Kohler KD83V16 Service And Repair Manual Download Page 266

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Tools and devices

Service and Repair Manual

Tools

4 Tools and devices

4.1 Tools

4.1.1 Special tools

Special tool

Designation

Qty Ident

KOHLER Ident
number

Turning device

11133437

230611637

Locking device

11343230

230612868

Guiding rod M30x2 - Cylinder head

11133371

230610035

Guiding rod M28x2 - Damper

11133372

230610036

Guiding rod M24x2 - Intermediate gear

11133373

230610037

266

KD83V16 33525088901_2_1 EN_US

2021-07

Summary of Contents for KD83V16

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

Page 2: ...G 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 v...

Page 3: ...n 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 202...

Page 5: ...t 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 impr...

Page 6: ...butable 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...

Page 7: ...her applicable documents Document Application Operation and Maintenance Manual Operator s manual for the engine operation Kodia Operation Manual Description of Kodia diagnosis software KD83V16 3352508...

Page 8: ...or 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 se...

Page 9: ...e 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 nomina...

Page 11: ...rnings 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...

Page 12: ...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 envi...

Page 13: ...llation 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 s...

Page 14: ...74 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 co...

Page 15: ...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 conversi...

Page 17: ...ywheel side 6 Charge air cooler 1 Engine brackets x4 7 Battery charging alternator 2 Flywheel 8 Oil dipstick 3 Fuel filter 9 Oil centrifuge assembly 4 Crankcase breather system filter 10 High pressure...

Page 18: ...tridge 4 Thermostat housing low temperature Fig 3 Diesel engine view from the damper side CCS Engine front vibration damper side 12 Cylinder head cover 9 Vibration damper cover 13 Charge air pipe 10 E...

Page 19: ...valves CS Engine rear coupling flywheel side L Left engine side CCS Engine front counter coupling damper side R Right engine side DoR Direction of rotation Firing order Cylinder B6 is located on the e...

Page 20: ...t 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 powe...

Page 21: ...ication types Fig 7 Engine nameplate location Engine serial number The engine serial number is stamped onto the engine nameplate Designation Description 2016 73 0001 Engine serial number 2016 Year of...

Page 22: ...gine control unit nameplates 1 Software nameplate 2 Hardware nameplate Fig 10 Software nameplate 1 Product designation 6 Engine serial number 2 Product type 7 Engine control unit ID number 3 Engine de...

Page 23: ...are updates in the field it may be the case that this infor mation is no longer up to date u The real information can be viewed in the device display or read out with the KOHLER diag nosis and service...

Page 24: ...Matching of the connecting rod and connecting rod bearing cap is identified by connecting rod number Turbocharger identification Fig 14 Turbocharger nameplate The turbocharger company nameplate is mo...

Page 25: ...15 Oil cooler nameplate The oil cooler company nameplate is mounted on the oil cooler Injector identification Fig 16 Injection number location The injector identification number is stamped on the sid...

Page 26: ...cal description High pressure pumps identification Fig 17 High pressure pump nameplate Fig 18 High pressure pump number The high pressure pump number is stamped on the pump 26 2021 by Kohler Co All ri...

Page 27: ...rge air cooler nameplates 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 thermosta...

Page 28: ...and Repair Manual Technical data 1 2 Technical data Information Refer also to the Technical data sheet For more information see 5 Appendix page 272 28 2021 by Kohler Co All rights reserved KD83V16 33...

Page 29: ...ntamination u Never release operating fluids while operating the engine u Check the electrical system Immediately rectify all errors such as loose connections and frayed cables u During refueling swit...

Page 30: ...702 After fuel filter Pres sure 7 Injectors A1 B8 2 1 Servicing point 5 High pressure pump A and B 8 Break leakage detection block if available 2 2 B710 WIF pre filter 1 5 1 Y703 and Y704 Fuel pump VC...

Page 31: ...12 4 Roller bearings B 21 HT coolant pump 4 Piston cooling jets 13 Crankshaft bearings 22 LT coolant pump 5 Centrifugal filter 13 1 Conrods A 23 Preheating port 6 Pressure Control Valve 13 2 Conrods B...

Page 32: ...tional 1 3 3 Cooling system Coolant diagram Fig 23 Coolant diagram a High temperature c Depending on engine config uration b Low temperature CR Customer responsibility 1 Aggregate support 8 LT Water r...

Page 33: ...nk including ventilation line 21 Coolant pump HT 2 Charge Air Cooler A 10 LT Expansion tank including ventilation line 22 Coolant pump LT 3 Charge Air Cooler B 11 Venting HT 23 Mechanical thermostat 4...

Page 34: ...lter B side 13 Engine B bank 4 Elbow B side 9 Exhaust catalyst 5 Elbow A side 10 Blowby filters Sensors list 14 B785x Exhaust gas temper ature on cylinder Ax optional 18 B780 Air intake pressure switc...

Page 35: ...4 Blowby connections 1 3 5 Charge air diagram engine with EATS Fig 26 Charge air diagram a Exhaust gas c Oil vapor e For odd number of turbo chargers only b Fresh air d Depending on engine config urat...

Page 36: ...ir tempera ture A after charge air cooler 16 B78xx Exhaust gas temper ature on cylinder Bx optional 20 B749 Air intake temperature A side 24 Bxx1 Atmospheric pressure on ECU 2 HD 17 B7811 Exhaust gas...

Page 38: ...ous situation that if not avoided could result in death or serious injury CAUTION Indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE Used to address pr...

Page 39: ...nd directives Follow these instructions and observe any additional or local rules and directives Note the following points Safety regulations applicable on site Guidelines provided by professional ass...

Page 40: ...ruc tions chapter the main tasks described in this manual or these instructions the tasks identified as requirements to prepare the main tasks For the SL1 maintenance of power generation engines Maint...

Page 41: ...d to service the engine or access the engine compartment or engine cover 2 3 Intended use The Diesel engines produced by Kohler Co are partly completed machinery according to Machi nery Directive 2006...

Page 42: ...s starting aids and coolants Use of the engine manipulated overspeeds controls Modifications of the engine mounting and suspensions Lifting of the engine using unforeseen lifting points Continued use...

Page 43: ...Maintenance Manual of the machinery before commissioning the machine Develop document implement and enforce a safety and health program adapted to the machinery and its environment and comply with th...

Page 44: ...uipment WARNING Hazards generated by exposure to environments temperatures Exposure to radiant heat sources in the engine compartment could result in death or serious inju ries u The manufacturer of t...

Page 45: ...ine according to the instructions in the instructions manual of the machinery u Ensure that the engine is started after all display units and control devices have been checked u Ensure that the engine...

Page 46: ...it ECU is hot while operating the engine u Avoid any contact with the engine parts carrying hot coolant or oil the exhaust system the turbocharger the heat protection the battery the covers and the EC...

Page 47: ...to engine u Ensure a good ventilation while refueling or prior to accessing to the engine u Regularly check all lines hoses and screw connections for leaks and damage Immediately rectify the leaks and...

Page 48: ...replace the damaged parts Safety instructions of the fluids have to be considered 2 6 5 Preventing electrical hazards WARNING Hazards by electrical shocks Contact with live conductor could result in...

Page 49: ...tive devices in the vicinity of the engine especially artificial health assist devices 2 6 9 Preventing falling risks CAUTION Hazards by slipping and falling Climbing on the engine or leakages could r...

Page 50: ...and from entanglement Additional protection against slipping Must be worn in the direct vicinity of the engine Safety gloves Protection against hot elements and chemicals Must be worn when handling ho...

Page 51: ...ected to the flywheel u Ensure the integrity of the machine and the engine before starting u All openings must be closed and the safe conditions established by the manufacturer of the machinery must b...

Page 52: ...tand the operational conditions kept visible and legible during the entire life cycle Additional emergency stops and measures according to project standards and local regulations and standards are pos...

Page 53: ...n Hot surface Severe injuries due to hot surfaces For more information see 2 6 2 Preventing burns page 46 ISO 7010 W025 Warning sign Counterrotating rollers Severe injuries due to drawing in movement...

