Service Parts
Marine Generator Sets
Models:
3.5EFOZ/4EOZ
TP-6138 5/02
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Numbering System Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Hardware References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Specification Number Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Group 1: Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Group 2: Crankshaft and Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Group 3: Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Group 4: Gear Timing and Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Group 5: Speed Control Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Group 6: Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Group 7: Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Group 8: Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Group 9: Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Group 10: Oil Cooler and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Group 11: Seawater Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Group 12: Oil Draining Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Group 13: Fuel Filter and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Group 14: Air Intake Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Group 15: Gasket Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Group 16: Base and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Group 17: Sound Shield . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Group 18: Generator and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Group 19: Controller and Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Group 20: Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Group 21: Siphon Break and Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Group 22: Literature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Paint and Miscellaneous Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Appendix A Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Appendix B Common Hardware Application Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . A-3 Appendix C General Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Appendix D Common Hardware Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 Appendix E Common Hardware List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Introduction
This manual lists service replacement parts for 4 kW generator sets.
At the time of print this manual applied to the generator set specification (spec) numbers listed in the Specification Number Index. On occasion this manual may apply to specs not listed in the Specification Number Index.
Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever.
This manual includes the following main sections:
Table of Contents. Lists the sections of the manual.
Introduction (and other information sections).
Contains introductory material about part numbers, illustrations, and hardware.
Specification Number Index. Lists the generator set specs and groups.
Group Parts Lists. List the part numbers of parts in the groups.
Kit Sections. List modules and accessories and their parts.
Appendices. Include Abbreviations, Common
Hardware Application Guidelines, General Torque
Specifications, Common Hardware Identification, and
Common Hardware List.
x:in:004:002
Numbering System Significance
This manual uses the following numbering systems:
Specification Number. The product identification number located on the generator set nameplate. Specification numbers break down into groups.
Group Number. A unique number representing a parts group needed to assemble a generator set function. For example, Group 101 is the Air Intake group.
Variation or Module Number. A group might have several variations. Each variation performs the same function with different parts lists. For example, a 50 Hz generator alternator and a 60 Hz generator alternator both perform the same function; however, with different parts. Each difference requires a group variation or module number.
Part Number. The part number identifies an individual assembly, subassembly, component, or accessory kit.
x:in:004:003:a
Illustrations
Illustrations (or exploded-view drawings) best representing the widest range of variations accompany most groups in this manual. Illustrations do not depict all details and may not show all parts. Do not use illustrations for assembly or disassembly.
x:in:004:004:a
How to Find Part Numbers
Use the following steps to locate a service replacement part.
1.Locate the generator set nameplate to identify the generator set spec number.
2.Locate a second generator set nameplate listing accessories to identify installed modules. On some models the accessory nameplate is mounted inside the generator junction box.
3.Turn to the Specification Number Index. The first column lists the generator set spec numbers. The headings identify the groups of parts that make up the generator set.
4.Identify the group most likely to include the service part number.
5.Find the group variation number at the intersection of the spec number row and the group column. Note the variation number.
6.Page forward to locate the group identified in step 4 or find the appropriate page in the Table of Contents.
7.Find the part on the illustration and note the item number of the part or find the part description in the parts list.
8.Select the part number that corresponds to your group variation. The first column lists the illustration item number. Find the variation identified in the Specification Number Index or the module number found on the generator set nameplate in the appropriate column on the right side of the parts list table. Find the quantity used at the intersection of the item number row and the variation column. A blank space at the intersection means the variation/module does not use that part number.
x:in:004:005
Hardware References
Many common hardware items do not appear in parts manuals or will appear as common hardware entries. A common hardware entry lists the size of the hardware. For example, an item that appears as “Hardware, 3/8-16” in the text means that the piece is 3/8-16 size. Obtain common hardware locally or, if contacting the factory, use the Common Hardware List in the appendix to identify the common hardware part number and specifications. See Common Hardware Application Guidelines in the appendix for mating hardware instructions.
