Kohler 4EOZ Assembly instructions

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

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.
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 Designation
Serial Number
x:in:007:001a

TP-6137 5/03 Table of Contents
Table of Contents
Product Identification Information Inside front cover............................................
Safety Precautions and Instructions I........................................................
Introduction i...............................................................................
Service Assistance i........................................................................
Section 1 Specifications 1...................................................................
1.1 General 1..............................................................
1.2 Generator 1............................................................
1.3 Service Views 2........................................................
1.4 Engine 3...............................................................
1.5 Torque Specifications 4..................................................
Section 2 Operation 5.......................................................................
2.1 Prestart Checklist 5.....................................................
2.2 Marine Inspection 5.....................................................
2.3 Angular Operation 5.....................................................
2.4 Operation in European Union Member Countries 5..........................
2.5 Exercising the Generator Set 6...........................................
2.6 Starting and Stopping Procedure 6........................................
2.6.1 Controls and Indicators 6........................................
2.6.2 Starting the Generator Set 7......................................
2.6.3 Stopping the Generator Set 7.....................................
2.6.4 Engine Safety 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 15............................................
3.5.2 Fuel System 15..................................................
3.5.3 Cooling System 15...............................................
3.5.4 Exterior 15......................................................
3.5.5 Battery 15.......................................................
Section 4 Intake and Exhaust System 17.......................................................
4.1 Air Intake Silencer/Filter 17................................................
4.2 Exhaust System 18......................................................
4.3 Mixing Elbow 18.........................................................
Section 5 Fuel System 19.....................................................................
5.1 General 19..............................................................
5.2 Fuel Specifications 19....................................................
5.3 Fuel Filter 20............................................................
5.4 Fuel Injector Nozzle 21...................................................
5.5 Excess Fuel Start Device 23...............................................
5.6 The Injection Pump’s Fuel Starting Delivery Point 24..........................
5.7 Fuel Pump Adjustment Timing 25..........................................

TP-6137 5/03Table of Contents
5.8 Fuel Pump and Gear Cover Installation 25..................................
5.9 Bleeding the Fuel System 26..............................................
5.10 Governor 27.............................................................
Section 6 Cooling System 31.................................................................
6.1 Direct Water Cooled 31...................................................
6.2 Thermostat 32...........................................................
6.3 Seawater Pump and Impeller 32...........................................
6.4 Siphon Break 33.........................................................
6.5 Anticorrosion Zinc Anode 35...............................................
Section 7 Troubleshooting 37.................................................................
7.1 General 37..............................................................
Section 8 Controller Troubleshooting 41.......................................................
8.1 General 42..............................................................
8.1.1 On/Off Switch 42.................................................
8.1.2 Start 42.........................................................
8.1.3 Run 42.........................................................
8.1.4 On/Off Switch (Stop) 42...........................................
8.2 Engine Safety Shutdown Switches 43.......................................
8.2.1 Low Oil Pressure (LOP) Shutdown 43...............................
8.2.2 High Water Temperature and High Exhaust Temperature
Shutdown Switch 43..............................................
8.3 Operation Sequence 45...................................................
8.4 Troubleshooting 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 Generator Alternator Reassembly 61.......................................
10.3 Generator Engine Disassembly 63.........................................
10.4 Generator Engine Reassembly 74..........................................
10.5 Engine Component Dimensions and Wear 88................................
Section 11 Wiring Diagrams 91...............................................................
11.1 Wiring Diagram, Schematic 92.............................................
11.2 Wiring Diagram, Point-to-Point 93..........................................
Appendix A Abbreviations A-1..................................................................
Appendix B Common Hardware Application Guidelines A-3........................................
Appendix C General Torque Specifications A-4...................................................
Appendix D Common Hardware Identification A-5.................................................
Appendix E Common Hardware List A-6.........................................................

