Operation and Maintenance Manual
Original Instructions
Diesel engine
KD83V16
From serial number 2018740033
EN_US
33521030601_0_1
07-2018
Operation and Maintenance 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
© 2018 by Kohler Co. All rights reserved.
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KD83V16 33521030601_0_1 EN_US
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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: (31) 168 331630
Fax: (31) 168 331631
Asia Pacific
Kohler Asia Pacific Headquarters
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455
China
North China Regional Office, Beijing
Phone: (86) 10 6518 7950
(86) 10 6518 7951
(86) 10 6518 7952
Fax: (86) 10 6518 7955
To order special tools, please refer to the cross reference list in the appendix.
China
East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: (91) 80 3366208
(91) 80 3366231
Fax: (91) 80 3315972
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax: (813) 3440-2727
KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
3
Operation and Maintenance 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.: +33 (0) 2 98 41 13 48
Fax: +33 (0) 2 98 41 13 57
MID-WEST
SDMO CHOLET
Tel.: +33 (0) 2 41 75 96 70
Fax: +33 (0) 2 41 75 96 71
PARIS/NORTH & NORMANDY
SDMO ARRAS
Tel.: +33 (0) 3 21 73 38 26
Fax: +33 (0) 3 21 73 14 59
SDMO GENNEVILLIERS
Tel.: +33 (0) 1 41 88 38 00
Fax: +33 (0) 1 41 88 38 37
EAST
SDMO METZ
Tel.: +33 (0) 3 87 37 88 50
Fax: +33 (0) 3 87 37 88 59
SOUTHWEST
SDMO TOULOUSE
Tel.: +33 (0) 5 61 24 75 75
Fax: +33 (0) 5 61 24 75 79
SUBSIDIARIES
GERMANY
SDMO GMBH
Tel.: +49 (0) 63 32 97 15 00
Fax: +49 (0) 63 32 97 15 11
LATIN AMERICA & CARRIBEAN
Tel.: +1 (305) 863 0012
Fax: +1 (954) 432 8330
BELGIUM
SDMO NV/SA
Tel.: +32 36 46 04 15
Fax: +32 36 46 06 25
BRAZIL
KOHLER MAQUIGERAL
Tel.: +55 (11) 37 89 60 00
BRANCH OFFICES
SOUTH AFRICA
SDMO SOUTH AFRICA
Tel.: +27 (0) 8 32 33 55 61
Fax: +33 (0) 1 72 27 61 51
ALGERIA
SDMO ALGIERS
Tel.: +213 (0) 21 68 12 12
Fax: +213 (0) 21 68 14 14
DUBAI
SDMO MIDDLE EAST
Tel.: +971 4 458 70 20
Fax: +971 4 458 69 85
EGYPT
SDMO KAIRO
Tel./Fax: +20 (2) 22 67 12 78
KENYA
SDMO NAIROBI
Tel./Fax: +25 (47) 07 60 54
00
SOUTH ESAT
SDMO AIX-EN-PROVENCE
Tel.: +33 (0) 4 42 52 51 60
Fax: +33 (0) 4 42 52 51 61
SDMO VALENCE
Tel.: +33 (0) 4 75 81 31 00
Fax: +33 (0) 4 75 81 31 10
SPAIN
SDMO INDUSTRIES IBERICA
Tel.: +34 (9) 35 86 34 00
Tel./Fax: +34 (9) 35 80 31 36
UK
SDMO ENERGY LTD.
Tel.: +44 (0) 16 06 83 81 20
Fax: +44 (0) 16 06 83 78 63
RUSSIA
SDMO MOSCOW
Tel./Fax: +7 495 665 16 98
TOGO
SDMO WEST AFRICA
Tel.: +228 22 22 65 65
TURKEY
SDMO ISTANBUL
Tel.: +90 53 07 35 09 10
Please consult the cross-reference list in the appendix when ordering special tools.
© 2018 by Kohler Co. All rights reserved.
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KD83V16 33521030601_0_1 EN_US
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Revision history
Version Author Modification Date
00 MUA First 3.01 version 25th of July 2018
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KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
5
Operation and Maintenance Manual
© 2018 by Kohler Co. All rights reserved.
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KD83V16 33521030601_0_1 EN_US
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Preface
About this document
This Operation and Maintenance Manual (OMM) has been written for the Diesel engine's operator
and maintenance personnel.
