistakes © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 7: 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 8: 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 9: 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 10: 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 39) Each task in this manual have the following structure: © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 11 Setting values spreadsheet to check the nominal and tolerances values of critical components Tightening specifications table for specific fastener Tightening sequence table if required 10. Data recording sheet, if required, to inform the engine manufacturer. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 13 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 2.6.1 Preventing bruising 2.6.2 Preventing burns © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 14 Inlet and outlet rocker arms removal and installation 3.4.2 Rocker arms housing removal and installation Cylinder head (SL 224) 3.5.1 Cylinder head removal and installation Driving gear 3.6.1 Power unit © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 15 3.12.1 Power take-off (PTO) and battery charging alternator removal and installation (SL 218, SL 223) 3.12.2 Starter removal and installation 3.12.3 Engine Control Unit (ECU) Tools and devices Tools © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 16 Pressure conversion factors 5.5.4 Volume conversion factors 5.5.5 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 17 Service and Repair Manual Contents 5.5.9 Temperature conversion factors 5.5.10 Density conversion factors Prefix © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 21: Product Description
Charge air cooler Engine brackets (x4) Battery charging alternator Flywheel Oil dipstick Fuel filter Oil centrifuge assembly Crankcase ventilation filter housing High pressure fuel pump (x2) Turbocharger assembly (x4) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 22 CCS Engine front (vibration damper side) Cylinder head cover Vibration damper cover Charge air pipe Engine control unit - ECU (x2) Starter (x2) Straight air intake (x4) Oil pan © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 23: Cylinder Designation, Direction Of Rotation
Direction of rotation 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 24: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 25: Engine Serial Number
The engine serial number is stamped into the engine nameplate. Designation Description 2016 0001 Engine serial number 2016 Year of manufacture Engine type code (73= KD62V12) (74= KD83V16) 0001 Incremential production number Tab. 3: Engine serial number © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 26 Service and Repair Manual Technical description Fig. 8: Serial number on nameplate Serial number Engine control nameplates Fig. 9: Example of engine control unit nameplates Software nameplate Hardware nameplate © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 27 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 28 The connecting rod identification is stamped on the connecting rod and on the connected rod bearing cap. Fig. 13: Connecting rod number location Matching of the connecting rod and connecting rod bearing cap is identified by connecting rod number. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 29: Turbocharger Identification
The turbocharger company nameplate is mounted on the turbocharger. Oil cooler identification Fig. 15: Oil cooler nameplate The oil cooler company nameplate is mounted on the oil cooler. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 30 Injector identification Fig. 16: Injection number location The injector identification number is stamped on the side of the injector. High-pressure pumps identification Fig. 17: High pressure pump nameplate © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 31 Technical description Fig. 18: High pressure pump number The high pressure pump number is stamped on the pump. Charge air cooler identification Fig. 19: Charge air cooler nameplates © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 32 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 33: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 34: Fuel Diagram
Fuel cooler (optional) Fuel prefilter & water sepa- Distribution Block rator Servicing point B710 – WIF pre-filter 1 B704 and B705 – HP pump (Bank A and B) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 35 Drain port Pressure Safety Valve 13.4 Pistons pins B Oil sampling Spin-on oil filter Support bearing Flywheel Prelubricating pump Gear box Turbochargers Bypass valve for cold start HP Pump © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 36 Charge Air Cooler A LT Expansion tank (including Water pump LT ventilation line) Charge Air Cooler B Venting HT Mechanical thermostat Elbow A Venting LT Manual venting point © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 37 Elbow - A side Engine A bank uration For odd number of turbo- Turbocharger Engine B bank chargers only See next page for continuation of the image legend © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 38 B781 - Air intake pressure B703 - Charged air pressure switch - B side (clogging) A after charge air cooler Engine type Number of turbochargers Tab. 4: Blowby connections © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 39: 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. 7: Additional symbols © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 40: Additional Rules And Directives
Follow these instructions and observe any additional or local rules and directives! Additional points that should be noted are: – the safety regulations which apply on site, – the guidelines provided by professional associations. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 41: 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 42: For The Sl3 Maintenance Of Power Generation Engines: Mechan- Ical Technician
– Completing and maintaining station records, logs and reports, and communicating with other plant personnel to assess equipment operating status. – Cleaning and maintaining equipment such as generators, pumps and compressors in order to prevent equipment failure or deterioration. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 43: Intended Use
Any other use above and beyond this is considered to be improper use. In this case, Kohler Co. is not liable for any damages. The risk is placed solely on the user.
