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Kohler 4EOZ manual

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Table of contents for the manual

  • Page 1

    Marine Generator Sets TP-6138 5/02 Service Parts Models: 3.5EFOZ/4EOZ[...]

  • Page 2

    T able o f Contents Int r oduct ion 1 ................................................................. Numbering S ys t em S ignif icanc e 1 ............................................... Illus t rat ions 1 .................................................................. How to F ind P art Numbers 1 .............................................[...]

  • Page 3

    1 TP-6138 5/02 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[...]

  • Page 4

    2 TP- 6138 5/02 Speci fi catio n Numb er Ind ex Gro u p No. 1 2 3 4 5 6 7 8 9 10 1 1 12 13 Sp ec. No . V ARI A T I O N NUMBE R Group T itle 3.5E F O Z GM20642- SA 1 1211 1 11111111 4EO Z GM20641- SA 1 1111 1 11111111 G r o u p N o . 1 41 5 1 6 1 7 1 81 92 0 2 12 2 Spec No. V ARI A T I O N NUMBE R Group T itle 3.5E F O Z GM20642- SA 1 1111 2 2111 4E[...]

  • Page 5

    TP- 6138 5/02 3 Gr ou p 1: Cr ankcase 6138_1 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24007 Cran kcase Asse m bl y 1 2 GM23884 Stud, C y linder Bloc k 2 3 GM23885 Stud, C y linder Bloc k 2 4 GM23886 Stud, Cr ank c as e 4 5 GM23870 Switch, Oil Pressure 1 7 GM23934 Ga sket , Cra n kcase 1 10 GM23955 O-r ing, 99 x 3 mm 1 [...]

  • Page 6

    TP- 6138 5/02 4 Gr ou p 2: Cr ankshaf t and Pi ston 6138_2[...]

  • Page 7

    TP- 6138 5/02 5 Gr ou p 2: Cran kshaf t and Pi ston Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 2 1 GM24009 Crank s haf t As s embly 1 1 3 GM23954 O- ring, 32 x 2 mm 1 1 4 GM23893 Ring, Angle 1 1 5 GM23946 W as her , S pring, 52 x 36 x 1. 2 mm 2 2 6 GM23891 Nut, Fly w heel 1 1 7 GM23879 Gear , Timing Cr ank s haft 1 1 8 GM239[...]

  • Page 8

    TP- 6138 5/02 6 Group 3: Cylinde r Hea d 6138_3[...]

  • Page 9

    TP- 6138 5/02 7 Group 3: Cylinde r Hea d Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24012 Head As s embly, Cy linder 1 2 GM23921 V alve, B reat her 1 3 GM23941 Gas k et , Cy linder H ead 1 4 GM23878 V alve, Intake 1 5 GM23990 Washer 2 6 GM23876 Guide, Valve 2 7 GM23964 Guide, O il S eal 2 8 GM23947 S pring, Valve 1 9 GM2[...]

  • Page 10

    TP- 6138 5/02 8 Gr ou p 4: Gear T iming an d Co ver 6138_4[...]

  • Page 11

    TP- 6138 5/02 9 Gr ou p 4: Gear T iming an d Co ver Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM23923 Cov er , Timing G ear 1 3 GM23933 Gasket , Co ve r 1 4 GM23976 Pin, 10 x 16 mm 2 8# Washer, Split, 5 mm ID 1 9 GM23887 Screw , Hex Head 1 10 GM23958 Ga sket 1 11 GM24003 C ap, O il F iller 1 12 GM23929 Dip stick 1 13 GM23[...]

  • Page 12

    TP- 6138 5/02 10 Group 5: Spee d Control Shaft 6138_5 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM23949 Spring, T ors ion R etur n 1 2 GM23916 Arm, G ov er nor 1 3 GM23888 Sc rew , Adjustme nt 1 4 GM23992 T ab, Loc k ing 1 5# Nut, H ex H ead, M6 1 6 GM23952 Retainer 1 7 GM23871 Shaft , S peed Cont rol 1 8 GM23953 O- ring,[...]

