4.part Catalouge 600-KVA

Service Part
Industrial Generator Sets
Models:
600-KVA
Table of Contents

Table of Contents Page No
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Section A. ENGINE ASSEMBLY ......................................................................................................................... 1
1. Engine System ........................................................................................................................................ 1
1.1 Cylinder Head SN-2016010024 ......................................................................................................... 1
1.2 Cylinder Head SN-2016010025.......................................................................................................... 4
1.3 Valve Cover ........................................................................................................................................ 7
1.4 Cylinder Block SN-2016010024 .......................................................................................................... 8
1.5 Cylinder Block SN-2016010025 ....................................................................................................... 10
1.6 Flywheel Housing ............................................................................................................................. 12
1.7 Adapter Flywheel and Flywheel Housing SAE-0 ............................................................................... 14
1.8 Valve Mechanism.............................................................................................................................. 15
1.9 Timing Gear ...................................................................................................................................... 19
1.10 Camshaft ........................................................................................................................................ 21
1.11 Crank Mechanism .......................................................................................................................... 23
1.12 Engine Mounting and Frame ........................................................................................................... 25
1.13 Lubrication System ......................................................................................................................... 27
1.14 Oil Filter Housing and Oil Filter Remote Mounting .......................................................................... 30
1.15 Oil Filter Housing and Oil Filter ....................................................................................................... 32
1.16 Oil Filter Housing and Oil Filter Remote Mounting. Components .................................................... 35
1.17 Oil Drain Pump and Installation Parts, Engine Mounting ............................................................... 38
1.18 Fuel System SN-2016008240 ......................................................................................................... 40
1.19 Fuel System SN-2016008241- SN-2016045622 ............................................................................. 43
1.20 Fuel System SN-2016045623 ......................................................................................................... 46
1.21 Fuel Filter, Components SN-2016045622....................................................................................... 49
1.22 Fuel Filter, Components SN-2016045623....................................................................................... 52
1.23 Fuel Pump....................................................................................................................................... 53
1.24 Fuel Cleaner/Water Separator ........................................................................................................ 54
1.25 Fuel Cleaner/Water Separator, Single. Classifiable fuel system .................................................... 56
1.26 Fuel Cleaner/Water Separator, Twin. Classification Fuel System. Later Production....................... 58
1.27 Fuel Cleaner/Water Separator, Twin............................................................................................... 60
1.28 Air Filter for Fuel Tank .................................................................................................................... 62
1.29 Unit Injector ..................................................................................................................................... 63
1.30 Intake and Exhaust Manifold ........................................................................................................... 65
1.31 Starter Element .............................................................................................................................. 67
1.32 Heat Shield for Exhaust Manifold and Valve Cover ........................................................................ 69
1.33 Turbocharger ................................................................................................................................. 70
1.34 Heat Shield for Turbo ...................................................................................................................... 72
1.35 Crank House Ventilation ................................................................................................................. 73
1.36 Crankcase Ventilation, Closed ........................................................................................................ 75
1.37 Air Filter with Installation Components, Standard ........................................................................... 79
1.38 Air Filter with Installation Components, Medium Duty ..................................................................... 81
1.39 Air Filter with Installation Components, Heavy Duty ....................................................................... 83
1.40 Air Cleaner, Heavy Duty ................................................................................................................. 85
1.41 Muffler ............................................................................................................................................. 86
1.42 Muffler, Engine Mounting ................................................................................................................ 87
1.43 Radiator and Pushing Fan. SN-2016028724 .................................................................................. 89
1.44 Radiator and Pushing Fan. SN-2016028725 .................................................................................. 92
1.45 Radiator with Connecting Components. Pushing Fan. SN-2016028724......................................... 95
1.46 Radiator with Connecting Components. Pushing Fan. SN-2016028725......................................... 97
1.47 Belt Guard ....................................................................................................................................... 99
1.48 Oil Cooler, Engine ........................................................................................................................ 101
1.49 Expansion Tank with Installation Components ............................................................................. 102
1.50 Protection Cover for Expansion Tank ........................................................................................... 103
1.51 Water Pump, Thermostat Housing and Water and Filter, Radiator Cooling .................................. 104
1.52 Cooling System, Alternative Mounting of Water Filter ................................................................... 107
1.53 Belt Transmission and Tensioned Device ..................................................................................... 109
1.54 Serpentine Belt System ................................................................................................................ 110
1.55 Battery Box ................................................................................................................................... 112
KOHLER POWER SYSTEM

Table of Contents

Table of Contents Page No
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1.56 Alternator, Single Mounting ............................................................................................................... 114

1.57 Starter Motor .................................................................................................................................... 116
1.58 Starter Motor, Components ............................................................................................................... 117
1.59 Control Panel, DCU ........................................................................................................................... 119
1.60 CIU .................................................................................................................................................... 121
1.61 Control Unit and Connector ............................................................................................................... 122
1.62 LCD Display ...................................................................................................................................... 124
1.63 Electrical System ............................................................................................................................... 125
1.64 Electrical Materials, Instrument ......................................................................................................... 127
1.65 Electrical Materials, Instrument EVC-A ............................................................................................. 129
1.66 Contacts and Sensors, Analog .......................................................................................................... 132
1.67 Contacts and Sensors ....................................................................................................................... 133
1.68 Elastic Coupling................................................................................................................................. 135
1.69 Engine Heater, Separately Mounting................................................................................................. 136
1.70 Tool Kit .............................................................................................................................................. 138
1.71 Fuel System, Venting SN-2016045623 ............................................................................................. 140
Section B. GENSET ENGINE ASSEMBLY ......................................................................................................... 142

1. Accessories for Engine Assembly 600KVA ........................................................................................ 142
1.1 Accessories for Engine Group STD ................................................................................................. 142
2. Alternator Group 600KVA ..................................................................................................................... 143

2.1 Alternator Group 600 Kva 3Phase ................................................................................................... 143
2.2 Alternator Group 600 Kva 3Phase................................................................................................... 144
3. Controller Assembly 600 KVA.............................................................................................................. 145

3.1 Control Panel Assembly for 600 kVA STD ...................................................................................... 145
5. Canopy Assembly ................................................................................................................................. 147

5.1 Skid Preparation Group 600 KVA ..................................................................................................... 147
6. INDEX……………………………………………………………………………………………………………....148
KOHLER POWER SYSTEM

MODIFICATIONS SUMMARY
Revision No. Document Number / Date Details of Modifications Page No

-- 10.03.2014 New Release --
KOHLER POWER SYSTEM

TAD1642GE
CYLINDER HEAD SN-2016010024
KOHLER POWER SYSTEM Page 1

TAD1642GE
Ref.
Part No. Part Name QTY. Remark
No.
1 KG3801395 CYLINDER HEAD, EXCH 1
When replacing one or more bearing houses the first time, all of the bearing
2 KG3184068 BEARING HOUSING, SET 1
houses must be replaced. Then each bearing house can be replaced separat
When replacing one or more bearing houses the first time, all of the bearing
3 KG3184012 BEARING HOUSING 1
houses must be replaced. Then each bearing house can be replaced separat
Obsolete part, When replacing one or more bearing houses the first time, all
4 KG-3184015 BEARING HOUSING 5 of the bearing houses must be replaced. Then each bearing house can be
replaced separat
Obsolete part, When replacing one or more bearing houses the first time, all
5 -KG3184018 BEARING HOUSING 1 of the bearing houses must be replaced. Then each bearing house can be
replaced separat
6 KG422426 PIVOT PIN 14
7 KG950550 PIN 7
9 KG975105 FLANGE SCREW 7
10 KG20533693 SCREW 14
11 KG21098621 INJECTOR SLEEVE 6
12 KG20536487 O-RING 1 -3165747
13 KG21261987 WASHER 1
14 KG3965955 VALVE SEAT 12
15 KG8131798 VALVE SEAT 12
16 KG20735572 INLET VALVE 12
17 KG20513285 EXHAUST VALVE 12
18 KG20562837 VALVE GUIDE 24 Replaced by 21067953
KG21067953 VALVE GUIDE 24
19 KG8131799 VALVE STEM SEAL 24
20 KG21326667 VALVE SPRING 12
23 KG20551396 VALVE SPRING WASHER 12
25 KG8170995 VALVE COLLET 48

TAD1642GE
CYLINDER HEAD SN-2016010024
Ref. No. Part No. Part Name QTY. Remark

26 KG8130035 CAP PLUG 12
27 KG8131706 CAP PLUG 4
28 KG968062 PLUG 1
29 KG20496040 CAP PLUG 1
30 KG1547252 SEALING RING 1
31 KG1546528 PLUG 1
32 KG1546531 LOCK BRACE 1
34 KG960628 PLUG 1
35 KG947281 GASKET 1
36 KG8131192 ROCKER ARM SHAFT 1
37 KG955096 EXPANSION PLUG 2
38 --- LIFTING EYE 1
42 KG1547040 SCREW 38 L=187mm

