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Kohler 4EOZ Service

Kohler 4EOZ Service

Marine generator sets
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See also: Instruction and Installation Manual
Service
Marine Generator Sets
(Includes Engine Maintenance)
Models:
4EOZ
3.5EFOZ
TP-6137 5/03

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Summary of Contents for Kohler 4EOZ

  • Page 1 Service Marine Generator Sets (Includes Engine Maintenance) Models: 4EOZ 3.5EFOZ TP-6137 5/03...

  • Page 2: Product Identification Information

    Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits.

  • Page 3: Table Of Contents

    ............. . Service Schedule—3.5EFOZ and 4EOZ Models .
  • Page 4 Fuel Pump and Gear Cover Installation ........Bleeding the Fuel System .

  • Page 5: Safety Precautions And Instructions

    Safety Precautions and Instructions IMPORTANT SAFETY Accidental Starting Battery electrolyte is a diluted INSTRUCTIONS. Electromechanical sulfuric acid. Battery acid can cause equipment, including generator sets, severe injury or death. Battery acid WARNING transfer switches, switchgear, and can cause blindness and burn skin. accessories, can cause bodily harm Always wear...
  • Page 6 Battery short circuits. Explosion Combustible materials. A fire can Copper tubing exhaust systems. cause severe injury or death. Carbon monoxide can cause severe can cause severe injury or death. Generator set engine fuels and fuel nausea, fainting, or death. Do not Short circuits can cause bodily injury vapors are flammable and explosive.
  • Page 7 Fuel System Pipe sealant. Explosive fuel vapors Hazardous Voltage/ can cause severe injury or death. Electrical Shock Fuel leakage can cause an explosion. Use pipe sealant on all threaded fittings WARNING to prevent fuel leakage. Use pipe WARNING sealant that resists gasoline, grease, lubrication oil, common bilge solvents, salt deposits, and water.

  • Page 8: Hot Parts

    Short circuits. Hazardous Hot Parts WARNING voltage/current can cause severe injury or death. Short circuits can WARNING cause bodily injury and/or equipment damage. Do not contact electrical connections with tools or jewelry while making adjustments repairs. Remove all jewelry before servicing the Airborne particles.
  • Page 9 Notice NOTICE NOTICE Hardware damage. The engine and Fuse replacement. Replace fuses generator set may use both American with fuses of the same ampere rating NOTICE Standard and metric hardware. Use and type (for example: 3AB or 314, the correct size tools to prevent ceramic).
  • Page 10 Notes Safety Precautions and Instructions TP-6137 5/03...

  • Page 11: Introduction

    Information in this publication represents data available Maintenance work must be performed by appropriately at the time of print. Kohler Co. reserves the right to skilled and suitably-trained maintenance personnel change this publication and the products represented familiar with generator set operation and service.
  • Page 12 Notes Service Assistance TP-6137 5/03...

  • Page 13: Section 1 Specifications

    Section 1 Specifications 1.1 General The 4EOZ/3.5EFOZ models are powered by a Farymann one-cylinder, direct water-cooled, four-cycle diesel engine. This manual covers the operation, maintenance, troubleshooting, and repair of the alternating current Kohler Co. develops all Kohlerr marine generator set marine generator sets.

  • Page 14: Service Views

    1.3 Service Views Circuit Breaker Panel Service-Side View Engine-End View Service-Side View (Shown without sound shield doors and panels) ADV6652- 1. Cooling air inlet 20. High engine water temperature safety shutdown switch 2. On/off button 21. Air cleaner 3. Hourmeter 22.

  • Page 15: Engine

    1.4 Engine Generator Model 4EOZ 3.5EFOZ Engine manufacturer Farymann Diesel Engine model 18 W Number of cylinders Cylinder block material Cast iron Cylinder head material Cast iron Piston rings 2 compression/1 oil Crankshaft material Stamped forging Connecting rod material Aluminum...

