Kohler 3.5EFOZ Service Download Page 11 | Manualshive

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TP-6137 5/03

i

Introduction

Introduction

This manual provides troubleshooting and repair
instructions for 4EOZ/3.5EFOZ model generator sets.

Refer to the engine service manual for generator set
engine service information.

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This manual may be used for models not listed on the
front cover.

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.

Read this manual and carefully follow all procedures
and safety precautions to ensure proper equipment
operation and to avoid bodily injury. Read and follow the
Safety Precautions and Instructions section at the
beginning of this manual. Keep this manual with the
equipment for future reference.

The equipment service requirements are important for
safe and efficient operation. Inspect the parts often and
perform required service at the prescribed intervals.
Maintenance work must be performed by appropriately
skilled and suitably-trained maintenance personnel
familiar with generator set operation and service.

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Service Assistance

For

professional

advice

on

generator

power

requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.

D

Consult the Yellow Pages under the heading

Generators—Electric

D

Visit

the

Kohler

Power

Systems

website

at

KohlerPowerSystems.com

D

Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents
included with the product

D

Call toll free in the US and Canada 1-800-544-2444

D

Outside the US and Canada, call the nearest regional

office

Africa, Europe, Middle East

London Regional Office
Langley, Slough, England
Phone: (44) 1753-580-771
Fax:

(44) 1753-580-036

Asia Pacific

Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax:

(65) 264-6455

China

North China Regional Office, Beijing
Phone: (86) 10 6518 7950

(86) 10 6518 7951
(86) 10 6518 7952

Fax:

(86) 10 6518 7955

East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
Fax:

(86) 21 6288 0550

India, Bangladesh, Sri Lanka

India Regional Office
Bangalore, India
Phone: (91) 80 3366208

(91) 80 3366231

Fax:

(91) 80 3315972

Japan, Korea

North Asia Regional Office
Tokyo, Japan
Phone: (813) 3440-4515
Fax:

(813) 3440-2727

Latin America

Latin America Regional Office
Lakeland, Florida, USA
Phone: (863) 619-7568
Fax:

(863) 701-7131

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Summary of Contents for 3.5EFOZ

Page 1: ...Marine Generator Sets Includes Engine Maintenance Models 4EOZ 3 5EFOZ TP 6137 5 03 Service ...

Page 2: ...r future reference Record field installed kit numbers after installing the kits Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate s Model Designation Specification Number Serial Number Accessory Number Accessory Description Engine Identification Record the product identification information from the engine nameplate Manufacturer Model D...

Page 3: ...ty Shutdown Switches 7 2 6 5 Circuit Protection 8 2 7 Remote Panel Kits 8 2 7 1 Remote Start Stop Panel Kit 8 2 7 2 Remote Panel Kit 8 Section 3 Scheduled Maintenance 9 3 1 General 9 3 2 Service Schedule 3 5EFOZ and 4EOZ Models 10 3 3 Lubrication System 12 3 3 1 Oil Specifications 12 3 3 2 Oil Check 12 3 3 3 Oil Change 12 3 4 Battery 14 3 5 Generator Storage Procedure 15 3 5 1 Lubricating System 1...

Page 4: ... 47 Section 9 Generator Troubleshooting 51 9 1 General 51 9 2 Theory of Operation Brushless Generator Sets 52 9 3 Output Voltage and Frequency 52 9 3 1 Voltage Rating and Rotation Speed 52 9 3 2 Bearing 52 9 4 Rotor Test 53 9 5 Field Diode Test 54 9 6 Stator Test 55 9 7 Alternator Excitation 56 Section 10 Generator and Engine Disassembly Reassembly 57 10 1 Generator Alternator Disassembly 57 10 2 ...

Page 5: ...lead last when reconnecting the battery Follow these precautions to prevent the starting of the generator set by the remote start stop switch Battery Sulfuric acid in batteries Can cause severe injury or death Wear protective goggles and clothing Battery acid may cause blindness and burn skin WARNING Battery electrolyte is a diluted sulfuric acid Batteryacid cancause severe injury or death Battery...

Page 6: ...g or death Carbon monoxideisapoisonousgaspresentin exhaust gases Carbon monoxide poisoning symptoms include but are not limited to the following D Light headedness dizziness D Physical fatigue weakness in joints and muscles D Sleepiness mental fatigue inability to concentrate or speak clearly blurred vision D Stomachache vomiting nausea If experiencing any of these symptoms and carbon monoxide poi...

Page 7: ...tion 33CFR183 requires thatallelectricaldevices ship to shore transfer switch remote start panel etc must be ignition protected when used in a gasoline and gaseous fueled environment The electrical devices listed above are not ignition protected and are not certified to operate in a gasoline and gaseous fueled environmentsuchasanengineroomor near fuel tanks Acceptable locations are the wheelhouse ...

Page 8: ... system to operate automatically 600 volts and under Hot Parts Hot engine and exhaust system Can cause severe injury or death Do not work on the generator set until it cools WARNING Servicing the exhaust system Hot parts can cause severe injury or death Do not touch hot engine parts The engine and exhaust system components become extremely hot during operation Moving Parts Hazardous voltage Can ca...

Page 9: ...ds and nuts NOTICE When replacing hardware do not substitute with inferior grade hardware Screws and nuts are available in different hardness ratings To indicate hardness American Standard hardware uses a series of markings and metric hardware uses a numeric system Check the markings on the bolt heads and nuts for identification NOTICE Fuse replacement Replace fuses with fuses of the same ampere r...