TAD1642GE
CYLINDER HEAD SN2016010025

TAD1642GE
Ref.
No.
1 KG3801394 CYLINDER HEAD, EXCH 1
5 KG950550 PIN 6
8 KG20533693 SCREW 12
10 KG21351717 INJECTOR SLEEVE 6
11 KG20536487 O-RING 1 -3165747
12 KG21261987 WASHER 1
13 KG20709467 VALVE SEAT, INTAKE 12
14 KG20564028 VALVE SEAT, EXHAUST 12
15 KG20739057 INLET VALVE 12
16 KG20513285 EXHAUST VALVE 12
17 KG20916916 VALVE GUIDE 24
18 KG20924435 VALVE STEM SEAL 24
25 KG24426721 CAP PLUG 16 D=29mm
KG24426723 CAP PLUG 6 D=50mm
26 KG24426722 CAP PLUG 6 D=40mm
27 KG968062 PLUG 1
28 KG20496040 CAP PLUG 1
30 KG20845995 PLUG 2

TAD1642GE
CYLINDER HEAD SN2016010025
Ref.
No.
33 KG960628 PLUG 1 M10
KG966142 PLUG 1 M12
34 KG947281 GASKET 1 For 966142
KG11994 GASKET 1 For 960628
35 KG24426580 ROCKER ARM SHAFT 1
36 KG955096 EXPANSION PLUG 2
37 --- LIFTING EYE 1
41 KG1547040 SCREW 38 L=187mm

TAD1642GE
VALVE COVER
Ref.
No.
1 KG3220709580 VALVE COVER 1
2 KG20736230 SEALING STRIP 1
4 KG20738123 CYLINDER HEAD GASKET 1 SN-2016010024
- KG20725045 CYLINDER HEAD GASKET 1 SN2016010025

TAD1642GE
CYLINDER BLOCK SN-2016010024

TAD1642GE
Ref.
No.
1 KG20521356 CYLINDER BLOCK 1
2 - MAIN BEARING CAP 1
6 KG8131967 GUIDE SLEEVE 14
7 KG20581443 FLANGE SCREW 14 -1543412
8 KG20722628 FRAME 1
12 KG950588 PIN 1
13 KG1546528 PLUG 1
14 KG8131937 CAP PLUG 4
15 KG20562189 PLUG 2
16 KG966378 FLANGE SCREW 1 M8x16mm
17 KG976944 WASHER 1
19 KG20529445 PLUG 2
20 KG20562189 PLUG 1
22 KG20381177 PLUG 1

TAD1642GE
CYLINDER BLOCK SN2016010025

TAD1642GE
Ref.
No.
1 KG20742700 CYLINDER BLOCK 1
7 KG20581443 FLANGE SCREW 14 -1543412
8 KG20722628 FRAME 1
12 KG950588 PIN 1
13 KG24426721 CAP PLUG 1
14 K8131937 CAP PLUG 4
15 KG2G0562189 PLUG 2
19 KG20529445 PLUG 2
20 KG20562189 PLUG 1
22 KG20381177 PLUG 1
23 KG20718731 YOKE 1
25 KG984793 PLUG 1
26 K979099 GASKET 1
27 KG1676622 NIPPLE 1
28 KG476279 PROTECTING CAP 1
30 KG20533497 CARDBOARD TUBE 1
31 KG20532891 GASKET -

TAD1642GE
FLYWHEEL HOUSING

TAD1642GE
Ref.
No.
1 KG3829060 FLYWHEEL HOUSING 1 Replaced by 21192873
KG21192873 FLYWHEEL HOUSING 1 Replaced by 21586308
KG21586308 FLYWHEEL HOUSING 1
2 KG85108352 CRANKSHAFT SEAL 1 -1543896
3 KG947760 FLANGE SCREW 4 L=40mm
KG965180 FLANGE SCREW 1 L=40mm
KG966366 FLANGE SCREW 6 M14x90mm
KG966367 FLANGE SCREW 1 M14x100mm
5 KG20853452 TIMING GEAR COVER 1
6 KG20747434 SEALING STRIP 1 Replaced by 20815558
KG20815558 SEALING STRIP 1
7 KG20572441 GASKET 2
8 KG1161231 SEALANT X 304ml
KG1161277 SEALANT X 20g
9 KG467367 PLUG 1
10 KG849405 SETTING INDICATOR 1
11 KG905654 DRIVE SCREW 2
12 KG4772168 COVER 1
14 KG4804167 GASKET 1
16 KG849135 COVER 1

TAD1642GE
ADAPTER FLYWHEEL AND FLYWHEEL HOUSING SAE 0
Ref.
No.
1 KG3826138 ADAPTER, FLYWHEEL COVER 1 From SAE 1 to SAE 0.
3 KG3826137 ADAPTER, FLYWHEEL 1 From SAE 1 to SAE 0.
4 KG963273 HEXAGON SCREW 8
5 KG955896 WASHER 8

TAD1642GE
VALVE MECHANISM

TAD1642GE
Ref.
No.
1 - ROCKER ARM SHAFT 7631
- - ROCKER ARM SHAFT 21772
2 KG20888104 ROCKER ARM, INTAKE 6
- KG21282818 ROCKER ARM, INTAKE 6
3 KG946911 HEXAGON NUT 1
4 KG20501055 ADJUSTING SCREW 1
5 KG20441753 BALL SOCKET 1
6 KG944364 O-RING 1
7 - BALL SEAT 1
8 KG20463791 VALVE YOKE, INTAKE 6
9 KG20857578 VALVE YOKE, EXHAUST 6
10 KG21160989 ROCKER ARM, FUEL INJECTOR 6
13 KG3964817 JET 1
14 KG20888089 ROCKER ARM, EXHAUST 6
18 KG944364 O-RING 1
19 - BALL SEAT 1
20 KG20554268 GUIDE PIN 6
21 KG20533693 SCREW 14

TAD1642GE
VALVE MECHANISM

TAD1642GE
Ref.
No.
1 - ROCKER ARM SHAFT - 21772
2 KG21325647 ROCKER ARM, INTAKE -
4 -KG20501055 ADJUSTING SCREW 1
6 KG944364 O-RING 1
7 - BALL SEAT 1
8 KG20463791 VALVE YOKE, INTAKE 1
9 KG20857578 VALVE YOKE, EXHAUST 6
10 KG21160989 ROCKER ARM, FUEL INJECTOR 6
12 -KG20501057 ADJUSTING SCREW 1
13 KG3964817 JET 1
14 KG20888089 ROCKER ARM, EXHAUST 1
18 KG944364 O-RING 1
19 - BALL SEAT 1
20 KG20554268 GUIDE PIN 1
21 KG2K0533693 SCREW 6

TAD1642GE
TIMING GEAR

TAD1642GE
Ref.
No.
1 KG20854044 TIMING GEAR PLATE 1
3 KG949656 O-RING 1
4 - SHAFT 1
5 KG914465 SNAP RING 1
6 KG21284699 IDLER GEAR 1
7 KG21057442 IDLER GEAR 1
8 KG471586 SCREW 6
9 KG20483919 HEX. SOCKET SCREW 6
10 KG8131123 IDLER GEAR 1 Relaced by 20743007
- KG20743007 IDLER GEAR 1
12 KG8131850 THRUST WASHER 1
13 KG20520535 HUB 1 Replaced by 21034938
- KG21034938 HUB 1 Replaced by 21012985
- KG21012985 HUB 1
15 KG948977 O-RING 1
16 KG953102 STUD 2
17 KG20531962 NUT 1
18 KG979230 FLANGE NUT 3

TAD1642GE
CAMSHAFT

TAD1642GE
Ref.
No.
1 KG20894565 CAMSHAFT 1 SN2016010025
- KG3829188 CAMSHAFT 1 SN-2016010024
2 KG20756108 CAMSHAFT BEARING KIT 1 Std SN2016010025-, Replaced by bearing kit 21006109.
- KG21006109 CAMSHAFT BEARING KIT 1

- KG20503200 CAMSHAFT BEARING KIT 1 Std SN-2016010024
-
- KG20503201
CAMSHAFT BEARING KIT 1
Obsolete part, O.S=0,25mm
-
- KG20503202
Obsolete part, O.S=0.50mm
-
- KG20503203
Obsolete part, O.S=0,75mm
3 KG21006103 CAMSHAFT BEARING KIT 6 Std SN2016010025
- KG276630 CAMSHAFT BEARING KIT 6 Std SN-2016010024
- KG276631 CAMSHAFT BEARING KIT 6 O.S=0,25mm
- KG276632 CAMSHAFT BEARING KIT 6 O.S=0.50mm
- KG276633 CAMSHAFT BEARING KIT 6 O.S=0,75mm
4 KG8131386 GEAR, CAMSHAFT GEAR 1 SN-2016016199
- KG20891469 GEAR, CAMSHAFT GEAR 1 SN2016016200
5 KG950551 PIN 1
6 KG20450049 VIBRATION DAMPER 1
When replacing one or more bearing houses the first time, all of the
8 KG3184068 BEARING HOUSING 1 bearing houses must be replaced. Then each bearing house can be
replaced separat
9 KG3184012 BEARING HOUSING, REAR 1

BEARING HOUSING, NO. 2-
10 -KG3184015 5 Obsolete part
6
11 -KG3184018 BEARING HOUSING, FRONT 1 Obsolete part