This OMM provides information regarding:
– Safety Regulations
– Handling and operation
– Maintenance
Anyone involved in working with or on the Diesel engine must read and follow the instructions in
the OMM carefully before the first commissioning and at regular intervals.
Work with the Diesel engine includes :
– Handling, storing of the components.
– Servicing, including inspections and preventive maintenance.
Information
u For any information concerning the machinery in which the engine is mounted, refer to the
instructions of the generator set.
u For further explanation or information, the Customer Service and Customer Service training
center departments of the Kohler Co. are available any time to answer any queries.
The OMM facilitates the operator's familiarization with the Diesel engine and prevents faults
through incorrect operation.
The machinery owner is responsible for supplementing the operating instructions of the engine with
its machinery and with instructions based on existing national regulations on accident prevention
and environmental protection. In addition to these operating instructions and the regulations on
accident prevention applicable in the user's country and at the place of use, it is also necessary to
comply with the recognized technical rules on safety and technically proficient working.
Some sections of this operating manual do not apply to all machines.
Some illustrations in this manual may show details and implements that are different from your
machine.
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 OMM.
If you require further explanations or information, please contact your nearest authorized Kohler
service representative.
KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
7
Preface Operation and Maintenance Manual
About this document
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 maintenance 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.
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, lubricants, 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 guarantees, 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.
© 2018 by Kohler Co. All rights reserved.
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KD83V16 33521030601_0_1 EN_US
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Contents
1 Product description
1.1 Technical description
1.1.1 Design overview
1.1.2 Cylinder designation, direction of rotation
1.1.3 Nameplates
1.1.4 Diesel engine accessory equipment
1.2 Technical data
1.2.1 Diesel engine
1.2.2 Cylinder head
1.2.3 Coolant thermostat
1.2.4 Battery charging alternator
1.2.5 Starter
1.2.6 Flywheel housing
2 Safety
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2.1 Identification of the warnings
2.1.1 Warnings
2.1.2 Additional identifications
2.1.3 Additional rules and directives
2.2 Target audience
2.2.1 Responsibility of machinery owner
2.2.2 International standard classification of occupations
2.2.3 Occupational references
2.2.4 For the SL1 maintenance of power generation engines: Maintenance
Technician 34
2.2.5 For the SL2 maintenance of power generation engines: Technician
2.2.6 For the SL3 maintenance of power generation engines: Mechanical
Technician 35
2.2.7 For the operation of power generation engines: Operator
2.2.8 Unauthorized personnel - servicing
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Contents Operation and Maintenance Manual
2.3 Intended use
2.4 Limitation of liability
2.5 Safety instructions
2.5.1 General safety instructions
2.5.2 Safety while commissioning
2.5.3 Safety when starting
2.6 Preventing injuries
2.6.1 Preventing bruising
2.6.2 Preventing burns
2.6.3 Preventing fires and explosion hazards
2.6.4 Preventing intoxication and poisoning hazards
2.6.5 Preventing electrical hazards
2.6.6 Preventing noise hazards
2.6.7 Preventing vibrations hazards
2.6.8 Preventing electro-magnetic hazards
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2.6.9 Preventing falling risks
2.7 Personal Protective Equipment (PPE)
2.8 Operating and maintenance areas
2.8.1 Engine ready for use or in operation
2.8.2 Engine in commissioning — test-run
2.8.3 Emergency stop
2.8.4 Signage recommendations
2.9 Prevent property damages
2.9.1 Safety instructions for engine control unit (ECU)
2.9.2 Alarm conditions
2.9.3 Safety instructions for the fuel system
2.9.4 Cleanliness standards and safety
2.10 Disposal and environment protection
3 Transportation - Storage
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3.1 Safe handling
3.2 Dimensions and weight
3.3 Transport
3.3.1 Safe transportation
3.3.2 Transport fastening
© 2018 by Kohler Co. All rights reserved.