  • Page 16: Torque Specifications

    1.5 Torque Specifications Torque Specifications—Nm (ft. lbs.) 4EOZ/3.5EFOZ Cylinder head nuts 30--33 (22--24.5) Connecting rod nuts 30--33 (22--24.5) Valve cover nuts 8--12 (6--9) Main bearing plate nuts 30--33 (22--24.5) Fuel pump nuts 30--33 (22--24.5) Delivery valve holder--fuel pump 34--39 (25--29) High pressure fuel pipe nut--fuel pump 18--22 (13.5--16)

  • Page 17: Section 2 Operation

    Check the silencer and piping condition and 2.2 Marine Inspection check for tight exhaust system connections. Kohler Co. recommends that all boat owners have their Inspect the exhaust system components (exhaust vessels—especially the exhaust system attached to the manifold, mixing elbow, exhaust line, hose clamps, generator set—inspected at the start of each boating...

  • Page 18: Exercising The Generator Set

    Water Figure 2-3. ingested into the engine may cause major engine damage that the Kohler Co. warranty does not A 25-pin connector underneath the cover. controller allows the connection of the (optional) remote start/stop switch,...

  • Page 19: Starting The Generator Set

    2.6.2 Starting the Generator Set The following table describes the actions required to start the generator set. Step Step Action Action Fuel shutoff valve Open the manual fuel shutoff valve, if equipped. Initiate Starting Press the controller on/off button to the ON position. Note: The controller’s oil pressure, engine, and exhaust lamps illuminate.

  • Page 20: Circuit Protection

    2.6.5 Circuit Protection 2.7.2 Remote Panel Kit The AC circuit breaker trips when a fault is detected in The remote panel kit includes a start button, an on/off the output circuit. After correcting the fault, reset the AC button, an hourmeter to record total generator set circuit breaker by placing in the ON position.

  • Page 21: Section 3 Scheduled Maintenance

    Section 3 Scheduled Maintenance 3.1 General NOTICE Saltwater damage. Saltwater quickly deteriorates metals. Wipe up saltwater on and around the generator set and WARNING remove salt deposits from metal surfaces. NOTICE Hardware damage. The engine and generator set may use both American Standard and metric hardware.

  • Page 22: Service Schedule-3.5Efoz And 4Eoz Models

    3.2 Service Schedule—3.5EFOZ and 4EOZ Models Every Every Every Every Every 50 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 600 Hrs. Perform Service at Intervals or 1 or 3 or 6 or 12 or 18 Indicated (X) Daily Month Months...
  • Page 23 Every Every Every Every Every 50 Hrs. 100 Hrs. 200 Hrs. 400 Hrs. 600 Hrs. Perform Service at Intervals or 1 or 3 or 6 or 12 or 18 Indicated (X) Daily Month Months Months Months Months INTAKE/EXHAUST SYSTEM Inspect the exhaust system components * (Before operation) Check the exhaust gas condition.

  • Page 24: Lubrication System

    Grade Change the oil more frequently if the generator operates 5W20/5W30 under dirty, dusty conditions. See Figure 3-3 for oil capacities. 10W30 20W40 Model L (Qts.) 3.5EFOZ/4EOZ 1.25 (1.32) 15W40 Figure 3-3 Oil Capacities 10W40 Oil Change Procedure °C °C...
  • Page 25 d. Remove the oil drain hose from its retaining clip. See Figure 3-4. Remove the cap from the oil drain hose and lower the hose into an oil collection container. Electric Oil Drain/Oil Fill Pump Procedure: Connect the pump to the end of the oil drain hose.

  • Page 26: Battery

    3.4 Battery Battery gases. Explosion can cause severe injury or death. Battery gases can cause an explosion. Do not smoke or permit flames or sparks to occur near a battery at any time, Consult battery manufacturer’s instructions particularly when it is charging. Do not dispose of a battery in a regarding battery care and maintenance.

  • Page 27: Generator Storage Procedure

    3.5 Generator Storage Procedure 1. Unscrew the seawater pump cover to drain the cooling water from the engine. Perform the following storage procedure before taking a 2. Remove the hose from the fitting to drain the generator set out of service for three months or longer. cooling water from the alternator.
  • Page 28 Notes Section 3 Scheduled Maintenance TP-6137 5/03...

  • Page 29: Section 4 Intake And Exhaust System

    Section 4 Intake and Exhaust System 4.1 Air Intake Silencer/Filter Air Cleaner Service/Replacement A dry-type air cleaner silences and filters the intake air. At the interval specified in the service schedule, clean The air intake silencer assembly connects to the intake the air intake screen.