Page 44 (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 45: 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 46: Safety When Starting
Loss of stability, hazards generated by vibration! Fatal or serious injuries. u Standing in the vicinity of the engine while starting or operating the manufacturer’s machinery is forbidden. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 47 Standing in the vicinity of the engine while starting or operating the machinery is forbidden. u Wear proper personal protective equipment. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 48: Preventing Injuries
Only check operating fluids level after the operating fluids temperature has cooled down to a level it can be touched. u Carefully open the lid in order to first reduce the excessive pressure. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 49: 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. © 2019 by Kohler Co. All rights reserved.
Page 50: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 51: Personal Protective Equipment (Ppe)
The manufacturer of the machinery shall forbid any accessories and loose clothing. Following personal protective equipment is necessary: © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 52 Must be worn in the direct vicinity of the engine Safety goggles Protection against flying splinters and chemical splashes. Must be worn when handling operating materials and during mechanical opera- tions. Tab. 8: Personal protective equipments © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 53: 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 54: Engine In Commissioning - Test-Run
Initiate an emergency stop only in emergency situations. Initiating an emergency stop:: u Press the emergency button. After an emergency stop: u Remedy to the emergency situation. u Acknowledge the emergency buttons and signals. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 55: 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. 9: Engine area signs requirement © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 56: Prevent Property Damages
In combination with the machinery diagnosis system, the fault code is shown via a display. u Switch over to appropriate backup/emergency functions for further, restricted operation of the engine (for example, constant limp-home speed). u Get faults immediately repaired. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 57: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 58: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 59: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 61 (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 62 3.2.1 Vibration damper cover removal and installation Previous work Safety Special tools Consumables Overview Fig. 49: Overview Screw (M8) Cover Protection plate Screw (M12) Removal u Remove screws 1. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 63: Installation
Respect the voltage indication of the engine’s technical data sheet. u Check the grounding connection to avoid any risk of electrical arc. u Observe the local safety regulations that apply to the machinery. Special tools © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 64 Fig. 50: Task overview Nut (M8) Distance sleeve Lock washer Vibration damper Captive screw (M8) Cover - front side Cover - back side Removal Fig. 51: Removing cover - front part © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 65 Remove nuts 6, vibration dampers 3, distance sleeves 2 and pins 1, 4. u Remove cover - back side 5 Installation Fig. 53: Installing pins u Screw pins 1, 4 on aggregate support and PTO bracket. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 66: Setting Values
Screw cover with nuts 6. Fig. 55: Installing cover u Mount cover 9 on pins 1, 4. u Fix cover 9 with lock washers 7 and screws 8. Setting values – / © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 67: Tightening Specifications
MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 3.2.3 Cylinder head cover removal and installation Previous work © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 68: Special Tools
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 Consumables © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 69 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 70 Tab. 11: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 72 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 73 A4, A6 B1, B3 rotation of the flywheel Tab. 13: Reference table for the flywheel positioning Set the valve clearance u Set flywheel in position of the mentioned grooves. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 74 Rotate crankshaft in direction of rotation with turning device until index 4 is reached the second time (see 4+360° in the table). u Set the valve clearance for cylinders A4, A6 and B1, B3. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 75: Checking Valve Clearance
