Kohler KD83V16 Installation and operating manual

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

Service and Repair Manual
For United States only
WARNING: This product can expose you to chemicals,
including carbon monoxide and benzene, which are known to
the State of California to cause cancer and birth defects or
other reproductive harm.
For more information go to www.p65warnings.ca.gov/
WARNING: Breathing diesel engine exhaust exposes you
to chemicals known to the State of California to cause cancer
and birth defects or other reproductive harm.
- Always start and operate the engine in a well-ventilated area.
- 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
2© 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Revision history
Version Author Modification Date
000 TB12 -
Technical
documen-
tation
First 3.01 engine version 2018-07
001 TB12 -
Technical
documen-
tation
First 3.02 engine version
Spelling mistakes 2019-02
002 TB12 -
Technical
documen-
tation
According to development and improvement 2021-07
KD83V16 33525088901_2_1 EN_US
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Service and Repair Manual
4© 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Preface
About this document
This repair and service manual is dedicated for the mechanics and the workshop personnel of the
Kohler Co. dealers and subsidiaries.
This repair manual provides information regarding the assembly, disassembly, and adjustment
tasks for KOHLER Diesel engines.
Information
Information for the United States
Failing to follow these instructions when installing a certified engine in a piece of nonroad equip-
ment violates federal law (40 CFR 1068.105(b)), subject to fines or other penalties as described in
the Clean Air Act.
If you install the engine in a way that makes the engine's emission control information label hard to
read during normal engine maintenance, you must place a duplicate label on the equipment, as
described in 40 CFR 1068.105.
Some sections of this manual do not apply to all engines.
Some illustrations in this repair and service manual show details and implements that may be
different from your engine and machinery.
Protective devices and covers have been removed to provide a clearer representation in some
illustrations.
KOHLER engines are subject to continuous development and improvement. This may result in
modifications to your engine which may not be referred to in this repair and service manual.
If you require further explanations or information, please contact your nearest authorized Kohler
service representative. 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. null and void without advance notice, if spare parts other
than original KOHLER spare parts or spare parts purchased by Kohler Co. are used for mainte-
nance or repair.
Fuels, lubricants and coolants
Only fuels, lubricants and coolants approved by Kohler Co. may be used for the operation of
KOHLER Diesel engines.
KD83V16 33525088901_2_1 EN_US
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Preface Service and Repair Manual
About this document
Kohler Co. will declare all possible undertakings carried out by Kohler Co. and/or their dealers,
such as guarantees, service orders, etc. null and void without advance notice, if fuel, lubricants and
coolants other than fuel, lubricants and coolants approved by Kohler Co. are used for maintenance
or repair.
Liability and warranty
Due to the wide variety of products offered by other manufacturers (e.g. service products, lubri-
cants, tool attachments and spare parts), Kohler Co. cannot examine the general suitability and
absence of defects in third-party products which are used in or on KOHLER products. The same
applies to possible interactions between third-party products and products approved by Kohler Co.
Third-party products are used in or on KOHLER engines at the user's own discretion. Kohler Co.
does not offer any warranty or accept any liability for losses of any kind caused by failures of or
damage to KOHLER engines attributable to the use of third-party products.
Furthermore, Kohler Co. will not recognize any warranty claims attributable to incorrect operation,
inadequate or insufficient maintenance or use of unapproved operating fluids or non-compliance
with safety regulations.
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. are used for maintenance and repairs.
The aforementioned provisions do not extend the warranty and liability conditions in the general
terms and conditions of business of Kohler Co.
Modifications, conditions, copyright
Kohler Co. reserves the right to make modifications in the course of technical development, without
issuing prior notification.
The aforementioned provisions do not extend the warranty and liability conditions in the general
terms and conditions of business of Kohler Co.
Copyright - Proprietary notice ISO16016
The reproduction, distribution, and utilization of this document as well as the communication of its
contents to others without express authorization is prohibited.
Offenders will be held liable for the payment of damage.
All rights reserved in the event of the grant of a patent, utility model, or design.
6© 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