  • Page 30: Exhaust System

    4.2 Exhaust System 4.3 Mixing Elbow Check the mixing elbow for carbon buildup and WARNING corrosion inside the pipe. Clean the residual carbon buildup with a wire brush. Inspect the exhaust manifold flange for cracking and corrosion. The mixing elbow combines high temperature exhaust and cooling seawater.

  • Page 31: Section 5 Fuel System

    Section 5 Fuel System 5.1 General WARNING Fire. Can cause severe injury or death. Do not smoke or permit flames or sparks near fuels or the fuel system. 1. Fuel tank 2. Electric fuel pump Combustible materials. A sudden flash fire can cause 3.

  • Page 32: Fuel Filter

    5.3 Fuel Filter 5. Remove and discard the fuel filter. Note: Dispose of all waste materials (engine oil, The fuel filter prevents the entry of dirt into the fuel fuel, filter, etc.) in an environmentally safe system and preserves the injector and fuel injection manner.

  • Page 33: Fuel Injector Nozzle

    5.4 Fuel Injector Nozzle Injector Pressure Test The fuel injector nozzle ejects and atomizes the fuel in WARNING the cylinder under high pressure. As it is located in the combustion chamber, it operates at high temperatures and strong mechanical stress. Clean and adjust the injector as described below.
  • Page 34 Injector Adjustment Injector Overhaul 1. If, during the injector pressure test, the pressure 1. Inspect the injector assembly to ensure that the values are not correct, replace the shims in the nozzle’s needle is in the hole of the pressure piece. injector.

  • Page 35: Excess Fuel Start Device

    5.5 Excess Fuel Start Device Before pulling down the device’s button, start the engine without load to allow it to reach it’s highest engine speed. The engine is equipped with a device that supplies extra Note: To avoid heavy engine damage and engine fuel to facilitate engine starting.

  • Page 36: The Injection Pump's Fuel Starting Delivery Point

    5.6 The Injection Pump’s Fuel 4. To locate the injection pump’s fuel starting delivery point, put the accelerator lever in the higher speed Starting Delivery Point position and keep the inner control lever in the higher fuel rate position. For proper engine operation, ensure the correct adjustment of the fuel starting delivery point.

  • Page 37: Fuel Pump Adjustment Timing

    5.7 Fuel Pump Adjustment Timing 5.8 Fuel Pump and Gear Cover Installation To obtain the correct adjustment timing of the fuel pump, use a ruler and measure the distance between the mark 1. If replacing one of these parts, check the distance on the flywheel and the mark on the crankcase when the between the fuel pump surface on the gear cover plunger is in the fuel starting delivery point.

  • Page 38: Bleeding The Fuel System

    5.9 Bleeding the Fuel System Procedure to Bleed the Fuel System 1. Loosen the vent screw. See Figure 5-15. Bleed air from the fuel system to prevent starting failures and/or erratic operation. One or more of the following Engine-End View causes air to collect in the fuel system: Operating the generator set until the fuel supply is emptied.

  • Page 39: Governor

    5.10 Governor 1. Governor body 2. Pin 3. Spacer 4. Bridge 5. Spring retainer 6. Full speed spring 7. Idle speed spring 8. Cross slot nut Figure 5-16 Governor Components The centrifugal, mechanical governor keeps the engine The governor is installed at the crankshaft and turns with speed constant by automatically adjusting the amount similar speed.
  • Page 40 5. Screw the taplet bolt completely until it rests on the inner control lever. 6. Insert a screwdriver between the flyweights and force them apart to the maximum opening. See Figure 5-19. 7. Turn the taplet bolt until it contacts the governor pin.
  • Page 41 13. If the engine speed needs modification, turn the Accelerator Lever cross slotted nuts. The accelerator lever is fixed by its hole at the pin of the eccentric shaft. The ratchet plate is installed with its slot at the eccentric shaft pin and kept in place with an 8 mm nut.
  • Page 42 Notes Section 5 Fuel System TP-6137 5/03...

  • Page 43: Section 6 Cooling System

    3. Seawater strainer 9. Exhaust hose 4. Engine-driven seawater pump 10. Silencer (customer supplied) 5. Oil exchanger 11. Outlet flapper (exhaust/water discharge) 6. Alternator water cooler Figure 6-1 Direct Water-Cooled Cooling System (3.5EFOZ and 4EOZ Models) TP-6137 5/03 Section 6 Cooling System...