Repeat procedure for next valve. u Mark cylinder when the operation is completed. u Repeat entire procedure for rocker arm exhaust 5. Setting values Use feeler gauge to set valve clearance. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 76 Inlet valve/ 0.5 mm +0.1 mm (0.00“ in) clearance 0.02“ in Outlet 1 mm +0.1 mm (0.00“ in) valve/ 0.04“ in clearance Tab. 14: Tolerance values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 77 Tab. 15: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 78 Special tools Special tool Designation Turning device. (For more information see: Use the turning device, page 197) Tab. 16: Special tools Consumables – Oil – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 79 Inlet shaft Pushrod Screw (M12) Valve bridge Rocker arm exhaust Fitting sleeve Exhaust shaft Rocker arm inlet Rocker arm housing Removal Fig. 70: Removing screws u Remove screws 7. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 80 Remove exhaust shaft 9 from rocker arm exhaust 8. Fig. 73: Removing pushrods and valve bridges u Remove valve bridges 3 and pushrods 2 from swing followers 1. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 81 Insert exhaust shaft 9 into rocker arm exhaust 8. Fig. 76: Installing pushrods and valve bridges u Insert pushrods 2 into cylinder head and fit it with swing followers 1. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 82 Angle (°) Screw connec- Screw type tion ± 5% ± 5° 081AC Hexagon head ISO 4762 1 100 Nm bolt M12x1.75x150-10. 74 ft-lb Tab. 17: Tightening specifications table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 83 Designation Turning device. (For more information see: Use the turning device, page 197) Coolant connector pipe tool Tab. 18: Special tools Consumables – Oil – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 84 Rocker arm housing Fitting sleeve (x5) Seal Removal WARNING The valve springs must not be under stress. Risk of injuries. u Turn crankshaft to another position using turning device. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 85 Service and Repair Manual Repair Rocker arms housing Fig. 82: Sliding locking ring u Slide locking ring 8. Fig. 83: Placing tool © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 86 Separate rocker arm housing from water pipe HT 7 and closing cover 3. u Remove seals 4, 6 from closing cover and water pipe HT. u Remove fitting sleeves 5. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 87 Grease water conduct. u Insert fitting sleeves 5. Fig. 87: Mounting closing cover u Mount closing cover 3 on rocker arm housing with screws 2 and seal 4. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 88 Insert water pipe HT 7 in rocker arm housing. Fig. 89: Inserting pins and seal u Position seal 10 on cylinder head. u Insert positioning pins 1 in rocker arm housing. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 89 Rocker arms housing Fig. 90: Placing tool Information Tighten screws from inlet and outlet rocker arms. u Place tool on pipe. u Insert pipe into rocker arm housing. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 90 Secure pipe with locking ring 8. u Mount rocker arm housing on cylinder head. Information Vent coolant circuit at the end of installation. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 91 – / Special tools – Lifting tool with steel bar – Socket – Torque spanner – T-bar – Marker Consumables – Vaseline – Molykote – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 92 Fig. 93: Lifting the cylinder head u Unscrew bolts 6. u Mount lifting device on cylinder head. u Lift and push cylinder head up and down to dismantle it. u Remove cylinder head. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 93 Mount flame ring 5 in liner. Fig. 95: Installing sealing carrier and O-rings u Mount locating pins 8. u Mount seal carrier 3 with O-rings 2. u Grease O-rings 2. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 94 Mount lifting device on cylinder head. u Mount cylinder head. Fig. 97: Inserting cylinder head bolts u Grease bolts 6 and washers 7. u Insert and tighten the bolts. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
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. Setting values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 96 Tab. 19: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 97 (For more information see: 3.7.4 Injector removal and installation (SL 205), page 107) Safety Special tools Special tool Designation Turning device. (For more information see: Use the turning device, page 197) Tab. 20: Special tool Consumables – / © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 99 Scratch traces Complete length 290° Dirt traces Center 2 cm (0.79“ in) 170° 200° Traces 80% of height Honing pattern visible Tab. 21: Example of note on endoscopy results © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 100: Fuel System