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Operation and Maintenance Manual Contents
3.3.3 Transport devices
3.3.4 Transport conditions
3.4 Storage
3.4.1 Storage conditions
3.4.2 Storage site foundation requirements
3.4.3 Storage up to 12 months
3.4.4 Storage over 12 months
3.5 Unpacking/Depreservation
3.5.1 Unpacking
3.5.2 Depreservation
3.6 Suspension of activity
3.7 Preservation, packaging
3.7.1 Preservation
4 Control and operation
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4.1 Filling lubricants and operating fluids
4.1.1 Engine oil
4.1.2 Coolant
4.1.3 Fuel
4.2 Starting the engine
4.2.1 Final check
4.2.2 Starting in cold temperatures
4.2.3 Monitoring the running engine
4.2.4 Exhaust
4.2.5 Drainage
4.2.6 Air filter
4.2.7 Engine and coolant pumps — Charge air cooler
4.2.8 Stopping the Diesel engine
4.2.9 Initial starting/test run/after out of service period
4.3 Dismantling
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4.4 Components disposal
4.5 Packaging material disposal
5 Maintenance
5.1 Inspection and maintenance schedule
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© 2018 by Kohler Co. All rights reserved.
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Contents Operation and Maintenance Manual
5.2 Maintenance plan use
5.3 Generator set ratings
5.3.1 Continuous Operating Power (COP)
5.3.2 Prime Power (PRP)
5.3.3 Emergency Standby Power (ESP)
5.3.4 Time between overhaul (TBO)
5.4 Service level definition
5.4.1 Daily or monthly maintenance activities (Level 1) - Version: 2018/07-2
5.4.2 Service level 1 — Engine Service, TBO 4000 hrs for ESP — Engine
Operation - Version: 2018/07-2 78
5.4.3 Service level 2— Engine Service, TBO 4000 hrs for ESP — Advanced
maintenance - Version: 2018/07-2 80
5.4.4 Service level 1 — Engine Service, TBO 15000 hrs for PRP — Engine
Operation - Version: 2018/07-2 82
5.4.5 Service level 2— Engine Service, TBO 15000 hrs for PRP — Advanced
maintenance - Version: 2018/07-2 84
5.4.6 Service level 1 — Engine Service, TBO 24000 hrs for COP — Engine
Operation - Version: 2018/07-2 86
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5.4.7 Service level 2— Engine Service, TBO 24000 hrs for COP — Advanced
maintenance - Version: 2018/07-2 88
5.5 Preparatory maintenance activities
5.6 Daily or monthly maintenance activities
5.6.1 Visual inspection — SL000
5.6.2 Observation of the engine while running — SL007
5.6.3 Removal of the battery charging alternator cover
5.6.4 Checking drive belt — SL109
5.6.5 Replacing V-ribbed belt — SL 109
5.6.6 Replacing tensioning device — SL110
5.6.7 Test run — SL008
5.7 Lubricating system
5.7.1 Oil sampling and analyze — SL100
5.7.2 Checking prelubricating pump (optional) — SL103
5.7.3 Checking the engine oil level — SL001
5.7.4 Changing oil filters — SL101
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5.7.5 Replacing centrifuge paper filter — SL102
5.7.6 Changing Diesel engine oil — SL101/SL121
5.8 Cooling system
© 2018 by Kohler Co. All rights reserved.
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Operation and Maintenance Manual Contents
5.8.1 Coolant sampling — SL120
5.8.2 Checking coolant level — SL001
5.8.3 Inspecting low temperature circuit (charge air cooler) — SL002
5.8.4 Checking relieve bores — water/coolant pump — SL003
5.8.5 Coolant drain points — SL116
5.9 Fuel system
5.9.1 Draining off water from fuel prefilter — SL004
5.9.2 Replacing main filter - SL105
5.9.3 Bleeding the fuel system
5.9.4 Checking differential pressure — fuel prefilter — SL005
5.10 Air system
5.10.1 Check service indicator on air filter — SL006
5.11 Lubricants and operating fluids
5.11.1 Handling lubricants and operating fluids
5.11.2 Filling volume
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5.11.3 Diesel fuels
5.11.4 Diesel engine lubricants
5.11.5 Diesel engine coolant
6 Operating faults
6.1 Diagnosis principles
6.2 Faults - Cause - Remedy
7 Tools and devices
7.1 Tools
7.1.1 Special tools
8 Appendix
8.1 Technical design documents
8.2 Error code
8.3 Cleaning agents, thread-locking adhesives and greases
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8.4 Standard tightening torques
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8.3.1 Cleaning agents and thread-locking adhesives
8.3.2 Greases
8.4.1 Screws pre-tightening, reuse and marking
© 2018 by Kohler Co. All rights reserved.