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
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Preface Service and Repair Manual
General information
General information
Manual structure
Information
Read and understand this manual before performing any service or maintenance procedures on
any component.
The procedures described in this manual are based on the following structure:
1. Product description (For more information see: 1 Product description, page 17.)
2. Safety (For more information see: 2 Safety, page 38.)
3. Repair (For more information see: 3 Repair, page 58.)
4. Tools and devices (For more information see: 4 Tools and devices, page 266.)
5. Appendix (For more information see: 5 Appendix, page 272.)
Task layout
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:
8© 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Service and Repair Manual Preface
General information
Task layout description
1. Chapter heading
2. Previous tasks with details of the chapter
3. Specific safety instructions which complete the general safety instructions
4. Special tools, consumables and equipment which are needed to fulfill the task
5. One or more overview(s) of the assembly with list of components
6. Instructions to remove and install the components, with additional directives
7. Specific values spreadsheet to check the nominal and tolerances values of critical components
and data recording sheet, if required, to inform the engine manufacturer.
8. Tightening sequence table if required
9. Tightening specifications table for specific fastener
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Preface Service and Repair Manual
General information
10 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Contents
1 Product description 17
1.1 Technical description 17
1.1.1 Cylinder designation, direction of rotation 18
1.1.2 Engine or component identification 20
1.2 Technical data 28
1.3 Function description 29
1.3.1 Fuel system 29
1.3.2 Lubricating system 31
1.3.3 Cooling system 32
1.3.4 Charge air system 34
1.3.5 Charge air diagram (engine with EATS) 35
2 Safety 38
2.1 Identification of the warnings 38
2.1.1 Warnings 38
2.1.2 Additional identifications 38
2.1.3 Additional rules and directives 39
2.2 Target audience 40
2.2.1 Responsibility of machinery owner 40
2.2.2 International standard classification of occupations 40
2.2.3 Occupational references 40
2.2.4 Unauthorized personnel - servicing 41
2.3 Intended use 41
2.4 Limitation of liability 42
2.5 Safety instructions 43
2.5.1 General safety instructions 43
2.5.2 Safety while commissioning 43
2.5.3 Safety when starting 44
2.6 Preventing injuries 46
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Contents Service and Repair Manual
2.6.1 Preventing bruising 46
2.6.2 Preventing burns 46
2.6.3 Preventing fires and explosion hazards 47
2.6.4 Preventing intoxication and poisoning hazards 48
2.6.5 Preventing electrical hazards 48
2.6.6 Preventing noise hazards 48
2.6.7 Preventing vibrations hazards 49
2.6.8 Preventing electro-magnetic hazards 49
2.6.9 Preventing falling risks 49
2.7 Personal Protective Equipment (PPE) 49
2.8 Accessible areas 51
2.8.1 Engine ready for use or in operation 51
2.8.2 Engine in commissioning — test-run 52
2.8.3 Emergency stop 52
2.8.4 Signage recommendations 53
2.9 Prevent property damage 54
2.9.1 Safety instructions for engine control unit (ECU) 54
2.9.2 Alarm conditions 54
2.9.3 Safety instructions for the fuel system 55
2.9.4 Cleanliness standards and safety 56
2.10 Disposal and environment protection 57
3 Repair 58
3.1 Prevent property damage 58
3.2 Covers 59
3.2.1 Vibration damper cover removal and installation 59
3.2.2 Battery charging alternator & PTO cover removal and installation 61
3.2.3 Cylinder head cover removal and installation 65
3.3 Rocker arms 69
3.3.1 Rocker arms - Valve clearance set (SL 204) 69
3.3.2 Inlet and outlet rocker arms removal and installation 76
3.3.3 Rocker arms housing removal and installation 82
3.4 Cylinder head (SL 224) 90
3.4.1 Cylinder head removal and installation 90
3.5 Driving gear 97
12 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Service and Repair Manual Contents
3.5.1 Power unit 97
3.5.2 Torsional vibration damper removal and installation - SL2-1340 99
3.6 Fuel system 110
3.6.1 Fuel return and venting pipes removal and installation 110
3.6.2 High pressure pipes removal and installation 113
3.6.3 Fuel supply pipes removal and installation 121
3.6.4 Injector removal and installation (SL 205) 122
3.6.5 Fuel filters removal and installation 131
3.6.6 Leakage fuel block removal and installation 133
3.6.7 Fuel pump HP and LP removal and installation (SL 250) 134
3.7 Charge air system 140
3.7.1 Air intake line removal and installation 140
3.7.2 Charge air line removal and installation 141
3.8 Exhaust gas system 159
3.8.1 Admission pipes to turbocharger removal and installation 159
3.8.2 Exhaust pipes to turbocharger removal and installation 161
3.8.3 Exhaust gas turbocharger removal and installation (SL 213) 170
3.8.4 Oil supply – turbocharger removal and installation 175
3.8.5 Turbocharger brackets removal and installation 180
3.8.6 Exhaust pipes and compensators (SL 214) 185
3.9 Lubricating system 191
3.9.1 Crankcase breather system rubber hoses (SL 219) 191
3.9.2 Oil centrifuge removal and installation (depending on application) 193
3.9.3 Spin-on oil filters removal and installation 196
3.9.4 Prelubricating pump removal and installation (depending on application) 198
3.10 Cooling system 201
3.10.1 Water pipes (rocker arm housing) removal and installation 201
3.10.2 Venting line removal and installation 205
3.10.3 Turbocharger cooling lines removal and installation 211
3.10.4 Thermostat HT and housing removal and installation (SL 217) 225
3.10.5 Thermostat LT and housing removal and installation (SL 217) 227
3.10.6 Coolant pump HT removal and installation (SL 216) 230
3.10.7 Coolant pump LT removal and installation (SL 215) 232
3.10.8 Fan drive (option) 235
3.11 Electrical system 241
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Contents Service and Repair Manual
3.11.1 Power take-off (PTO) and battery charging alternator removal and
installation (SL 223) 241
3.11.2 Starter removal and installation (SL 260) 248
3.12 Exhaust aftertreatment system 254
3.12.1 Diesel exhaust fluid injector removal and installation (SL2-5330) 254
3.12.2 Diesel exhaust fluid pump removal and installation (SL2-5340) 260
4 Tools and devices 266
4.1 Tools 266
4.1.1 Special tools 266
4.1.2 Turning device 269
5 Appendix 272
5.1 Technical design documents 272
5.2 Cleaning agents, thread-locking adhesives and greases 273
5.2.1 Cleaning agents and thread-locking adhesives 273
5.2.2 Greases 273
5.3 Standard tightening torques 274
5.3.1 Lubricant and threadlocker application rules 274
5.3.2 Screws pre-tightening, reuse and marking 274
5.3.3 Standard torques for hexagonal / socket / flange screws and
hexagonal / flange nuts 277
5.3.4 Standard torques for internal drive pipe plug with conical thread 278
5.3.5 Standard torques for screws according to DIN 7643, DIN 910, DIN 908 278
5.3.6 Standard torques for flange joints 280
5.3.7 Assembling pipes with cutting rings 286
5.3.8 Standard torques for triple lock flange joints 287
5.3.9 Standard torques for VSTI screw plugs for steel 288
5.3.10 Standard torques for VSTI screw plugs for aluminium 289
5.3.11 Assembling pipes with DKO connectors (EL, ET, EW, GZ, GZR, RED) 291
5.3.12 Standard torques for collar clamps 292
5.4 Abbreviations - Acronyms 293
5.5 Unit conversion tables 295
5.5.1 Length conversion factors 295
5.5.2 Mass conversion factors 295
5.5.3 Pressure conversion factors 295
14 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Service and Repair Manual Contents
5.5.4 Volume conversion factors 295
5.5.5 Power conversion factors 296
5.5.6 Moment of inertia and torque conversion factors 296
5.5.7 Fuel consumption conversion factors 296
5.5.8 Flow conversion factors 296
5.5.9 Temperature conversion factors 296
5.5.10 Density conversion factors 296
5.6 Prefix 298
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Contents Service and Repair Manual
16 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