  • Page 44: Thermostat

    6.2 Thermostat 3. Remove the impeller. 4. Inspect the impeller for damaged, cracked, broken, In a direct seawater cooling system, the impeller pump missing or flattened vanes. The impeller vanes circulates the seawater around the cylinder and through should be straight and flexible. See Figure 6-4. the cylinder head.

  • Page 45: Siphon Break

    6.4 Siphon Break 6. Install the reed valve into the mounting base with the valve downward. See Figure 6-5, item 3. A siphon break prevents seawater entry into the 7. Install and only finger tighten the retaining cap. Do generator set’s engine when the engine exhaust not overtighten it.
  • Page 46 Waterline TP-5586-3 1. Silencer vertical lift 1.2 m (4 ft.) max. 8. Intake strainer 2. Exhaust outlet distance from the waterline. Use a siphon break if 9. Gear-driven seawater pump the exhaust mixer outlet is located less than 23 cm (9 in.) above 10.

  • Page 47: Anticorrosion Zinc Anode

    6.5 Anticorrosion Zinc Anode Anticorrosion Zinc Anode Replacement New Anode Replace When Percent The generator set includes an anticorrosion zinc anode Dimensions mm (in.) of Zinc Remaining Is: (plug) to prevent electrolytic corrosion by seawater. <50% of 10 (0.39) x 20 (0.79) length/diameter Check and replace the anticorrosion zinc anode at intervals recommended in the service schedule.
  • Page 48 Notes Section 6 Cooling System TP-6137 5/03...

  • Page 49: Section 7 Troubleshooting

    Bleed the air. Water or dirt in the fuel system. Drain and flush the fuel system. Dirty or faulty fuel injectors. Contact your local Kohler generator set distributor for service. Incorrect compression. Contact your local Kohler generator set distributor for service.
  • Page 50 (HET), low oil pressure (LOP), and/or high switch(es). water temperature (HWT) shutdown switch(es). Loss of AC output. Contact your local Kohler generator set distributor for service. Operates erratically Air intake clogged. Service the air intake screen. Stale or bad fuel.
  • Page 51 Engine overloaded. Reduce the load. Dirty fuel filter. Service the fuel filter. Improper valve clearance. Contact your local Kohler generator set distributor for service. Dirty or faulty injectors. Contact your local Kohler generator set distributor for service. Incorrect fuel injection timing.
  • Page 52 Clogged or dirty air intake screen. Service the air intake screen. Engine overloaded. Reduce the load. Incorrect valve clearance. Contact your local Kohler generator set distributor for service. Incorrect fuel injection timing. Contact your local Kohler generator set distributor for service.

  • Page 53: Section 8 Controller Troubleshooting

    Section 8 Controller Troubleshooting Starter motor K1 relay protects the starter motor in the event of an improper engine start. K2 relay energizes the fuel pump (FP) and the fuel solenoid (FS). If the fuel solenoid (FS) is energized, fuel flows to the injection The electric fuel pump.

  • Page 54: General

    8.1 General 8.1.1 On/Off Switch After pressing the On/Off switch on the control panel following section covers controller (local or remote), two green LEDs and one red LED (oil troubleshooting procedure. Refer to Figure 8-2 to engine) light. This operation energizes the control panel identify the controller components.

  • Page 55: Engine Safety Shutdown Switches

    8.2 Engine Safety Shutdown 8.2.2 High Water Temperature and High Exhaust Temperature Shutdown Switches Switch 8.2.1 Low Oil Pressure (LOP) Shutdown If high engine water temperature or exhaust gas temperature is encountered, the normally open contacts If the oil pressure drops while operating the engine, the of the HCHT and HET switch close.
  • Page 56 1. Control panel 2. Connector (to STD control panel connector) 3. 0.63 amp fuse 4. J3 connector (to control panel) 5. P5 connector (to remote panel harness) 6. P6 connector (to remote start/stop switch connector) 7. J6 remote start/stop switch connector 8.