Page 54: ...easures at plug connectors u Connecting the sensors or actuators individually to or between external voltage sources for testing purposes is prohibited Risk of destruction or malfunction of the engine...

Page 55: ...ure When the engine is running the fuel lines are under a constant pressure of up to 2000 bar 29 007 40 psi Fuel escaping under pressure can penetrate the skin or vaporize and explode when an ignition...

Page 56: ...aint chips and insulation material with suitable equipment u Cover the areas of the engine compartment which could produce dirt particles with a new and clean covering film u Before beginning the dism...

Page 57: ...scrap materials u Before disposing or recycling waste products ask for the correct method at the responsible environmental or recycling center u When handling waste lubricants and fuel make sure that...

Page 58: ...und in the Standard tight ening torques chapter For more information see 5 3 Standard tightening torques page 274 Replace self locking screw connections Clean the Diesel engine connections and screw c...

Page 59: ...ks Not applicable Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Not applicable Overview Fig 51 Task overview 1 Screw M8 3 Cover 2 Protection plate...

Page 60: ...erence Key Screw specifications Lubricant Reuse Torque Angle Step 5 Step 5 1 055AA DIN 6929 M12x1 75x155 10 9 FLZN Yes 1 70 Nm 52 ft lb Tab 11 Tightening specifications table Lubricants MG Molykote G...

Page 61: ...tions established by the manufacturer of the machinery must be fulfilled u Standing in the vicinity of the engine while starting or operating the manufacturer s machinery is forbidden WARNING Hazards...

Page 62: ...ance sleeve 7 Lock washer 3 Vibration damper 8 Captive screw M8 4 Pin 9 Cover front side 5 Cover back side Removal Fig 54 Removing cover front part u Remove screws 8 and lock washers 7 u Remove cover...

Page 63: ...art u Remove nuts 6 vibration dampers 3 distance sleeves 2 and pins 1 4 u Remove cover back side 5 Installation Fig 56 Installing pins u Screw pins 1 4 on aggregate support and PTO bracket KD83V16 335...

Page 64: ...4 u Mount cover back side 5 on pins 1 4 u Mount distance sleeves 2 and vibration dampers 3 on pins 1 4 u Screw cover with nuts 6 Fig 58 Installing cover u Mount cover 9 on pins 1 4 u Fix cover 9 with...

Page 65: ...8 10 FLZN Yes 1 34 Nm 25 ft lb Tab 12 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer...

Page 66: ...or oil the exhaust system the turbocharger the heat protection the battery and the covers u After the temperature has cooled down to a level it can be touched proceed with the tasks on the engine u Sh...

Page 67: ...screw 2 u Remove cylinder head cover 1 and seal 3 Installation u 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 c...

Page 68: ...Specific values Not applicable Tightening specifications Refer to standard tightening torques For more information see 5 3 Standard tightening torques page 274 68 2021 by Kohler Co All rights reserve...

Page 69: ...1 Turning device installed Specific safety instructions WARNING Injuries by contact with hot surfaces Engine is hot near operating temperature The contact with hot surfaces could lead serious injuries...

Page 70: ...verview Fig 63 Cylinder designation direction of rotation according to ISO 1204 A1 A8 Series of cylinders Exhaust valves B1 B8 Series of cylinders Inlet valves CS Engine rear flywheel side L Left engi...

Page 71: ...16 Bank A Bank B 1 TDC overlap A1 1 1st turn No action No action 2 2 A7 A8 B2 B4 3 6 No action No action 4 3 No action No action 5 4 A3 A5 B6 B8 6 5 No action No action 7 TDC injection A1 1 2nd turn N...

Page 72: ...ing device to index 2 u Set valve clearance for cylinders A7 A8 and B2 B4 For more information see Checking valve clearance page 74 For more information see Setting valve clearance page 74 Step 3 u Pa...

Page 73: ...more information see Checking valve clearance page 74 For more information see Setting valve clearance page 74 Valve set order alternative method Information There is a marking on the flywheel to set...

Page 74: ...alve set clearance procedure For more informa tion see Setting valve clearance page 74 Setting valve clearance u Loosen locknut 2 of inlet rocker arm 1 u Position feeler gauge with correct value betwe...

Page 75: ...ue Lower value Maximum wear Calcu lated gap min max Actual value a Inlet valve clearance 500 m 19 69 th 100 m 3 94 th 0 b Exhaust valve clear ance 1 mm 0 04 in 100 m 3 94 th 0 Tab 16 Tolerance values...

Page 76: ...age 274 3 3 2 Inlet and outlet rocker arms removal and installation Previous tasks q Remove retaining plate and high pressure pipe For more information see 3 6 4 Injector removal and installation SL 2...

Page 77: ...3 Valve bridge 8 Exhaust rocker arm 4 Fitting sleeve 9 Exhaust shaft 5 Inlet rocker arm 10 Rocker arm housing Removal WARNING The valve springs must not be under stress Risk of injuries u Turn cranks...

Page 78: ...rocker arms u Remove inlet rocker arm assembly 5 and exhaust rocker arm assembly 8 Fig 74 Removing shafts from rocker arms u Remove inlet shaft 6 from inlet rocker arm 5 u Remove exhaust shaft 9 from...

Page 79: ...e bridges 3 and pushrods 2 from swing followers 1 Installation Information Put matching cylinder in firing TDC position Fig 76 Preparing inlet and exhaust shafts u Inspect presence of plug in inlet sh...

Page 80: ...s outwards u Insert exhaust shaft 9 into exhaust rocker arm 8 making sure the plug on the shaft faces outwards Fig 78 Installing pushrods and valve bridges u Insert pushrods 2 into cylinder head and f...

Page 81: ...rms with screws 7 in inlet shaft exhaust shaft and fitting sleeves 4 Specific values For more information see 3 3 1 Rocker arms Valve clearance set SL 204 page 69 Tightening specifications Fig 80 Rock...

Page 82: ...see 3 8 3 Exhaust gas turbocharger removal and installation SL 213 page 170 q Remove turbocharger brackets For more information see 3 8 5 Turbocharger brackets removal and installation page 180 q Rem...

Page 83: ...ine oil Rags Cleaner Overview Fig 82 Task overview 1 Positioning pin 6 Seal x4 2 Screw M8 7 Coolant pipe HT 3 Closing cover 8 Locking ring 4 Seal 9 Rocker arm housing 5 Fitting sleeve x5 10 Seal KD83V...

Page 84: ...Repair Service and Repair Manual Rocker arms Removal Fig 83 Sliding locking ring u Slide locking ring 8 84 2021 by Kohler Co All rights reserved KD83V16 33525088901_2_1 EN_US 2021 07...

Page 85: ...lace tool on pipe u Slide pipes out of rocker arm housing Fig 85 Removing rocker arm housing u Lift rocker arm housing 9 u Move rocker arm housing and coolant pipe HT to remove the assembly KD83V16 33...

Page 86: ...Separate rocker arm housing from coolant pipe HT 7 and closing cover 3 u Remove seals 4 6 from closing cover and coolant pipe HT u Remove fitting sleeves 5 Installation Fig 87 Preparing rocker arm ho...

Page 87: ...r 3 on rocker arm housing with screws 2 and seal 4 Fig 89 Mounting coolant pipe HT u Put seals 6 and locking ring 8 on coolant pipe HT 7 u Insert coolant pipe HT 7 in rocker arm housing Fig 90 Inserti...

Page 88: ...head u Insert positioning pins 1 in rocker arm housing Fig 91 Placing tool Information Tighten screws from inlet and outlet rocker arms u Place tool on pipe u Insert pipe into rocker arm housing 88 2...

Page 89: ...rm housing on cylinder head Information Vent cooling system at the end of installation Specific values Not applicable Tightening specifications Refer to standard tightening torques For more informatio...

Page 90: ...more information see 3 6 4 Injector removal and installation SL 205 page 122 q Remove oil supply turbocharger For more information see 3 8 4 Oil supply turbocharger removal and installation page 175...