Page 10: ...TP 6137 5 03 VI Safety Precautions and Instructions Notes ...

Page 11: ...ration and service x in 001 003 Service Assistance For professional advice on generator power requirements and conscientious service please contact your nearest Kohler distributor or dealer D Consult the Yellow Pages under the heading Generators Electric D Visit the Kohler Power Systems website at KohlerPowerSystems com D Look at the labels and stickers on your Kohler product or review the appropr...

Page 12: ...TP 6137 5 03 ii Service Assistance Notes ...

Page 13: ...ccepted reference conditions of 25_C 77_F and pressure of 98 9 kPa 29 2 in Hg dry barometer ISO 3046 and ISO 8528 1 include reference conditions and output calculations Obtain technical information bulletin TIB 101 on ratings guidelines for complete ratings definitions 1 2 Generator Generator Model 4EOZ 3 5EFOZ Dimensions mm in Length 560 22 05 Width 390 15 35 Height 490 19 29 Weight kg lbs 209 5 ...

Page 14: ...e safety shutdown switch 21 Air cleaner 22 Fuel feed pump 23 Governor 24 Battery connection 25 Oil check 26 Battery connection 27 Starter solenoid starter motor 28 Lifting eye 29 Mixing elbow 30 High exhaust temperature safety shutdown switch 31 Low oil pressure safety shutdown switch 32 Control panel connector 33 Seawater inlet 34 Ground lug equipment ground 35 Seawater pump water inlet 36 Antico...

Page 15: ...ter L qts 1 25 1 32 Oil recommendation API CD CD CC or CC Fuel injection timing BTDC 22 22 5 17 18 5 Fuel injection pressure bar psi 200 2900 Combustion system Direct injection Battery voltage 12 volt negative ground Battery recommendation min 500 CCA 100 amp hr Battery charging alternator 15 amps 12 volts Fuel recommendation Diesel DIN 51601 ASTM D 975 67 ID 2D BS 2869 1967 A1 A2 Fuel shutoff sol...

Page 16: ... pipe nut fuel pump 18 22 13 5 16 High pressure fuel pipe nut injector 25 30 18 5 22 Injector clamp nuts 8 12 6 9 Governor on crankshaft 55 60 40 5 44 5 Flywheel nut 216 226 159 5 166 5 Gear cover screws 34 38 25 28 Tappet block screws 8 10 6 7 5 Oil pump screws 16 20 12 15 Oil cooler screws 9 11 6 5 8 Banjo bolt on fuel pump 25 35 18 5 26 Body injector nut 25 30 18 5 22 Starter screws 20 15 Flywh...

Page 17: ... operates Note Never operate the generator set without a functioning carbon monoxide detector Fuel Level Check the fuel level and keep the tank s full to ensure adequate fuel supply Oil Level Maintain the oil level at or near not over the full mark on the dipstick Operating Area Check for obstructions that could block the flow of cooling air Keep the air intake area clean Do not leave rags tools o...

Page 18: ...ized Kohlerr distributor dealer Note Starter motor cooldown Do not crank the engine continuously for more than 10 seconds at a time Allow a 60 second cooldown period between cranking attempts if the engine does not start If the unit fails to start after 3 attempts contact an authorized Kohlerr distributor dealer for repair Failure to follow these guidelines may result in starter motor burnout 2 6 ...

Page 19: ... Stopping the Generator Set The following table describes the actions required to stop the generator set Step Action Step Action 1 Cooldown Run the generator set at no load for 5 minutes to ensure adequate engine cooldown 2 Stopping Press the controller on off button to the OFF position to stop the generator set Note The controller s oil pressure engine and exhaust lamps darken 3 Fuel shutoff valv...

Page 20: ...onnector for connection of the remote start stop panel Order a 4 to 6 pin harness kit to connect the panel to the 4 pin connector located at the controller See Figure 2 4 and Figure 2 5 A 226965 A 1 2 3 1 Hourmeter 2 Start Stop switch 3 6 pin connector Figure 2 4 Remote Start Stop Panel Features 1 1 Start Stop switch connection Figure 2 5 Remote Start Stop Panel Connection 2 7 2 Remote Panel Kit T...

Page 21: ...aving the belts and pulleys exposed Sound shield equipped models only NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces NOTICE Hardware damage The engine and generator set may use bothAmericanStandardandmetrichardware Usethecorrect size tools to prevent rounding of the bolt heads and nuts See...

Page 22: ...ace the fuel filter X Check the fuel injection nozzles check the injection spray condition X LUBRICATION SYSTEM Check the crankcase oil level and add oil as necessary X Before operation Replace the oil in the crankcase X Break in period X Clean the oil strainer X COOLING SYSTEM Check the seawater outlet and clean as necessary X Check the function of the siphon break if equipped X Check the anticor...

Page 23: ...charged and in good condition w X Before operation Check and tighten the electrical connections X Clean the battery cables X ENGINE AND MOUNTING Check for water fuel and oil leakage X After operation Retighten any loose nuts and bolts X Before operation X Check the mounting bolts vibromounts and tighten if necessary X Adjust the intake exhaust valve clearance X Head bolt retightening X REMOTE CONT...

Page 24: ...ing difficulties 3 3 2 Oil Check Check the oil level in the crankcase daily or before each startup to ensure that the level is in the safe range To check the oil level remove the dipstick and wipe the end clean reinsert as far as possible and remove Maintain the oil level between the Min and Max marks on the dipstick as shown in Figure 3 2 See Section 1 Figure 1 1 for dipstick location 1 2 TP 5586...