TP-6137 5/03 ISafety Precautions and Instructions
Safety Precautions and Instructions
IMPORTANT SAFETY
INSTRUCTIONS. Electromechanical
equipment, including generator sets,
transfer switches, switchgear, and
accessories, can cause bodily harm
and pose life-threatening danger when
improperly installed, operated, or
maintained. To prevent accidents be
aware of potential dangers and act
safely. Read and follow all safety
precautions and instructions. SAVE
THESE INSTRUCTIONS.
This manual has several types of safety
precautions and instructions: Danger,
Warning, Caution, and Notice.
DANGER
Danger indicates the presence of a
hazard that will cause severe
personal injury, death,orsubstantial
property damage.
WARNING
Warning indicates the presence of a
hazard that can cause severe
personal injury, death, or substantial
property damage.
CAUTION
Caution indicates the presence of a
hazard that will or can cause minor
personal injury or property damage.
NOTICE
Notice communicates installation,
operation, or maintenance information
that is safety related but not hazard
related.
Safety decals affixed to the equipment
in prominent places alert the operator
or service technician to potential
hazards and explain how to act safely.
The decals are shown throughout this
publication to improve operator
recognition. Replace missing or
damaged decals.
Accidental Starting
Accidental starting.
Can cause severe injury or death.
Disconnect the battery cables before
working on the generator set.
Remove the negative (--) lead first
when disconnecting the battery.
Reconnect the negative (--) lead last
when reconnecting the battery.
WARNING
Disabling the generator set.
Accidental starting can cause
severe injury or death. Before
working on the generator set or
equipment connected to the set,
disable the generator set as follows:
(1) Press the generator set on/off
button to shut down the generator set.
All indicator lamps dim. (2) Disconnect
the power to the battery charger, if
equipped. (3) Remove the battery
cables, negative (--) lead first.
Reconnect the negative (--) 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. Battery acid can cause
severe injury or death. Battery acid
can cause blindness and burn skin.
Always wear splashproof safety
goggles, rubber gloves, and boots
when servicing the battery. Do not
open a sealed battery or mutilate the
battery case. If battery acid splashes in
the eyes or on the skin, immediately
flush the affected area for 15 minutes
with large quantities of clean water.
Seek immediate medical aid in the 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 acid cleanup. Battery acid
can cause severe injury or death.
Battery acid is electrically conductive
and corrosive. Add 500 g (1 lb.) of
bicarbonate of soda (baking soda) to a
containerwith4L(1gal.)ofwaterand
mix the neutralizing solution. Pour the
neutralizing solution on the spilled
battery acid and continue to add the
neutralizing solution to the spilled
battery acid until all evidence of a
chemical reaction (foaming) has
ceased. Flush the resulting liquid with
water and dry the area.
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. Do not dispose of a
battery in a fire. To prevent burns and
sparks that could cause an explosion,
avoid touching the battery terminals
with tools or other metal objects.
Remove all jewelry before servicing the
equipment. Discharge static electricity
from your body before touching
batteries by first touching a grounded
metal surface away from the battery. To
avoid sparks, do not disturb the battery
charger connections while the battery
is charging. Always turn the battery
charger off before disconnecting the
battery connections. Ventilate the
compartments containing batteries to
prevent accumulation of explosive
gases.

TP-6137 5/03II Safety Precautions and Instructions
Battery short circuits. Explosion
can cause severe injury or death.
Short circuits can cause bodily injury
and/or equipment damage.
Disconnect the battery before
generator set installation or
maintenance. Remove all jewelry
before servicing the equipment. Use
tools with insulated handles. Remove
the negative (--) lead first when
disconnecting the battery. Reconnect
the negative (--) lead last when
reconnecting the battery. Never
connect the negative (--) battery cable
to the positive (+) connection terminal
of the starter solenoid. Do not test the
battery condition by shorting the
terminals together.
Engine Backfire/Flash
Fire
Fire.
Can cause severe injury or death.
Do not smoke or permit flames or
sparks near fuels or the fuel system.
WARNING
Servicing the fuel system. A flash
fire can cause severe injury or death.
Do not smoke or permit flames or
sparks near the carburetor, fuel line,
fuel filter, fuel pump, or other potential
sources of spilled fuels or fuel vapors.
Catch fuels in an approved container
when removing the fuel line or
carburetor.
Servicing the air cleaner. A sudden
backfire can cause severe injury or
death. Do not operate the generator
set with the air cleaner/silencer
removed.
Combustible materials. A sudden
flash fire can cause severe injury or
death. Do not smoke or permit flames
or sparks near the fuel system. Keep
the compartment and the generator set
clean and free of debris to minimize the
risk of fire. Wipe up spilled fuels and
engine oil.
Combustible materials. A fire can
cause severe injury or death.
Generator set engine fuels and fuel
vapors are flammable and explosive.
Handle these materials carefully to
minimize the risk of fire or explosion.
Equip the compartment or nearby area
with a fully charged fire extinguisher.
Select a fire extinguisher rated ABC or
BC for electrical fires or as
recommended by the local fire code or
an authorized agency. Train all
personnel on fire extinguisher
operation and fire prevention
procedures.
Exhaust System
Carbon monoxide.
Can cause severe nausea,
fainting, or death.
The exhaust system must be
leakproof and routinely inspected.
WARNING
Carbon monoxide symptoms.
Carbon monoxide can cause severe
nausea, fainting, or death. Carbon
monoxide is a poisonous gas present in
exhaust gases. Carbon monoxide
poisoning symptoms include but are
not limited to the following:
DLight-headedness, dizziness
DPhysical fatigue, weakness in
joints and muscles
DSleepiness, mental fatigue,
inability to concentrate
or speak clearly, blurred vision
DStomachache, vomiting, nausea
If experiencing any of these symptoms
and carbon monoxide poisoning is
possible, seek fresh air immediately
and remain active. Do not sit, lie down,
or fall asleep. Alert others to the
possibility of carbon monoxide
poisoning. Seek medical attention if
the condition of affected persons does
not improve within minutes of breathing
fresh air.
Copper tubing exhaust systems.
Carbon monoxide can cause severe
nausea, fainting, or death. Do not
use copper tubing in diesel exhaust
systems. Sulfur in diesel exhaust
causes rapid deterioration of copper
tubing exhaust systems, resulting in
exhaust/water leakage.
Inspecting the exhaust system.
Carbon monoxide can cause severe
nausea, fainting, or death. For the
safety of the craft’s occupants, install a
carbon monoxide detector. Consult the
boat builder or dealer for approved
detector location and installation.
Inspect the detector before each
generator set use. In addition to routine
exhaust system inspection, test the
carbon monoxide detector per the
manufacturer’s instructions and keep
the detector operational at all times.
Operating the generator set. Carbon
monoxide can cause severe nausea,
fainting, or death. Carbon monoxide
is an odorless, colorless, tasteless,
nonirritating gas that can cause death if
inhaled for even a short time. Use the
following precautions when installing
and operating the generator set. Do not
install the exhaust outlet where exhaust
can be drawn in through portholes,
vents, or air conditioners. If the
generator set exhaust discharge outlet
is near the waterline, water could enter
the exhaust discharge outlet and close
or restrict the flow of exhaust. Never
operate the generator set without a
functioning carbon monoxide detector.
Be especially careful if operating the
generator set when moored or
anchored under calm conditions
because gases may accumulate. If
operating the generator set dockside,
moor the craft so that the exhaust
discharges on the lee side (the side
sheltered from the wind). Always be
aware of others, making sure your
exhaust is directed away from other
boats and buildings. Avoid overloading
the craft.