TAD1642GE
CRANK MECHANISM

TAD1642GE
Ref.
No.
1 KG8131247 CRANKSHAFT 1
2 KG270929 THRUST WASHER KIT 1 Std
3 KG20586595 MAIN BEARING KIT 7 SN-002476., Std
4 KG20578853 MAIN BEARING KIT 1 SN002477- Bearing no 7., Std
5 KG3886442 CYLINDER LINER KIT 6
6 -- CYLINDER LINER
7 KG20520607 SEALING RING KIT 6
9 KG3589667 PISTON RING KIT 6
10 --- PISTON
11 KG8131232 PISTON PIN 6
12 KG20523555 SHIM X TH=0,2mm
13 KG20898595 CONNECTING ROD 6
14 KG20898010 BUSHING 6 -8131244
15 KG8G131198 SCREW 24
16 KG20586602 BIG-END BEARING KIT 6 Std
17 KG3837975 FLYWHEEL 1
18 KG20711957 RING GEAR 1 -8193939
19 KG3155075 SCREW 12
21 KG20480505 GEAR 1 Replaced by gear 20801971.
22 KG950658 PIN 1
23 KG984127 O-RING 1
24 KG20777233 COVER 1 -20513482
25 --- LOCK 1
26 KG85108423 CRANKSHAFT SEAL 1 -1549398
27 KGKG946671 FLANGE SCREW 8
28 KG3837486 PULLEY 1
29 KG9G93179 FLANGE SCREW 12
31 KG3838497 SPACER 1
33 KG3838498 ADAPTER 1

TAD1642GE
ENGINE MOUNTING AND FRAME

TAD1642GE
Ref.
No.
1 KG3808749 FRAME 1 OBSOLETE PART
2 KG3826669 ENGINE BRACKET 4
5 KG971100 FLANGE LOCK NUT 8
6 KG11158125 ENGINE MOUNTINGS 1
7 KG974008 FLANGE SCREW 1 L=70MM
9 KG862347 RUBBER CUSHION 4
12 KG3812095 CROSS MEMBER 1
14 -KG3589803 FRAME 1 OBSOLETE PART

TAD1642GE
LUBRICATING SYSTEM

TAD1642GE
Ref.
No.
1 KG20875333 OIL PAN 1
2 --- OIL PAN 1
3 KG20724256 PIPE 1
4 KG949656 O-RING 1
6 KG2G4424110 SENSOR 1 Replaced by sender 21042447.
- KG21042447 OIL LEVEL SENSOR 1

7 KG990719 O-RING 1
10 KG20700754 RETAINER 2
11 KG20579690 GASKET 1
12 KG20571854 MAGNETIC PLUG 1
14 KG20586720 O-RING 1
18 KG20808091 OIL FILLER PIPE 1
19 KG20807510 OIL FILLER CAP 1
20 KG20365079 GASKET 1
21 KG20462497 CONNECTION PIPE 1
23 KG3829069 BRACKET 1
25 KG3831383 HOSE 1
26 KG943476 HOSE CLAMP 2
27 KG3829068 PIPE 1 L=369mm
28 KG975371 6 POINT SOCKET SCREW 1
29 KG3829070 DIPSTICK 1
30 KG949187 O-RING 2

TAD1642GE
LUBRICATING SYSTEM
Ref.
No.
31 KG20553753 OIL PUMP 1
32 KG21344756 SCREW 4
33 KG20708889 PRESSURE PIPE 1
34 --- FITTING SCREW 1
35 KG980790 FERRULE 1
38 KG20553751 SUCTION PIPE 1
39 KG20547257 OIL STRAINER 1
40 KG8131965 STRAINER 1
41 KG20547263 SPACER SLEEVE 1
43 KG3839496 PISTON COOLING JET 6
44 KG955982 O-RING 6
46 KG20540340 INTERMEDIATE HOUSING 1
48 KG20571452 OUTLET PIPE 1

TAD1642GE
OIL FILTER HOUSING AND OIL FILTER,

REMOTE MOUNTING

TAD1642GE
Ref.
No.
1 KG21169074 OIL FILTER HOUSING 1
2 KG466623 NIPPLE 2
3 KG469904 NIPPLE 1
4 KG21145970 COVER 2
5 KG21145971 COVER 1
6 KG993235 X-RING 3
8 KG947627 GASKET 1
9 KG471598 PLUG 1
10 KG466623 NIPPLE 2
12 KG942352 PLUG 2
14 KG20459641 PLUG 2
15 KG478736 OIL FILTER 2
16 -- GASKET 2
18 -- GASKET 1
19 KG21174316 HOSE 1
20 KG25167 HOLLOW SCREW 1
22 KG3819332 PIPE 1
25 KG20405767 HOSE NIPPLE 1
27 KG21169079 HOSE 2
28 KG11158220 ADAPTER 2

TAD1642GE
OIL FILTER HOUSING AND OIL FILTER

TAD1642GE
Ref.
No.
2 KG8131101 OIL FILTER HOUSING 1 Obsolete part
3 KG947627 GASKET 2
4 KG471598 PLUG 2
5 KG471085 VALVE CONE 2
6 KG466653 COMPRESSION SPRING 2
7 KG11998 GASKET 2
8 KG960632 PLUG 2
9 KG960628 PLUG 1
11 KG20478143 CAP PLUG 2
12 KG20381215 PLUG 2
14 KG3169687 DELIVERY VALVE 1
15 -- VALVE 1
16 -- VALVE GUIDE 1
18 KG976039 O-RING 1
19 -- SPRING 1
20 KG949659 O-RING 1
21 KG3184806 COVER 1
23 KG3826265 REDUCTION VALVE 1
25 KG471648 COVER 2
26 KG949659 O-RING 2
28 KG20440781 PISTON 1
29 KG20464676 SPRING 2

TAD1642GE
OIL FILTER HOUSING AND OIL FILTER
Ref.
No.
31 KG946778 CAP PLUG 1
39 KG20823322 GASKET 1
ELBOW NIPPLE, PRESSURE MONITOR/PISTON
40 KG990916 1 REPLACED BY ELBOW NIPPLE 992106.
COOLING
ELBOW NIPPLE, PRESSURE MONITOR/PISTON
-- KG992106
COOLING
1

TAD1642GE

REMOTE MOUNTED. COMPONENTS

TAD1642GE
Ref.
No.
2 --- OIL FILTER HOUSING 1
3 KG960632 PLUG 1
4 KG947627 GASKET 1
5 KG471598 PLUG 1
6 KG11998 GASKET 1
9 KG948610 O-RING 2
10 KG960632 PLUG 2
11 KG11998 GASKET 2
12 KG3835956 NIPPLE 1
13 KG976030 O-RING 1
15 KG984793 PLUG 1
16 KG946778 CAP PLUG 1
17 KG3169687 DELIVERY VALVE 1
18 --- VALVE GUIDE 1
19 KG976039 O-RING 1
21 --- SPRING 1
22 --- VALVE 1
23 KG949659 O-RING 3 -980936
24 KG3184806 COVER 1
26 KG20440781 PISTON 1
27 KG20464676 SPRING 2
29 KG20381215 PLUG 2

TAD1642GE

REMOTE MOUNTED. COMPONENTS
Ref.
No.
32 KG471648 COVER 2
40 KG20823322 GASKET 1
41 KG992106 ELBOW NIPPLE 1

TAD1642GE
OIL DRAIN PUMP AND INSTALLATION PARTS,

ENGINE MOUNTED

TAD1642GE
Ref.
No.
1 KG3827475 OIL DRAIN PUMP 1
4 KG975127 FLANGE SCREW 3 L=90mm
- KG975130 FLANGE SCREW 3 L=120mm
5 KG3838152 OIL HOSE 1
11 KG949379 CLAMP 1
14 KG18813 GASKET 2

TAD1642GE
FUEL SYSTEM SN-2016008240

TAD1642GE
Ref.
No.
1 KG20873675 FUEL FILTER HOUSING 1
2 --- HOUSING 1
3 --- NIPPLE 1
4 KG20511511 NIPPLE 1
5 KG20528999 BALL 2
6 KG20784020 PUMP SHAFT 1
7 --- WASHER
8 KG20528992 PLUNGER 1
9 KG20528991 SUPPORT RING 1
10 --- O-RING 1
11 --- SPRING 1
12 --- PRESSURE SENSOR 1
13 --- BRACKET 1
16 --- PLUG
17 KG20430751 FUEL FILTER 1
KG20976003 FUEL FILTER 1
18 KG20514654 PRIMARY FILTER 1
KG20998367 FUEL FILTER 1
19 KG20771574 BOWL 1
20 KG967344 O-RING 1
21 --- FUEL PUMP 1
22 KG20909808 FUEL PIPE 1
27 KG969011 GASKET 11
29 KG20562394 RADIATOR 1
30 KG190390 BANJO NIPPLE 1

TAD1642GE
FUEL SYSTEM SN-2016008240
Ref.
No.
36 KG20450468 OVERFLOW VALVE 1
37 KG11996 GASKET 4
39 KG976971 O-RING 1
41 KG949747 CLAMP 9
43 KG948211 CABLE TIE 6
47 --- BRACKET 1
48 --- BRACKET 1
49 KG990494 WING SCREW 1
50 --- RUBBER CLOTH 1
51 --- SCREW 1