Page 25: ...te materials engine oil fuel filter etc in an environmentally safe manner 2 Oil Strainer Service Clean the oil strainer at the interval listed in the Service Schedule a Remove the flange on the crankcase See Figure 3 5 for location b Remove the end of the oil drain hose c Remove the metallic screen oil strainer d Clean the oil stainer using diesel oil but no gasoline Consult the engine operation m...

Page 26: ...e case of eye contact Never add acid to a battery after placing the battery in service as this may result in hazardous spattering of battery acid 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 particularly when it is charging Donot disposeof abattery ina fire To prevent burns ...

Page 27: ...the fuel filter and bleed the fuel system See Section 5 x sm 002 004 3 5 3 Cooling System Prepare the cooling system for storage as follows 1 Unscrew the seawater pump cover to drain the cooling water from the engine 2 Remove the hose from the fitting to drain the cooling water from the alternator 3 5 4 Exterior Prepare the exterior for storage as follows 1 Clean the exterior surface of the genera...

Page 28: ...TP 6137 5 03 16 Section 3 Scheduled Maintenance Notes ...

Page 29: ...s and filters the intake air The air intake silencer assembly connects to the intake manifold via a flexible hose 1 Remove the four screws to remove the air cleaner cover 2 Remove the air cleaner screen 3 Tap the screen lightly against a flat surface to dislodge loose surface dirt Do not clean in any liquid or use compressed air as these will damage the screen 4 Examine the screen and housing for ...

Page 30: ...eaks or dents Replace the hoses as needed D Check for corroded or broken metal parts and replace them as needed D Check for loose corroded or missing clamps Tighten or replace the hose clamps and or hangers as needed D Check that the exhaust outlet is unobstructed D Visually inspect for exhaust leaks blowby Check for carbon or soot residue on exhaust components Carbon and soot residue indicates an...

Page 31: ...sure before the piston reaches TDC Any excess fuel returns to the tank The rubber pipe located between the mechanical pump and the injector s banjo return bolt allows for bleeding air from the fuel system 1 Fuel tank 2 Electric fuel pump 3 Fuel supply line 4 Fuel filter 5 Stop solenoid 6 Air bleeding pipe 7 Injector assembly 8 High pressure fuel line 9 Fuel injection pump mechanical 10 Fuel return...

Page 32: ...3 To avoid fuel leakage clamp off the fuel supply line near the filter 4 Disconnect the inlet and outlet lines to the fuel filter Ensure that dirt does not enter the fuel system See Figure 5 3 Figure 5 3 Disconnect the Fuel Line 5 Remove and discard the fuel filter Note Dispose of all waste materials engine oil fuel filter etc in an environmentally safe manner 6 Replace the fuel filter with the ar...

Page 33: ...rface 2 A special tool needle is required to clean the injector nozzle s spray hole Consult the engine service manual for more information Figure 5 5 Injector Injector Pressure Test Explosive fuel vapors Can cause severe injury or death Use extreme care when handling storing and using fuels WARNING 1 Connect the injector to a tester to check the injection pressure value See Figure 5 6 2 Using the ...

Page 34: ...ector of 10 bar 145 psi The thicker shim increases the pressure value of the injector while the thinner shim decreases the pressure value of the injector Add or remove shims to obtain the correct pressure value 1 Injector nut 2 Nozzle assembly 3 Pressure piece 4 Spring seat s conical stop 5 Spring 1 2 3 5 4 Figure 5 7 Injector Components Injector Overhaul 1 Inspect the injector assembly to ensure ...

Page 35: ...tart the engine without load to allow it to reach it s highest engine speed Note To avoid heavy engine damage and engine overload never operate with the device s button pulled down The engine s output power is dependant upon the position of the upper conical surface of the excess fuel button in the gear cover The shorter its insertion in the gear cover the more fuel arrives at the injector The lon...

Page 36: ...tween the pump and the tube See Figure 5 10 Note Fuel will flow from the pump immediately after loosening the allen screw Figure 5 10 Drip Tube 4 To locate the injection pump s fuel starting delivery point put the accelerator lever in the higher speed position and keep the inner control lever in the higher fuel rate position Note In order for fuel to reach the injection pump perform this check wit...

Page 37: ...ms between the gear cover and the fuel pump s body decreases or increases the distance between the fuel pump flange and the cam of the camshaft Adjust the starting delivery point so that its value is within the above mentioned value Figure 5 12 Flywheel Mark 5 8 Fuel Pump and Gear Cover Installation 1 If replacing one of these parts check the distance between the fuel pump surface on the gear cove...

Page 38: ...l supply is emptied D Developing air leaks in the suction side of the fuel system D Replacing the fuel filter Procedure to Bleed the Fuel System 1 Loosen the vent screw See Figure 5 15 1 1 Vent screw Engine End View ADV 6652 Figure 5 15 Vent Screw Location 2 Operate the generator set until fuel free of air bubbles flows from the vent screw 3 Tighten the screw Note Wipe up all spilled diesel fuel a...

Page 39: ...two flyweights and a set of springs that balance the centrifugal forces of the governor flyweights The governor is installed at the crankshaft and turns with similar speed If the engine operates with a decreasing load the engine speed will increase The centrifugal force spreads the governor weights and its pin pushes the tappet bolt of the inner control lever It pivots on the eccentric shaft so th...

Page 40: ...ert 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 Note No play should be felt when pushing the inner control lever with the hand 8 Release the flyweights and turn the taplet bolt a half turn further Figure 5 19 Taplet Bolt Position 9 Hold the taplet bolt in this position and tighten the nut...