  • Page 57: Operation Sequence

    Follow Consult the safety precautions in the beginning of this the wiring diagram sequence shown in Section 10. If a manual. 3.5EFOZ/4EOZ Kohler generator starting operation. By the operator. By the separate control. Push the ON/OFF switch.
  • Page 58 4EOZ/3.5EFOZ Kohler generator stopping operation. The unit stops due to High The operator stops the unit (local The unit stops due to a Low Oil Cylinder Head Temperature or remote). Pressure (LOP) condition. (HCHT) or High Exhaust Temperature (HET) condition.

  • Page 59: Troubleshooting

    8.4 Troubleshooting Use the following flowcharts as an aid in troubleshooting replace the control panel. Consult the safety the main control panel and the entire generator set. If precautions in the beginning of this manual. the prescribed remedy does not correct the problem, Push the on/off switch (local or remote).
  • Page 60 Go to B Does the engine crank? (next page). Is the 12 DC voltage present on the K2 relay coil? Is current present on the coils D Check the conditions of the of the fuel pump (FP) and the K2 connections (6-GND). cut-off solenoid (FS)? D Check the conditions of the TB1 connections (6-GND).
  • Page 61 After the start switch is Generator set checks out Can you stop the engine release, is the engine okay. using the on/off switch? operating? Is 12 DC voltage present on Are the 30-87 terminals of Change the K2 relay. the K2 relay coil? the K2 relay open? D LOP—Check the oil level, Is any red LEDs (LOP, HET,...
  • Page 62 If there AC output when the Is AC output at the correct Is 12 volts DC present on on/off switch is held and the voltage (e.g. 120 volts AC)? the coil of the K3 relay? unit is running? Is AC voltage present on the Check the stator and the Are the K3 relay contacts capacitor (CAP) connections...

  • Page 63: Section 9 Generator Troubleshooting

    Section 9 Generator Troubleshooting 9.1 General Grounding electrical equipment. Hazardous voltage can cause severe injury or death. Electrocution is possible whenever electricity is present. Open the main circuit Before beginning following troubleshooting breakers of all power sources before servicing the equipment. procedures, read all the safety precautions at the Configure the installation to electrically ground the generator beginning of this manual.

  • Page 64: Theory Of Operation

    9.3 Output Voltage and Frequency. The 3.5EFOZ model generator set supplies 230 volts at 50 Hz while the 4EOZ model supplies 120/240 volts at 60 Hz in accordance with the preselected winding connection and engine speed.

  • Page 65: Rotor Test

    9.4 Rotor Test Procedure to test the rotor’s continuity. 1. Using an Ohmmeter test, check if the rotor winding The two-pole rotor creates the magnetic field needed to is opened. See Figure 9-3. If an accurate raise the alternating current in the stator windings. ohmmeter is not available, check the circuit’s continuity using a 12 VDC battery and a suitable Before testing, inspect the rotor for visible damage to the...

  • Page 66: Field Diode Test

    1. Check that the arrow on the diode surface direct in Ohms at 20_ C (68 _ F) towards the fixing plate. 2.57 ±10% 4EOZ (60 Hz) 2. Check that the wire end with the eye terminal is 2.57 ±10% 3.5EFOZ (50 Hz) located between the diode and the fixing plate.

  • Page 67: Stator Test

    Stator Windings Resistance in Ohms at 20_ C (68_ F) Stator Leads 1--2 1--2 3--4 C1--C2 10--11 Model 0.96 2.32 0.068 4EOZ (60 Hz) ±10% ±10% ±10% 1.23 2.87 0.091 3.5EFOZ (50 Hz) ±10% ±10% ±10% Figure 9-9 Resistance Values...

  • Page 68: Alternator Excitation

    Alternator Troubleshooting and Corrective Action Problem Possible Cause Corrective Action No output Low revolving speed Check and adjust the revolving speed. Incorrect connections Check the wiring diagram and reset the connections. Inoperative capacitor Replace the capacitor. Winding breakage Check the winding resistance and replace the damaged parts.