TAD1642GE
FUEL SYSTEM SN2016008241- SN2016045622

TAD1642GE
Ref.
No.
1 --- FILTER HOUSING 1
8 --- FUEL PUMP 1
15 KG3888420 FUEL HOSE 1
18 KG1545432 CLAMP 1
23 KG3593826 FUEL HOSE 1 REPLACED BY 21187595
IF A FUEL HOSE IS CHANGED, MUST ALSO VALVE BE MOUNTED IN THE
KG21187595 FUEL HOSE 1
FUEL FILTER HOUSING
26 3848156 RISER 2 REPLACED BY 21143551
IF CHANGE OF RISER MUST ALSO CLAMP, HOLLOW SCREW, SPACER
KG21143551 RISER 2
TUBE, RETAINER AND GASKETS BE CHANGED
28 KG3849956 SPACER TUBE 1
29 KG20899253 GASKET 2

TAD1642GE
FUEL SYSTEM SN2016008241- SN2016045622
Ref.
No.
32 KG20548012 FAUCET 1
33 KG20547976 PROTECTING COVER 1
34 KG845999 BRACKET 4 Only for TAD1640GE, TAD1641GE, TAD1642GE
35 KG946440 FLANGE SCREW X
36 KG942542 CLAMP 4
38 KG992272 REDUCTION NIPPLE 2
42 KG943717 CLAMP 1
44 KG3594418 STAY 1
45 KG949747 CLAMP X
48 KG948211 CABLE TIE X Only for TWD1643GE
50 KG3587322 BANJO NIPPLE 1 Only for TAD1640GE, TAD1641GE, TAD1642GE
51 KG993850 BANJO NIPPLE 1 Only for TAD1640GE, TAD1641GE, TAD1642GE
52 KG861057 FUEL HOSE X 3/8'', Only for TAD1640GE, TAD1641GE, TAD1642GE
- -- BULLETIN P-23-4-4 Fuel hose p/n 861057
53 KG993979 HOSE CLAMP X Only for TAD1640GE, TAD1641GE, TAD1642GE
54 KG965560 BRACKET 1 Only for TWD1643GE
55 KG946502 FLANGE SCREW 1 Only for TWD1643GE
56 KG945408 FLANGE NUT 1 Only for TWD1643GE

TAD1642GE
FUEL SYSTEM SN2016045623

TAD1642GE
Ref.
No.
2 KG949747 CLAMP 9
6 KG21143551 RISER 2
7 KG20899253 GASKET 4
17 KG20548012 FAUCET 1
20 KG21140647 VALVE 1
22 KG11998 GASKET 1
23 KG946444 SHIM 1
24 KG982258 CLAMP 1
28 KG21132217 BRACKET 6

TAD1642GE
FUEL SYSTEM SN2016045623
Ref.
No.
31 KG20902698 TANDEM PUMP 1 With servo pump., Compl, (20482482)
- KG3885173 FUEL PUMP 1 Without servo pump., Compl, (3594872)

TAD1642GE
FUEL FILTER, COMPONENTS SN-2016045622

TAD1642GE
Ref.
No.
Replaced by filter housing 3848884, 3 pcs rubber element 21091546, 3
pcs screw 20739547
- KG3848884 FUEL FILTER HOUSING 1
2 -- FUEL FILTER HOUSING 1 Not as sparepart. Included only in filter housing assy 3848884

4 KG20528999 BALL 2
Obsolete part, Not as sparepart. Included only in filter housing assy
5 KG20784020 PUMP SHAFT 1
3848884
6 KG20542751 PLUG 1 Not as sparepart. Included only in filter housing assy 3848884
Obsolete part, Not as sparepart. Included only in filter housing assy

7 KG20733505 VALVE 1
3848884
8 KG20511534 SLEEVE 1 Not as sparepart. Included only in filter housing assy 3848884
9 -- NIPPLE 1 Not as sparepart. Included only in filter housing assy 3848884
10 KG20511511 NIPPLE 1 Not as sparepart. Included only in filter housing assy 3848884
11 KG20976003 FUEL FILTER 1 -20430751

12 KG20998367 FUEL FILTER 1 -20514654
13 KG20771574 BOWL 1
14 KG967344 O-RING 1
23 KG949747 CLAMP 1

TAD1642GE
FUEL FILTER, COMPONENTS SN-2016045622
Ref.
No.
26 KG976971 O-RING 1
27 KG3888904 AIR VENT PIPE 1
28 --- BRACKET 1
31 KG3594288 VALVE 1
37 KG20898038 PRESSURE SENSOR 1
39 KG861057 FUEL HOSE X 03-Aug
- --- BULLETIN P-23-4-4 Fuel Hose P/N 861057
42 KG21091546 RUBBER ELEMENT 3

TAD1642GE
FUEL FILTER, COMPONENTS SN2016045623
Ref.
No.
4 KG20771574 BOWL 1
6 KG21091546 RUBBER ELEMENT 1
9 KG3594288 VALVE 1

TAD1642GE
FUEL PUMP
Ref.
No.
1 KG3885173 Fuel pump 1 Without servo pump., Compl, (3594872)
2 KG8131292 Gear 1
3 KG20367040 Castle nut 1
4 KG20902698 Tandem pump 1 With servo pump., Compl, (20482482)
5 KG20367040 Castle nut 1
6 KG8131292 Gear 1
7 KG1505357 Woodruff key 1
8 KG85103703 O-ring 1
9 KG85103779 Constant velocity jo 1
10 KG20997341 Fuel pump 1 -85103778
11 KG85103780 Hex. socket screw 1 L=55mm
12 KG965216 Flange screw 1 L=30mm

KG947760 Flange screw 3
13 KG977030 O-ring 2
14 KG946671 Flange screw 3

TAD1642GE
FUEL CLEANER/ WATER SEPARATOR

TAD1642GE
Ref.
No.
2 KG838506 O-RING 1
3 KG846719 GASKET 3
4 KG3825028 TURBINE 1
5 KG3838852 FUEL FILTER INSERT 1 (3825027) 10 micron
KG889419 FILTER INSERT 1 30 micron
6 KG3838851 BOWL 1 Metal bowl., (848293)
7 KG846620 NIPPLE 2
8 KG952075 PLUG 1
10 KG3885070 SENSOR 1
11 KG21415866 EXTENSION CABLE'VERL 1 L=3m

- KG21415883 EXTENSION CABLE'VERL 1 L=5m

TAD1642GE
FUEL CLEANER/ WATER SEPARATOR,

SINGLE. CLASSIFIABLE FUEL SYSTEM

TAD1642GE
Ref.
No.
1 KG3825018 FUEL FILTER 1 REPL BY 877768
- --- BULLETIN 50-11A - FUEL FILTERS / WATER SEPARATORS
2 KG838506 O-RING 1
3 KG846719 GASKET 3
5 KG3838852 FUEL FILTER INSERT 1 (3825027) 10 MICRON
6 KG3838851 BOWL 1 METAL BOWL., (848293)
7 KG846620 NIPPLE 2
8 KG952075 PLUG 1

TAD1642GE
FUEL CLEANER / WATER SEPARATOR,

TWIN. CLASSIFIABLE FUEL SYSTEM.
LATER PRODUCTION

TAD1642GE
Ref.
No.
2 KG838505 O-RING 2
3 KG846719 GASKET 6
4 --- TURBINE 2
5 KG3838852 FUEL FILTER INSERT 2
6 KG3838851 BOWL 2
8 KG952075 PLUG 2
9 KG3827300 BLOCK 2
10 KG3827299 MANOMETER 2

TAD1642GE
FUEL CLEANER/ WATER SEPARATOR, TWIN.

TAD1642GE
Ref.
No.
1 KG3825022 FUEL FILTER 1 Repl by 877770
- --- BULLETIN 50-11A Fuel Filters / Water Separators
2 KG838505 O-RING 2
3 KG846719 GASKET 6
5 KG3838852 FUEL FILTER INSERT 2 (3825027) 10 micron
6 KG3838851 BOWL 2 Metal bowl., (848293)
8 KG952075 PLUG 2

TAD1642GE
AIR FILTER FOR FUEL TANK
Ref.
No.
1 KG3173995 MANIFOLD 1
2 KG3944785 AIR CLEANER 1
5 KG968695 NIPPLE 1
6 KG976445 NIPPLE 1
7 KG968061 PLUG 1

TAD1642GE
UNIT INJECTOR

TAD1642GE
Ref.
No.
1 KG3803637 UNIT INJECTOR, EXCH 6
2 KG276948 O-RING KIT 1 -276935
3 KG21261987 WASHER 1 SN2016021776
4 KG20440280 YOKE 6
6 KG983472 CABLE TIE 1 For cable to unit injectors.
7 KG8131393 RETAINER 1 For cable to unit injectors.