Page 91: ...tools Consumables and equipment Vaseline Castrol Optimol paste white T Rags Cleaner Overview Fig 94 Task overview 1 Cylinder head 5 Flame ring 2 O ring set 6 Bolt M30 3 Seal carrier 7 Washer 4 Cylinde...

Page 92: ...s 7 u Mount lifting device on cylinder head u Lift and push cylinder head up and down to dismantle it u Remove cylinder head u Remove cylinder head gasket 4 u Remove flame ring 5 Installation Fig 96 I...

Page 93: ...5 in liner Fig 97 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 Fig 98 Installing cylinder head u Mount lifting device on cyl...

Page 94: ...nder head bolts u Lubricate bolts 6 and washers 7 with Castrol Optimol paste white T u Insert and tighten the bolts Fig 100 Mounting lifting lug u Mount lifting lug 10 with extended length bolts 9 94...

Page 95: ...inder heads are connected with a lifting lug bracket both need to be taken off and replaced Information Vent coolant circuit at the end of installation Specific values Not applicable Tightening specif...

Page 96: ...RW 11342818 M30x2x377 MW No 1 280 Nm 207 ft lb 2 180 Tab 22 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243...

Page 97: ...and installation page 65 q Remove injectors For more information see 3 6 4 Injector removal and installation SL 205 page 122 Specific safety instructions Not applicable Special tools Special tool Des...

Page 98: ...scopy u Place endoscope in injector hole on top of cylinder head u 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 R...

Page 99: ...es Complete length 290 Dirt traces Center 2 cm 170 200 Traces 80 of height Honing pattern visible Tab 24 Example of note on endoscopy results 3 5 2 Torsional vibration damper removal and installation...

Page 100: ...failure u Observe the lifting instructions u Use only adapted lifting devices u In case of shock or damage always replace the torsional vibration damper Special tools Special tool Designation Guiding...

Page 101: ...Allen screw M12 4 Bolt M28 Removal Fig 109 Lifting thread location u Using the turning device rotate the torsional vibration damper so that the lifting thread is located at the top For more informatio...

Page 102: ...rankshaft u Remove two diametrically opposed bolts 4 u Install guiding rods u Remove bolts 4 and disk 3 Fig 111 Lifting thread location u Install lifting device on the lifting thread u Remove screws 2...

Page 103: ...Installation Fig 112 Locking device u Install locking device with screws M16 to lock crankshaft Fig 113 Lifting thread location u Install lifting device on the lifting thread u Lift torsional vibrati...

Page 104: ...al vibration damper 1 using guiding rod u Screw torsional vibration damper 1 with screws 2 u Tighten screws 2 to torque u Position disk 3 and bolts 4 u Tighten bolts 4 to torque u Remove locking devic...

Page 105: ...o screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 Sampling silicon oil from torsional vibration damper SL2 1345 Previous tasks Make sure that the fol...

Page 106: ...lection sampling instructions form sample container sample plugs padded return envelope Overview Fig 116 Task overview 1 Upper sample opening 2 Lower sample opening Sample collection Fig 117 Collectin...

Page 107: ...er Information Place the sample container cap in a safe place u Make sure that silicon oil flows from the torsional vibration damper into the sample container Information If the flow of silicon oil is...

Page 108: ...e form delivered with the sampling kit u Place the sample container and form into the padded envelope and send them for analysis Specific values Not applicable Tightening specifications Fig 118 Screw...

Page 109: ...ual Repair Driving gear O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules Otherwise refer to standard tightening torques KD83V16 33525088901_2_1 EN_US 2021 07 2021 by Kohler Co Al...

Page 110: ...as loose connections and frayed cables u During refueling switch off any additionally installed heater optional u Lock out and tag out the engine prior to accessing to engine u Ensure a good ventilat...

Page 111: ...Service and Repair Manual Repair Fuel system Overview Fig 119 Fuel return and venting pipes Fig 120 Fuel pump pipes KD83V16 33525088901_2_1 EN_US 2021 07 2021 by Kohler Co All rights reserved 111...

Page 112: ...el from nozzles B bank 10 Connection to tank 4 Connection leakage fuel HP pump B bank 11 Leakage fuel detection block to leakage fuel distributor block 5 Sensor B 12 Leakage fuel detection block to le...

Page 113: ...to the crankcase u Tighten fuel return and venting pipes to torque Specific values Not applicable Tightening specifications Refer to standard tightening torques For more information see 5 3 Standard...

Page 114: ...release the screws on the fuel circuit especially between the high pressure pump and the injector when the engine is running u Before starting any task on the fuel system ensure the build up pressure...

Page 115: ...uel pipe 2 Fuel pipe 6 Retaining plate 3 Screw M10 7 Clamp 4 Distributor block Fig 124 Task overview 8 Screw M10 14 Clamp 9 Clamp 15 Screw M10 10 Clamp 16 Plate 11 Holder 17 Clamp 12 Screw M8 18 Clamp...

Page 116: ...el pipe 23 Fuel pipe 21 Fuel pipe 24 Flange joint Removal Fig 126 Removing high pressure piping u Remove screw 1 with retaining plate 6 and clamp 7 u Remove screw 3 u Remove distributor block 4 u Remo...

Page 117: ...ws 8 15 u Remove clamps 9 10 17 18 and plate 16 u Remove holder 11 u Remove screws 12 u Remove clamps 13 14 Fig 128 Removing high pressure piping u Remove fuel pipes 19 20 21 22 23 with flange joints...

Page 118: ...l Paste White T u Lubricate threads and cones of fuel pipes 19 20 with clean engine oil u Install fuel pipes 19 20 21 22 23 with flange joints 24 Fig 130 Installing clamps u Install clamps 13 14 with...

Page 119: ...u Install clamp 7 with retaining plate 6 and screw 1 u Pre tighten all fuel pipes to torque For more information see Tightening specifications page 119 u Tighten all fuel pipes and screws to torque Fo...

Page 120: ...2 O Yes 1 26 Nm 19 ft lb 2 150 Nm 111 ft lb Tab 28 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Locti...

Page 121: ...e Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Rags Cleaner Overview Fig 133 Low pressure circuit piping Removal u Remove fuel supply pipes Inform...

Page 122: ...g the fuel lines are under a constant pressure of up to 2000 bar 29 007 40 psi Fuel escaping under pressure can penetrate the skin or vaporize and explode when an ignition source is present which will...

Page 123: ...sumables and equipment Rags Cleaner Loctite 243 Engine oil Castrol Optimol Paste White T Overview Fig 135 Task overview 1 Injector sleeve 6 Screw M12 2 Retaining plate 7 Injector clamp 3 Screw M12 8 C...

Page 124: ...ts from injector u Disconnect injector cable on both ends u Disconnect HT sensor on both ends if installed u Remove both adaptors from rocker arm housing Fig 137 Removing high pressure pipe u Take off...

Page 125: ...plate u Remove retaining plate 2 with screws 3 u Close all open connections with the matching plugs available as replacement parts Fig 139 Removing clamp u Remove clamp 7 by opening screw 6 KD83V16 3...

Page 126: ...ector 4 with extracting tool Installation Fig 141 Lubricating injector O rings u Clean carbon from injector seat surface on injector sleeve u Lubricate injector 4 O rings with Castrol Optimol Paste Wh...

Page 127: ...s present before installing the injector u Position injector 4 with its connection upwards into sleeve 1 u Install clamp 7 with screw 6 Fig 143 Positioning injector and clamp Information Injectors can...

Page 128: ...back the union nut of fuel pipe u Install high pressure pipe 5 above the adaptor 9 u Pre tighten screw 6 to torque For more information see Tightening specifications page 129 u Pre tighten high pressu...

Page 129: ...n to torque Specific values Not applicable Tightening specifications q Put all parts in place and tighten by hand before following the sequence Information Refer to screws reuse rules For more informa...

Page 130: ...ft lb 5 Injector nut 2 Tighten 150 Nm 111 ft lb 6 Electrical wires 3 Tighten 0 5 Nm 0 36 ft lb Tab 30 Tightening sequence Injector Fig 148 Retaining plate screws Reference Key Screw specifications Lu...