Some hardware items require a specific size or some other characteristic. In that case, use the part number listed in the text.
When replacing hardware, do not substitute inferior grade hardware. Replacement hardware grade should be equal to or better than the grade of the manufacturer’s original hardware. Use the Common Hardware List in the appendix to identify the common hardware hardness.
x:in:004:006
TP-6138 5/02 |
1 |
Specification Number Index
Group Title |
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Group No. |
1 |
2 |
3 |
4 |
5 |
6 |
7 |
8 |
9 |
10 |
11 |
12 |
13 |
Spec. No. |
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VARIATION NUMBER |
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3.5EFOZ |
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GM20642-SA1 |
1 |
2 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
4EOZ |
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GM20641-SA1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
Group Title |
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Group No. |
14 |
15 |
16 |
17 |
18 |
19 |
20 |
21 |
22 |
Spec No. |
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VARIATION NUMBER |
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3.5EFOZ |
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GM20642-SA1 |
1 |
1 |
1 |
1 |
2 |
2 |
1 |
1 |
1 |
4EOZ |
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GM20641-SA1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
1 |
2 |
TP-6138 5/02 |
Group 1: Crankcase
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6138_1 |
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Quantity |
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Part |
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Variation No. |
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Item |
Number |
Description |
1 |
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1 |
GM24007 |
Crankcase Assembly |
1 |
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2 |
GM23884 |
Stud, Cylinder Block |
2 |
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3 |
GM23885 |
Stud, Cylinder Block |
2 |
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4 |
GM23886 |
Stud, Crankcase |
4 |
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5 |
GM23870 |
Switch, Oil Pressure |
1 |
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7 |
GM23934 |
Gasket, Crankcase |
1 |
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10 |
GM23955 |
O-ring, 99 x 3 mm |
1 |
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11 |
GM23927 |
Housing, Main Bearing |
1 |
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12 |
GM23965 |
Retainer, Ring |
1 |
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13 |
GM23973 |
Seal, Oil, 60 x 80 x 8 mm |
1 |
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14 |
# |
Nut, Hex Head, M8 |
4 |
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15 |
# |
Washer, Tooth, 18 mm |
4 |
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16 |
GM23925 |
Pump Assembly, Oil |
1 |
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17 |
GM23937 |
Gasket, Oil Pump |
1 |
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18 |
# |
Washer, Split, 6 mm ID |
3 |
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19 |
# |
Screw, Hex Head Cap, M6 x 20 |
1 |
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20 |