TAD1642GE
INTAKE AND EXHAUST MANIFOLD

TAD1642GE
Ref.
No.
1 KG20570212 INLET PIPE 1 SN - 2016010024
KG20970998 INLET PIPE 1 SN 2016010025-
KG1161277 SEALANT X 10g
4 KG960628 `PLUG 1
5 KG947281 GASKET 1
6 KG11158142 EXHAUST MANIFOLD 1 Replaced by exhaust manifold 11447007.
KG11447007 EXHAUST MANIFOLD -
7 --- EXHAUST MANIFOLD 1
8 --- EXHAUST MANIFOLD 2

12 KG20744865 GASKET 6
13 KG20784537 GASKET 1
14 KG1676806 SPACER 1
16 KG3838354 CHARGE AIR PIPE 1

TAD1642GE
STARTER ELEMENT

TAD1642GE
Ref.
No.
1 KG3834466 STARTER ELEMENT 1
2 --- INTERMEDIATE SECTION 1
3 --- WIRE ELEMENT 1
4 KG468468 SLEEVE 12
7 KG468825 TERMINAL SCREW 2
8 KG192288 WASHER 2
9 KG468511 BUSHING 2
10 --- ISOLATION PLATE 2
11 --- ISOLATION PLATE 4
13 KG478896 SLEEVE 1
16 KG3888621 WIRING HARNESS 1
17 KG873789 DIODE 1
18 KG471476 ATTACHING PLATE 1
19 KG873962 RELAY 1
23 KG1581123 CASING 1
24 KG421692 SUPPORT 1

TAD1642GE
HEAT SHIELD FOR EXHAUST MANIFOLD

AND VALVE COVER
Ref.
No.
1 KG3818518 RADIATION SHIELD 1
5 KG3884338 HEAT SHIELD 1

TAD1642GE
TURBOCHARGER

TAD1642GE
Ref.
No.
1 KG3802140 TURBOCHARGER, EXCH 1
2 KG20784537 GASKET 1 -470939
4 KG20579303 STUD 4 -977299
6 KG3836392 OIL FEED HOSE 1
7 KG8192268 FLANGE 1
8 KG976971 O-RING 1
11 KG3841514 RETURN PIPE 1
14 KG8148729 CONNECTOR 1
18 KG948980 O-RING 1

TAD1642GE
HEAT SHIELD FOR TURBO
Ref.
No.
8 KG942810 CLAMP 1

TAD1642GE
CRANK HOUSE VENTILATION

TAD1642GE
Ref.
No.
1 KG20519942 BREATHER PIPE 1
3 KG20519944 FLANGE 1
7 KG941976 CLAMP 2
8 KG3809016 PIPE 1 FOR THRUST FAN.
9 KG3838740 CLAMP 2
11 KG3839144 RUBBER HOSE 1 L=90mm
13 KG3839144 RUBBER HOSE 1 L=500mm

TAD1642GE
CRANKCASE VENTILATION, CLOSED

TAD1642GE
Ref.
No.
1 KG3825036 VENTILATION FILTER 1
2 KG3829152 PIPE 1
6 KG949722 O-RING 1
7 KG942707 HOSE X
10 KG941976 CLAMP 1

TAD1642GE
CRANKCASE VENTILATION, CLOSED

TAD1642GE
Ref.
No.
1 KG3848875 SEPARATOR 1
2 KG3886256 PIPE 1
4 KG20580933 HOSE 2
6 KG20532891 GASKET 2
7 KG942707 HOSE X L=950mm
8 KG3883943 SPACER 1
10 KG981440 STUD 2
13 KG941976 CLAMP 1
14 KG20519944 FLANGE 1
16 KG21369237 BREATHER PIPE 1
18 KG947827 CLAMP 1

TAD1642GE
AIR FILTER WITH INSTALLATION COMPONENTS, STANDARD

TAD1642GE
Ref.
No.
1 KG21186950 AIR FILTER 1
- KG21233121 AIR FILTER 1
2 --- FILTER HOUSING 1
3 --- TENSIONING BAND 2
4 --- SCREW 2
5 --- NUT 2
6 --- LOCK 1
7 KG21186955 INSERT 1
KG21212204 INSERT 1
9 KG3830971 RAIN CAP 1
10 KG930760 EXPANDING NUT 4
17 KG20560843 VACUUM SWITCH 1
18 KG949931 HOSE X
19 KG948702 CABLE TIE X

TAD1642GE
AIR FILTER WITH INSTALLATION COMPONENTS, MEDIUM DUTY

TAD1642GE
Ref.
No.
1 KG3829102 AIR FILTER 2
2 -- HOUSING 1
3 KG3837728 RAIN CAP 1
4 KG3839340 INSERT 1
5 --- LOCK 1
6 --- MOUNTING STRAP 2
9 KG3586028 RUBBER COLLAR 2
14 KG16218 ELBOW NIPPLE 1
18 KG949931 HOSE 1

TAD1642GE
AIR FILTER WITH INSTALLATION COMPONENTS, HEAVY DUTY

TAD1642GE
Ref.
No.
8 KG845422 PLASTIC PLUG 1
10 KG21380418 RUBBER COLLAR 1
11 KG8149322 HOSE 1
14 KG949931 HOSE X

TAD1642GE
AIR CLEANER, HEAVY DUTY
Ref.
No.
2 --- FILTER HOUSING -
3 KG21386706 FILTER INSERT 1
4 KG21386644 FILTER INSERT 1
5 --- COVER -

TAD1642GE
MUFFLER
Ref.
No.
1 KG863049 MUFFLER 1
- KG849832 MUFFLER 1
2 KG846413 WELD FLANGE 2
- KG849981 FLANGE 2
3 KG862976 GASKET 2
- KG862950 GASKET 2
4 KG941912 SPRING WASHER 16

TAD1642GE
MUFFLER, ENGINE MOUNTED

TAD1642GE
Ref.
No.
4 KG3838156 RISER 1
- KG3838157 RISER 1
5 KG479979 PLUG 1
7 KG1624612 CLAMP 1
10 KG3819614 MUFFLER 1
12 KG3837622 END PIPE 1
13 KG3837623 CLAMP 2
17 KG3828218 EXHAUST PIPE 1
21 KG941912 SPRING WASHER 8
23 KG3818518 RADIATION SHIELD 1

TAD1642GE
RADIATOR AND PUSHING FAN. SN-2016028724

TAD1642GE
Ref.
No.
1 --- COOLING PACKAGE 1
2 KG3587701 FRAME PROFILE 1
5 KG3838129 INTERCOOLER 1
7 KG3587694 O-RING 8
8 KG3587693 INTERMEDIATE PIPE 2
9 KG3587695 RADIATOR PIPING 1
11 KG3587350 O-RING 6
15 KG3587729 SCREW 22
18 KG3838131 FAN SHROUD 1
21 KG889223 STAY 1
23 KG866857 RUBBER BUSHING 2
30 KG3808825 BRACKET 1 LEFT
- KG3808827 BRACKET 1 RIGHT

TAD1642GE
RADIATOR AND PUSHING FAN. SN-2016028724
Ref.
No.
31 KG3827612 FAN RING 1
32 KG3828964 FAN 1
34 KG130204 STUD 6
35 KG3825490 FAN GUARD 2
36 KG3829537 FAN HUB 1
38 KG3828043 PULLEY 1 FOR TAD1640GE
- KG3829958 PULLEY 1 FOR TAD1641,1642GE
39 KG3827075 V-RIBBED BELT 1 FOR TAD1640GE SN-2016029184
- KG3819398 V-RIBBED BELT 1 FOR TAD1640GE SN2016029185-
- KG3838617 V-RIBBED BELT 1 FOR TAD1641,1642GE
40 KG21159130 FAN HUB 1
44 KG3888997 RADIATOR GRILLE 2
45 KG846118 EMBLEM 1
46 KG941651 CROSS RECESSED SUNK 2
48 KG3830509 BRACKET 1 LEFT
- KG3830508 BRACKET 1 RIGHT
50 KG3809808 RADIATOR HOSE 1

TAD1642GE
RADIATOR AND PUSHING FAN. SN2016028725

TAD1642GE
Ref.
No.
1 KG3885433 COOLING PACKAGE 1
6 KG3587694 O-RING 8
7 KG3587693 INTERMEDIATE PIPE 2
9 KG3587729 SCREW 18
12 KG21134129 HOSE 2
15 KG3838131 FAN SHROUD 1
16 KG21134779 BASE 2
18 --- SCREW 24
- KG3830509 BRACKET 1
22 KG21134796 HOSE CONNECTION 2
23 KG21138584 O-RING 4
24 KG21147027 O-RING 2
25 KG21147028 DRAIN PLUG 2
- KG3808827 BRACKET 1
30 KG3593807 STAY 1
33 KG866857 RUBBER BUSHING 4

TAD1642GE
RADIATOR AND PUSHING FAN. SN2016028725
Ref.
No.
39 KG3827612 FAN RING 1
40 KG9G46173 FLANGE SCREW 12
41 KG3825490 FAN GUARD 2
- KG21206539 FAN GUARD 2
42 KG3828964 FAN 1
43 KG3829537 FAN HUB 1
44 KG130204 STUD 6
46 KG21159130 FAN HUB 1
49 KG3829958 PULLEY 1
50 KG3838617 V-RIBBED BELT 1
52 KG3829123 RADIATOR PROTECTOR 1
53 KG846118 EMBLEM 1
54 KG941651 CROSS RECESSED SUNK 2

TAD1642GE
RADIATOR WITH CONNECTING COMPONENTS.

PUSHING FAN. SN-2016028724

TAD1642GE
Ref.
No.
1 --- RADIATOR -
4 KG3829133 CHARGE AIR HOSE 2
6 KG3887193 KIT 1
12 KG941976 CLAMP 1
16 KG1556930 CLAMP 2
17 KG949647 O-RING 2
28 --- CHARGE AIR PIPE -
32 KG952630 CLAMP 1

TAD1642GE
RADIATOR WITH CONNECTING COMPONENTS.