Page 131: ...on Previous tasks q Disconnect fuel pipes and sensors q Close fuel supply Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Rags Cleaner Bucket for fue...

Page 132: ...ith screws 7 u Tighten screws 7 to torque u Screw protection guard 2 with screws 1 u Tighten screws 1 to torque u Install flange joints 3 4 5 6 Specific values Not applicable Tightening specifications...

Page 133: ...king page 274 3 6 6 Leakage fuel block removal and installation Previous tasks q Disconnect leak fuel piping and sensors Specific safety instructions Not applicable Special tools Not applicable Consum...

Page 134: ...ghtening specifications Refer to standard tightening torques For more information see 5 3 Standard tightening torques page 274 3 6 7 Fuel pump HP and LP removal and installation SL 250 Previous tasks...

Page 135: ...l Castrol Optimol paste white T Rags Cleaner Overview Fig 154 Task overview 1 HP Fuel pump without LP pump 3 Screw M12 2 HP Fuel pump with LP pump Removal u Remove a first screw 3 and a second one dia...

Page 136: ...pump lifting device u Remove fuel pumps u Remove guiding rods Installation u Install new O ring Information Lubricate HP connection o ring with Castrol Optimol paste white T Lubricate shaft teeth and...

Page 137: ...e screw 3 u Remove guiding rods u Place remaining screws and remove lifting tools u Tighten screws to torque following the given order For more information see Tightening speci fications page 138 u In...

Page 138: ...rew specifications Lubricant Reuse Torque Angle Step 5 Step 5 1 171AA DIN 34800 M12x1 75x55 10 9 FLZN Yes 1 60 Nm 44 ft lb 2 120 Nm 89 ft lb 2 171AB 22L M26x1 5 O Yes 1 140 Nm 103 ft lb 3 212AA 22L M2...

Page 139: ...W Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 K...

Page 140: ...Not applicable Special tools Not applicable Consumables and equipment Vaseline Rags Overview Fig 160 Task overview 1 Charge air pipe end segment B bank 7 Screw M10 2 O ring 8 Screw plug 3 Pipe 9 Conn...

Page 141: ...9 with screws 7 u Mount charge air pipe 4 next to connection piece 9 using gasket 5 and screws 6 to fix charge air pipe to cylinder heads u Repeat procedure for next charge air pipes 4 using pipe 3 u...

Page 142: ...erview 1 Nut M10 10 Screw M10 2 Seal 11 Screw M10 3 Screw M10 12 Compensator 4 Nut M10 13 End cover 5 Compensator 14 Screw M10 6 Pipe 15 Screw M10 7 Clamp 16 Screw M12 8 Screw M12 17 Distance sleeve S...

Page 143: ...e 18 Clamp Fig 162 Task overview 19 Distance sleeve 22 Screw M12 20 Screw M10 23 Pipe 21 Pipe 24 Screw plug Removal Fig 163 Removing charge air lines u Remove screws 3 10 with nuts 1 4 KD83V16 3352508...

Page 144: ...seals 2 u Remove screws 14 u Remove end covers 13 with seals 2 Fig 164 Removing charge air lines u Remove screws 3 10 with nuts 1 u Remove compensator 5 with seals 2 u Remove screws 8 16 with locking...

Page 145: ...venly Fig 165 Installing charge air lines u Screw end covers 13 with screws 14 and seals 2 u Screw compensator 12 to charge air cooler with screws 3 11 15 and seal 2 u Screw compensator 5 to turbochar...

Page 146: ...166 Installing clamps u Pretighten both screws 8 simultaneously to ensure 1 2 after tightening Information Bend locking plates 9 after assembly u Tighten screws 8 to torque 146 2021 by Kohler Co All...

Page 147: ...nuts 1 u Install screw plug 24 u Assemble pipe 23 with compensators 5 on both sides using screws 10 seals 2 and nuts 4 u Screw assembly to charge air cooler with screws 11 and seal 2 u Screw assembly...

Page 148: ...FLZN Yes 1 43 Nm 32 ft lb Tab 35 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to s...

Page 149: ...pplicable Consumables and equipment Rags Cleaner Grease Optimol Overview Fig 169 Task overview 1 Nut M10 9 Locking plate 2 Seal 10 Screw M10 3 Screw M10 11 Screw M10 4 Nut M10 12 Screw M10 5 Compensat...

Page 150: ...overview 17 O ring 21 Screw M10 18 O ring 22 Screw M10 19 Flap with actuator 23 Compensator 20 Flange joint Fig 171 Task overview 24 Distance sleeve 27 Screw M10 25 Screw M10 28 Pipe 26 Pipe 29 Screw...

Page 151: ...eals 2 u Remove screw 14 and distance sleeve 15 u Remove screws 8 and locking plates 9 u Remove clamps 7 16 u Remove screws 3 10 and nuts 1 4 u Remove compensator 5 and seals 2 u Remove screws 10 and...

Page 152: ...12 u Remove compensator 5 and seals 2 u Remove screws 14 and distance sleeves 15 u Remove screws 8 and locking plates 9 u Remove clamps 7 16 u Remove screws 3 10 and nuts 1 4 u Remove compensator 5 a...

Page 153: ...ve flap with actuator 19 and compensator 23 as an assembly u Remove compensator 23 from flap with actuator 19 Installation Information Preassemble all seals on compensators Information At first instal...

Page 154: ...Install flange joints 20 Fig 176 Installing charge air lines u Install compensator 13 with seals 2 screws 3 11 12 and nuts 1 u Assemble pipe 6 with compensators 5 and seals 2 using screws 10 and nuts...

Page 155: ...tance sleeve 15 and locking plates 9 Fig 177 Installing clamps u Pretighten both screws 8 simultaneously to ensure 1 2 after tightening Information Bend locking plates 9 after assembly u Tighten screw...

Page 156: ...turbocharger with screws 25 distance sleeves 24 seal 2 and nuts 1 u Install screw plug 29 u Assemble pipe 28 with compensators 5 using screws 10 seals 2 and nuts 4 u Install assembly to charge air co...

Page 157: ...taneously to ensure 1 2 after tightening Information Bend locking plates 9 after assembly u Tighten screws 8 to torque u Tighten all screws to torque making sure that compensators are aligned evenly S...

Page 158: ...0 Nm 30 ft lb 2 230AH EN 1665 M10x1 5x80 10 9 FLZN Yes 1 43 Nm 32 ft lb Tab 36 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine...

Page 159: ...lication set Specific safety instructions NOTICE Risk of property damage by reuse of sealing Leakage by faulty seal u Replace all sealings Special tools Not applicable Consumables and equipment Rags C...

Page 160: ...ll straight air intake connections 2 7 with nuts 1 u Install flanges 5 8 with o rings 6 and screws M8 4 u Install screw plugs 3 in straight air intake connections 2 7 Specific values Not applicable Ti...

Page 161: ...tion Previous tasks q Disconnect application set exhaust system Specific safety instructions WARNING Risk of injuries by contact with hot surfaces Engine is hot near operating temperature u Avoid any...

Page 162: ...e supports 3 u Remove nuts 7 with clamp segments 6 u Remove exhaust elbow 4 Installation u Install screw plugs 10 with washers 11 into exhaust elbows 4 u Tighten screw plugs 10 to torque u Position ex...

Page 163: ...lb 2 412AB DIN 908 G1 4 A MH No 1 30 Nm 22 ft lb 3 430AA DIN 939 M10x1 5x22 MH Yes 1 24 Nm 18 ft lb Tab 38 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste whit...

Page 164: ...ny contact with the engine parts carrying hot coolant or oil the exhaust system the turbocharger the heat protection the battery and the covers u After the temperature has cooled down to a level it ca...

Page 165: ...Exhaust gas turbocharger 7 Screw plug 3 Nut M10 8 Distance sleeve 4 Seal 9 Retaining plate 5 Orifice plate 10 Screw M12 Fig 186 Task overview 11 Screw M8 15 Compensator 12 Cover 16 O ring 13 O ring 1...