Page 41: ...onment on a test bench or with a revolution counter Accelerator Lever 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 As the ratchet plate spring is used as a buffer for engine deceleration it holds the accelerator lever in the higher engine speed position the cor...

Page 42: ...TP 6137 5 03 30 Section 5 Fuel System Notes ...

Page 43: ...he cooling water circuit diagrams NOTICE Saltwater damage Saltwater quickly deteriorates metals Wipe up saltwater on and around the generator set and remove salt deposits from metal surfaces 1 TP 6134 1 Intake strainer 2 Seacock 3 Seawater strainer 4 Engine driven seawater pump 5 Oil exchanger 6 Alternator water cooler 7 Zinc plug 8 Exhaust manifold elbow 9 Exhaust hose 10 Silencer customer suppli...

Page 44: ... the seacock 2 Remove the seawater pump coverplate See Figure 6 3 1 2 3 4 5 6 1 Seawater pump 2 Coverplate 3 Gasket 4 Impeller 5 Bearing 6 Housing TP 6053 Figure 6 3 Seawater Pump Typical 3 Remove the impeller 4 Inspect the impeller for damaged cracked broken missing or flattened vanes The impeller vanes should be straight and flexible See Figure 6 4 Replace the impeller if it is damaged 1 2 3 1 F...

Page 45: ...d in the service schedule Siphon Break Inspection 1 Stop the generator set 2 Remove the retaining cap and remove the reed valve for inspection See Figure 6 5 3 Use a mild detergent to remove residue and oxidation from the reed valve 4 Clear blockages from the reed valve opening 5 Replace the siphon break if the reed valve is cracked or if the reed valve material has hardened or deteriorated 6 Inst...

Page 46: ...5 cm 1 ft min 4 Siphon break 5 Exhaust outlet 6 Seawater strainer 7 Seacock 8 Intake strainer 9 Gear driven seawater pump 10 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min 11 Water lock optional 12 Silencer distance from exhaust outlet 3 m 10 ft max 13 Silencer customer supplied 14 Exhaust hose pitch 1 3 cm per 30 5 cm 0 5 in per ft min 15 Exhaust outlet distance above the waterline 10 cm...

Page 47: ...ion on the anticorrosion zinc anode Replace the anode according to Figure 6 8 and Figure 6 9 Anticorrosion Zinc Anode Replacement New Anode Dimensions mm in Replace When Percent of Zinc Remaining Is 10 0 39 x 20 0 79 50 of length diameter Figure 6 8 Anticorrosion Zinc Anode Plug Measurements TP 5586 3 1 2 1 Diameter 9 5 mm 0 375 in 2 Length 19 05 mm 0 75 in Figure 6 9 Anticorrosion Zinc Anode Plug...

Page 48: ...TP 6137 5 03 36 Section 6 Cooling System Notes ...

Page 49: ... as necessary Unit cranks but will not start Fault shutdown Check the shutdown switches Out of fuel Replenish fuel supply Fuel shut off valve closed Open the fuel shut off valve Inoperative fuel feed pump Replace the fuel feed pump Clogged fuel filter Service the fuel filter element Air in the fuel system Bleed the air Water or dirt in the fuel system Drain and flush the fuel system Dirty or fault...

Page 50: ...faulty injectors Contact your local Kohler generator set distributor for service Faulty governor link Contact your local Kohler generator set distributor for service Inoperative fuel feed pump Replace the fuel feed pump Incorrect valve clearance Contact your local Kohler generator set distributor for service Inoperative valve spring Contact your local Kohler generator set distributor for service I...

Page 51: ...ling water leaks from the water passage Check the water passage Engine emits black or gray exhaust smoke Incorrect fuel type Use correct fuel Clogged or dirty air intake screen Service the air intake screen Inoperative injection pump Contact your local Kohler generator set distributor for service Faulty injectors Contact your local Kohler generator set distributor for service Incorrect fuel inject...

Page 52: ...oise Worn or inoperative bearing or gear Contact your local Kohler generator set distributor for service Loose bolt or screw Tighten the hardware Low lube oil level Add lube oil Battery will not charge Loose or corroded connections Clean and tighten connections Sulfated or worn battery connections Check the electrolyte level and specific gravity batteries with filler caps only Inoperative battery ...

Page 53: ... relay energizes the fuel pump FP and the fuel solenoid FS Engine battery charger regulator The generator set starts The starting cycle is completed The low oil pressure switch LOP contacts open The generator set starts The electric fuel pump FP refills the fuel supply line If the fuel solenoid FS is energized fuel flows to the injection pump Figure 8 1 Generator Set Starting Cycle ...

Page 54: ...tart Press the START switch local or remote the K1 relay energizes The normally open K1 contacts close allowing DC to the normally open contacts of the starter motor s solenoid S The energized starter starts the generator set s engine 8 1 3 Run After reaching correct engine and generator set performance the two generator set wires marked 10 and 11 energize the K3 relay AC crank disconnect that ope...

Page 55: ...ights immediately while the green oil pressure LED cuts off Check and correct the generator set fault 8 2 2 High Water Temperature and High Exhaust Temperature Shutdown Switch If high engine water temperature or exhaust gas temperature is encountered the normally open contacts of the HCHT and HET switch close DC travels to connection 3 or 4 on the control panel deenergizing the K2 relay DC does no...

Page 56: ... 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 Remote start stop switch 1 3 4 2 5 6 7 8 8 Figure 8 3 Control Panel ...