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Contents Operation and Maintenance Manual
8.4.2 Standard torques for hexagonal / cylinder / external hexalobular heads
8.4.3 Standard torques for locking screws and banjo bolts
8.4.4 Standard torques for metric flange joints
8.4.5 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) 164
8.4.6 Standard torques for metric thread unions S series (up to 800 bar/
11603 Psi) 165
8.4.7 Standard torques for imperial thread unions L series (up to 500 bar/
7252 Psi) 166
8.4.8 Standard torques for imperial thread unions S series (up to 800 bar/
11603 Psi) 167
8.4.9 Standard torques for metric thread unions L series (up to 500 bar/7252
Psi) for aluminum 167
8.4.10 Standard torques for cutting ring flange joints
8.4.11 Standard torques for triple lock flange joints
8.4.12 Standard torques for VSTI screw plugs
8.5 Abbreviations - Acronyms
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8.6 Unit conversion tables
8.6.1 Length conversion factors
8.6.2 Mass conversion factors
8.6.3 Pressure conversion factors
8.6.4 Volume conversion factors
8.6.5 Power conversion factors
8.6.6 Moment of inertia and torque conversion factors
8.6.7 Fuel consumption conversion factors
8.6.8 Flow conversion factors
8.6.9 Temperature conversion factors
8.6.10 Density conversion factors
8.7 Prefix
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© 2018 by Kohler Co. All rights reserved.
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© 2018 by Kohler Co. All rights reserved.
15
Operation and Maintenance Manual
16
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
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1 Product description
1.1 Technical description
1.1.1 Design overview
Fig. 1: Diesel engine / view from the flywheel side
CS Engine rear (flywheel 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 ventilation filter housing 10 High pressure fuel pump (x2)
5 Turbocharger assembly (x4)
KD83V16 33521030601_0_1 EN_US
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17
Product description Operation and Maintenance Manual
Technical description
Fig. 2: Diesel engine / view from the damper side
CCS Engine front (vibration damper side) 5 Exhaust gas connection (x4)
1 Water pump high temperature 6 Lifting lug (x4)
2 Thermostat housing high temperature 7 Oil cooler (x2)
3 Water pump low temperature 8 Oil filter cartridge
4 Thermostat housing low temperature
18
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
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Operation and Maintenance Manual Product description
Technical description
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 Engine control unit - ECU (x2) 14 Starter (x2)
11 Straight air intake (x4) 15 Oil pan
Design
Water-cooled Diesel engine with common rail (CR), exhaust gas turbo charging and air to water
charge air cooling.
Characteristics
A robust basic design and generous dimensioning form the basis for high operational safety and a
long service life. Low fuel consumption and exhaust gas emissions by optimized combustion
process adapted to the emission requirements. Minimized maintenance obtained by optimized
engine components and accessories lead to higher availability and increased efficiency.
Driving gear
The V16 Diesel engine has a quench tempered steel crankshaft with inductively hardened pins and
fillets. A torsional vibration damper is mounted on the crankshaft on the engine damper side.
Precisely forged con-rod, driving gear bearings are sputtered. Steel top weld pistons with stage
support and cooling duct
KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
19
Product description Operation and Maintenance Manual
Technical description
Housing
Rigid, laterally drawn down crankcase upper section with optimized structure and an oil pan as
lower section. Four–valve single cylinder heads with flow optimized ports as well as replaceable
valve seats and valve guide. Brackets, flywheel housing, aggregate support and oil pan on the
bottom close the Diesel engine.
Drive control
Two inlet and outlet valves mounted in the cylinder head for each cylinder. Actuated through steel
camshaft via cam follower, push rod and rocker arm.
Driven by gear train on the flywheel side:
– Camshaft
– High pressure pump
– Fuel pre-feed pump
– Oil pump
Driven by gear train on the damper side:
– Water pumps
– Battery charging alternator
– Air conditioning compressor (depending on application)
– Air compressor (depending on application)
Lubrication
Force-feed lubrication with lubricating oil pump for crankshaft bearing, con-rod bearing and
camshaft bearing as well as piston pin bushings, cam followers, rocker arms and gear bearings.