Page 166: ...ompensators u Remove screws 11 u Remove compensators 14 15 17 u Remove cover 12 Fig 188 Removing elbows u Remove screws 10 and distance sleeves 8 u Remove retaining plates 9 u Remove exhaust elbow 1 1...

Page 167: ...gs 7 with washers 6 into exhaust elbow 1 u Tighten screw plugs 7 to torque u Install exhaust elbow 1 and seal 15 on turbocharger outlet u Install retaining plates 9 with screws 10 and distance sleeves...

Page 168: ...over 12 with screws 11 and o ring 13 u Install compensators 14 17 with screws 11 and o rings 13 u Install compensator 15 with screws 11 and o rings 13 16 u Tighten screws 11 to torque Specific values...

Page 169: ...Nm 22 ft lb 3 412AD M12x1 75x50 C3J Yes 1 56 Nm 41 ft lb 4 430AA DIN 939 M10x1 5x22 MH Yes 1 24 Nm 18 ft lb Tab 39 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol pa...

Page 170: ...es by burns The engine control unit ECU is hot while operating the engine u Avoid any contact with the engine parts carrying hot coolant or oil the exhaust system the turbocharger the heat protection...

Page 171: ...r 9 V clamp 3 Stud 10 O ring 4 Turbocharger 11 O ring 5 Seal 12 Turbocharger 6 Compensator 13 Screw plug 7 Distance sleeve 14 Screw M10 Removal Fig 193 Removing turbocharger u Remove screws 1 and wash...

Page 172: ...eal 5 u Repeat procedure for all turbochargers Installation Fig 194 Installing turbocharger u Place the turbocharger on a workbench u Install the straight air intake connection For more information se...

Page 173: ...n u Position the turbocharger on the bracket so that the compensator is aligned with the exhaust pipe connection u Tighten screws 1 with washers 2 to torque u Install V clamp 9 on exhaust pipe connect...

Page 174: ...es 1 230 Nm 170 ft lb 2 430AD M16x2x90 C3J MH No 1 120 Nm 89 ft lb 3 430AE M8x1 25 MH Yes 1 20 Nm 15 ft lb 4 430AF M22x1 5 O Yes 1 90 Nm 66 ft lb 4 430AG M10x1 5 Yes 1 20 Nm 15 ft lb Tab 40 Tightening...

Page 175: ...removal and installation Previous tasks Not applicable Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Rags Cleaner Overview Fig 197 Task overview 1...

Page 176: ...system 4 Plate 11 Screw M10 5 Screw M8 12 Orifice 6 Screw M8 13 O ring 7 Distribution block Fig 198 Task overview 14 O ring 17 O ring 15 Flange 18 Pipe 16 Screw M8 176 2021 by Kohler Co All rights re...

Page 177: ...nd pipes u Remove screws 5 with plate 4 and clamps 3 u Remove pipe 2 u Remove screws 11 u Remove pipe 10 orifice 12 and o ring 13 u Remove screws 6 u Remove distribution block 7 and o ring 9 u Remove...

Page 178: ...14 and pipe 18 Installation Fig 201 Installing flanges and pipes u 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 be...

Page 179: ...u Grease orifice 12 u Install pipe 10 with orifice 12 screws 11 and seal 13 between flange joint 8 and crankcase u Install pipe 2 with flange joints 1 on oil entry of turbocharger bracket u Tighten s...

Page 180: ...pes For more information see 3 8 4 Oil supply turbocharger removal and installation page 175 Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Rags Cle...

Page 181: ...8 Screw M8 3 Holder 9 Screw M8 4 Screw M12 10 Screw M12 5 Holder 11 Holder 6 Holder Fig 205 Task overview 12 Screw plug 18 Seal 13 Turbocharger bracket 19 Oil return pipe 14 Fitting 20 O ring 15 Screw...

Page 182: ...17 Holder Removal Fig 206 Removing holders u Remove screws 1 2 u Remove holders 3 6 u Remove screws 4 u Remove holder 5 u Remove screws 8 9 u Remove holder 7 u Remove screws 4 10 u Remove holder 11 1...

Page 183: ...rews 15 u Lift off turbocharger brackets 13 u Remove screws 21 u Remove oil return pipe 19 with seal 18 and o ring 20 u Repeat procedure for all oil return pipes 19 u Remove screws 16 u Remove bracket...

Page 184: ...s 19 with seals 18 and screws 21 NOTICE Misalignment Parts damage u Pay attention to align oil return pipes in camshaft cover plate properly u Tighten screws 21 to torque u Insert o rings 20 on the oi...

Page 185: ...stall holder 11 with screws 4 10 Specific values Not applicable Tightening specifications Refer to standard tightening torques For more information see 5 3 2 Screws pre tightening reuse and marking pa...

Page 186: ...em the turbocharger the heat protection the battery and the covers u After the temperature has cooled down to a level it can be touched proceed with the tasks on the engine Special tools Not applicabl...

Page 187: ...15 ft lb Tab 41 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules...

Page 188: ...rger the heat protection the battery and the covers u After the temperature has cooled down to a level it can be touched proceed with the tasks on the engine Special tools Not applicable Consumables a...

Page 189: ...13 14 with seals 1 and screws 3 u Mount outlet manifolds 12 on outlet manifolds 13 14 with seals 4 V clamps 5 and compen sator 6 u Place outlet manifolds 12 with seals 1 and screws 3 u Mount outlet ma...

Page 190: ...AD DIN 908 G3 8 A MH Yes 1 60 Nm 44 ft lb 4 410AE DIN 908 M16x1 5 MH Yes 1 50 Nm 37 ft lb 5 410AF M8x1 25 MH Yes 1 20 Nm 15 ft lb Tab 42 Tightening specifications table Lubricants MG Molykote G n plus...

Page 191: ...tasks q Not applicable Specific safety instructions WARNING Risks of burns u Wait until the engine has cooled down Special tools Not applicable Consumables and equipment Not applicable Overview Fig 21...

Page 192: ...d Repair Manual Lubricating system Removal Fig 216 Removing hoses u Remove screw 3 u Remove clamp 4 u Loosen clamps 1 u Remove hoses 2 5 192 2021 by Kohler Co All rights reserved KD83V16 33525088901_2...

Page 193: ...applicable Tightening specifications Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 3 9 2 Oil centrifuge removal and installation dependin...

Page 194: ...6 O ring 18 Flange 7 Oil centrifuge base 19 O ring 8 Screw M12 20 Pipe 9 Screw M8 21 O ring 10 Screw M12 22 Flange 11 Holder 23 Distance sleeve 12 Screw M8 Removal u Remove screws 10 with distance sl...

Page 195: ...ance sleeves 23 u Assemble oil centrifuge base 7 and oil centrifuge 1 with screws 8 and o rings 2 3 u Install holders 11 with screws 12 u Install oil centrifuge assembly to oil pan with o ring 13 and...

Page 196: ...Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 3 9 3 Spin...

Page 197: ...or all filters Installation u Clean sealing area u Lubricate filter seal 3 with engine oil u Screw spin on oil filter 1 in filter head 2 until it contacts base u Tighten filter by hand by 1 2 turn Spe...

Page 198: ...ific safety instructions Not applicable Special tools Not applicable Consumables and equipment Rags Overview Fig 221 Task overview 1 Screw M8 8 Return valve 2 Clamp 9 Oil line 3 Prelubricating pump 10...

Page 199: ...llation Information Do not install relay 11 on the engine u Install holders 7 with screws 4 distance sleeves 5 and nuts 6 u Tighten screws 4 u Hand tighten prelubricating pump 3 with clamps 2 and scre...

Page 200: ...9 FLZN Yes 1 66 Nm 49 ft lb 3 M12 10 9 FLZN Yes 1 113 Nm 83 ft lb 4 M33x2 O Yes 1 340 Nm 251 ft lb Tab 44 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste whit...