# |
Screw, Hex Head Cap, M6 x 30 |
2 |
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# Common hardware; procure locally.
TP-6138 5/02 |
3 |
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Group 2: Crankshaft and Piston
6138_2
4 |
TP-6138 5/02 |
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Group 2: Crankshaft and Piston
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Quantity |
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Part |
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Variation No. |
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Item |
Number |
Description |
1 |
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2 |
1 |
GM24009 |
Crankshaft Assembly |
1 |
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1 |
3 |
GM23954 |
O-ring, 32 x 2 mm |
1 |
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1 |
4 |
GM23893 |
Ring, Angle |
1 |
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1 |
5 |
GM23946 |
Washer, Spring, 52 x 36 x 1.2 mm |
2 |
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2 |
6 |
GM23891 |
Nut, Flywheel |
1 |
|
1 |
7 |
GM23879 |
Gear, Timing Crankshaft |
1 |
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1 |
8 |
GM23942 |
Bushing, Main (Standard) |
1 |
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1 |
8 |
GM23943 |
Bushing, Main (0.25 mm Undersize) |
1 |
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1 |
8 |
GM23944 |
Bushing, Main (0.50 mm Undersize) |
1 |
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1 |
9 |
GM24000 |
Bearing (Standard) |
1 |
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1 |
9 |
GM24001 |
Bearing (0.25 mm Undersize) |
1 |
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1 |
9 |
GM24002 |
Bearing (0.50 mm Undersize) |
1 |
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1 |
10 |
GM23975 |
Key, 6 x 4 x 12 mm |
2 |
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2 |
11 |
GM23945 |
Bearing, Main |
1 |
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1 |
12 |
GM23906 |
Governor Assembly (RPM=3000E) |
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1 |
12 |
GM23907 |
Governor Assembly (RPM=3000) |
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1 |
12 |
GM23908 |
Governor Assembly (RPM=3600E) |
1 |
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13 |
GM23974 |
Pin, 4 x 27.8 mm |
1 |
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1 |
15 |
GM24010 |
Piston Assembly |
1 |
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1 |
16 |
GM24006 |
Set, Piston Ring |
1 |
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1 |
17 |
GM23983 |
Clip, Piston Pin |
2 |
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2 |
18 |
GM23874 |
Pin, Piston |
1 |
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1 |
19 |
GM23926 |
Rod Assembly, Connecting |
1 |
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1 |
20 |
GM23883 |
Bolt, Connecting Rod |
2 |
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2 |
21 |
GM23890 |
Nut, Collar |
2 |
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2 |
22 |
GM23882 |
Bushing, Connecting Rod |
1 |
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1 |
24 |
# |
Plug, 22 mm |
4 |
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4 |
25 |
GM23997 |
Connector, Water Tube |
2 |
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2 |
26 |
GM23953 |