PUSHING FAN. SN2016028725

TAD1642GE
Ref.
No.
1 --- RADIATOR -
6 KG3887193 KIT 1
12 KG941976 CLAMP 1
16 KG1556930 CLAMP 2
17 KG949647 O-RING 2
28 --- CHARGE AIR PIPE -
32 KG952630 CLAMP 1

TAD1642GE
BELT GUARD

TAD1642GE
Ref.
No.
1 KG3829260 PROTECTING SCREEN 1
21 --- BRACKET 1

TAD1642GE
OIL COOLER, ENGINE
Ref.
No.
1 KG1675774 OIL COOLER 1
- KG20700516 OIL COOLER 1
3 KG8131970 SEAL 2
- KG21302234 GASKET 1
6 KG20581617 COVER 1
- KG21426900 COVER 1

TAD1642GE
EXPANSION TANK WITH INSTALLATION COMPONENTS
Ref.
No.
1 KG1674916 EXPANSION TANK 1
2 KG1674922 FILLER CAP 1
3 KG1674083 PRESSURE CAP 1
9 KG952973 HOSE X
11 KG943367 RUBBER HOSE X
- KG943367 RUBBER HOSE X

TAD1642GE
PROTECTION COVER FOR EXPANSION TANK
Ref.
No.
1 KG3839467 PROTECTING CASING 1
2 KG3830539 COVER 1
6 KK946173 FLANGE SCREW 1

TAD1642GE
WATER PUMP, THERMOSTAT HOUSING AND WATER FILTER,

RADIATOR COOLING

TAD1642GE
Ref.
No.
1 KG20451516 PUMP UNIT 1
- KG20744939 PUMP UNIT 1
- KG3801102 COOLANT PUMP, EXCH, EXCH 1
- KG21420336 CONNECTION PIPE -
- KG20818346 GASKET 1
9 KG21237213 THERMOSTAT 1
- KG21412639 THERMOSTAT 1
10 KG3838404 COVER 1
12 KG975675 O-RING 2
13 KG3809986 COOLANT PIPE 1
17 KG20727018 COVER 1
19 KG3838168 COOLANT PIPE 1
25 KG952973 HOSE X

TAD1642GE
WATER PUMP, THERMOSTAT HOUSING AND WATER FILTER,

RADIATOR COOLING
Ref.
No.
27 KG1676622 NIPPLE 1
29 KG476279 PROTECTING CAP 1
32 KG20729344 HOSE 1
33 KG20532237 COOLANT FILTER 1
34 KG20459650 BRACKET 1
38 KG1676554 NIPPLE 1
40 KG8149475 PULLEY 1
- KG20538853 PULLEY 1
- KG947107 FLANGE SCREW 5

TAD1642GE
COOLING SYSTEM. ALTERNATIVE MOUNTING OF WATER FILTER

TAD1642GE
Ref.
No.
3 KG20532237 COOLANT FILTER 1
4 --- GASKET 1
5 KG969011 GASKET 2
6 KG941754 NIPPLE 2
7 KG11033093 RISER 2
9 KG3830315 HOSE 2
10 KG21182000 ADAPTER 1

TAD1642GE
BELT TRANSMISSION AND BELT TENSIONER DEVICE
Ref.
No.
1 KG20762060 BELT TENSIONER 1
2 KG21344756 SCREW 2
5 KG3887305 IDLER PULLEY 1

TAD1642GE
SERPENTINE BELT SYSTEM

TAD1642GE
Ref.
No.
1 KG3838617 V-RIBBED BELT 1 FOR TAD1640/41/42/50/51GE, RATIO 1.0:1, L=1620MM
- KG3827075 V-RIBBED BELT 1 FOR TAD1640/41/42/50/51GE, RATIO 0.93:1, L=1635MM
- KG3883978 V-RIBBED BELT 1 ONLY FOR TWD1643GE, RATIO 1.0:1, L=1695MM
2 KG3829958 PULLEY 1 RATIO 1.0:1, D=227MM
- KG3828043 PULLEY 1 RATIO 0.93:1, D=244MM
3 KG20851842 IDLER PULLEY 1
4 KG8097084 COVER 1
6 KG21479276 BELT TENSIONER 1 ONLY FOR TWD1643GE
- KG21145261 BELT TENSIONER 1 FOR TAD1640/41/42/50/51GE
9 KG21344756 SCREW 2

TAD1642GE
BATTERY BOX

TAD1642GE
Ref.
No.
2 KG846284 WASHER 2
4 KG863627 BATTERY BOX 1
6 KG3987034 MAIN SWITCH 1
7 KG8157766 KEY 1
13 --- ELECTRICAL MATERIALS X
14 KG1587694 COVER 1
15 KG1582293 BELLOWS 1

TAD1642GE
ALTERNATOR, SINGLE MOUNTED

TAD1642GE
Ref.
No.
1 KG3803639 ALTERNATOR, EXCH 1
5 KG3589388 INSULATING BUSHING 2
8 KG3589369 INSULATING BUSHING 2

TAD1642GE
STARTER MOTOR
Ref.
No.
1 KG3803838 STARTER MOTOR, EXCH 1
- KG3801289 STARTER MOTOR, EXCH 1
2 KG953098 STUD 3

TAD1642GE
STARTER MOTOR, COMPONENTS

TAD1642GE
Ref.
No.
1 KG3803838 STARTER MOTOR, EXCH 1 Replaced by starter motor 3801289
- KG3801289 STARTER MOTOR, EXCH 1
2 --- SHAFT 1
3 --- LEVER 1
4 KG874738 STARTER PINION 1
5 KG874745 SOLENOID 1
6 --- ROTOR 1
7 --- STATOR 1
8 KG874741 CARBON BRUSH RETAINE 1
9 --- BEARING SHIELD 1
10 KG874743 STARTER RELAY 1
11 KG874747 SCREW KIT 1
12 KG874746 GASKET KIT 1

TAD1642GE
CONTROL PANEL, DCU

TAD1642GE
Ref.
No.
SOFTWARE ORDERED SEPARATELY OR DOWNLOADED WITH
1 KG881776 CONTROL UNIT, NOT PROGRAMMED 1
VODIA., REPLACED BY CONTROL UNIT 12330500
KG12330500 CONTROL UNIT, NOT PROGRAMMED 1
WAREHOUSE PROGRAMMING. THIS P/N CAN NOT BE ORDERED,
KG3587268 SOFTWARE 1
BUT WILL BE USED FOR INVOICING.
VODIA-PROGRAMMING. THIS P/N CAN NOT BE ORDERED, BUT
WILL BE USED FOR INVOICING.
2 KG969407 6 POINT SOCKET SCREW 6 -965200
8 --- HORN 1

TAD1642GE
CIU
Ref.
No.
CONTROL UNIT, NOT INSTRUMENT PANEL / CIU, SOFTWARE ORDERED SEPARATELY OR DOWNLOADED
1 KG874239 1
PROGRAMMED WITH VODIA.
WAREHOUSE PROGRAMMING. THIS P/N CAN NOT BE ORDERED, BUT WILL BE USED
FOR INVOICING.
VODIA-PROGRAMMING. THIS P/N CAN NOT BE ORDERED, BUT WILL BE USED FOR
INVOICING.

TAD1642GE
CONTROL UNIT AND CONNECTOR

TAD1642GE
Ref.
No.
1 KG20429842 HOUSING 1 Black
- KG20429843 HOUSING 1 Gray
3 KG949997 CLAMP 2
CONTROL UNIT, NOT
5 KG20814594 1 -24425461
PROGRAMMED
WAREHOUSE PROGRAMMING. THIS P/N CAN NOT BE ORDERED,
- KG3586269 SOFTWARE 1
BUT WILL BE USED FOR INVOICING.
VODIA-PROGRAMMING. THIS P/N CAN NOT BE ORDERED, BUT
- KG3586268 SOFTWARE 1
WILL BE USED FOR INVOICING.

TAD1642GE
LCD DISPLAY
Ref.
No.
1 KG3807892 DISPLAY 1
- KG3840167 DISPLAY 1
2 KG830928 STUD 4
3 KG830930 NUT 4

TAD1642GE
ELECTRICAL SYSTEM

TAD1642GE
Ref.
No.
1 KG21345091 WIRING HARNESS 1 -3843030
2 KG8131655 BOX 1 OBSOLETE PART
3 KG8131657 COVER 1
5 KG8131656 BOX 1
8 KG828586 NUT 1
9 KG873959 BREAKER 1
10 --- NUT 1
11 --- WASHER 1
12 --- NUT 1
15 KG1079677 PLUG 5
17 --- SWITCH 2
18 KG3587172 RELAY SOCKET 1
19 --- GASKET 1
20 KG20374662 RELAY 1
21 KG3587173 RELAY BOX 1
22 KG949997 CLAMP 1 D=31,8MM
- KG949746 CLAMP 2 D=12,7MM
23 KG946440 FLANGE SCREW X M8X16MM
24 KG948211 CABLE TIE X D=67MM
- KG983472 CABLE TIE X D=35MM
25 KG8131393 RETAINER X
26 KG3963413 RING 1
28 KG20563691 BRACKET 1 OBSOLETE PART