Page 57: ...P is energized AC is supplied for the load and for the static exiting circuit AC energizes the relay K3 that disconnects the starter The relay K1 is deenergized Release the START switch The generator set is operating because the relay K2 is energized by the control panel The relay K2 is energized The battery charging voltage regulator VR is excited The stop solenoid FS is energized and opens Fuel ...

Page 58: ...relay K2 The high temperature contacts deenergizes the relay K2 Push the ON OFF switch The electric fuel pump FP and the stop solenoid FS are deenergized and the unit stops The electric fuel pump FP and the stop solenoid FS are deenergized and the unit stops The relay K2 is deenergized Check the unit for causes of the low oil pressure failure Check the unit for causes of the high temperature failu...

Page 59: ...he K1 connections 5 GND D Checktheconditionsofthe K3 connections 5 D Checktheconditionsofthe TB1 connections 5 GND D Checktheconditionsofthe P3 connections 5 GND D Checktheconditionsofthe 2 6 connections on the terminal board of the control panel D Reset the failed connections to energize the coil of the K1 relay D Checktheconditionsofthe S connections 9 GND D Checktheconditionsofthe P1 connection...

Page 60: ...ections 8 GND D Checktheconditionsofthe FS connections 8 GND D Checktheconditionsofthe P1 connections 8 GND D Checktheconditionsofthe TB1 connections 8 GND D Check the continuity of the K2 connections 7 8 D Reset the failed connections to energize the fuel pump FP and the cut off solenoid FS No Is the 12 DC voltage present on the K2 relay coil Is current present on the coils of the fuel pump FP an...

Page 61: ... checks okay No Can you stop the engine using the on off switch Change the control panel Yes After the start switch is release is the engine operating No Is 12 DC voltage present on the K2 relay coil No Is any red LEDs LOP HET HCHT lit No Change the control panel Generator set checks out okay No Are the 30 87 terminals of the K2 relay open Change the K2 relay Yes Yes Figure 8 8 Troubleshooting Rel...

Page 62: ...acitor CAP connections C1 C2 See Section 11 No Are the CAP connections C1 C2 okay No Reset the connections Is 12 volts DC present on the coil of the K3 relay No Check the stator and the rotor See Section 9 Yes No Yes Yes Are the K3 relay contacts opened 30 87a Change the K3 relay No Yes Is the 10 amp fuse F2 okay Change the fuse F2 Is the bridge rectifier BR1 okay No Yes Change the bridge rectifie...

Page 63: ...s of all power sources before servicing the equipment Configure the installation to electrically ground the generator set transfer switch and related equipment and electrical circuits to comply with applicablecodes andstandards Never contact electrical leads or appliances when standing in water oronwetgroundbecause theseconditions increasethe riskof electrocution High voltage test Hazardous voltag...

Page 64: ... the load additional current is induced in the rotor field to supplement the current being supplied by the stator auxiliary winding The generator cannot be disconnected or removed from the engine as a single unit 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 windin...

Page 65: ...in Section 11 2 Using a Megger set at 500 volts DC check the winding insulation resistance value to ground Check every part isolated from the others See Figure 9 2 Normally windings with a resistance value to ground greater than 1 MOhm are considered good If resistance is lower than 1 MOhm replace the rotor Figure 9 2 Rotor Insulation Test Procedure to test the rotor s continuity 1 Using an Ohmmet...

Page 66: ...r Figure 9 7 Field Diodes and Varistors Test Failed Diodes Replacement The rectifier assemblies are two sets of diodes and two varistors one for each rotor winding Take care to ensure that each diode is installed with the correct polarity 1 Check that the arrow on the diode surface direct towards the fixing plate 2 Check that the wire end with the eye terminal is located between the diode and the ...

Page 67: ...k the circuit s continuity using a 12 volt DC battery and a suitable lamp 5 Replace the stator if it has an open or short circuit in the windings Note Some generators have ground connections to the frame to ground check the Wiring Diagrams in Section 11 6 Using a Kelvin bridge or an accurate microhmmeter test the resistance of each stator windings and compare the resistances obtained See Figure 9 ...

Page 68: ... capacity g g High speed Adjust the revolving speed Correct no load voltage but low l l d Rotating diode s damage Check and replace the diode s g voltage at load Low speed at full load Operate on the speed governor Load too high Reduce the voltage supplied Unstable voltage Uneven rotation Check the engine g Poor connection contacts Check the wiring diagram and reset the connections Uneven load Che...

Page 69: ...rness outlet hole to the remote control panel 3 AC harness inlet holes to the control panel 1 2 3 3 Figure 10 1 Remote Controller Panel Components 1 Controller box 2 Circuit breaker 3 Controller fuse 1 2 3 Figure 10 2 Controller Components 1 Standard controller panel 2 Hourmeter 3 On Off switch 4 Start switch 5 Engine low oil pressure LEDs 6 Engine water overheating temperature LEDs 7 Exhaust gas ...

Page 70: ... cover See Figure 10 6 Note Remove the entire seawater pump every time alternator disassembly is required in order to check electrical components Figure 10 6 Seawater Pump Cover Removal Seawater Pump Impeller Removal 1 Carefully remove the seawater pump impeller from its housing See Figure 10 7 Figure 10 7 Seawater Pump Impeller Seawater Pump Housing Removal 1 After disconnecting the inlet and out...

Page 71: ...140 screws to disconnect the alternator from the engine flywheel housing See Figure 10 11 1 1 M10 x 140 Screws qty 4 Figure 10 11 Disconnect the Alternator 3 Release the two M8 nuts from the vibromounts using a 13 mm socket wrench 4 Using a hoist hook the stator bracket and lift the alternator to release the vibromount bolts from the alternator bracket 5 Install a jawpuller with three M5 threaded ...