  • Page 69: Section 10 Generator And Engine Disassembly/Reassembly

    Section 10 Generator and Engine Disassembly/Reassembly 10.1 Generator Alternator Disassembly Disconnect all the external connections—battery cables at the battery (negative (--) lead first), AC-output leads in the controller, remote start panel at the controller connector, water line at the seawater pump, fuel line at the fuel pump filter inlet, and exhaust line at the mixing elbow.
  • Page 70 Note: It is possible to connect the output leads in various positions for different volt configurations. Marks the leads for correct reconnection. 3. Carefully lift the controller box. See Figure 10-5. Figure 10-7 Seawater Pump Impeller Seawater Pump Housing Removal Figure 10-5 Controller Box Removal 1.
  • Page 71 1. M10 x 140 Screws (qty. 4) Figure 10-11 Disconnect the Alternator 3. Release the two M8 nuts from the vibromounts 1. Cover for field diode and rotor inspection using a 13 mm socket wrench. 2. Stator housing (alternator) 3. Seawater pump shaft 4.
  • Page 72 Note: With a suitable puller it is possible to reuse the Engine and Rotor Hub Disconnection original seawater pump screws. 1. Using a 13 mm socket wrench, loosen the four M8 x 35 screws and remove the alternator/engine 8. Remove the stator housing from the rotor. See hub from the engine flywheel.

  • Page 73: Generator Alternator Reassembly

    10.2 Generator Alternator Reassembly Note: See Section 1.5 for specified torque values. Engine and Rotor Hub Installation 1. To reinstall the engine/rotor hub at the flywheel, tighten the four M8 x 35 screws at the specified torque (see section 1.5) with a 13 mm socket wrench.
  • Page 74 Figure 10-20 Stator Housing Figure 10-22 Seawater Pump Shaft 5. Tighten the four M10 x 140 screws at the specified Seawater Pump Installation torque. See section 1.5. See Figure 10-21. 1. Assemble on the rear side of the stator housing the seawater pump housing.

  • Page 75: Generator Engine Disassembly

    10.3 Generator Engine Disassembly 2. Before removing the electric fuel pump, clean the inside of the antiresonator housing with a rag. Disconnect all the external connections—battery cables 3. Ensure that dirt or debris does not enter the at the battery (negative (--) lead first), AC-output leads in cylinder.
  • Page 76 5. Discard the gasket located between the exhaust elbow and the engine head. Figure 10-27 Rocker Cover Disconnect the high-pressure fuel line 1. Hold a 14 mm wrench on the fuel injector pump’s nipple valve. See Figure 10-28. Figure 10-26 Exhaust Elbow (Mixer) 2.
  • Page 77 3. Repeat this procedure on the nut that connects the Remove the cylinder head high-pressure line to the injector body. 1. Remove the two locknuts and washers that hold Figure 10-29. the protective tube retaining spring. 2. Loosen and remove the four cylinder head nuts. See Figure 10-31.
  • Page 78 Replacing the valve guides 1. If valve guide replacement is necessary, use the proper driver and press out the old guides from the head. See Figure 10-35. Figure 10-33 Protective Tube Disassembly the valves 1. Use the special tool shown in Figure 10-34 to disassemble the valves.
  • Page 79 Cylinder 1. Rotate the flywheel until the piston reaches the Bottom Dead Center (BDC) so that the studs are a guideline to remove the cylinder from the crankcase. See Figure 10-38. Note: If the repair does not require replacing the piston or liner, keep the liner on the piston.
  • Page 80 Piston 2. Move the flywheel until the piston reaches the Bottom Dead Center (BDC) of its stroke. 1. Rotate the flywheel until the piston reaches Top Dead Center (TDC). 3. Loosen the six hex cap head screws of the oil cooler housing and remove it from the engine.
  • Page 81 Gear Cover 1. Remove the six hex cap head screws to remove the gear cover. If necessary, tap the cover with a soft-faced hammer to remove it. See Figure 10-43. 2. If, during cover removal, the cover catches on the governor, move the flywheel to release the governor’s cover.
  • Page 82 Camshaft Camshaft Bearing 1. Release the snap ring that holds the camshaft in 1. Remove the camshaft’s ball bearing from inside of the gear cover. the gear cover by using a socket pushed with a hydraulic press. See Figure 10-48. 2.
  • Page 83 Speed Control Shaft Governor 1. Put the gear cover on the work bench. 1. Install a holding device and remove the governor pin. See Figure 10-50. 2. Using a pliers, remove the inner retainer ring from the eccentric shaft. 2. Spread the flyweights with a sturdy driver. 3.
  • Page 84 Oil Pump 1. Loosen the three hex cap screws to remove the oil pump from the crankcase. See Figure 10-51. Figure 10-52 Flywheel Nut Figure 10-51 Oil Pump Flywheel 1. Use a socket wrench and striker tool to loosen the flywheel nut two turns.
  • Page 85 Main Bearing Cover 1. Put the engine crankcase on the work bench so that the flywheel side is in the upper position. 2. Remove the four main bearing cover nuts and washers. 3. Install two screws (M6 x 30) in the threaded holes of the cover and turn them until the cover is released from the crankcase.