3.7.1 Venting pipes removal and installation Previous work q Fuel supply closed. Safety – / Special tools – / Consumables – Rags – Cleaner – Bucket for fuel © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 101 Service and Repair Manual Repair Fuel system Overview Fig. 104: Venting circuit – Fuel return pipes Fig. 105: Venting circuit - Fuel pumps piping © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 102 Leakage indication high pressure system Leakage fuel distributor block Removal u Remove venting pipes. Installation u Mount venting pipes. u Tighten according to standard tightening specifications. Setting values – / © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 103 Keep the engine away from heat, sparks, open flame, or any other ignition source. Special tools – Plugs for piping Consumables – Rags – Cleaner – Bucket for fuel © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 104 Repair Service and Repair Manual Fuel system Overview Fig. 107: High pressure piping – pumps Fig. 108: High pressure piping – engine © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 105 Mount high pressure circuit pipes. u Tighten according to tightening specifications. Setting values Tightening specifications Fig. 109: High pressure pipes Fig. 110: High pressure pipes to cylinder © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 106 XX = Loctite 243 3.7.3 Fuel supply pipes removal and installation Previous work q Fuel supply line closed. Safety – / Special tools – / Consumables – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 107 Tightening specifications 3.7.4 Injector removal and installation (SL 205) Previous work q Cylinder head covers removed, (For more information see: 3.2.3 Cylinder head cover removal and installation, page 67) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 108 Leakage by faulty seal. u Replace all sealings. Special tools Special tool Designation Injector extractor Tab. 23: Special tools Consumables – Vaseline – Molykote – Rags – Cleaner – Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 109 Fuel system Overview Fig. 113: Task overview Injector sleeve Screw (M12) Retaining plate Injector clamp Screw (M12) Collet Injector Adaptor High pressure pipe Removal Fig. 114: Removing electrical contacts © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 110 Take off high pressure pipe 5 from adaptor 9. Fig. 116: Removing retaining plate u Remove retaining plate 2 with screws 3. u Close all open connections with the matching plugs (available as spare parts). © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 111 Service and Repair Manual Repair Fuel system Fig. 117: Removing clamp u Remove clamp 7 by opening screw 6. Fig. 118: Extracting injector u Remove injector 4 with extracting tool. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 112 Fig. 120: Installing injector and clamp u Position injector 4 with its connection upwards into sleeve 1. u Introduce clamp 7 with screw 6. u Screw the collet 8 of 90° back. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 113 Information Injectors can be mounted in two positions. Note that only one position is correct. Fig. 122: Installing retaining plate u Position retaining plate 2 with screws 3. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 114 Proceed to tightening sequence, see section “Tightening specifications”. Fig. 124: Connecting electrical contacts u Connect electrical cables on the corresponding solenoid connector. u Tighten to torque. Setting values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 115 Tab. 24: Tightening sequence Injector Sequence Side Bolt / Tie rod. Angle (°) Checked From to Electrical wires 0,5 Nm (0.36 ft.lb) Tab. 25: Electrical Group - Tightening values Fig. 125: Injector © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 116 Tab. 26: Tightening values Injector *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 117 Flange joint Protection guard Flange joint Flange joint Screw (M10) Flange joint Fuel filter unit Removal u Remove flange joints 3, 4, 5, 6. u Remove screws 1. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 118 Tab. 27: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 119 Removal u Remove screws 5 and break leakage detection block 6. u Remove screws 4 and retaining plate 3. u Remove screws 2 and fuel return block 1. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 120 Replace all sealings. Special tools Special tool Designation HP Fuel Pump Lifting Device Guiding rod M12 (x2) Tab. 28: Special tools Consumables – Vaseline – Oil – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 121 Removal u Remove a first screw 3 and a second one diametrically opposed. u Place guiding rods in place of the two screws. u Remove remaining screws 3. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 122 Install fuel pump lifting device. u Remove fuel pumps. u Remove guiding rods. Installation u Install new O-ring. Fig. 133: Fuel pump O-rings u Place guiding rods. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 123 Place remaining screws and remove lifting tools. u Tighten screws to torque following the given order. u Install HP pump piping. u Perform the venting on the fuel circuit. Setting values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 124 (°) Injection pump 1 -> 6 Tighten 60 Nm screws 44 ft-lb Injection pump 1 -> 6 Tighten 120 Nm screws 89 ft-lb Tab. 29: Tightening values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 125 – / Consumables – Rags – Cleaner – Grease (Optimol) Overview Fig. 136: Task overview Nut (M10) Screw (M10) See next page for continuation of the image legend © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 126 Screw (M10) Screw (M12) Screw (M12) Clamp Distance sleeve Screw (M10) Clamp Fig. 137: Task overview Distance sleeve Screw plug Screw (M10) Pipe Screw (M10) Screw (M12) Pipe © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 127 Remove screws 3, 10, 15 with nuts 1 and washers 14. u Remove compensator 11 with seals 2. u Remove screws 13. u Remove end covers 12 with seals 2. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 128 Remove screws 20 with distance sleeves 19 and nuts 1. u Remove screws 3, 22. u Remove pipe 21 with seals 2. u Remove screws 10, 15 with washers 14. u Remove compensator 4 with seals 2. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 129 Screw clamps 8, 18 with screws 7, 16, locking plates 6 and distance sleeves 17. Information Bend locking plates 6 after assembly. u Tighten screws 7 to torque. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 130 Screw clamps 8, 18 with screws 7, 16, 26, locking plates 6 and distance sleeves 17. Information Bend locking plates 6 after assembly. u Tighten screws 7, 26 to torque. Setting values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 131 3.8.2 Charge air cooler removal and installation (SL 220) Previous work q Venting line removed, (For more information see: 3.11.1 Venting line removal and installation, page 158) q LT coolant water drained. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 132 Insert o-ring 5 in charge air cooler 4. u Insert pipes 6 in aggregate support. u Position charge air cooler 4. u Screw charge air cooler 4 with screws 1, 2 and distance sleeve 3. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 133 Tab. 31: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 134: Exhaust Gas System
Replace all sealings. Special tools – / Consumables – Rags – Cleaner Overview Fig. 145: Task overview Terminal flange See next page for continuation of the image legend © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 135 Setting values Tightening specifications Fig. 146: Admission pipes Torque Angle (°) Screw connection Screw type ± 5% ± 5° 221AA EN 1664 M10x1,5-10.9-FLZN 1 35 Nm 26 ft-lb © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 136 Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. Special tools – / Consumables – Hot temperature grease – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 137 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 138 Tab. 33: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 139 Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. Special tools – / Consumables – Hot temperature grease – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 140 Washer V-clamp Turbocharger Gasket Seal O-ring Compensator O-ring Distance sleeve Removal Fig. 150: Removing turbocharger u Remove screws 1 and washers 2. u Open and loosen V-clamp 8. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 141 Tighten screws 7 with applied distance sleeves 6 and seal 4 to torque. u Insert o-rings 10, 11 in turbocharger bracket. u Grease V-clamp lips and on the thread with Molykote HSC. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 142 Tab. 34: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 143 – Rags – Cleaner Overview Fig. 154: Task overview Flange joint Flange joint Pipe O-ring Clamp Pipe Plate Screw (M10) Screw (M8) Orifice Screw (M8) O-ring Distribution block © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 144 Repair Service and Repair Manual Exhaust gas system Fig. 155: Task overview O-ring O-ring Flange Pipe Screw (M8) Removal Fig. 156: Removing distribution block and pipes © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 145 Remove distribution block 7 and o-ring 9. u Remove flange joints 1, 8. Fig. 157: Removing flanges and pipes u Remove screws 16. u Remove flanges 15 with o-rings 14 and pipe 18. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 146 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. u Tighten screws 16 to torque. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 147 Install pipe 2 with flange joints 1 on oil entry of turbocharger bracket. u Tighten screws 11 to torque. u Install plate 4 and clamps 3 with screws 5. u Tighten screws 5 to torque. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 148 – Cleaner Overview Fig. 160: Task overview Screw (M12) Holder Screw (M12) Holder Holder Washer Screw (M12) Screw (M12) Holder Screw (M12) Screw (M12) Screw (M8) Screw (M12) Holder © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 149 Fig. 161: Task overview Screw plug Seal Turbocharger bracket Oil return pipe Fitting O-ring Screw (M16) Screw (M8) Screw (M10) Screw plug Holder Removal Fig. 162: Removing holders © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 150 Remove oil return pipe 22 with seal 21 and o-ring 23. u Repeat procedure for all oil return pipes 22. u Remove screws 19. u Remove bracket 20. u Repeat procedure for all brackets 20. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 151 Insert o-rings 23 on the oil return pipes 22. u Position turbocharger brackets 16 on the rocker arm housings with screws 18. u Tighten screws 18 to torque. u Install screw plugs 15, 25. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 152 Screw holder 8 with screws 6, 7. u Screw holder 9 with screws 11, 12 and washers 10. u Screw holder 14 with screws 4, 13. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 153: Lubricating System