Page 72: ...on between the rotor and the alternator through stud See Figure 10 14 Figure 10 14 Rotor Removal Engine and Rotor Hub Disconnection 1 Using a 13 mm socket wrench loosen the four M8 x 35 screws and remove the alternator engine hub from the engine flywheel See Figure 10 15 Figure 10 15 Engine Rotor Hub Stator Removal 1 The moveable and permanent magnet rotor is connected at the engine flywheel with ...

Page 73: ...Note To prevent the rotor from falling screw without tightening the 27 mm nut of the seawater pump shaft on the rotor through stud Figure 10 18 Rotor Replacement Stator Housing Installation 1 Guide the stator housing towards the engine flywheel housing as far as possible An O ring in the bearing seat hole stops it 2 Ensure that the holes of the fixing stator housing screws M10 x 140 are aligned wi...

Page 74: ...emble on the rear side of the stator housing the seawater pump housing Tighten the three M5 x 40 screws at the specified torque see section 1 5 with a 4 mm setscrew wrench 2 Push the impeller in the housing turning it slowly until it is on the shaft See Figure 10 23 Figure 10 23 Seawater Pump Impeller 3 Set the O ring and install the seawater pump cover Tighten the four M4 x 8 screws at the specif...

Page 75: ...e oval flange of the oil drain See Figure 10 24 3 Drain the oil Allow time for a complete oil drain Note If necessary slightly tip the engine to ensure a complete oil drain Figure 10 24 Oil Drain Remove the air intake s antiresonator device 1 Remove the air cleaner cover s four flat screws 2 Before removing the electric fuel pump clean the inside of the antiresonator housing with a rag 3 Ensure th...

Page 76: ...r and the electric fuel pump 2 Close the fuel return line to the tank using another clamp located after the injector s banjo fitting Remove the rocker cover 1 Remove the two rocker cover nuts washer cover and gasket See Figure 10 27 Note If the cover is difficult to remove tap it lightly with a soft faced hammer Figure 10 27 Rocker Cover Disconnect the high pressure fuel line 1 Hold a 14 mm wrench...

Page 77: ...damage the injector Note Remove the copper washer located between the head and the injector Figure 10 30 Fuel Injector Remove the cylinder head 1 Remove the two locknuts and washers that hold the protective tube retaining spring 2 Loosen and remove the four cylinder head nuts See Figure 10 31 Figure 10 31 Cylinder Head Remove the rocker arms 1 Using a chisel and hammer drive out the rocker arm sha...

Page 78: ...h two valve ring seats of wear resistant steel Consult the engine service manual and the following procedure if the head seats are so worn that a grinding valve rework will not ensure a good gas proof Use a valve seat cutter if a surface rework is needed 1 Insert the guide pin into the valve guide 2 Rotate the cutting surface of the T handled tool applying light pressure to touch the ring seat See...

Page 79: ...case See Figure 10 37 Figure 10 37 Gear Case 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 Lift up the liner enough so that the piston pin hole is free Continue with the follo...

Page 80: ...re 10 40 Piston Connecting Rod 1 Lay the engine on its flywheel side on a work bench 2 Move the flywheel until the piston reaches the Bottom Dead Center BDC of its stroke 3 Loosen the six hex cap head screws of the oil cooler housing and remove it from the engine If the screws are tight tap them with a hammer and a flat faced punch to loosen them See Figure 10 41 4 Using a 13 mm socket wrench unsc...

Page 81: ...of the fuel pump gear timing adjustment and the engine speed values may be required Figure 10 43 Gear Cover 3 If disassembly of the injection pump camfollower camshaft camshaft gear or camshaft bearing is necessary proceed to the following sections Injection Pump 1 Remove the two hex nuts of the injection pump and remove the pump from the gear cover Note To avoid losing the shims or the gasket rei...

Page 82: ...t the camshaft See Figure 10 46 Figure 10 46 Camshaft Camshaft Gear 1 Remove the gear from the camshaft using a puller or by pressing it off from the shaft See Figure 10 47 Figure 10 47 Camshaft Camshaft Bearing 1 Remove the camshaft s ball bearing from inside of the gear cover by using a socket pushed with a hydraulic press See Figure 10 48 Figure 10 48 Camshaft Bearing ...

Page 83: ...and covers are in place WARNING 4 Carefully using a pliers unhook the outer torsional return spring from its boss 5 Hold the inner control lever and turn down the accelerator lever until the inner torsional return spring releases its tension 6 Release the inner control lever from the eccentric shaft Figure 10 49 Speed Control Shaft Governor 1 Install a holding device and remove the governor pin Se...

Page 84: ...s Keep the flywheel nut on the shaft See Figure 10 52 Note If removing the flywheel from the engine without removing the governor place the accelerator lever in the higher speed full load position Otherwise damage may occur to the regulation linkage 2 Install the flywheel puller 3 Turn the two screws until the flywheel breaks loose from the tapered side of the engine crankshaft See Figure 10 53 4 ...

Page 85: ... turn them until the cover is released from the crankcase See Figure 10 54 4 Remove the key O ring two angle rings and two elastic washers See Figure 10 55 and Figure 10 56 Figure 10 54 Main Bearing Cover Figure 10 55 Main Bearing Figure 10 56 Main Bearing Crankshaft 1 Carefully remove the crankshaft from the crankcase Note Avoid touching scratching the main bearing bushing 2 Use a puller to relea...

