Kohler TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE, TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE Workshop Manual (tp6958)

These Kohler TAD/TWD/TAD VE generator engines usually sit in hot, dusty plant rooms or out in weatherproof enclosures, running hard when the site needs power most. This workshop manual is what I’d keep open on the bench when tearing one down for a major overhaul or putting it back together after a failure. If you’ve got a unit that’s been shut down on low oil pressure and you find worn bearings, this book walks you through the strip-down, inspection points, and the correct order to build it back up so you don’t miss a seal, shim, or alignment step.

Applications & Use Cases

• Full engine rebuilds: Follow a logical teardown and reassembly sequence to avoid mixing parts or having to redo work.
• Head and valve work: Verify wear limits and adjustment logic so the engine starts clean and doesn’t hammer valvetrain components.
• Fuel and injection issues: Trace hard-start or smoke problems by methodically inspecting and refitting pumps, lines, and injectors.
• Front and rear end service: Align couplings, housings, and accessory drives so the generator runs smoothly without vibration.
• Post-repair checks: Use the reinstallation and inspection steps to test, bleed, and verify everything before you sign off the job.

FAQ

Q: Can I keep this manual on a tablet in the generator room?

A: Yes, it’s practical to use digitally; you can zoom diagrams and search terms instead of flipping pages with greasy hands.

Q: Is it worth printing sections of this manual?

A: Printing the procedures you’re doing that day works well—tape them near the set, mark notes, then update your copy later.

Safety Note

Always lock out the generator set and verify it cannot start automatically before opening, loosening, or removing any engine components.

Kohler TAD1640GE, TAD1641GE, TAD1642GE, TWD1643GE, TAD1641VE, TAD1642VE, TAD1643VE, TAD1650VE Index:

Safety Precautions and Instructions ………………………………………………………………………………………………………………………. 5
Introduction ………………………………………………………………………………………………………………………………………………………… 11
Service Assistance………………………………………………………………………………………………………………………………………………. 12
Section 1. Scheduled Maintenance ………………………………………………………………………………………………………… 13
1.1 Introduction ………………………………………………………………………………………………………………………………………… 13
1.2 Safety Precautions ………………………………………………………………………………………………………………………………. 13
1.3 Generator Set Service ………………………………………………………………………………………………………………………….. 14
1.3.1 Engine Service ……………………………………………………………………………………………………………………….. 14
1.4 Service Schedule ………………………………………………………………………………………………………………………………… 15
1.5 Controller Maintenance ………………………………………………………………………………………………………………………… 17
1.6 Engine Control System …………………………………………………………………………………………………………………………. 17
1.7 Alternator Maintenance ………………………………………………………………………………………………………………………… 18
1.7.1 Check the Operation ……………………………………………………………………………………………………………….. 19
1.7.2 Check the Ventilation ………………………………………………………………………………………………………………. 19
1.7.3 Check the Windings ………………………………………………………………………………………………………………… 19
1.7.4 Check the Bearings …………………………………………………………………………………………………………………. 19
1.8 Diesel Fuel Systems…………………………………………………………………………………………………………………………….. 20
1.8.1 Bleeding Air from Fuel System ………………………………………………………………………………………………….. 20
1.8.2 Subbase Fuel Day Tank Electronic Control Module (ECM) …………………………………………………………… 20
1.8.3 Subbase Inner Fuel Tank Alarm ……………………………………………………………………………………………….. 22
1.9 Air Cleaner Restrictor Indicator (if equipped) …………………………………………………………………………………………… 23
1.10 Cooling System …………………………………………………………………………………………………………………………………… 23
1.10.1 Coolant Level Check ……………………………………………………………………………………………………………….. 24
1.10.2 Cooling System Component Inspection ……………………………………………………………………………………… 24
1.10.3 Procedure to Drain Cooling System …………………………………………………………………………………………… 24
1.10.4 Procedure to Flush and Clean Cooling System …………………………………………………………………………… 24
1.10.5 Procedure to Refill Cooling System …………………………………………………………………………………………… 25
1.11 Battery ……………………………………………………………………………………………………………………………………………….. 26
1.11.1 Clean Battery …………………………………………………………………………………………………………………………. 27
1.11.2 Electrolyte Level Inspection ……………………………………………………………………………………………………… 27
1.11.3 Specific Gravity Check …………………………………………………………………………………………………………….. 28
1.11.4 Charge Battery ……………………………………………………………………………………………………………………….. 28
1.12 Storage Procedure ………………………………………………………………………………………………………………………………. 29
1.12.1 Lubrication System …………………………………………………………………………………………………………………. 29
1.12.2 Cooling System ………………………………………………………………………………………………………………………. 30
1.12.3 Diesel Fuel System Storage……………………………………………………………………………………………………… 30
1.12.4 Exterior………………………………………………………………………………………………………………………………….. 30
1.12.5 Alternator ………………………………………………………………………………………………………………………………. 30
1.12.6 Battery ………………………………………………………………………………………………………………………………….. 30
Appendix A. Abbreviations ……………………………………………………………………………………………………………………….. 31
Appendix B. Common Hardware Application Guidelines ……………………………………………………………………………. 35
Appendix C. Operating Hour Service Log ………………………………………………………………………………………………….. 37
Appendix D. Operating Hour Service Log ………………………………………………………………………………………………….. 3

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