1 Product description
1.1 Technical description
Fig. 1: Diesel engine / view from the flywheel side
CS Engine rear (flywheel side) 6Charge air cooler
1Engine brackets (x4) 7Battery charging alternator
2Flywheel 8Oil dipstick
3Fuel filter 9Oil centrifuge assembly
4Crankcase breather system filter 10 High pressure fuel pump
5Turbocharger assembly
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Product description Service and Repair Manual
Technical description
Fig. 2: Diesel engine / view from the damper side
CCS Engine front (vibration damper side) 5Exhaust gas connection
1Water pump high temperature 6Lifting lug
2Thermostat housing high temperature 7Oil cooler
3Water pump low temperature 8Oil filter cartridge
4Thermostat housing low temperature
Fig. 3: Diesel engine / view from the damper side
CCS Engine front (vibration damper side) 12 Cylinder head cover
9Vibration damper cover 13 Charge air pipe
10 Engine control unit - ECU 14 Starter
11 Straight air intake 15 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.
18 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07

Service and Repair Manual Product description
Technical description
Fig. 4: Cylinder designation - direction of rotation according to ISO 1204
A1-A8 Series of cylinders – Bank A -Exhaust valves
B1-B8 Series of cylinders – Bank B +Inlet valves
CS Engine rear (coupling/flywheel side) LLeft engine side
CCS Engine front (counter-coupling/damper
side) RRight engine side
DoR 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.
Fig. 5: Cylinder valves order
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Product description Service and Repair Manual
Technical description
Firing order
ISO 1204 A1 B7 A2 B5 A4 B3 A6 B1 A8 B2 A7 B4 A5 B6 A3 B8
Tab. 1: Firing order
1.1.2 Engine or component identification
Type designation
Designation Description
K D 83 V 16 - 5 A F C Engine type description
K Engine manufacturer
D Fuel type (D=Diesel)
83 Total displacement in liter
V Cylinder configuration
16 Number of cylinders
5 Frequency. 5=50Hz; 6=60Hz
A Power level. A=power level designation,
where A= the lowest power level, B=next
higher power level, C=next higher power
level…
F Emissions or fuel optimization. F=Fuel Opti-
mized, 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.
20 © 2021 by Kohler Co. All rights reserved. KD83V16 33525088901_2_1 EN_US 2021-07