Page 86: ...that are questionable 10 4 Generator Engine Reassembly Crankcase Bushing 1 Using a driver press the crankshaft s bush bearing on the crankcase Ensure that its edge is inside the crankcase as indicated in Figure 10 59 Also ensure that its oil holes are horizontal and aligned with the crankcase groove Figure 10 59 Crankcase Bushing Crankshaft Gear 1 To install the crankshaft gear heat it in an oil b...

Page 87: ... of the bearing seat 4 Put the main bearing cover on the crankshaft so that the snap ring is towards the flywheel side 5 Using a socket press the main bearing cover on the crankshaft until the inner race bearing is in its seat against the shoulder of the crankshaft 6 Lubricate the oil seal lip and the tapered surface of the crankshaft and assemble the oil seal on the cover Do not use grease 7 Put ...

Page 88: ...lywheel Oil Pump 1 Assemble the oil pump together with the thin covering plate valve and gasket to the crankcase See Figure 10 65 and Figure 10 66 2 Pull the pump downwards before tightening the screws at the specified torque See Section 1 5 3 The clearance on the pump screw holes allows enough backlash between the crankshaft gear and the pump gear Note The 4EOZ 3 5EFOZ model s engine have a count...

Page 89: ...shells take a half shell and place it about 3 4 into the connecting rod cap 2 Using a sliding movement press the shell in its seat until the lip goes into its relief Note Avoid touching scratching the connecting rod bushing 3 Repeat this procedure for the other half shell to be placed in the connecting rod trunk 4 Find the casting numbers located on the connecting rod trunk and cap surfaces See Fi...

Page 90: ...specified value See Section 1 5 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 Figure 10 70 Camshaft Gear ...

Page 91: ...t Injection Pump Camfollower 1 Assemble the injection pump camfollower and tighten its fixing nut through the oil fill hole Speed Control Shaft 1 Set the inner torsion return spring in the control lever s fuel pump lever s hole See Figure 10 73 2 Insert the end leg of the spring in the inner control lever hole 3 Put the control lever on the bench 4 Install the ratchet plate and the accelerator lev...

Page 92: ...ion until the inner spring can be hooked with the other end leg at the groove of the eccentric shaft 8 Move the ratchet plate between its two stop notches on the gear housing 9 Use a looping wire to move and to hook the other end leg of the outer spring at the gear housing boss See Figure 10 76 Figure 10 76 Gear Housing Boss 10 Push the eccentric speed shaft further until it locks with the inner r...

Page 93: ... direction See Figure 10 79 Figure 10 79 Ratchet Plate 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 2 Lubricate the rings and the piston skirt 3 Check that the piston ring gaps are at 120_ offset 4 Put the cylinder on the bench with its upper side touching the bench Note N...

Page 94: ...ts lower part is inserted into the block 8 Align the piston and connecting rod holes and install the pin with its retainers See Figure 10 82 Note If the piston has to be reinstalled on the engine mark it before its removal Figure 10 82 Piston Assembled Valve Guides 1 Press the valve guides in the proper head holes Carefully ensure that they are installed in an upright position at the head surface ...

Page 95: ... and set new cup seals on the valve guide s head 3 Before installing the rotocap check for proper operation by spinning the cap washer and releasing it Replace the rotocap if it produces a an ununiform rattling sound or if it is hard to move 4 Fit the cylinder head gasket See Figure 10 85 5 Slide the head onto the cylinder Figure 10 85 Cylinder Head and Gasket 6 On the shorter stud put the engine ...

Page 96: ...ollow this procedure to install the cover a Move the flywheel until its mark aligns with the threaded hole on the crankcase at the 1 o clock position See Figure 10 88 b Move the camshaft gear until its mark is exactly three teeth to the left of the gear cover mark See Figure 10 89 c Install the gear cover and turn the flywheel until the camshaft mark aligns with the one on the gear cover d Check t...

Page 97: ... 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 Figure 10 92 Retainer Spring In Cylinder Head Rocker Arms 1 Ensure that the piston is in the Top Dead Center TDC position 2 Lubricate and then drive the rocker arm shaft into its support 3 Align the push rods...

Page 98: ...se only a gasket under the injector and ensure that the old gasket is removed 2 Install the injector and the clamp 3 Tighten the injector nuts at the specified torque See Section 1 5 Injection Pump and Speed Control Shaft Connection 1 Keep the accelerator lever in the higher position 2 Pull down the fuel excess start device s button Note As the inner return spring pushes the control lever it goes ...

Page 99: ...urn valve nipples with a 14 mm wrench See Figure 10 97 2 Tighten the fuel line nuts with a 17 mm wrench Figure 10 97 High Pressure Line Valve Cover 1 Install the valve cover gasket on the upper surface of the head See Figure 10 98 2 Reinstall the valve cover 3 Put the synthetic rubber washers under the cover nuts and tighten at the specified torque See Section 1 5 Note To avoid oil leaks check and...

Page 100: ...0 0 0043 1 000 0 0394 1st and 2nd compression ring gaps oil scrapper ring gap 0 500 0 0197 0 500 0 0197 0 300 0 0118 0 250 0 0098 1 000 0 0394 1 000 0 0394 oil scrapper ring gap 0 500 0 0197 0 250 0 0098 1 000 0 0394 Note The excessive clearances or gaps are because of the abnormal wears of the cylinder liner piston and rings We always suggest to exchange the cylinder together with the piston and ...