O-ring, 10 x 2.2 mm |
2 |
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2 |
27 |
GM24011 |
Cylinder Assembly |
1 |
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1 |
# Common hardware; procure locally.
TP-6138 5/02 |
5 |
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Group 3: Cylinder Head
6138_3
6 |
TP-6138 5/02 |
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Group 3: Cylinder Head
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Quantity |
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Part |
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Variation No. |
Item |
Number |
Description |
1 |
1 |
GM24012 |
Head Assembly, Cylinder |
1 |
2 |
GM23921 |
Valve, Breather |
1 |
3 |
GM23941 |
Gasket, Cylinder Head |
1 |
4 |
GM23878 |
Valve, Intake |
1 |
5 |
GM23990 |
Washer |
2 |
6 |
GM23876 |
Guide, Valve |
2 |
7 |
GM23964 |
Guide, Oil Seal |
2 |
8 |
GM23947 |
Spring, Valve |
1 |
9 |
GM23895 |
Retainer, Valve Spring |
2 |
10 |
GM24005 |
Valve, Cotter |
2 |
11 |
GM23877 |
Valve, Exhaust |
1 |
12 |
GM23894 |
Ring |
1 |
14 |
GM23911 |
Rotocap, Valve |
1 |
15 |
GM23948 |
Spring, Valve |
1 |
16 |
GM23951 |
Spring, Retainer |
1 |
17 |
GM23967 |
Stud, M5 x 10 |
2 |
18 |
# |
Washer, 5 mm ID |
2 |
19 |
# |
Nut, Hex Head, M5 |
2 |
20 |
GM23872 |
Shaft, Rocker Arm |
1 |
21 |
GM23919 |
Arm Assembly, Rocker |
1 |
22 |
GM23918 |
Arm Assembly, Rocker |
1 |
23 |
GM23889 |
Screw, Adjusting |
2 |
24 |
# |
Nut, Hex Head, M7 |
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25 |
GM23902 |
Injector, Fuel |
1 |
26 |
GM23962 |
Washer |
1 |
27 |
GM23903 |
Nozzle, Fuel Injector |
1 |
28 |
GM23904 |
Seat, Spring |
1 |
29 |
GM23905 |
Spring, Nozzle |
1 |
30 |
GM23991 |
Flange, Injector |
1 |
31 |
GM23972 |
Stud, M6 x 50 |
1 |
32 |
GM23971 |
Stud, M6 x 45 |
1 |
33 |
# |
Washer, Split, 6 mm ID |
2 |
34 |
# |
Nut, Hex Head, M6 |
2 |
35 |
GM23987 |
Tube, Push Rod |
1 |
36 |
GM23956 |
O-ring, 24 x 3.5 mm |
1 |
37 |
# |
Plug, 22 mm |
2 |
38 |
# |
Plug, 18 mm |
1 |
39 |
GM23932 |
Gasket, Rocker Cover |
1 |
40 |
GM23920 |
Cover, Rocker |
1 |
41 |
# |
Washer, 5 mm ID |
2 |
42 |
GM23989 |
Bracket, Lifting |
1 |
44 |
GM23890 |
Nut, Collar |
6 |
45 |
# |
Plug, 18 mm |
1 |
47 |
GM23914 |
Switch, Temperature Alarm |
1 |
48 |
GM23981 |
Washer, Copper, 14 mm ID |
1 |
49 |
# |
Screw, Hex Head Cap, M8 x 20 |
2 |
50 |
# |
Washer, Split, 8 mm ID |
2 |
52 |
GM23931 |
Gasket |
2 |
53 |
GM23912 |
Thermostat |
1 |
54 |
GM24140 |
Cover, Thermostat |
1 |
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# Common hardware; procure locally.
TP-6138 5/02 |
7 |
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Group 4: Gear Timing and Cover
6138_4
8 |
TP-6138 5/02 |
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Group 4: Gear Timing and Cover
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Quantity |
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Part |
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Variation No. |
Item |
Number |
Description |
1 |
1 |
GM23923 |
Cover, Timing Gear |
1 |
3 |
GM23933 |
Gasket, Cover |
1 |
4 |
GM23976 |
Pin, 10 x 16 mm |
2 |
8 |
# |
Washer, Split, 5 mm ID |
1 |
9 |
GM23887 |
Screw, Hex Head |
1 |
10 |
GM23958 |
Gasket |
1 |
11 |
GM24003 |
Cap, Oil Filler |
1 |
12 |
GM23929 |
Dipstick |
1 |
13 |
GM23968 |
Stud, M8 x 20 |
2 |
14 |
GM24013 |
Screen Assembly, Oil Filter |
1 |
17 |
GM23938 |
Gasket, Oil Filter |
1 |