TAD1642GE
ELECTRICAL MATERIALS, INSTRUMENT

TAD1642GE
Ref.
No.
1 KG849849 OIL PRESSURE GAUGE 1
2 KG849848 THERMOMETER 1
3 KG873196 THERMOMETER 1
4 KG873198 OIL PRESSURE GAUGE 1
5 KG873998 TACHOMETER KIT 1
6 KG862096 VOLTMETER 1
7 KG863408 THERMOMETER, OIL 1
8 KG808175 LAMP SOCKET 1 FOR 849849, 849848, 862096, 863408.
- KG863945 LAMP SOCKET 1 FOR 873196, 873198, 873998.
9 KG182059 BULB 1 FOR 849849, 849848.
- KG863947 BULB 1 INCLUDED IN 873196, 873198, 873998, 872479.
- KG828818 BULB 1 FOR 862096, 863408.
10 KG874050 HORN 1
13 --- BATTERY BOX 1
14 KG3808418 WIRING HARNESS 1 CABLE KIT CIU.
15 KG874414 EXTENSION CABLE'VERL 1 CONNECTION CABLE EDC, CIU., L=3.0M
- KG874119 EXTENSION CABLE'VERL 1 CONNECTION CABLE EDC, CIU., L=5.0M

TAD1642GE
ELECTRICAL MATERIALS, INSTRUMENT EVC-A

TAD1642GE
Ref.
No.
1 KG874903 TACHOMETER 1 Black D=85mm
- KG874928 TACHOMETER 1 White D=85mm
2 KG874910 TURBO PRESSURE GAUGE 1 Black 0-3 bar
- KG874920 TURBO PRESSURE GAUGE 1 Black 0-45 psi
- KG874911 PRESSURE GAUGE, FRESHWATER 1 Black 0-3 bar
- KG874912 PRESSURE GAUGE, SEA WATER 1 Black 0-3 bar
3 KG874908 OIL PRESSURE GAUGE, ENGINE 1 Black 0-7 bar
- KG874919 OIL PRESSURE GAUGE, ENGINE 1 Black 0-100 psi
- KG874909 OIL PRESSURE GAUGE, REVERSE GEAR 1 Black 0-25 bar
- KG874951 OIL PRESSURE GAUGE, REVERSE GEAR 1 Black 0-350 psi
4 KG874904 THERMOMETER, COOLANT WATER 1 Black 0-120°C
- KG874918 THERMOMETER, COOLANT WATER 1 Black 40-250 °F
- KG874905 THERMOMETER, OIL-ENGINE 1 Black 0-150°C
- KG881857 THERMOMETER, OIL-ENGINE 1 Black 40-300 °F
- KG874906 THERMOMETER, REVERSE GEAR 1 Black 0-120°C
5 KG874907 THERMOMETER, EXHAUST TEMP 1 Black 0-600°C
6 KG874913 VOLTMETER 1 Black
7 KG874915 INSTRUMENT, ALARM 1 Black
8 KG874914 FUEL GAUGE 1 Black
9 KG874709 MOUNTING KIT 1 Black D=52mm
10 KG874450 ATTACHING RING 1
11 KG874448 RING 1
13 KG874708 MOUNTING KIT 1 Black D=85mm
14 KG874449 ATTACHING RING 1
15 KG874447 RING 1
17 KG881611 BRACE KIT 1 Black D=52mm
18 KG881607 BRACE 1
19 KG881610 NUT 2
20 KG881609 STUD 2

TAD1642GE
ELECTRICAL MATERIALS, INSTRUMENT EVC-A
Ref.
No.
22 KG874448 RING 1
23 KG881612 BRACE KIT 1 BLACK D=85MM
24 KG881608 BRACE 1
25 KG881610 NUT 2
26 KG881609 STUD 2
28 KG874447 RING 1
29 KG874759 EXTENSION CABLE'VERL, INSTRUMENT 1 L=1000MM
30 KG3808852 CABLE KIT, INSTRUMENT 1
31 KG828587 BUZZER 1

TAD1642GE
CONTACTS AND SENSORS, ANALOG
Ref.
No.
1 KG862154 TEMPERATURE SENSOR 1
2 KG11998 GASKET 1
3 KG3832778 REDUCTION NIPPLE 1
4 KG866835 SENSOR 1
- --- BULLETIN P-38-6-1 VIBRATION DAMPING KIT
5 KG862251 TACHOMETER SENSOR 1
6 KG948884 GASKET 1

TAD1642GE
CONTACTS AND SENSORS

TAD1642GE
Ref.
No.
1 KG8140024 SENSOR, EXPANSION TANK 1
2 KG20524936 PRESSURE SENSOR, PRESSURE/TEMP 1
3 --- SENDER, PRESSURE/TEMP 1
4 KG969161 FUSE 1
5 KG21302639 PRESSURE SENSOR, OIL PRESSURE 1 -20898038
6 KG21302639 PRESSURE SENSOR, FUEL PRESSURE 1 -20898038
7 KG21042447 OIL LEVEL SENSOR, LEVEL 1 -24424110
8 KG20796744 PRESSURE SENSOR, CRANKCASE PRESSURE 1 -20499340
9 KG20513343 SENSOR 1
10 KG20513340 SENSOR, COOLANT WATER TEMP. 1
11 KG874673 PRESSURE SWITCH, PISTON COOLING 1 Replaced by 21202753.
- KG21202753 PRESSURE SWITCH 1
12 KG20513343 SENSOR 1

TAD1642GE
ELASTIC COUPLING
Ref.
No.
1 --- ELASTIC CLUTCH 1 CF D-275
2 KG864155 COMPANION FLANGE 1
3 KG864156 HUB 1
4 KG864157 RUBBER CUSHION, KIT 1 CONTAINS 16 PCS OF RUBBER CUSHIONS.

TAD1642GE
ENGINE HEATER, SEPARATELY MOUNTED

TAD1642GE
Ref.
No.
1 KG3828447 ENGINE HEATER 1 220-240V, 750W
- KG3828643 ENGINE HEATER 1 220-240V, 2000W
7 KG3830493 TUBE 1 REPLACED BY PIPE 3884715 OCH HOSE 943369
- KG3884715 WATER PIPE 1
8 --- SCREW 1
14 KG945081 CLAMP 2
19 KG3587616 PIPE 1

TAD1642GE
TOOL KIT

TAD1642GE
Ref.
No.
1 KG3832808 TOOL BOX 1
2 KG3841091 TOOL BOX 1 -842021
3 KG962045 ADJUSTABLE WRENCH 1 OBSOLETE PART
4 KG962032 PLIERS 1 OBSOLETE PART
5 KG804771 SCREWDRIVER 1
6 KG978201 COMBINATION SCREWDRI 1
7 KG884573 TOOL 1
8 KG962295 EXTENSION 1 OBSOLETE PART
9 KG962291 JOINTED HANDLE 1 OBSOLETE PART
10 KG884912 OPEN-END WRENCH 1 10-11MM, OBSOLETE PART
11 KG884913 OPEN-END WRENCH 1 OBSOLETE PART, 12-13MM
15 KG962259 SLEEVE 1 OBSOLETE PART, 10MM

TAD1642GE
FUEL SYSTEM, VENTING SN2016045623

TAD1642GE
Ref.
No.
2 KG949747 CLAMP 4
6 KG21143551 RISER 2
7 KG20899253 GASKET 4
17 KG20548012 FAUCET 1
20 KG21140647 VALVE 1
22 KG11998 GASKET 1
23 KG946444 SHIM 1
24 KG982258 CLAMP 1
28 KG21132217 BRACKET 6
31 KG20902698 TANDEM PUMP 1
- KG3885173 FUEL PUMP 1

TAD1642GE
ACCESSORIES FOR ENGINE GROUP FOR 600 KVA
Ref.
No.
KGI151289 ACCESSORIES FOR ENGINE GROUP 600 KVA 1
1 KG30901181201NE HEAT GUARD KIT FOR TAD164XGE VOLVO ENGINE 1
2 KGI115053 ANTI VIBRATION MOUNT FOR KVS600 ENGINE SIDE 4
3 KGI105034 ENGINE MOUNTING FEET ASSLY 2
4 KGI101060 TAD1642GE VOLVO ENGINE (600 KVA) 1
- KGI105073 ENGINE FRONT MOUNTING LEG 2
5 KG811374 BEND CONNECTOR 1
6 KG272701 VALVE OIL DRAIN 1
7 KGX-582-1 CONNECTOR HOSE ADAPTOR 1
- KGGM31185 BUSHING ADAPTER 1

TAD1642GE
ALTERNATOR GROUP FOR KVS600 CGL
Ref.
No.
KGI151375 ALTERNATOR GROUP FOR KVS600 CGL 1
1 KGI115054 Anti vibration Mount For KVS600 Alternator Side 4
- KGI151373 KVS600 set FOR 57F4 1

TAD1642GE
ALTERNATOR
Ref.
No.
- KG60162416 Rotor Wound Exciter Stator 355 FRAME 1
- KG60162425 WOUND EXCITER ROTOR 355 FRAME 1
- KG60192430 DE END SHIELD (G2R/S) 355 FRAME 1
- KG6016243012 DE END SHIELD (G2R/S) G1R 355/SAE1 1
- KG60132432 NDE END SHIELD 355 FRAME 1
- KG60152161 BRG COVER DE O/S 355 FRAME 1
- KG60152163 BRG COVER DE I/S 355 FRAME 1
- KG60192423 FAN 355 FRAME 1
- KG361055004 T. BOX ASSLY. G1R 355 1
- KG361055014 END COVER 355 FRAME 1
- KG361034042 DE VENT COVER G1R 355 SAE1 1
- KG6015243212 COUPLING HUB SAE 14 FOR 355 FRAME 1
- KG361049013 COUPLING DISC SPACER 355 FRAME 14 1
- KG379086902 MAIN TERMINAL BOARD WITH 6 TERMINAL 355 FRAME 1
- KG60162411 M/C STATOR BODY G1R355M 1
- KG361041022 ROTOR MISC. ITEMS MID COIL SUPPORT STUD G1R355 1