Previous work – HT coolant water drained. Safety Special tools Special tool Designation Guiding rod M12x600 - Oil cooler (x2) Tab. 35: Special tools Consumables – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 154 Position oil cooler on oil cooler casing 1. u Tighten by hand screws 4 with sleeves 3. u Remove guiding rods. u Mount remaining screws 4. u Tighten all screws to torque according tightening specifications. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 155 Safety NOTICE Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. Special tools – / Consumables – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 156 Remove by-pass valve 1. Installation u Insert by-pass valve 1. u Tighten by-pass valve to torque. Setting values Tightening specifications Fig. 169: Oil cooler by pass valve © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 157 Tab. 36: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 158: Cooling System
– / Consumables – Rags – Cleaner Overview Fig. 170: Task overview Venting LT turbocharger Venting LT charge air cooler See next page for continuation of the image legend © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 159 Venting LT turbocharger Screw (M10) Venting HT collecting pipe Distribution block Fig. 171: Task overview Screw (M8) Holder Screw (M6) Holder Clamp Holder Nut (M6) Holder Holder Holder Distance sleeve © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 160 Repair Service and Repair Manual Cooling system Fig. 172: Task overview Venting line Removal Fig. 173: Removing venting lines u Remove venting line 23 with flange joints 2. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 161 Remove holders 16, 18, 19, 20, 21, 22 with screws 5, 12, and distance sleeve 17. Fig. 175: Removing venting lines u Remove venting pipes 1, 3, 7, 9, 10, 11. u Remove screws 5. u Remove distributor block 6. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 162 Install venting pipes 1, 3, 7, 9, 10, 11 with T connector 4 and flange joints 2, 8. Fig. 177: Installing venting lines u Install holders 16, 18, 19, 20, 21, 22 with screws 5, 12, and distance sleeve 17. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 163 Safety NOTICE Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. Special tools Consumables – Vaseline – Rags – Cleaner © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 164 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 165 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 166 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 167 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 168 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 169 Screw retaining plate 12 with screws 10, 11 and distance sleeve 8. u Install retaining plate 27 with screws 1, plate 2 and clamp 3. u Install plates 2 and clamps 3 with screws 1, 9. Setting values © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 170: Tightening Specifications
3.11.3 Thermostat HT and housing removal and installation (SL 217) Previous work q HT coolant circuit drained. Safety NOTICE Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 171 O-ring Removal u Remove two screws 4 diametrically opposed. u Place guiding rods in place of the two screws 4. u Remove remaining screws 4 and screws 7. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 172 (For more information see: 3.11.1 Venting line removal and installation, page 158) Safety NOTICE Risk of property damages by reuse of sealing ! Leakage by faulty seal. u Replace all sealings. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 173 Guiding rod M12x230 – Thermostat (x2) Tab. 39: Special tools Consumables – Vaseline – Rags – Cleaner Overview Fig. 189: Task overview Thermostat Flange Thermostat housing Screw (M10) Screw (M12) O-ring O-ring Pipe © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 174 Thermostats LT start to open at 45 °C (113 °F) and are fully opened at 57 °C (135 °F). Tightening specifications 3.11.5 Water pump HT removal and installation (SL 216) Previous work q HT coolant circuit drained. q Machinery HT cooling system piping removed. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 175 Tab. 40: Special tools Consumables – Rags – Cleaner – Vaseline Overview Fig. 191: Task overview Screw (M12) O-ring See next page for continuation of the image legend © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 176 Position assembly with screws 1, 5 and tighten according to tightening specifications. u Install test point fitting 8 on water pump. Information Vent coolant circuit at the end of installation. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 177 Leakage by faulty seal. u Replace all sealings. Special tools Special tool Designation Guiding rod M12x100 - Water pump (x2) Tab. 41: Special tools Consumables – Rags – Cleaner – Vaseline © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 178 Branch pipe O-ring O-ring O-ring O-ring O-ring Pipe Water pump LT Screw (M10) Screw Fig. 194: Task overview O-ring O-ring Flange Elbow pipe O-ring Screw (M12) Screw (M10) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 179 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. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 180: Electrical System