18 |
GM23977 |
Washer, Copper, 6 mm ID |
2 |
19 |
# |
Screw, Hex Head, M6 x 20 |
2 |
20 |
# |
Screw, Hex Head Cap, M8 x 70 |
2 |
21 |
GM24004 |
Handle |
1 |
24 |
GM24008 |
Primer Assembly |
1 |
25 |
# |
Screw, Hex Head Cap, M8 x 80 |
3 |
26 |
GM23993 |
Shim, Adjusting, 0.2 mm |
1 |
26 |
GM23994 |
Shim, Adjusting, 0.5 mm |
1 |
26 |
GM23995 |
Shim, Adjusting, 0.4 mm |
1 |
26 |
GM23996 |
Shim, Adjusting, 1.0 mm |
1 |
27 |
GM23939 |
Gasket |
1 |
28 |
GM23901 |
Roller, Tappet |
1 |
29 |
GM23896 |
Pump, Fuel Injection |
1 |
30 |
# |
Washer, Split, 8 mm ID |
1 |
31 |
# |
Nut, Hex Head, M8 |
2 |
32 |
GM23897 |
Washer |
1 |
33 |
GM23900 |
Valve |
1 |
34 |
GM23898 |
Spring, Valve |
1 |
35 |
GM23899 |
Plunger, Fuel |
1 |
36 |
GM23875 |
Push Rod |
2 |
37 |
GM23957 |
O-ring, 32 x 3 mm |
1 |
38 |
# |
Screw, Hex Head Cap, M5 x 30 |
2 |
39 |
GM23922 |
Release, Compression |
1 |
40 |
GM23936 |
Gasket, Plate, 0.3 mm |
1 |
40 |
GM23940 |
Gasket, Plate, 0.4 mm |
1 |
42 |
GM23966 |
Bearing, Grooved Ball |
1 |
43 |
GM23960 |
O-ring, 32.7 x 1.3 mm |
1 |
44 |
GM23873 |
Bolt |
1 |
45 |
GM23924 |
Camshaft |
1 |
46 |
GM23880 |
Gear |
1 |
47 |
GM23975 |
Key, 6 x 4 x 12 mm |
1 |
53 |
GM23917 |
Cover |
1 |
55 |
GM23961 |
O-ring, 57 x 2.5 mm |
1 |
56 |
# |
Washer, Split, 6 mm ID |
2 |
57 |
# |
Screw, Hex Head, M6 x 16 |
2 |
58 |
GM23930 |
Gasket, Plate |
1 |
59 |
GM23985 |
Cover |
1 |
60 |
GM23979 |
Washer, Copper, 5 mm ID |
2 |
61 |
# |
Screw, Hex Head, M5 x 16 |
2 |
62 |
GM24511 |
Ring, snap |
1 |
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# Common hardware; procure locally.
TP-6138 5/02 |
9 |
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Group 5: Speed Control Shaft
6138_5
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Quantity |
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Part |
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Variation No. |
Item |
Number |
Description |
1 |
1 |
GM23949 |
Spring, Torsion Return |
1 |
2 |
GM23916 |
Arm, Governor |
1 |
3 |
GM23888 |
Screw, Adjustment |
1 |
4 |
GM23992 |
Tab, Locking |
1 |
5 |
# |
Nut, Hex Head, M6 |
1 |
6 |
GM23952 |
Retainer |
1 |
7 |
GM23871 |
Shaft, Speed Control |
1 |
8 |
GM23953 |
O-ring, 10 x 2.2 mm |
1 |
9 |
GM23950 |
Spring, Torsion Return |
1 |
10 |
GM23986 |
Plate, Control |
1 |
11 |
GM23984 |
Lever |
1 |
12 |
# |
Washer, Tooth, 8 mm |
1 |
13 |
# |
Nut, Hex Head, M8 |
1 |
14 |
GM23913 |
Bolt |
1 |
|
|
|
|
# Common hardware; procure locally.
10 |
TP-6138 5/02 |
|
Group 6: Fuel Lines
|
|
|
|
6138_6 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Quantity |
|
|
|
Part |
|
Variation No. |
|
|
Item |
Number |
Description |
1 |
|
|
1 |
GM23999 |
Line, Return Fuel |
1 |
|
|
2 |
GM23982 |
Bolt, Banjo Union |
2 |
|
|
3 |
GM23959 |
Washer, Copper, 8 mm ID |
1 |
|
|
4 |
GM23978 |
Washer, Copper, 8 mm ID |
3 |
|
5 |
GM23892 |
Connector |
1 |
|
|
6 |
GM23980 |
Washer, Copper, 12 mm ID |
4 |
|
|
|
7 |
GM23988 |
Clamp, Fuel Line |
1 |
|
|
8 |
GM23998 |
Pipe, Fuel Injector |
1 |
|
|
9 |
GM24072 |
Solenoid, Shutoff |
1 |
|
|
10 |
GM24099 |
Bolt, Banjo Union |
1 |
|
11 |
# |
Eye, Fuel Supply Line |
1 |
|
|
|
|
|
|
|
|
# Common hardware; procure locally.
TP-6138 5/02 |
11 |
|
Group 7: Flywheel
6138_7
|
|
|
Quantity |
|
Part |
|
Variation No. |
Item |
Number |
Description |
1 |
1 |
GM23928 |
Flywheel |
1 |
2 |
GM23881 |
Gear |
1 |
|
|
|
|
# Common hardware; procure locally.
12 |
TP-6138 5/02 |
|