TAD1642GE
CONTROLLER GROUP FOR KVS600 W/O POWER PANEL

TAD1642GE
Ref.
No.
KGI151376 CONTROLLER GROUP FOR KVS600 W/O POWER PANEL 1
1 KG919036 BATTERY 2 180AH (MHD1800)
2 KGI116188 BATTERY CABLES FOR 600 KVA 1
3 KGI110024 BATTERY SWITCH BRACKET FOR KVS RANGE 1
4 KGI116378 BATTERY SWITCH CABLES FOR KVS600 1
5 KGI116323 BATTERY SWITCH 1 (Model: MCS/5266),12V/24V
6 KGI116122 CONTROL PANEL FOR 600KVA W/O MCCB 1
7 KGI116207 CT 1200/5A10VA NE615 3
8 KGI116281 EMERGENCY STOP WITH NC ELEMENT 1
ENGINE WIRING HARNESS FOR KVS RANGE WITH DEUTCH
9 KGI116370 1
PIN
10 KGI118120 FUEL LEVEL INDICATOR 24 VOLT(FOR OCTA) 1
11 KGI116309 GC1F CONTROLLER WITH 1 B3 - H5
12 KGX-6046-5 GROUND STRAP 1
13 KGI105058 OCTA FUEL GAUGE FOR 630 KVA 1 (191 mm Effective Tank Height)
- KGI110001 P TYPE CLAMP 2

TAD1642GE
CANOPY GROUP FOR 600 KVA
Ref.
No.
KGI151291 CANOPY GROUP FOR 600 KVA 1
- KGI115040 KT 75 FUEL LINE INLET/KVS320-380 FUEL IN 2
- KGI118021 OIL & COOLANT DRAIN HOSE 500 KVA 1 17mm (Length-820mm)
1 KG815221 OIL DRAIN PIPE 1 Dia 16mm (L=1.5Mtr)
2 KG811377 DRAIN PLUG FOR OIL & FUEL & COOLANT 2
3 KG811372 HOSE CLAMP FOR OIL DRAIN 4 (17mm) Klipco Size - 25A
4 KGI105054 KOHLER NAME PLATE 1
5 KGI232020 RIVET FOR GENSET NAME PLATE 4
- KGI118173 CANOPY FOR 600 KVA 1
- KGI216013 EXHAUST BELLOW FOR KVS600 1
- KGI218039 EXHAUST SILENCER KVS600 1

Index
Description Page No
A
Air Filter with Installation Components, Standard 79, 80
Air Filter with Installation Components, Medium Duty 81, 82
Air Filter with Installation Components, Heavy Duty 83, 84
Air Filter for Fuel Tank 62
Adapter Flywheel and Flywheel Housing SAE-0 14
Alternator, Single Mounting 114, 115
Accessories for Engine Group STD 142
Alternator Group 600 Kva 3Phase 143
Alternator Group 600 Kva 3Phase 144
B
Belt Guard 99, 100
Belt Transmission and Tensioned Device 109
Battery Box 112, 113
C
Cylinder Head SN-2016010024 1, 3
Cylinder Head SN-2016010025 4, 6
Cylinder Block SN-2016010024 8, 9
Cylinder Block SN-2016010025 11, 12
Camshaft 21, 22
Crank Mechanism 23, 24
Crank House Ventilation 73, 74
Crankcase Ventilation, Closed 75, 78
Cooling System, Alternative Mounting of Water Filter 107, 108
Control Panel, DCU 119, 120
CIU 121
Control Unit and Connector 122, 123
Contacts and Sensors, Analog 132
Contacts and Sensors 133, 134
Control Panel Assembly for 600 kVA STD 145, 146
E
Engine Mounting and Frame 25, 26
Expansion Tank with Installation Components 102
Electrical System 125, 126
Electrical Materials, Instrument 127, 128
Electrical Materials, Instrument EVC-A 129, 131
Elastic Coupling 135
Engine Heater, Separately Mounting 136, 137
F
Fuel System SN-2016008240 40, 42
Fuel System SN-2016008241- SN-2016045622 43, 45
KOHLER POWER SYSTEM

Index
Description Page No
Fuel System SN-2016045623 46, 48

Fuel Filter, Components SN-2016045622 49, 51
Fuel Filter, Components SN-2016045623 52
Fuel Pump 53
Fuel Cleaner/Water Separator 54, 55
Fuel Cleaner/Water Separator, Single. Classifiable fuel system 56, 57
Fuel Cleaner/Water Separator, Twin. Classification Fuel System. Later Production 58, 60
Fuel Cleaner/Water Separator, Twin 60, 61
Fuel System, Venting SN-2016045623 140, 141
H
Heat Shield for Exhaust Manifold and Valve Cover 69
Heat Shield for Turbo 72
I
Intake and Exhaust Manifold 65, 66
L
Lubricating System 27, 29
LCD Display 124
O
Oil Filter Housing and Oil Filter Remote Mounting 30, 31
Oil Filter Housing and Oil Filter 32, 34
Oil Filter Housing and Oil Filter Remote Mounting. Components 35, 37
Oil Drain Pump and Installation Parts, Engine Mounting 38, 39
Oil Cooler, Engine 101
R
Radiator and Pushing Fan. SN-2016028724 89, 91
Radiator and Pushing Fan. SN-2016028725 92, 94
Radiator with Connecting Components. Pushing Fan. SN-2016028724 95, 96
Radiator with Connecting Components. Pushing Fan. SN-2016028725 97, 98
S
Starter Element 67, 68
Serpentine Belt System 110, 111
Starter Motor 116
Starter Motor, Components 117, 118
T
Timing Gear 19, 20
Turbocharger 70, 71
KOHLER POWER SYSTEM

Index
Description Page No
Tool Kit 138, 139
U
Unit Injector 63, 64
V
Valve Cover 7
Valve Mechanism 15, 18
W
Water Pump, Thermostat Housing and Water and Filter, Radiator Cooling 104, 106
KOHLER POWER SYSTEM

4.part Catalouge 600-KVA

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4.part Catalouge 600-KVA

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Service Part

Industrial Generator Sets

KOHLER POWER SYSTEM

1.56 Alternator, Single Mounting ............................................................................................................... 114

Section B. GENSET ENGINE ASSEMBLY ......................................................................................................... 142

2. Alternator Group 600KVA ..................................................................................................................... 143

3. Controller Assembly 600 KVA.............................................................................................................. 145

5. Canopy Assembly ................................................................................................................................. 147

KOHLER POWER SYSTEM

Revision No. Document Number / Date Details of Modifications Page No

KOHLER POWER SYSTEM

CYLINDER HEAD SN-2016010024

KOHLER POWER SYSTEM Page 1

KOHLER POWER SYSTEM Page 2

CYLINDER HEAD SN-2016010024

Ref. No. Part No. Part Name QTY. Remark

21 KG21448332 VALVE SPRING 12

KOHLER POWER SYSTEM Page 3

CYLINDER HEAD SN2016010025

KOHLER POWER SYSTEM Page 4

KOHLER POWER SYSTEM Page 5

CYLINDER HEAD SN2016010025

KOHLER POWER SYSTEM Page 6

KOHLER POWER SYSTEM Page 7

CYLINDER BLOCK SN-2016010024

KOHLER POWER SYSTEM Page 8

KOHLER POWER SYSTEM Page 9

CYLINDER BLOCK SN2016010025

KOHLER POWER SYSTEM Page 10

KOHLER POWER SYSTEM Page 11

KOHLER POWER SYSTEM Page 12

KOHLER POWER SYSTEM Page 13

ADAPTER FLYWHEEL AND FLYWHEEL HOUSING SAE 0

KOHLER POWER SYSTEM Page 14

KOHLER POWER SYSTEM Page 15

KOHLER POWER SYSTEM Page 16

KOHLER POWER SYSTEM Page 17

KOHLER POWER SYSTEM Page 18

KOHLER POWER SYSTEM Page 19

KOHLER POWER SYSTEM Page 20

KOHLER POWER SYSTEM Page 21

- KG21006109 CAMSHAFT BEARING KIT 1

9 KG3184012 BEARING HOUSING, REAR 1

11 -KG3184018 BEARING HOUSING, FRONT 1 Obsolete part

KOHLER POWER SYSTEM Page 22

KOHLER POWER SYSTEM Page 23

KOHLER POWER SYSTEM Page 24

ENGINE MOUNTING AND FRAME

KOHLER POWER SYSTEM Page 25

KOHLER POWER SYSTEM Page 26

KOHLER POWER SYSTEM Page 27

- KG21042447 OIL LEVEL SENSOR 1

KOHLER POWER SYSTEM Page 28

KOHLER POWER SYSTEM Page 29

OIL FILTER HOUSING AND OIL FILTER,

KOHLER POWER SYSTEM Page 30

KOHLER POWER SYSTEM Page 31

OIL FILTER HOUSING AND OIL FILTER

KOHLER POWER SYSTEM Page 32

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OIL FILTER HOUSING AND OIL FILTER

KOHLER POWER SYSTEM Page 34