Kohler KD83V16 Generator Set

⚠ Hot surfaces - wait until engine has cooled.

Tools: Turning device, Feeler gauge, Allen key

1. Remove cylinder head covers.
2. Install turning device.
3. Rotate crankshaft to index 1 (TDC scavenging cylinder A1).
4. Verify scavenging TDC; if not, turn crankshaft another 360°.
5. Rotate to index 2; set clearance for A7, A8, B2, B4.
6. Rotate to index 4; set clearance for A3, A5, B6, B8.
7. Rotate to index 2+360°; set clearance for A1, A2, B5, B7.
8. Rotate to index 4+360°; set clearance for A4, A6, B1, B3.
9. Loosen locknut, adjust with allen key until feeler gauge shows slight resistance, tighten locknut.

⚠ Dismount the turning device and mount the cover before operating the engine.

1. Unscrew screws 4.
2. Remove cover 3.
3. Position turning device 2.
4. Mount and tighten screws 1 according standard torque values.

⚠ Fuel supply closed

1. Remove flange joints 3, 4, 5, 6.
2. Remove screws 1.
3. Remove protection guard 2.
4. Remove screws 7.
5. Remove fuel filter units 8.
6. Install fuel filter units 8 with screws 7 and tighten.
7. Screw protection guard 2 with screws 1.
8. Install flange joints 3, 4, 5, 6.

⚠ Risk of crushing, shearing, cutting or severing by use of the turning device.

⚠ Risk of injuries by ejected tools or turning device parts.

Tools: Manual wrench tool

1. Engage a manual wrench tool to turn the wheel that drives the flywheel gear rim.
2. Turn the engine flywheel to the required position.
3. Disengage the manual wrench each time you stop to turn.
4. At the end, dismount the turning device and mount the cover on the flywheel housing.
5. Tighten the turning device cover bolts according standard torque values.

⚠ Replace all sealings.

1. Remove screws 1, 2.
2. Remove charge air cooler 4.
3. Insert o-ring 5 in charge air cooler 4.
4. Insert pipes 6 in aggregate support.
5. Position charge air cooler 4.
6. Screw charge air cooler 4 with screws 1, 2 and distance sleeve 3.
7. Vent coolant circuit at the end of installation.

⚠ Replace all sealings.

1. Remove screws with nuts and remove compensators with seals.
2. Remove screws with locking plates and distance sleeves.
3. Remove clamps.
4. Remove pipes and end covers with seals.
5. Install end covers with screws and seals.
6. Screw compensators to charge air cooler and turbocharger with seals.
7. Assemble pipes with compensators, seals and nuts.
8. Screw clamps with screws, locking plates and distance sleeves; bend locking plates after assembly.

⚠ Hot surfaces - avoid contact with hot engine and covers.

1. Remove screw 2.
2. Remove cylinder head cover 1 and seal 3.
3. Mount a new seal 3 on cylinder head cover 1.
4. Position screws 2 into cover bores.
5. Position cylinder head cover 1 on rocker arm housing.
6. Tighten screws 2.

⚠ Replace all sealings.

Tools: HP Fuel Pump Lifting Device, Guiding rod M12 (x2)

1. Remove a first screw and a second diametrically opposed.
2. Place guiding rods in place of the two screws.
3. Remove remaining screws.
4. Install fuel pump lifting device and remove fuel pumps.
5. Remove guiding rods.
6. Install new O-ring.
7. Place guiding rods, use lifting device to position pumps into gearbox.
8. Place screw, remove guiding rods, place remaining screws and tighten per order.
9. Install HP pump piping and vent the fuel circuit.

⚠ Replace all sealings.

⚠ Lethal injury by flammable fluids under high pressure up to 2000 bar.

Tools: Injector extractor

1. Remove electrical contacts from injector.
2. Take off high pressure pipe 5 from adaptor 9.
3. Remove retaining plate 2 with screws 3.
4. Remove clamp 7 by opening screw 6.
5. Remove injector 4 with extracting tool.
6. Clean carbon from injector seat on sleeve.
7. Lubricate sleeve and injector O-rings with Molykote DX or Castrol Optimol Paste White.
8. Position injector with connection upwards; install clamp, retaining plate and high pressure pipe.
9. Tighten per tightening sequence.

⚠ Replace all sealings.

1. Remove by-pass valve 1.
2. Insert by-pass valve 1.
3. Tighten by-pass valve to torque.

⚠ Lethal or heavy injury due to electrical shocks - lockout and tagout.

⚠ Replace all sealings.

Tools: Pin for belt tensioner (x1), Frequency meter

1. Use 1/2" toggle in tensioning device 11; pivot back to limit stop.
2. Use guiding rod to lock tensioning device.
3. Remove V-belt 15; remove guiding rod.
4. Remove screws 4, 23 and remove battery charging alternator 1.
5. Remove sleeve 24.
6. Remove screws 8 and remove auxiliary PTO 14; remove o-rings 12, 13.
7. Remove tensioning device 11 and plate 18.
8. Install in reverse: grease o-rings, mount PTO, alternator, tensioning device, then V-belt.
9. Tension V-belt and check belt tension.

1. Unplug wiring harness connection 3.
2. Remove nut from ground connection 1 and disconnect ground cable 6.
3. Remove nut from power supply 5 and disconnect power supply cable.
4. Remove screws 4 and remove starter 2.
5. Position starter 2 and tighten screws 4.
6. Connect plug 3.
7. Connect power supply 5 with nut and tighten.
8. Connect ground cable 6 with nut and tighten.