  • Page 13

    TP- 6138 5/02 11 Group 6: Fuel Line s 6138_6 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM23999 Line, Ret urn F uel 1 2 GM23982 B olt, B anjo Union 2 3 GM23959 Washer , Copper, 8 mm ID 1 4 GM23978 W as her , Copper, 8 mm ID 3 5 GM23892 Connec tor 1 6 GM23980 W as her , Copper, 12 mm ID 4 7 GM23988 Clamp, F uel Line 1 8 GM2[...]

  • Page 14

    TP- 6138 5/02 12 Gr ou p 7: Flyw heel 6138_7 Qu a n tity Part Var i a t i o n N o . It em Number Descr i pti on 1 1 GM23928 F ly wheel 1 2 GM23881 G ear 1 # Common har dwar e; pr oc ure loc ally.[...]

  • Page 15

    TP- 6138 5/02 13 Group 8: Starte r Motor 6138_8 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM23910 Star ter A s s embly, 12 V olt 1 2 # Sc rew, Hex Head Cap, M8 x 20 4 3 GM24083 Plate, C onnec ting 1 4 GM24109 Spac er 3 5# Washer, T ooth, 8 mm ID 4 6 GM24097 Housing, F ly wheel 1 7 GM23909 Bushing 1 8 GM23969 Stud, M10 x 2[...]

  • Page 16

    TP- 6138 5/02 14 Group 9: Exha ust Sy ste m 6138_9 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24074 Tube, Mixing 1 2 # Washer, Plain, 8 mm ID 2 3 # Washer, Split, 8 mm ID 2 4# Sc rew, Hex H ead Cap, M8 x 55 2 5 GM24021 Clamp, Hos e 8 6 GM24120 Hose 1 7 GM24103 N ipple 1 8 GM24512 Hose 1 9 GM24119 Adapter, Rubber Tube 1 1[...]

  • Page 17

    TP- 6138 5/02 15 Group 10: Oil Cooler a nd Lines 6138_10 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24114 Element, O il C ooler 1 2 GM24112 Elbow 2 3 # Washer, T ooth, 6 mm ID 6 4# Sc rew, Hex H ead Cap, M6 x 30 6 5 GM24021 Clamp, Hos e 8 6 GM24121 Hose 1 7 GM24104 Tube 1 8 GM24122 Hose 1 9 GM24118 Ho se 1 10 GM24116 Hos[...]

  • Page 18

    TP- 6138 5/02 16 Gr ou p 1 1: Seawat er Pu mp 6138_1 1 Qu a n tity Part Var i a t i o n N o . It em Number Descri pti on 1 1 GM24052 Pump As s embly, Seaw ater 1 2 GM24106 Shaft , Seaw ater P ump 1 3 GM24032 S eal 1 4 GM24053 Housing, S eawat er Pump 1 5# Sc rew, Hex H ead Cap, M5 x 40 3 6 GM24031 O-ring 1 7 GM20852 I mpeller 1 8 GM24054 Cov er , S[...]

  • Page 19

    TP- 6138 5/02 17 Group 12: Oil Draining Line s 6138_12 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24143 Bus hing, Reduc er 1 2 GM23980 Washer , Copper, 12 mm ID 2 3 GM24142 Ey e, Banjo Union 1 4 GM24141 Bolt, Banjo U nion 1 5 GM24020 Clamp, Hos e 2 6 GM24117 Hos e, O il D raining 1 7 G M 2 4 111 A dapter, Rubber Hos e 1 [...]

  • Page 20

    TP- 6138 5/02 18 Group 13: Fue l Filter a nd Pump 6138_13 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24125 Hos e, Fuel 1 2 GM24020 Clamp, Hos e 8 3 GM20850 F ilter, Fuel 1 4 GM24126 Hose, F uel Supply 2 5 GM24055 Pump, Fuel 1 6# Washer, Plain, 6 mm ID 2 7 # Washer, Split, 6 mm ID 2 8 # Sc rew, Hex Head, M6 x 16 2 9 GM241[...]