Page 101: ...e diameter 22 031 0 8674 22 000 0 8661 21 970 0 8650 21 930 0 8634 22 022 0 8670 21 980 0 8654 21 960 0 8645 21 910 0 8626 21 990 0 8657 21 860 0 8606 Cylinder Head Inner guide diameter 7 014 0 2761 7 005 0 2758 Inner guide diameter Outer guide diameter Head protrusion of the intake valve guide 7 014 0 2761 10 019 0 3944 5 700 0 2244 7 005 0 2758 10 010 0 3941 Head protrusion of the intake valve g...

Page 102: ...TP 6137 5 03 90 Section 10 Generator and Engine Disassembly Reassembly Notes ...

Page 103: ...aus Naimler American Solenoid Newer Round Design 2 1 3 4 6 5 7 8 1 2 6 5 3 4 8 7 L1 L2 To Generator Set To Shore Power To Load 3 2 4 1 7 6 8 5 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets 2 1 3 4 6 5 7 8 L0 10 9 11 12 1 2 6 5 3 4 8 7 9 10 14 13 L1 L2 To Generator Set To Shore Power To Load 3 Wire Generator Sets L0 3 2 4 1 7 6 8 5 11 10 12 9 L1 L2 To Generator Set To Shore Po...

Page 104: ...TP 6137 5 03 92 Section 11 Wiring Diagrams 11 1 Wiring Diagram Schematic GM20645 B ...

Page 105: ...TP 6137 5 03 93 Section 11 Wiring Diagrams 11 2 Wiring Diagram Point to Point GM20645 B ...

Page 106: ...TP 6137 5 03 94 Section 11 Wiring Diagrams Notes ...

Page 107: ...ooled cyl cylinder D A digital to analog DAC digital to analog converter dB decibel dBA decibel A weighted DC direct current DCR direct current resistance deg degree dept department dia diameter DI EO dual inlet end outlet DIN Deutsches Institut fur Normung e V also Deutsche Industrie Normenausschuss DIP dual inline package DPDT double pole double throw DPST double pole single throw DS disconnect ...

Page 108: ...nal OS oversize overspeed OSHA Occupational Safety and Health Administration OV overvoltage oz ounce p pp page pages PC personal computer PCB printed circuit board pF picofarad PF power factor ph phase PHC Phillips head crimptite screw PHH Phillips hex head screw PHM pan head machine screw PLC programmable logic control PMG permanent magnet generator pot potentiometer potential ppm parts per milli...

Page 109: ...Below top of nut Figure 1 Acceptable Bolt Lengths Steps for common hardware application 1 Determine entry hole type round or slotted 2 Determine exit hole type fixed female thread weld nut round or slotted For round and slotted exit holes determine if hardware is greater than 1 2 inch in diameter or 1 2 inch in diameter or less Hardware that is greater than 1 2 inch in diameter takes a standard nu...

Page 110: ... 27 7 16 14 ft lbs Nm 29 39 44 60 63 85 7 16 20 ft lbs Nm 32 43 50 68 70 95 1 2 13 ft lbs Nm 44 60 68 92 96 130 1 2 20 ft lbs Nm 49 66 76 103 108 146 9 16 12 ft lbs Nm 60 81 98 133 138 187 9 16 18 ft lbs Nm 67 91 109 148 154 209 5 8 11 ft lbs Nm 83 113 135 183 191 259 5 8 18 ft lbs Nm 94 128 153 208 216 293 3 4 10 ft lbs Nm 147 199 240 325 338 458 3 4 16 ft lbs Nm 164 222 268 363 378 513 1 8 ft lb...

Page 111: ...nal External Tooth Lock Hardness Grades American Standard Grade 2 Grade 5 Grade 8 Grade 8 9 Hex Socket Head Metric Number stamped on hardware 5 8 shown 5 8 Allent head screw is a trademark of Holo Krome Co Phillipsr screw is a registered trademark of Phillips Screw Company Sample Dimensions 1 4 20 x 1 Major Thread Diameter In Fractional Inches Or Screw Number Size Length In Inches Screws and Bolts...

Page 112: ... 6024 2 7 16 14 x 1 00 X 6024 8 7 16 14 x 1 25 X 6024 3 7 16 14 x 1 50 X 6024 4 7 16 14 x 2 00 X 6024 11 7 16 14 x 2 75 X 6024 12 7 16 14 x 6 50 X 129 15 1 2 13 x 75 X 129 17 1 2 13 x 1 00 X 129 18 1 2 13 x 1 25 X 129 19 1 2 13 x 1 50 X 129 20 1 2 13 x 1 75 X 129 21 1 2 13 x 2 00 X 129 22 1 2 13 x 2 25 X 129 23 1 2 13 x 2 50 X 129 24 1 2 13 x 2 75 X 129 25 1 2 13 x 3 00 X 129 27 1 2 13 x 3 50 X 12...

Page 113: ...1 25 x 20 M933 10020 60 M10 1 50 x 20 M933 10025 60 M10 1 50 x 25 M933 10030 60 M10 1 50 x 30 M933 10030 82 M10 1 50 x 30 M961 10035 60 M10 1 25 x 35 M933 10035 60 M10 1 50 x 35 M933 12016 60 M12 1 75 x 16 M933 12020 60 M12 1 75 x 20 M933 12025 60 M12 1 75 x 25 M933 12025 82 M12 1 75 x 25 M933 12030 60 M12 1 75 x 30 M933 12040 60 M12 1 75 x 40 M933 12040 82 M12 1 75 x 40 M961 14025 60 M14 1 50 x 2...

Page 114: ......

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Page 116: ...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 ...

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