Oil filtration depending on requirements such as automatic oil filter with centrifugal filter (optional).
Following auxiliary units are also connected to the Diesel engine — lubricant oil circuit:
– High pressure pumps
– Coolant pumps
– Turbochargers
– Air compressor (depending on application)
Crankcase ventilation
As modular arrangement depending on requirements, up to four high efficiency passive filter units
are mounted on top of the engine.
The blow by gases leaving the filter system are fed back to the turbocharger intake by pipes made
of galvanized steel.
20
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
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Operation and Maintenance Manual Product description
Technical description
Oil sampling location
Fig. 4: Sampling point on engine left side
1 Sampling point
The oil sampling point is located on the engine left side.
High/low temperatures coolant circuits
Thermostatically controlled coolant with separate pumps for high and low tempera-ture coolant.
Individual supply of each cylinder unit via distribution channels cast into the crank-case.
Pistons are cooled by the engine lubricating system. Each piston is supplied with oil by piston
cooling jets.
Fuel filters
Depending on requirements, several filters combinations such as prefilter unit or working filter
ensure the fuel conditioning.
Therefore a high contamination retention capacity between tank and engine is ensured.
Injection system
The high pressure fuel system is supplied by a high pressure pump.
The low pressure system is supplied by the fuel pre-feed pump which ensures the circulation from
the tank and pre-feeds the high pressure system.
The high pressure system leads the pressurized fuel from high pressure pump to the injectors.
The high pressure system is secured by a pressure control valve.
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21
Product description Operation and Maintenance Manual
Technical description
Electronic Control System
Information
To connect the interfaces, refer to the "Electrical Installation Guideline" of your engine application
and generation.
The information on the engine control unit nameplate corresponds to the delivery status.
Depending on software updates in the field, it may be the case that this information is no longer up
to date.
The real information can be viewed in the device display or read out with the diagnosis and service
tool KODIA.
The engine control system consists of an programmable engine control unit.
The ECU controls the actuators and reads values from the sensors to ensure optimal engine
performance.
The ECU is programmed according to configuration and application. Mappable parameters among
others are:
– Ignition timing,
– Maximal RPM,
– Cooling temperature correction,
– Transient fueling,
– Closed loop lambda,
– Waste gate control, ...
The diagnosis and service tool KODIA provides several functions including:
– General information,
– Status overview,
– Configuration adjustement,
– Error list information,
– Process data list,
– Oscilloscope,
– Direct triggering,
– Main values display,
– CRS visualization and operation,
– Long-term error memory,
– Fault Reactions.
Engine electronic sensors
The engine sensors are interfaces for external monitoring such as:
– charge air pressure,
– fuel pressure,
– rail pressure,
– oil pressure,
– coolant temperature,
– charge air temperature,
– engine speed and position.
22
and actuators for control functions:
– starters,
– volume control valve,
– pressure control valve,
– injectors.
The individual functions and error messages are described in the instructions manual of the manufacturer’s machinery.
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
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Operation and Maintenance Manual Product description
Technical description
1.1.2 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.
Fig. 5: 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) L Left engine side
CCS Engine front (counter-coupling/damper
side)
DoR Direction of rotation
1.1.3 Nameplates 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
R Right engine side
V Cylinder configuration
16 Number of cylinders
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5 Frequency. 5=50Hz; 6=60Hz
© 2018 by Kohler Co. All rights reserved.
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Product description Operation and Maintenance Manual
Technical description
Designation Description
K D 83 V 16 - 5 A F C Engine type description
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. 1: Engine type description
Emission control information label
The emission control information label is attached on the crankcase.
Fig. 6: Engine nameplate
1 Engine main values 4 Notes regarding emissions exemptions,
fuel and application types
2 USA regulations references 5 Country of assembly
3 QR code area
Fig. 7: Engine nameplate location
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© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
2018-07
Operation and Maintenance Manual Product description
Technical description
Engine serial number
The engine serial number is stamped into the engine nameplate.
Designation Description
2016 73 0001 Engine serial number
2016 Year of manufacture
73 Engine type code (73= KD62V12) (74=
KD83V16)
0001 Incremential production number
Tab. 2: Engine serial number
Fig. 8: Serial number on nameplate
1 Serial number
Engine control nameplates
Fig. 9: Example of engine control unit nameplates
1 Software nameplate 2 Hardware nameplate
KD83V16 33521030601_0_1 EN_US
2018-07
© 2018 by Kohler Co. All rights reserved.