  • Page 21

    TP- 6138 5/02 19 Gr ou p 14: Air I nt ake Filt er 6138_14 Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24073 Sc reen, A ir Int ak e 1 2 # Washer, Plain , 8 mm ID 2 3 # W a s h e r ,S p l i t,8m m I D 2 4# Sc rew, Hex Head, M8 x 25 2 5 GM20848 Sc reen 1 6# Washer, Plain, 5 mm ID 2 7 # Washer, Split, 5 mm ID 2 8 # Sc rew, He[...]

  • Page 22

    TP- 6138 5/02 20 Gr ou p 15: Gasket S et 6138_15[...]

  • Page 23

    TP- 6138 5/02 21 Gr ou p 15: Gasket S et Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24014 Set, Ga sket 1 2 GM23934 Gas k et , Cr ank c as e 1 3 GM23955 O- ring, 99 x 3 mm 1 4 GM23937 Ga sket , Oil Pu m p 1 5 GM23954 O-r ing, 32 x 2 mm 1 6 GM23953 O-r ing, 10 x 2.2 mm 3 7 GM23941 Gas k et , Cy linder H ead 1 8 GM23962 Was[...]

  • Page 24

    TP- 6138 5/02 22 Group 16: Ba se and Mounting 6138_16[...]

  • Page 25

    TP- 6138 5/02 23 Gr ou p 16: Base and M ou nti ng Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 1 GM24080 Tr a y 1 2 GM24044 Vibromount 4 3 # Washer, Plain 6 4# Washer, Split, 8 mm ID 11 5# Nut, Hex Hea d , M 8 8 6# Sc rew, Hex Head, M10 x 70 4 7 GM24047 Ring, Rubber 2 8 GM24078 Brac k et , E ngine Right 1 9 GM24110 Spacer 2 10[...]

  • Page 26

    TP- 6138 5/02 24 Group 17: Sound Shie ld 6138_17[...]

  • Page 27

    TP- 6138 5/02 25 Group 17: Sound Shie ld Part Qua n tity P a r t Va r i a t i o n N o . Item Number Descri pt ion 1 1 GM24159 Junc t ion, Cor ner 4 2 GM24145 Mounting, Upper R ear 1 3 GM24148 Mounting, Upper F ront 1 4 GM24146 Mounting, Upper Left , Right 2 5 GM24147 Mounting, V ertic al 4 6 GM24019 Clip 10 7 # Sc rew, Self-T hreading 8 8 GM24095 H[...]

  • Page 28

    TP- 6138 5/02 26 Group 18: Gene rator a nd Mounting 6138_18[...]

  • Page 29

    TP- 6138 5/02 27 Group 18: Gene rator a nd Mounting Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 2 1 GM24070 Alter nator, Engine Char ging 1 1 2 GM24085 Brac k et , Lift ing 1 1 3 GM24100 Hub, Engine- St ator C onnec tion 1 1 4# Washer, Special Notc h, 8 mm ID 4 4 5# Sc rew, Hex Head, M8 x 35 4 4 6 GM24101 Stud 1 1 7 GM24065 V[...]

  • Page 30

    TP- 6138 5/02 28 Group 19: Controlle r and Mounting 6138_19[...]

  • Page 31

    TP- 6138 5/02 29 Group 19: Controlle r and Mounting Qu a n tity Part Var i a t i o n N o . It em Number Descri ption 1 2 1 GM24098 Box, Controll er 1 1 2 GM24015 B reak er, Circ uit , 15 A mp 2 Pole 1 2 GM24016 B reak er, Circ uit , 16 A mp 2 Pole 1 3 GM24093 Plate, Cir c uit Br eak er 1 1 4# Sc rew, Round Phillips Head, M3 x 6 4 4 5# Sc rew, Round[...]