  • Page 86: Generator Engine Reassembly

    a. Place the main bearing cover under a press and support its outer side with two mountings. b. Press out the crankshaft. See Figure 10-58. Figure 10-58 Crankshaft Figure 10-59 Crankcase Bushing c. Remove the snap ring of the bearing’s outer Crankshaft Gear race.
  • Page 87 2. Lock the bearing’s outer race with the snap ring in the cover. 3. Set the crankshaft on the board of a press and carefully clean the tapered surface of the bearing seat. 4. Put the main bearing cover on the crankshaft so that the snap ring is towards the flywheel side.
  • Page 88 Figure 10-66 Oil Pump enough backlash between the crankshaft gear and the pump gear. Note: The 4EOZ/3.5EFOZ model’s engine have a counterclockwise rotation (as viewed from the engine flywheel). Also, the oil pump is located on the crankcase’s left side.
  • Page 89 Governor Connecting Rod 1. Install the holding device so that all of its teeth are 1. To install new bearing shells, take a half shell and engaged with the teeth of the crankshaft gear. See place it about 3/4 into the connecting rod cap. Figure 10-67.
  • Page 90 Camshaft Gear 1. Put the camshaft gear wheel in an oil bath or an electric heater plate at a temperature of 90--100_ C (95--210_ F). See Figure 10-70. 2. Using a socket and hydraulic press, push the gear in its seat on the camshaft. Note: For a correct gear adjustment timing, the chisel mark on the gear must face the camshaft side.
  • Page 91 Camshaft Bearing Injection Pump Camfollower 1. Using a socket, install the camshaft bearing on the 1. Assemble the injection pump camfollower and gear cover until it is against its seat. tighten its fixing nut through the oil fill hole . Figure 10-71.
  • Page 92 6. Guide the eccentric shaft through the bushing housing until it meets the inner control lever. See Figure 10-75. Figure 10-75 Eccentric Shaft 7. Turn the ratchet plate towards the lower position Figure 10-76 Gear Housing Boss until the inner spring can be hooked with the other end leg at the groove of the eccentric shaft.
  • Page 93 Piston 1. Using a ring expander tool, install the piston rings so that the “Top Marks” are towards the piston crown. See Figure 10-80. Figure 10-80 Piston and Ring Expander Tool Figure 10-78 Inner Spring 2. Lubricate the rings and the piston skirt. 11.
  • Page 94 6. Guide the piston into the cylinder liner until the Valve Guides piston hole is slightly to the upper edge of the 1. Press the valve guides in the proper head holes. cylinder. This will allow for the connection between Carefully ensure that they are installed in an the piston assembly and the connecting rod.
  • Page 95 Valve Note: The exhaust valve has a larger counterbore than the intake valve when viewing the head from the upper surface. The exhaust valve has a smaller hole when viewing the head from the opposite side. Note: The rotocap and conical shaped spring belong to the exhaust valve.
  • Page 96 2. Set the governor pin into the governor hole using grease to keep it in place. 3. Align the mark on the camshaft gear with the mark on the gear cover. See Figure 10-87. 4. Put the cover gasket in place. Slowly guide the gear cover towards the crankcase without moving the camshaft.
  • Page 97 2. Put the retainer spring in the upper side of the head as shown in Figure 10-92. 3. Do not tighten the nuts. 4. Guide the push rods in the tube until they touch the tappets. Note: Both rods look alike. However, place the intake valve’s push rod in the hole closer to the crankcase.
  • Page 98 Valve Adjustment Fuel Injector 1. Move the piston in the compression stroke until it’s 1. Replace the washer located under the injector and at Top Dead Center (TDC). in the seat of the cylinder head. 2. Loosen the locknuts of the valve adjustment Note: Use only a gasket under the injector and ensure screws and drive a 0.2 mm (0.78 in.) feeler gage that the old gasket is removed.
  • Page 99 High Pressure Line Valve Cover 1. Install the high pressure line and tighten the nuts at 1. Install the valve cover gasket on the upper surface the injector nipple and at the nonreturn valve nipple of the head. See Figure 10-98. located on the fuel injection pump body.

