Kohler 3.5EFOZ, 4EOZ User Manual

5 (1)

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

Kohler 3.5EFOZ, 4EOZ User Manual

Specification Number Index

Group Title

 

 

 

 

 

 

 

 

 

 

 

 

 

Group No.

1

2

3

4

5

6

7

8

9

10

11

12

13

Spec. No.

 

 

 

 

 

VARIATION NUMBER

 

 

 

 

 

3.5EFOZ

 

 

 

 

 

 

 

 

 

 

 

 

 

GM20642-SA1

1

2

1

1

1

1

1

1

1

1

1

1

1

4EOZ

 

 

 

 

 

 

 

 

 

 

 

 

 

GM20641-SA1

1

1

1

1

1

1

1

1

1

1

1

1

1

Group Title

 

 

 

 

 

 

 

 

 

Group No.

14

15

16

17

18

19

20

21

22

Spec No.

 

 

 

 

 

VARIATION NUMBER

 

3.5EFOZ

 

 

 

 

 

 

 

 

 

GM20642-SA1

1

1

1

1

2

2

1

1

1

4EOZ

 

 

 

 

 

 

 

 

 

GM20641-SA1

1

1

1

1

1

1

1

1

1

2

TP-6138 5/02

Group 1: Crankcase

 

 

 

 

6138_1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Quantity

 

 

 

Part

 

Variation No.

 

 

Item

Number

Description

1

 

 

1

GM24007

Crankcase Assembly

1

 

 

2

GM23884

Stud, Cylinder Block

2

 

 

3

GM23885

Stud, Cylinder Block

2

 

 

4

GM23886

Stud, Crankcase

4

 

5

GM23870

Switch, Oil Pressure

1

 

7

GM23934

Gasket, Crankcase

1

 

 

10

GM23955

O-ring, 99 x 3 mm

1

 

 

11

GM23927

Housing, Main Bearing

1

 

 

12

GM23965

Retainer, Ring

1

 

 

13

GM23973

Seal, Oil, 60 x 80 x 8 mm

1

 

14

#

Nut, Hex Head, M8

4

 

15

#

Washer, Tooth, 18 mm

4

 

 

16

GM23925

Pump Assembly, Oil

1

 

 

17

GM23937

Gasket, Oil Pump

1

 

 

18

#

Washer, Split, 6 mm ID

3

 

 

19

#

Screw, Hex Head Cap, M6 x 20

1

 

20

#

Screw, Hex Head Cap, M6 x 30

2

 

# Common hardware; procure locally.

TP-6138 5/02

3

 

Group 2: Crankshaft and Piston

6138_2

4

TP-6138 5/02

 

Group 2: Crankshaft and Piston

 

 

 

 

Quantity

 

Part

 

 

Variation No.

Item

Number

Description

1

 

2

1

GM24009

Crankshaft Assembly

1

 

1

3

GM23954

O-ring, 32 x 2 mm

1

 

1

4

GM23893

Ring, Angle

1

 

1

5

GM23946

Washer, Spring, 52 x 36 x 1.2 mm

2

 

2

6

GM23891

Nut, Flywheel

1

 

1

7

GM23879

Gear, Timing Crankshaft

1

 

1

8

GM23942

Bushing, Main (Standard)

1

 

1

8

GM23943

Bushing, Main (0.25 mm Undersize)

1

 

1

8

GM23944

Bushing, Main (0.50 mm Undersize)

1

 

1

9

GM24000

Bearing (Standard)

1

 

1

9

GM24001

Bearing (0.25 mm Undersize)

1

 

1

9

GM24002

Bearing (0.50 mm Undersize)

1

 

1

10

GM23975

Key, 6 x 4 x 12 mm

2

 

2

11

GM23945

Bearing, Main

1

 

1

12

GM23906

Governor Assembly (RPM=3000E)

 

 

1

12

GM23907

Governor Assembly (RPM=3000)

 

 

1

12

GM23908

Governor Assembly (RPM=3600E)

1

 

 

13

GM23974

Pin, 4 x 27.8 mm

1

 

1

15

GM24010

Piston Assembly

1

 

1

16

GM24006

Set, Piston Ring

1

 

1

17

GM23983

Clip, Piston Pin

2

 

2

18

GM23874

Pin, Piston

1

 

1

19

GM23926

Rod Assembly, Connecting

1

 

1

20

GM23883

Bolt, Connecting Rod

2

 

2

21

GM23890

Nut, Collar

2

 

2

22

GM23882

Bushing, Connecting Rod

1

 

1

24

#

Plug, 22 mm

4

 

4

25

GM23997

Connector, Water Tube

2

 

2

26

GM23953

O-ring, 10 x 2.2 mm

2

 

2

27

GM24011

Cylinder Assembly

1

 

1

# Common hardware; procure locally.

TP-6138 5/02

5

 

Group 3: Cylinder Head

6138_3

6

TP-6138 5/02

 

Group 3: Cylinder Head

 

 

 

Quantity

 

Part

 

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

 

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

 

 

 

 

# Common hardware; procure locally.

TP-6138 5/02

7

 

Group 4: Gear Timing and Cover

6138_4

8

TP-6138 5/02

 

Group 4: Gear Timing and Cover

 

 

 

Quantity

 

Part

 

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

 

 

 

 

# Common hardware; procure locally.

TP-6138 5/02

9

 

Group 5: Speed Control Shaft

6138_5

 

 

 

Quantity

 

Part

 

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

 

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