  • Page 32

    TP- 6138 5/02 30 Gr ou p 20: Con tr ol Pan el 6138_20 Qu a n tity Part Var i a t i o n N o . Item P a r t Number Descr i pti on 1 1 GM24161 Panel, Cont rol 1 2 # Sc rew, Flat Phillips H ead, M3 x 12 4 3 GM24069 C onnec tor 1 4 GM24156 Connect or t o Remot e St a rt/Stop Switch Harn ess 1 5 GM24152 Connect or t o Remot e Cont rol P anel Har nes s 1 [...]

  • Page 33

    TP- 6138 5/02 31 Group 21: Siphon Bre ak and Lines 6138_21 Qu a n tity Part Var i a t i o n N o . Item Number Descri pt ion 1 1 P A-229928 Kit, S iphon Br eak 1 2 GM24021 Clamp, Hos e 4 3 GM24105 Connec tion, H os e 2 4 GM24023 Hose 2 5 GM24035 Gr ommet 2[...]

  • Page 34

    TP- 6138 5/02 32 Group 22: Lite rature Qu a n tity Part Var i a t i o n N o . Item Number Descri pt ion 1 1 TP- 5620 Safet y P rec aut ions , Marine 1 2 TP- 6069 I/M 3. 5-150E O Z/ EF O Z, Mar ine 1 3 TP- 6134 O/M 3.5EFOZ/4EOZ, Marin e 1 4 TP- 6137 S/M 4EOZ/3.5EFOZ, Mari ne 1 5 TP-6138 P/ C 4E O Z/ 3.5E FO Z F ary mann 18W 1 6 TP-6143 O /M F ary ma[...]

  • Page 35

    TP-6138 5/02 Appendix A-1 Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere ABDC after bottom dead center AC alternating current A/D analog to digital ADC analog to digital converter adj. adjust, adjustment ADV advertising dimensional drawing AHWT anticipatory high water temperatur[...]

  • Page 36

    TP-6138 5/02 A-2 Appendix k kilo (1000) K kelvin kA kiloampere KB kilobyte (2 10 bytes) kg kilogram kg/cm 2 kilograms per square centimeter kgm kilogram-meter kg/m 3 kilograms per cubic meter kHz kilohertz kJ kilojoule km kilometer kOhm, k W kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kV A kilovolt ampere kV AR kilovolt ampere react[...]

  • Page 37

    TP-6138 5/02 Appendix A-3 Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length : When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one threa[...]

  • Page 38

    TP-6138 5/02 A-4 Appendix Appendix C General T orque Specifications Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/ - - 10%. American Standard [...]

  • Page 39

    TP-6138 5/02 Appendix A-5 Appendix D Common Hardware Identification Screw/Bolts/Studs Head Styles Hex Head or Machine Head Hex Head or Machine Head with Washer Flat Head (FHM) Round Head (RHM) Pan Head Hex Socket Head Cap or Allen t Head Cap Hex Socket Head or Allen t Head Shoulder Bolt Sheet Metal Screw Stud Drive Styles Hex Hex and Slotted Philli[...]

  • Page 40

    TP-6138 5/02 A-6 Appendix Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Hex Head Bolts (Grade 5) X-465-17 1/4-20 x .38 X-465-6 1/4-20 x .50 X-465-2 1/4-20 x .62 X-465-16 1/4-20 x .75 X-465-18 1/4-20 x .88 X-465-7 1/4-20 x 1.00 X-465-8 1/4-2[...]

  • Page 41

    TP-6138 5/02 Appendix A-7 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Hex Head Bolts (partial thread) M931-05055-60 M5-0.80 x 55 M931-06040-60 M6-1.00 x 40 M931-06055-60 M6-1.00 x 55 M931-06060-60 M6-1.00 x 60 M931-06070-60 M6-1.00 x 70 M931-06070-SS M6-1.00 x 70 M931-06075-60 M6-1.00 x 75 M931-06090-60 M6-1.00 x [...]

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    E 2002 by Kohler Co. All rights reserved. TP-6138 5/02 KOHLER CO. Kohler , Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65)264-6422, Fax (65)264-6455[...]