Kohler KD83V16 Installation and operating manual

Service and Repair Manual
Original Instructions
Diesel engine
KD83V16
From serial number 2019740015
EN_US
33525088901_1_1
02-2019

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© 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Service Assistance
For professional advice on generator set power requirements and conscientious service, please
contact your nearest 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.
– Outside the US and Canada, call the nearest regional office.
Headquarters Europe, Middle East, Africa
(EMEA)
Kohler EMEA Headquarters
Netherlands B.V.
Kristallaan 1
4761 ZC Zevenbergen
The Netherlands
Phone: [phone]
Fax: [phone]
China
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
To order special tools, please refer to the cross reference list in the appendix.
KD83V16 33525088901_1_1 EN_US
2019-02 © 2019 by Kohler Co. All rights reserved. 3

Service and Repair Manual
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.
– Call the nearest regional office.
SALES OFFICE FRANCE
WEST
SDMO BREST
Tel.: [phone]
Fax: [phone]
SOUTHWEST
SDMO TOULOUSE
Tel.: [phone]
Fax: [phone]
BRANCH OFFICES
SOUTH AFRICA
SDMO SOUTH AFRICA
Tel.: [phone]
Fax: [phone]
MID-WEST
SDMO CHOLET
Tel.: [phone]
Fax: [phone]
SUBSIDIARIES
GERMANY
SDMO GMBH
Tel.: [phone]
Fax: [phone]
ALGERIA
SDMO ALGIERS
Tel.: [phone]
Fax: [phone]
PARIS/NORTH & NORMANDY
SDMO ARRAS
Tel.: [phone]
Fax: [phone]
SDMO GENNEVILLIERS
Tel.: [phone]
Fax: [phone]
LATIN AMERICA & CARRIBEAN
Tel.: [phone]
Fax: [phone]
DUBAI
SDMO MIDDLE EAST
Tel.: [phone]
Fax: [phone]
BELGIUM
SDMO NV/SA
Tel.: [phone]
Fax: [phone]
EGYPT
SDMO KAIRO
Tel./Fax: [phone]
EAST
SDMO METZ
Tel.: [phone]
Fax: [phone]
BRAZIL
KOHLER MAQUIGERAL
Tel.: [phone]
KENYA
SDMO NAIROBI
Tel./Fax: [phone]
00
SOUTH ESAT
SDMO AIX-EN-PROVENCE
Tel.: [phone]
Fax: [phone]
SDMO VALENCE
Tel.: [phone]
Fax: [phone]
SPAIN
SDMO INDUSTRIES IBERICA
Tel.: [phone]
Tel./Fax: [phone]
RUSSIA
SDMO MOSCOW
Tel./Fax: [phone]
UK
SDMO ENERGY LTD.
Tel.: [phone]
Fax: [phone]
TOGO
SDMO WEST AFRICA
Tel.: [phone]
TURKEY
SDMO ISTANBUL
Tel.: [phone]
Please consult the cross-reference list in the appendix when ordering special tools.
4© 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Revision history
Version Author Modification Date
00 MUA First edition (3.01 engine version) July 2018
01 MUA First 3.02 engine version,
Spelling mistakes 26th of February 2019
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Service and Repair Manual
6© 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

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_1_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 damages.
All rights reserved in the event of the grant of a patent, utility model or design.
8© 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