Replace all sealings. Special tools Special tool Designation Pin for belt tensioner (x1) Frequency meter Tab. 42: Special tools Consumables – Vaseline – Rags – Belt tension frequency meter © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 181 Washer Distance sleeve Plate Plate Distance sleeve Washer Screw (M12) Screw (M10) Roller Screw (M8) Screw (M10) Screw (M10) Tensioning device Sleeve O-ring Nut (M10) O-ring Screw (M12) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 182 Remove V-belt 15. u Remove guiding rod. Fig. 198: Removing battery charging alternator u Remove screws 4, 23. u Remove battery charging alternator 1. u Remove sleeve 24. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 183 Fig. 200: Removing tensioning device and plate u Remove screws 16, washer 17 and nut 25. u Remove tensioning device 11. u Remove plate 18 with pin 20 and distance sleeve 19. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 184 Remove plate 6. Installation Fig. 202: Installing auxiliary PTO u Grease o-rings 12, 13. u Insert o-rings in auxiliary PTO 14. u Mount auxiliary PTO with screws 8. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 185 Screw roller 9 with screw 10. u Screw plate 6 with screws 8, 21, 22, washers 7, 17 and distance sleeve 5. u Tighten screw 10 to torque. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 186 Use a guiding rod in the specified location to lock the tensioning device. u Mount V-belt 15 on the alternator and PTO pulleys. u Remove the guiding rod. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 187 Tab. 43: Tightening specifications table *Lubricants: MG = Molykote G-n-plus MW = Castrol Optimol paste white T MH = Molykote HSC O = Engine oil XX = Loctite 243 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 188: Starter Removal And Installation
– / Consumables – Rags – Cleaner Overview Fig. 208: Task overview Ground connection - Screw (M16) Starter Power supply T30, battery + Wiring harness connection Ground cable © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 189 Setting values Tightening specifications Fig. 209: Starter nuts Torque Angle (°) Screw connec- Screw type tion ± 5% ± 5° 22 Nm (16 ft-lb) -30 Nm (22 ft-lb) © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 190 Rubber hoses removal and installation (SL219) Previous work Safety WARNING Risks of burns u Wait until the engine has cooled down. Special tools Consumables – Bucket – Rags © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 191 Repair Electrical system Overview Fig. 210: Task overview Clamp Hose Hose Screw (M8) Hose Clamp Clamp Hose Hose Fig. 211: Task overview Hose unit Hose unit Hose unit © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 192 Install hoses 2, 3, 5, 6, 9 with clamps 1, 4, 8. u Screw clamp 8 with screw 7. u Install hose units 10, 11, 12. Setting values Tightening specifications © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 193: Tools And Devices
230611637 Flywheel lock 11343230 230612868 Guiding rod M30x2 - Cylinder head 11133371 230610035 Guiding rod M28x2 - Damper 11133372 230610036 Guiding rod M24x2 - Intermediate gear 11133373 230610037 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 194 Guiding rod M12 - Oil cooler 11133377 230610040 Guiding rod M10 - Exhaust line 11133379 230610041 Guiding rod M12 Water pump 12427300 230610042 Guiding rod M12 Thermostat 12465862 230611638 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 195 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 196 Dismount immediately the turning device and mount the cover on the flywheel housing. Information The wrench tool and the turning device are available for maintenance task only. Please contact your nearest authorized Kohler service representative. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US...
Page 197 Position turning device 2. u Mount and tighten screws 1 according 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. Depending on the required setting: u Engage a manual wrench tool to turn the wheel from the turning device which drives the flywheel gear rim.
Page 198 Remove turning device 2. u Position cover 3. u Mount and tighten screws 4 according standard torques values. Information For queries, please contact your nearest authorized Kohler service representative. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 199: 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. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US...