Page 201: ...For more information see 3 3 3 Rocker arms housing removal and installation page 82 Specific safety instructions NOTICE Risk of property damage by reuse of sealing Leakage by faulty seal u Replace al...

Page 202: ...over u Remove screws 9 u Remove cover 4 Fig 225 Removing water pipe u Move clamp 7 to the middle of the pipe 3 u Push pipe 3 towards the left housing u Remove rocker arm housing u Remove pipe 3 202 20...

Page 203: ...2 u Push pipe 2 towards the left housing u Remove rocker arm housing u Remove pipe 2 Fig 227 Removing collector u Remove screws 6 u Remove collector 1 Installation Fig 228 Installing collector u Inse...

Page 204: ...B bank pipe 2 into rocker arm housing u After housing is installed push pipes to the right until clamp 7 can be placed in its groove Fig 230 Installing water pipe u Insert o rings 8 u Position clamp 7...

Page 205: ...more information see 5 3 Standard tightening torques page 274 3 10 2 Venting line removal and installation Previous tasks Not applicable Specific safety instructions NOTICE Risk of property damage by...

Page 206: ...er 7 Venting LT charge air cooler 2 Flange joint 8 Flange joint 3 Venting LT charge air cooler 9 Venting HT thermostat 4 T connector 10 Venting LT turbocharger 5 Screw M10 11 Venting HT collecting pip...

Page 207: ...Task overview 12 Screw M8 18 Holder 13 Screw M6 19 Holder 14 Clamp 20 Holder 15 Nut M6 21 Holder 16 Holder 22 Holder 17 Distance sleeve Fig 234 Task overview 23 Venting line KD83V16 33525088901_2_1 E...

Page 208: ...ines u Remove venting line 23 with flange joints 2 Fig 236 Removing venting lines u Remove clamps 14 with screws 13 and nuts 15 u Remove holders 16 18 19 20 21 22 with screws 5 12 and distance sleeve...

Page 209: ...tem Fig 237 Removing venting lines u Remove venting pipes 1 3 7 9 10 11 u Remove screws 5 u Remove distributor block 6 Installation Fig 238 Installing venting lines KD83V16 33525088901_2_1 EN_US 2021...

Page 210: ...10 11 with T connector 4 and flange joints 2 8 Fig 239 Installing venting lines u Install clamps 14 and holders 16 18 19 20 21 22 with screws 5 12 13 distance sleeve 17 and nuts 15 Information Use Lo...

Page 211: ...3 Standard tightening torques page 274 3 10 3 Turbocharger cooling lines removal and installation Previous tasks q Remove venting lines For more information see 3 10 2 Venting line removal and install...

Page 212: ...lamp 17 O ring 4 T connector 18 O ring 5 Screw M8 19 Aggregate support connector 6 Pipe 20 Screw M10 7 Pipe 21 Pipe 8 Distance sleeve 22 Retaining plate 9 Screw M8 23 Pipe 10 Screw M8 24 Fitting 11 Sc...

Page 213: ...29 Fitting 38 Aggregate support connector 30 Fitting 39 Screw M10 31 90 connector 40 Pipe 32 T connector 41 Screw M8 33 Pipe 42 Retaining plate 34 Flange joint 43 Pipe 35 Adaptor 44 Retaining plate 3...

Page 214: ...Remove screws 9 11 and distance sleeve 8 u Remove screws 16 20 u Remove aggregate support connector 19 u Unscrew connection nuts of pipes 6 7 15 21 23 25 26 u Remove fittings 24 u Remove screws 10 11...

Page 215: ...Remove screws 1 16 39 u 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 KD83V16...

Page 216: ...gate support connector 38 with screws 16 and o ring 18 u Mount T connector 14 and flange joints 13 34 with adaptor 35 on pipe 36 u Mount pipes 33 40 43 45 with T connectors 14 28 32 u Install 90 conne...

Page 217: ...u Mount pipes 6 7 15 21 23 25 26 with T connectors 4 14 and flange joint 13 u Install fittings 24 u Screw retaining plate 12 with screws 10 11 and distance sleeve 8 u Install retaining plate 27 with...

Page 218: ...olykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and...

Page 219: ...ine Rags Cleaner Overview Fig 248 Task overview 1 Screw M10 14 Adaptor 2 Plate 15 Pipe 3 Clamp 16 Screw M10 4 T connector 17 O ring 5 Screw M8 18 O ring 6 Pipe 19 Aggregate support connector 7 Pipe 20...

Page 220: ...ng 29 Fitting 40 Aggregate support connector 30 90 connector 41 Screw M10 31 T connector 42 Pipe 32 Pipe 43 Screw M10 33 Pipe 44 Retaining plate 34 Coupling 45 Pipe 35 Flange joint 46 Retaining plate...

Page 221: ...nd clamps 3 u Remove clamp 11 u Remove screws 16 20 u Remove aggregate support connector 19 u Unscrew connection nuts of pipes 6 7 15 21 23 25 26 u Remove fittings 24 u Remove screws 10 12 and distanc...

Page 222: ...screws 43 u Remove retaining plates 44 46 u Remove screws 16 41 u Remove aggregate support connector 38 u Unscrew connection nuts of pipes 32 33 37 38 42 45 47 u Remove pipes 32 33 37 38 42 45 47 u D...

Page 223: ...16 and o ring 18 u Mount T connector 36 and flange joint 35 with coupling 34 between pipes 33 38 u Mount pipes 32 42 45 47 with T connectors 27 31 u Install 90 connectors 30 and fittings 29 on pipe a...

Page 224: ...u Mount pipes 6 7 15 21 23 25 26 with T connectors 4 14 and adaptor 14 u Install pipe 37 u Install fittings 24 u Screw retaining plate 13 with screws 10 12 and distance sleeve 8 u Install retaining p...

Page 225: ...strol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 3 10...

Page 226: ...ine Rags Cleaner Overview Fig 256 Task overview 1 Thermostat 6 Flange 2 Screw plug 7 Screw M10 3 Thermostat housing 8 O ring 4 Screw M12 9 Pipe 5 O ring 10 Screw plug depending on application Removal...

Page 227: ...l remaining screws u Install thermostat housing 3 with screws 4 7 u Install new screw plugs 2 10 u Tighten screws to torque Information Vent coolant circuit at the end of installation Specific values...

Page 228: ...ty damage by reuse of sealing Leakage by faulty seal u Replace all sealings Special tools Special tool Designation Guiding rod M12x230 Thermostat x2 Tab 48 Special tools Consumables and equipment Vase...

Page 229: ...ace of the two screws 3 u Remove remaining screws 3 and screws 6 u Remove thermostat housing 2 u Remove guiding rods u Remove thermostats 1 u Remove pipe 8 with flange 5 Installation u Assemble pipe 8...

Page 230: ...3 F and are fully opened at 57 C 135 F Tightening specifications Refer to standard tightening torques For more information see 5 3 Standard tightening torques page 274 3 10 6 Coolant pump HT removal a...

Page 231: ...ipe 6 Flange 15 Screw M12 7 O ring 16 Screw M12 8 Test point fitting 17 O ring 9 Coolant pump HT Removal u Remove screws 1 5 u Remove piping assemblies 2 4 6 u Remove two screws 16 u Install guiding r...

Page 232: ...Information Vent coolant circuit at the end of installation Specific values Not applicable Tightening specifications Refer to standard tightening torques For more information see 5 3 Standard tighteni...

Page 233: ...pump x2 Tab 50 Special tools Consumables and equipment Rags Cleaner Vaseline Overview Fig 262 Task overview 1 Screw M12 7 Flange 2 Branch pipe 8 O ring 3 O ring 9 O ring 4 O ring 10 O ring 5 Pipe 11 C...

Page 234: ...ant pump LT 11 u Place four screws 12 u Remove guiding rods u Place the remaining screws 12 u Assemble elbow pipe 18 with flange 14 and o rings 13 15 17 u Tighten screws 16 19 according to tightening...

Page 235: ...n drive option Previous tasks q Remove vibration damper cover For more information see 3 2 1 Vibration damper cover removal and installation page 59 Specific safety instructions Not applicable Special...