  • Page 100: Engine Component Dimensions And Wear

    10.5 Engine Component Dimensions and Wear Dimensions Original Max. Limit Max. mm (in.) Min. mm (in.) mm (in.) Part Description Cylinder Liner Bore: Bore: upper diameter upper diameter 81 900 (3 2244) 81.900 (3.2244) 81 880 (3 2236) 81.880 (3.2236) 82 000 (3 2283) 82.000 (3.2283) below diameter...
  • Page 101 10.6 Engine Component Dimensions and Wear (Continued) Dimensions Original Max. Limit Max. mm (in.) Min. mm (in.) mm (in.) Part Description Connecting Rod Large bore diameter (without bearing) 43.666 (1.7191) 43.650 (1.7185) Small bore diameter (without bearing) Small bore diameter (without bearing) 24 986 (0 9837) 24.986 (0.9837) 24 974 (0 9832)
  • Page 102 Notes Section 10 Generator and Engine Disassembly/Reassembly TP-6137 5/03...

  • Page 103: Section 11 Wiring Diagrams

    Section 11 Wiring Diagrams Electroswitch 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator Power To Load To Load Kraus Naimler/American Solenoid (Early Rectangular Design) 2-Wire Generator Sets 3-Wire Generator Sets To Generator To Shore Power To Shore To Generator...

  • Page 104: Wiring Diagram, Schematic

    11.1 Wiring Diagram, Schematic GM20645-B Section 11 Wiring Diagrams TP-6137 5/03...

  • Page 105: Wiring Diagram, Point-To-Point

    11.2 Wiring Diagram, Point-to-Point GM20645-B TP-6137 5/03 Section 11 Wiring Diagrams...
  • Page 106 Notes Section 11 Wiring Diagrams TP-6137 5/03...

  • Page 107: Appendix A Abbreviations

    Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ampere center of gravity fglass. fiberglass ABDC after bottom dead center cubic inch displacement flat head machine (screw) alternating current centerline fl. oz. fluid ounce analog to digital centimeter flex.
  • Page 108 kilogram megawatt root mean square kg/cm kilograms per square milliwatt rnd. round centimeter µF microfarad read only memory kilogram-meter N, norm. normal (power source) rot. rotate, rotating kg/m kilograms per cubic meter not available, not applicable revolutions per minute kilohertz nat.

  • Page 109: Appendix B Common Hardware Application Guidelines

    Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to Steps for common hardware application identify proper fastening techniques when no specific 1. Determine entry hole type: round or slotted. reference for reassembly is made. 2.

  • Page 110: Appendix C General Torque Specifications

    Appendix C General Torque Specifications Use the following torque specifications when service oiled threads. Increase values by 15% for nonplated literature instructions give no specific torque values. threads. All torque values are +0%/--10%. The charts list values for new plated, zinc phosphate, or American Standard Fasteners Torque Specifications Assembled into Cast Iron or Steel Assembled into...

  • Page 111: Appendix D Common Hardware Identification

    Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head Lock or Elastic Grade 5 with Washer Flat Head (FHM) Square Grade 8 Grade 8/9 (Hex Socket Round Head (RHM)

  • Page 112: Appendix E Common Hardware List

    Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont. Hex Nuts X-465-17 1/4-20 x .38 X-6238-14...
  • Page 113 Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (partial thread) Hex Head Bolts (full thread) Hex Nuts M931-06040-60 M6-1.00 x 40 M933-04006-60 M4-0.70 x 6 M934-03-50 M3-0.50 Standard...
  • Page 116 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 TP-6137 5/03 7 Jurong Pier Road Singapore 619159 E2003 by Kohler Co. All rights reserved. Phone (65)264-6422, Fax (65)264-6455...

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