Kohler 4EOZ User Manual

Marine Generator SetsTP-6138 5/02Service PartsModels:3.5EFOZ/4EOZ

TP-6138 5/028Group 4: Gear Timing and Cover6138_4

TP-6138 5/029Group 4: Gear Timing and CoverQuantityPart Variation No.Item Number Description 11 GM23923 Cover, Timing Gear 13 GM23933 Gasket, Cover 14

TP-6138 5/0210Group 5: Speed Control Shaft6138_5QuantityPart Variation No.Item Number Description 11 GM23949 Spring, Torsion Return 12 GM23916 Arm, Go

TP-6138 5/0211Group 6: Fuel Lines6138_6QuantityPart Variation No.Item Number Description 11 GM23999 Line, Return Fuel 12 GM23982 Bolt, Banjo Union 23

TP-6138 5/0212Group 7: Flywheel6138_7QuantityPart Variation No.Item Number Description 11 GM23928 Flywheel 12 GM23881 Gear 1# Common hardware; procure

TP-6138 5/0213Group 8: S tarter Motor6138_8QuantityPart Variation No.Item Number Description 11 GM23910 Starter Assembly, 12 Volt 12 # Screw, Hex Head

TP-6138 5/0214Group 9: Exhaust System6138_9QuantityPart Variation No.Item Number Description 11 GM24074 T ube, Mixing 12 # W asher, Plain, 8 mm ID 23

TP-6138 5/0215Group 10: Oil Cooler and Lines6138_10QuantityPart Variation No.Item Number Description 11 GM24114 Element, Oil Cooler 12 GM24112 Elbow 2

TP-6138 5/0216Group 11: Seawater Pump6138_11QuantityPart Variation No.Item Number Description 11 GM24052 Pump Assembly, Seawater 12 GM24106 Shaft, Sea

TP-6138 5/0217Group 12: Oil Draining Lines6138_12QuantityPart Variation No.Item Number Description 11 GM24143 Bushing, Reducer 12 GM23980 W asher , Co

Table of ContentsIntroduction 1...Numbering System Significance 1...

TP-6138 5/0218Group 13: Fuel Filter and Pump6138_13QuantityPart Variation No.Item Number Description 11 GM24125 Hose, Fuel 12 GM24020 Clamp, Hose 83 G

TP-6138 5/0219Group 14: Air Intake Filter6138_14QuantityPart Variation No.Item Number Description 11 GM24073 Screen, Air Intake 12 # W asher, Plain ,

TP-6138 5/0220Group 15: Gasket Set6138_15

TP-6138 5/0221Group 15: Gasket SetQuantityPart Variation No.Item Number Description 11 GM24014 Set, Gasket 12 GM23934 Gasket, Crankcase 13 GM23955 O-r

TP-6138 5/0222Group 16: Base and Mounting6138_1624

TP-6138 5/0223Group 16: Base and MountingQuantityPart Variation No.Item Number Description 11 GM24080 Tray 12 GM24044 V ibromount 43 # W asher, Plain

TP-6138 5/0224Group 17: Sound Shield6138_17

TP-6138 5/0225Group 17: Sound ShieldPart QuantityPartVariation No.ItemNumberDescription 11 GM24159 Junction, Corner 42 GM24145 Mounting, Upper Rear 13

TP-6138 5/0226Group 18: Gene rator and Mounting6138_18

TP-6138 5/0227Group 18: Gene rator and MountingQuantityPart Variation No.Item Number Description 1 21 GM24070 Alternator, Engine Charging 1 12 GM24085

1TP-6138 5/02IntroductionThis manual lists service replacement parts for 4 kWgenerator sets.At the time of print this manual applied to the generators

TP-6138 5/0228Group 19: Controller and Mounting6138_19

TP-6138 5/0229Group 19: Controller and MountingQuantityPart Variation No.Item Number Description 1 21 GM24098 Box, Controller 1 12 GM24015 Breaker, Ci

TP-6138 5/0230Group 20: Control Panel6138_20QuantityPartVariation No.ItemPartNumberDescription 11 GM24161 Panel, Control 12 # Screw, Flat Phillips Hea

TP-6138 5/0231Group 21: Siphon Break and Lines6138_21QuantityPart Variation No.Item Number Description 11 PA-229928 Kit, Siphon Break 12 GM24021 Clamp

TP-6138 5/0232Group 22: Lite ratureQuantityPart Variation No.Item Number Description 11 TP-5620 Safety Precautions, Marine 12 TP-6069 I/M 3.5-150EOZ/E

TP-6138 5/02 Appendix A-1Appendix A AbbreviationsThe following list contains abbreviations that may appear in this publication.A, amp ampereABDC after

TP-6138 5/02A-2 Appendixk kilo (1000)K kelvinkA kiloampereKB kilobyte (210bytes)kg kilogramkg/cm2kilograms per squarecentimeterkgm kilogram-meterkg/m3

TP-6138 5/02 Appendix A-3Appendix B Common Hardware Application GuidelinesUse the information below and on the following pages toidentify proper faste

TP-6138 5/02A-4 AppendixAppendix C General Torque SpecificationsUse the following torque specifications when serviceliterature instructions give no sp

TP-6138 5/02 Appendix A-5Appendix D Common Hardware IdentificationScrew/Bolts/StudsHead StylesHex Head or Machine HeadHex Head or Machine Headwith Was

2TP-6138 5/02Specification Number IndexGroup No. 1 2 3 4 5 6 7 8 9 10 11 12 13Spec. No.VARIATION NUMBERGroup Title3.5EFOZGM20642-SA1 1 2 1 1 1 1 1 1 1

TP-6138 5/02A-6 AppendixAppendix E Common Hardware ListThe Common Hardware List lists part numbers and dimensions for common hardware items.American S

TP-6138 5/02 Appendix A-7MetricHex head bolts are hardness grade 8.8 unless noted.Part No. DimensionsHex Head Bolts (partial thread)M931-05055-60 M5-0

E 2002 by Kohler Co. All rights reserved.TP-6138 5/02KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Fax 920-459-1646For the nearest sales/servi

TP-6138 5/023Group 1: Crankcase6138_1QuantityPart Variation No.Item Number Description 11 GM24007 Crankcase Assembly 12 GM23884 Stud, Cylinder Block 2

TP-6138 5/024Group 2: Crankshaft and Piston6138_2

TP-6138 5/025Group 2: Crankshaft and PistonQuantityPart Variation No.Item Number Description 1 21 GM24009 Crankshaft Assembly 1 13 GM23954 O-ring, 32

TP-6138 5/026Group 3: Cylinder Head6138_3

TP-6138 5/027Group 3: Cylinder HeadQuantityPart Variation No.Item Number Description 11 GM24012 Head Assembly, Cylinder 12 GM23921 Valve, Breather 13