Page 236: ...verview Fig 265 Task overview 1 Screw M16 4 Screw M28 2 Washer 5 Axle 3 Pulley Removal Fig 266 Locking device u Install locking device with screws M16 to lock crankshaft 236 2021 by Kohler Co All righ...

Page 237: ...u Remove screws 1 and washers 2 u Remove pulley 3 u Remove screws 4 u Remove axle 5 u Remove locking device Installation Fig 268 Locking device u Install locking device with screws M16 to lock cranksh...

Page 238: ...5 with screws 4 Information Observe screws 4 tightening sequence and tightening torque u Tighten screws 4 to torque u Install pulley 3 with screws 1 and washers 2 u Tighten screws 1 to torque Specifi...

Page 239: ...70 Tightening sequence of pulley axle screws Fig 271 Screws of fan drive pulley Reference Key Screw specifications Lubricant Reuse Torque Angle Step 5 Step 5 1 M16x55 10 9 FLZN No 1 275 Nm 203 ft lb K...

Page 240: ...t lb 2 75 Tab 52 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer to screws reuse rules...

Page 241: ...e parts shall only be possible with voluntary action u Proceed to lock out and tag out prior to accessing to the engine u Respect the voltage indication of the engine s technical data sheet u Check th...

Page 242: ...y PTO 2 Bracket 13 Belt 3 Pin 14 Screw M10 4 Screw M10 15 Tensioning device 5 Retaining plate 16 Screw M10 6 Washer 17 Washer 7 Screw M12 18 Screw M10 8 Screw M8 19 Screw M12 9 Roller 20 Distance slee...

Page 243: ...e against the spring force to the limit stop u Use a guiding rod in the specified location to lock the tensioning device u Remove belt 13 u Remove guiding rod Fig 275 Removing battery charging alterna...

Page 244: ...e 21 Fig 276 Removing auxiliary PTO u Remove screws 7 u Remove auxiliary PTO 12 u Remove o rings 10 11 Fig 277 Removing tensioning device u Remove screw 14 u Remove tensioning device 15 244 2021 by Ko...

Page 245: ...Remove roller 9 u Remove screws 7 8 16 and washers 6 17 u Remove plate 5 Installation Fig 279 Installing auxiliary PTO u Grease o rings 10 11 u Insert o rings 10 11 in auxiliary PTO 12 u Install auxil...

Page 246: ...ery charging alternator 1 in bracket u Install battery charging alternator 1 with screw 4 and screw 18 with distance sleeve 20 Fig 281 Installing roller u Install roller 9 on plate 5 u Install plate 5...

Page 247: ...device 15 u Pivot back the tensioning device 15 against the spring force to the limit stop u Use a guiding rod in the specified location to lock the tensioning device 15 u Install belt 13 on the PTO...

Page 248: ...c Coating Yes 1 50 Nm 37 ft lb Tab 54 Tightening specifications table Lubricants MG Molykote G n plus MW Castrol Optimol paste white T MH Molykote HSC O Engine oil XX Loctite 243 YY Loctite 577 Refer...

Page 249: ...ask overview 1 Ground connection 4 Screw M16 2 Starter 5 Power supply T30 battery 3 Wiring harness connection 6 Ground cable Removal u Unplug wiring harness connection 3 u Remove nut from ground conne...

Page 250: ...ghtening specifications Specific values Not applicable Tightening specifications Fig 286 Starter nuts Reference Key Screw specifications Lubricant Reuse Torque Angle Step 5 Step 5 1 M12 Yes 1 22 Nm 16...

Page 251: ...Prestolite starter removal and installation option Previous tasks q Disconnect the battery Specific safety instructions Not applicable Special tools Not applicable Consumables and equipment Not applic...

Page 252: ...ations Fig 288 Starter screws and connections Reference Key Screw specifications Lubricant Reuse Torque Angle Step 5 Step 5 1 450AA ISO 4762 M16x2x35 10 9 FLZN Yes 1 180 Nm 133 ft lb 2 Nut 1 9 5 Nm 7...

Page 253: ...r Electrical system Refer to screws reuse rules For more information see 5 3 2 Screws pre tightening reuse and marking page 274 25 Accuracy is accepted KD83V16 33525088901_2_1 EN_US 2021 07 2021 by Ko...

Page 254: ...Engine is hot near operating temperature u Avoid any contact with the engine parts carrying hot coolant or oil the exhaust system the exhaust gas turbocharger the heat protection the battery and the c...

Page 255: ...fluid injector 7 Gasket 4 Shipping cap Removal Fig 290 Disconnecting return line and electrical connector u Disconnect the diesel exhaust fluid return line from the injector u Disconnect the electric...

Page 256: ...ove the injector fixing nuts 9 and washers 8 Fig 292 Removing injector assembly u Remove the injector 3 and the retaining plate 10 together as an assembly Information Make sure the screws remain in pl...

Page 257: ...t line Information Make sure that dust cannot go into the system u Discard the injector and the injector gasket Installation Fig 294 Preparing reactor surface u Clean the sealing surface on the reacto...

Page 258: ...ward the reactor At this stage do not tighten the nuts 9 so that the injector 3 can be installed u Install a new gasket 7 to the new injector 3 u Slide the injector 3 and gasket 7 assembly between the...

Page 259: ...tightening sequence Fig 297 Removing shipping caps u Remove the shipping caps 1 2 4 from the injector u Connect the diesel exhaust fluid inlet line u Connect the diesel exhaust fluid return line u Co...

Page 260: ...Crushing shearing or impact hazards by instable transportation conditions or losing control of the means of transport load or loose part Loss of control of the load of any loose part or means of trans...

Page 261: ...esel exhaust fluid pump 5 Connection M26 M22 2 Screw M10 6 10 pin connector 3 Lifting hook 7 48 pin connector 4 Connection M26 M22 Removal Fig 299 Securing pump u Using the lifting hooks 3 secure the...

Page 262: ...301 Connector locking device handling forbidden u Disconnect the 10 pin connector 6 Information It is forbidden to handle the connector locking device 8 on the pump side Only use the lock on the harn...

Page 263: ...Fig 302 Removing screws u Remove the screws 2 u Remove the pump 1 Installation Fig 303 Installing pump u Install the pump 1 with screws 2 u Tighten the screws 2 to 33 3 Nm 24 2 ft lb KD83V16 335250889...

Page 264: ...ors 4 5 u Tighten connectors 4 5 to 35 5 Nm 26 4 ft lb u Connect the 48 pin connector 7 to the pump 1 u Tighten the fastening screws of the 48 pin connector 7 to 4 0 5 Nm 3 0 ft lb Fig 305 Connector l...

Page 265: ...e harness side to connect the 10 pin connector 6 u Run the system for 30 min to confirm successful priming and leak free operation Specific values Not applicable Tightening specifications Refer to sta...

Page 266: ...ent KOHLER Ident number Turning device 1 11133437 230611637 Locking device 1 11343230 230612868 Guiding rod M30x2 Cylinder head 2 11133371 230610035 Guiding rod M28x2 Damper 2 11133372 230610036 Guidi...

Page 267: ...20 Oil filter 2 11133375 230610038 Guiding rod M16 Oil cooler support 2 11133376 230610039 Guiding rod M12 Oil cooler 2 11133377 230610040 Guiding rod M10 Exhaust line 2 11133379 230610041 Guiding rod...

Page 268: ...12691409 230612675 Sampling Tube for each liquid sampling 1 7002475 230612676 Handling bar 1 11344345 230612677 Electric Torque Multiplier 1 12226986 230612678 Torque Reaction Arm for Electric Torque...

Page 269: ...ne main failure by forgotten turning device Keeping the turning device screwed on the flywheel housing while operating the engine will lead to a break of the turning device and to an engine main failu...

Page 270: ...ce 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 represen...

Page 271: ...device WARNING Risk of injuries by ejected tools or turning devices parts Keeping the turning device screwed on the flywheel housing could result in death or serious injuries by tool ejection or break...