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
KD83V16 33525088901_1_1 EN_US
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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 21) .
2. Safety. (For more information see: 2 Safety, page 39) .
3. Repair. (For more information see: 3 Repair, page 61) .
4. Tools and devices. (For more information see: 4 Tools and devices, page 193) .
5. Appendix. (For more information see: 5 Appendix, page 199) .
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 39) .
Each task in this manual have the following structure:
10 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Service and Repair Manual Preface
General information
Task layout description
1. Chapter heading
2. Previous work with details of the chapter
3. Specific safety instructions which complete the general safety instructions
4. Special tools and consumables 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. Setting values spreadsheet to check the nominal and tolerances values of critical components
8. Tightening specifications table for specific fastener
9. Tightening sequence table if required
10. Data recording sheet, if required, to inform the engine manufacturer.
KD83V16 33525088901_1_1 EN_US
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Preface Service and Repair Manual
General information
12 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Contents
1 Product description 21
1.1 Technical description 21
1.1.1 Cylinder designation, direction of rotation 23
1.1.2 Nameplates 24
1.2 Function description 33
1.2.1 Fuel system 33
1.2.2 Lubricating system 35
1.2.3 Cooling system 36
1.2.4 Charge air system 37
2 Safety 39
2.1 Identification of the warnings 39
2.1.1 Warnings 39
2.1.2 Additional identifications 39
2.1.3 Additional rules and directives 40
2.2 Target audience 41
2.2.1 Responsibility of machinery owner 41
2.2.2 International standard classification of occupations 41
2.2.3 Occupational references 41
2.2.4 Unauthorized personnel - servicing 42
2.3 Intended use 43
2.4 Limitation of liability 43
2.5 Safety instructions 45
2.5.1 General safety instructions 45
2.5.2 Safety while commissioning 45
2.5.3 Safety when starting 46
2.6 Preventing injuries 48
2.6.1 Preventing bruising 48
2.6.2 Preventing burns 48
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Contents Service and Repair Manual
2.6.3 Preventing fires and explosion hazards 49
2.6.4 Preventing intoxication and poisoning hazards 50
2.6.5 Preventing electrical hazards 50
2.6.6 Preventing noise hazards 50
2.6.7 Preventing vibrations hazards 51
2.6.8 Preventing electro-magnetic hazards 51
2.6.9 Preventing falling risks 51
2.7 Personal Protective Equipment (PPE) 51
2.8 Accessible areas 53
2.8.1 Engine ready for use or in operation 53
2.8.2 Engine in commissioning — test-run 54
2.8.3 Emergency stop 54
2.8.4 Signage recommendations 55
2.9 Prevent property damages 56
2.9.1 Safety instructions for engine control unit (ECU) 56
2.9.2 Alarm conditions 56
2.9.3 Safety instructions for the fuel system 57
2.9.4 Cleanliness standards and safety 58
2.10 Disposal and environment protection 59
3 Repair 61
3.1 Prevent property damages 61
3.2 Covers 62
3.2.1 Vibration damper cover removal and installation 62
3.2.2 Battery charging alternator & PTO cover removal and installation 63
3.2.3 Cylinder head cover removal and installation 67
3.3 Rocker arms - Valve clearance set (SL 204) 71
3.3.1 Setting valve clearance 71
3.4 Rocker arms housing 78
3.4.1 Inlet and outlet rocker arms removal and installation 78
3.4.2 Rocker arms housing removal and installation 83
3.5 Cylinder head (SL 224) 91
3.5.1 Cylinder head removal and installation 91
3.6 Driving gear 97
3.6.1 Power unit 97
14 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Service and Repair Manual Contents
3.7 Fuel system 100
3.7.1 Venting pipes removal and installation 100
3.7.2 High pressure pipes removal and installation 103
3.7.3 Fuel supply pipes removal and installation 106
3.7.4 Injector removal and installation (SL 205) 107
3.7.5 Fuel filters removal and installation 117
3.7.6 Leakage fuel block removal and installation 119
3.7.7 Fuel pump HP and LP removal and installation (SL 209) 120
3.8 Charge air system 125
3.8.1 Charge air line removal and installation 125
3.8.2 Charge air cooler removal and installation (SL 220) 131
3.9 Exhaust gas system 134
3.9.1 Admission pipes to turbocharger removal and installation 134
3.9.2 Exhaust pipes to turbocharger removal and installation 136
3.9.3 Turbocharger removal and installation (SL 213) 139
3.9.4 Oil supply – turbocharger removal and installation 143
3.9.5 Turbocharger brackets removal and installation 148
3.10 Lubricating system 153
3.10.1 Oil cooler inspection (removal and installation) (SL 221) 153
3.10.2 Oil cooler by-pass valve (SL 212) 155
3.11 Cooling system 158
3.11.1 Venting line removal and installation 158
3.11.2 Turbocharger cooling lines removal and installation 163
3.11.3 Thermostat HT and housing removal and installation (SL 217) 170
3.11.4 Thermostat LT and housing removal and installation (SL 217) 172
3.11.5 Water pump HT removal and installation (SL 216) 174
3.11.6 Water pump LT removal and installation (SL 215) 177
3.12 Electrical system 180
3.12.1 Power take-off (PTO) and battery charging alternator removal and
installation (SL 218, SL 223) 180
3.12.2 Starter removal and installation 188
3.12.3 Engine Control Unit (ECU) 190
4 Tools and devices 193
4.1 Tools 193
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Contents Service and Repair Manual
4.1.1 Special tools 193
4.1.2 Turning device 196
5 Appendix 199
5.1 Technical design documents 199
5.2 Cleaning agents, thread-locking adhesives and greases 200
5.2.1 Cleaning agents and thread-locking adhesives 200
5.2.2 Greases 200
5.3 Standard tightening torques 201
5.3.1 Screws pre-tightening, reuse and marking 201
5.3.2 Standard torques for hexagonal / socket / flange screws 203
5.3.3 Standard torques for internal drive pipe plug with conical thread 204
5.3.4 Standard torques for locking screws and banjo bolts 205
5.3.5 Standard torques for metric flange joints 206
5.3.6 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) 206
5.3.7 Standard torques for metric thread unions S series (up to 800 bar/
11603 Psi) 207
5.3.8 Standard torques for imperial thread unions L series (up to 500 bar/
7252 Psi) 208
5.3.9 Standard torques for imperial thread unions S series (up to 800 bar/
11603 Psi) 209
5.3.10 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) for aluminum 209
5.3.11 Standard torques for cutting ring flange joints 210
5.3.12 Standard torques for triple lock flange joints 211
5.3.13 Standard torques for VSTI screw plugs 212
5.4 Abbreviations - Acronyms 215
5.5 Unit conversion tables 217
5.5.1 Length conversion factors 217
5.5.2 Mass conversion factors 217
5.5.3 Pressure conversion factors 217
5.5.4 Volume conversion factors 217
5.5.5 Power conversion factors 218
5.5.6 Moment of inertia and torque conversion factors 218
5.5.7 Fuel consumption conversion factors 218
5.5.8 Flow conversion factors 218
16 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02

Service and Repair Manual Contents
5.5.9 Temperature conversion factors 218
5.5.10 Density conversion factors 218
5.6 Prefix 220
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Contents Service and Repair Manual
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Service and Repair Manual
20 © 2019 by Kohler Co. All rights reserved. KD83V16 33525088901_1_1 EN_US 2019-02