25
Product description Operation and Maintenance Manual
Technical description
Fig. 10: Software nameplate
1 Product designation 6 Engine serial number
2 Product type 7 Engine control unit ID number
3 Engine designation 8 Certification ID number
4 QR Code 9 Data set ID number
5 Delivery date
Fig. 11: Hardware nameplate
1 Product designation 5 Serial number
2 Engine control unit ID number 6 Supplier number
3 Hardware version 7 QR Code
4 Delivery date
Information
u The information on the engine control unit nameplate corresponds to the delivery status (ex:
works Kohler Co.). Depending on software updates in the field, it may be the case that this information 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 tool KODIA.
1.1.4 Diesel engine accessory equipment
Information
For more information about the accessories attached on auxiliary drives and their respective range
of use of engine, contact your nearest authorized Kohler service representative.
26
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
2018-07
Operation and Maintenance Manual Product description
Technical description
Air Conditioning (A/C) compressor (depending on application)
The engine is optionally equipped with an A/C compressor which can be directly mounted on the
Diesel engine counter coupling side and powered via a V-ribbed belt.
Battery charging alternator
The engine is equipped with a battery charging alternator: 28V / 140A.
Fig. 12: Battery charging alternator
Retrofitting preheating devices
Information
For the connections dimensions provided, contact your nearest authorized Kohler service representative.
The interfaces for retrofitting preheating devices such as coolant, fuel and Diesel engine oil have
already been integrated.
Battery charging alternator cover
Technical solution
The battery charging alternator cover is a protective device fixed directly behind the battery
charging alternator. It ensures a global protection to the alternator environment while the engine is
running.
KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
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Product description Operation and Maintenance Manual
Technical description
Fig. 13: Battery charging alternator cover
28
Fig. 14: Task overview
1 Pin 6 Nut (M8)
2 Distance sleeve 7 Lock washer
3 Vibration damper 8 Captive screw (M8)
4 Pin 9 Cover - front side
5 Cover - back side
Features
– Protection device ensuring insulation of moving parts
– Adapted fixation points
– Ease of (dis)-assembly, free of maintenance
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
2018-07
Operation and Maintenance Manual Product description
Technical description
– Captive screws
– Additional solution to fulfill the machine compliance with the applicable regulations.
Vibration damper cover
Technical solution
The vibration damper cover is a protective device fixed directly into the front end of the engine. It
ensures a global protection to the vibration damper environment while the engine is running.
Fig. 15: Vibration damper cover details
1 Plate 4 Washer
2 Screw (M8) 5 Cover
3 Screw (M12)
Features
– Protection device ensuring insulation of moving parts
– Adapted fixation points
– Ease of (dis)-assembly, free of maintenance
– Additional solution to fulfill the machine compliance with the applicable regulations.
KD83V16 33521030601_0_1 EN_US
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© 2018 by Kohler Co. All rights reserved.
29
Product description Operation and Maintenance Manual
Technical data
1.2 Technical data
1.2.1 Diesel engine
Designation Unit Value
Cylinder configuration V-Diesel engine
Number of cylinders 16
Firing order A1–B7–A2–B5– A4–B3–A6–B1– A8–
B2–A7–B4– A5–B6–A3–B8
Bore mm 175
inch 6.889
Stroke mm 215
inch 8.464
Displacement liter 83
Compression ratio 16
Direction of rotation of the diesel engine
(seen from flywheel)
Power specificationas per ISO3046-1
Rated power see nameplate
Rated speed see nameplate
Emission limit stage see nameplate
Tab. 3: General technical data table — Diesel engine
1.2.2 Cylinder head
Designation Unit Value
Inlet valve clearance, cold mm 0,5
Outlet valve clearance, cold mm 1
Tab. 4: Technical data table — Cylinder head
Counterclockwise
inch 0.0196
inch 0.0393
1.2.3 Coolant thermostat
Designation Unit Values
Low Temperature
(LT) Thermostat
30
Opening start °C 45
°F 113
Completely open °C 57
°F 134.6
© 2018 by Kohler Co. All rights reserved.
KD83V16 33521030601_0_1 EN_US
2018-07
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