Page 200: 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. 48: Greases © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 201: Standard Tightening Torques
Use the torque wrench to tighten until the marking of the initial position is aligned with the marking on the component. u Repeat process for the other screws, according to standard or described sequence. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 202 On fuel and HP injections pipes: u Replace connections after first dismouting. u Change connections after 3 tightenings. For cutting rings: u Replace connections after first dismouting. u Change connections after 3 tightenings. © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 203 Quality class 8.8 Quality class 10.9 (mm) Hexagonal Socket Flange Hexagonal Socket Flange screw screw screw screw screw screw 9 Nm 14 Nm 7 ft-lb 10 ft-lb © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 204 Tab. 50: Standard torques for internal drive pipe plug with conical thread Special tolerance: +0.5 Information Tolerances of the indicated tightening torques: 10 %. Always lubricate the thread before tightening these parts (engine oil). © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 205: Standard Torques For Locking Screws And Banjo Bolts
M 42 x 2 177.01 M 64 x 2 420.41 M 45 x 1.5 199.14 M 65 x 2 457.29 M 45 x 2 199.14 M 48 x 1.5 221.27 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 206: Standard Torques For Metric Flange Joints
177.01 368.78 331.9 154.89 M 48 x 2,0 213.89 464.66 398.28 191.77 Tab. 52: Standard torques for metric thread unions L series, part 1 – see figure above © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 207 40.57 40.57 36.88 M 16 x 1,5 44.25 M 18 x 1,5 73.76 73.76 M 20 x 1,5 92.2 92.2 81.13 M 22 x 1,5 99.57 99.57 88.51 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 208 236.02 236.02 G 1 1/4A 398.28 398.28 G 1 1/2A 516.29 516.29 Tab. 57: Standard torques for imperial thread unions L series, part 2 – see figure above © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 209 Form A with sealing Form B with Form E with flat ring sealing edge sealing ft/lb ft/lb ft/lb M 10 x 1,0 11.06 8.85 M 12 x 1,5 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 210: Standard Torques For Cutting Ring Flange Joints
M 30 × 2 184.39 M 36 × 2 331.9 M 45 × 2 442.54 M 52 × 2 553.17 Tab. 61: Standard torques for cutting ring flange joints © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 211: Standard Torques For Triple Lock Flange Joints
(see: fig. 247, page 211) u If foreseen, proceed with the mounting of support clamps. 5.3.12 Standard torques for triple lock flange joints Fig. 248: Triple lock flange joints © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 212: Standard Torques For Vsti Screw Plugs
12 Nm 20 Nm G 1/4 30 Nm 9 ft-lb 15 ft-lb 22 ft-lb M12x1.5 25 Nm 35 Nm G 3/8 60 Nm 18 ft-lb 26 ft-lb 44 ft-lb © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 213 28 Nm 36 Nm G 1/2 65 Nm 21 ft-lb 27 ft-lb 48 ft-lb M16x1.5 40 Nm 44 Nm G 3/4 112 Nm 30 ft-lb 32 ft-lb 83 ft-lb © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 214 Tab. 64: VSTI screw plug tightening torques for aluminium parts Do not use hydropneumatic screwdriver. Information Tolerances of the indicated tightening torques: 10 %. Always lubricate the thread before tightening these parts (engine oil). © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 215: Abbreviations - Acronyms
OMM Operation and Maintenance Manual Pressure control valve Personal Protective Equipment Power Take-Off Repair and Service Manual Safe Work Procedure Top Dead Center Volume control valve Tab. 65: Abbreviations table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 216 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. 66: Acronyms table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 217: Unit Conversion Tables
Tab. 69: 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. 70: Volume conversion factors table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 218 °K K = C + 273.15 Tab. 75: 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 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 219 Service and Repair Manual Appendix Unit conversion tables Convert from Multiply by Kg/m lb/ft 0.0624 Tab. 76: Density conversion factors table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...
Page 220 Appendix Service and Repair Manual Prefix 5.6 Prefix Name Symbol Factor tera giga mega kilo milli μ micro nano Tab. 77: Common prefix multipliers table © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02...

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