Page 272: ...ents 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 serv...

Page 273: ...e 7063 500 16 9 Loctite Loctite 243 250 8 4 Loctite Loctite 270 or Omnifit 200 M 250 8 4 Loctite Loctite 577 250 8 4 Loctite Loctite 648 or Omnifit 230 M 250 8 4 Loctite Loctite 5900 50 1 7 Loctite Lo...

Page 274: ...reuse of screws or nuts Improper pre tightening turning angle or reuse of screws or nuts could lead to the rupture of the screw or nut and lead to property damage by malfunction ejection fall or tilti...

Page 275: ...et key of the torque wrench 2 mark the initial position aligned with the marking on the component u Use the torque wrench to tighten until the marking of the initial position is aligned with the marki...

Page 276: ...g u Replace screws after each dismounting Counterweight u Untightening screws is forbidden Screw plugs u Replace screw plugs after each dismounting On fuel and HP injections pipes u Replace connection...

Page 277: ...ance with ISO 4014 ISO 4017 For socket screws in accordance with ISO 4762 For flange screws in accordance with EN 1665 For hexagonal nuts in accordance with ISO 4032 ISO 4034 ISO 4035 For flange nuts...

Page 278: ...hread Tightening torque Thread Tightening torque Thread Tightening torque M 6 x 1 5 Nm 4 ft lb1 M 14 x 1 5 57 Nm 42 ft lb M 20 x 1 5 98 Nm 72 ft lb M 8 x 1 12 Nm 9 ft lb M 16 x 1 5 68 Nm 50 ft lb M 36...

Page 279: ...x 1 15 Nm 11 ft lb M 30 x 1 5 115 Nm 85 ft lb M 48 x 1 5 300 Nm 221 ft lb M 10 x 1 25 15 Nm 11 ft lb M 30 x 2 115 Nm 85 ft lb M 48 x 2 300 Nm 221 ft lb M 12 x 1 5 20 Nm 15 ft lb M 33 x 2 120 Nm 89 ft...

Page 280: ...lb 30 Nm 22 ft lb 25 Nm 18 ft lb 25 Nm 18 ft lb M 14 x 1 5 35 Nm 26 ft lb 45 Nm 33 ft lb 45 Nm 33 ft lb 35 Nm 26 ft lb M 16 x 1 5 45 Nm 33 ft lb 65 Nm 48 ft lb 55 Nm 41 ft lb 40 Nm 30 ft lb M 18 x 1...

Page 281: ...ft lb 70 Nm 52 ft lb M 20 x 1 5 55 Nm 41 ft lb 150 Nm 111 ft lb 125 Nm 92 ft lb 80 Nm 59 ft lb M 22 x 1 5 65 Nm 48 ft lb 170 Nm 125 ft lb 135 Nm 100 ft lb 100 Nm 74 ft lb M 27 x 2 0 90 Nm 66 ft lb 270...

Page 282: ...40 Nm 398 ft lb Tab 68 Standard torques for imperial thread unions L series for steel see figure above Standard torques for imperial thread unions S series up to 800 bar 11603 Psi for steel According...

Page 283: ...g edge Form B with sealing ring Form E with flat sealing Form F with O ring M 10 x 1 0 7 Nm 5 ft lb 14 Nm 10 ft lb 14 Nm 10 ft lb 12 Nm 9 ft lb M 12 x 1 5 16 Nm 12 ft lb 24 Nm 18 ft lb 20 Nm 15 ft lb...

Page 284: ...lb 56 Nm 41 ft lb M 20 x 1 5 44 Nm 32 ft lb 120 Nm 89 ft lb 100 Nm 74 ft lb 64 Nm 47 ft lb M 22 x 1 5 52 Nm 38 ft lb 136 Nm 100 ft lb 108 Nm 80 ft lb 100 Nm 74 ft lb M 27 x 2 0 72 Nm 53 ft lb 216 Nm...

Page 285: ...m 319 ft lb Tab 72 Standard torques for imperial thread unions L series for aluminium see figure above Standard torques for imperial thread unions S series up to 800 bar 11603 Psi for aluminium Accord...

Page 286: ...9 ft lb 360 Nm 266 ft lb G 1 1 2A 232 Nm 171 ft lb 560 Nm 413 ft lb 432 Nm 319 ft lb Tab 73 Standard torques for imperial thread union S series for aluminium see figure above 5 3 7 Assembling pipes wi...

Page 287: ...10S 34 Nm 25 ft lb 90 12L 30 Nm 22 ft lb 90 12S 36 Nm 27 ft lb 90 15L 50 Nm 37 ft lb 90 14S 58 Nm 43 ft lb 90 18L 82 Nm 60 ft lb 90 16S 70 Nm 52 ft lb 90 22L 120 Nm 89 ft lb 90 20S 130 Nm 96 ft lb 90...

Page 288: ...4 ft lb 28 42 2 1 4 12 380 Nm 280 ft lb 400 Nm 295 ft lb 32 2 2 1 2 12 450 Nm 332 ft lb 470 Nm 347 ft lb Tab 75 Standard torques for triple lock flange joints Information To tighten the screwed socket...

Page 289: ...295 ft lb M22x1 5 90 Nm 66 ft lb 100 Nm 74 ft lb G 1 1 2 450 Nm 332 ft lb M24x1 5 90 Nm 66 ft lb M26x1 5 125 Nm 92 ft lb 3 4 16 UNF 70 Nm 52 ft lb M30x1 5 240 Nm 177 ft lb 7 8 1 4 UNF 100 Nm 74 ft lb...

Page 290: ...28 Nm 21 ft lb 36 Nm 27 ft lb G 1 2 65 Nm 48 ft lb M16x1 5 40 Nm 30 ft lb 44 Nm 32 ft lb G 3 4 112 Nm 83 ft lb M18x1 5 52 Nm 38 ft lb 56 Nm 41 ft lb G 1 160 Nm 118 ft lb M20x1 5 60 Nm 44 ft lb 64 Nm 4...

Page 291: ...g torques 10 Always lubricate the thread before tightening these parts engine oil Information To assemble pipes with DKO connectors observe the following steps u When tightening the nut make sure the...

Page 292: ...103 ft lb 28L 160 Nm 118 ft lb 25S 190 Nm 140 ft lb 35L 250 Nm 184 ft lb 30S 270 Nm 199 ft lb 42L 380 Nm 280 ft lb 38S 400 Nm 295 ft lb Tab 78 Alternative tightening torques for DKO connectors 5 3 12...

Page 293: ...Frequency Reciprocating Rig Measured value for the lubricity of diesel fuels HP High Pressure HT High Temperature JSA Job Safety Analysis LAN Local Area Network LED Light Emitting Diode LOTO LockOut...

Page 294: ...DIN German standard EN European standard EU European Union ILO International Labor Organisation ISCED International Standard Classification of Education SAE Society of Automotive Engineers WHO World H...

Page 295: ...sion factors Convert from To Multiply by kg lb 2 205 kg oz 35 274 Tab 83 Mass conversion factors table 5 5 3 Pressure conversion factors Convert from To Multiply by kPa psi lbf in 0 145 kPa lbf ft 20...

Page 296: ...s Convert from To Multiply by g kWh g hph 0 736 g kWh lb hph 0 00162 Tab 88 Fuel consumption conversion factors table 5 5 8 Flow conversion factors Convert from To Multiply by m3 h liquid US gallon mi...

Page 297: ...epair Manual Appendix Unit conversion tables Convert from To Multiply by Kg m3 lb ft3 0 0624 Tab 91 Density conversion factors table KD83V16 33525088901_2_1 EN_US 2021 07 2021 by Kohler Co All rights...

Page 298: ...refix 5 6 Prefix Name Symbol Factor tera T 1012 giga G 109 mega M 106 kilo k 103 milli m 10 3 micro 10 6 nano n 10 9 Tab 92 Common prefix multipliers table 298 2021 by Kohler Co All rights reserved KD...

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Kohler KD83V16, Service And Repair Manual

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