TP-6137 5/03 IIISafety Precautions and Instructions
Fuel System
Explosive fuel vapors.
Can cause severe injury or death.
Use extreme care when handling,
storing, and using fuels.
WARNING
The fuel system. Explosive fuel
vapors can cause severe injury or
death. Vaporized fuels are highly
explosive. Use extreme care when
handling and storing fuels. Store fuels
inawell-ventilatedareaawayfrom
spark-producing equipment and out of
the reach of children. Never add fuel to
the tank while the engine is running
because spilled fuel may ignite on
contact with hot parts or from sparks.
Do not smoke or permit flames or
sparks to occur near sources of spilled
fuel or fuel vapors. Keep the fuel lines
and connections tight and in good
condition. Do not replace flexible fuel
lines with rigid lines. Use flexible
sections to avoid fuel line breakage
caused by vibration. Do not operate the
generator set in the presence of fuel
leaks, fuel accumulation, or sparks.
Repair fuel systems before resuming
generator set operation.
Draining the fuel system. Explosive
fuel vapors can cause severe injury
or death. Spilled fuel can cause an
explosion. Use a container to catch fuel
when draining the fuel system. Wipe up
spilled fuel after draining the system.
Installing the fuel system. Explosive
fuel vapors can cause severe injury
or death. Fuel leakage can cause an
explosion. Do not modify the tank or
the propulsion engine fuel system.
Equip the craft with a tank that allows
one of the two pickup arrangements
described in the installation section.
The tank and installation must conform
to USCG Regulations.
Pipe sealant. Explosive fuel vapors
can cause severe injury or death.
Fuel leakage can cause an explosion.
Use pipe sealant on all threaded fittings
to prevent fuel leakage. Use pipe
sealant that resists gasoline, grease,
lubrication oil, common bilge solvents,
salt deposits, and water.
Ignition-protected equipment.
Explosive fuel vapors can cause
severe injury or death. Gasoline
vapors can cause an explosion.
USCG Regulation 33CFR183 requires
that all electrical devices (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
environment such as an engine room or
near fuel tanks. Acceptable locations
are the wheelhouse and other living
areas sheltered from rain and water
splash.
Hazardous Noise
Hazardous noise.
Can cause hearing loss.
Never operate the generator set
without a muffler or with a faulty
exhaust system.
CAUTION
Engine noise. Hazardous noise can
cause hearing loss. Generator sets
not equipped with sound enclosures
can produce noise levels greater than
105 dBA. Prolonged exposure to noise
levels greater than 85 dBA can cause
permanent hearing loss. Wear hearing
protection when near an operating
generator set.
Hazardous Voltage/
Electrical Shock
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Grounding electrical equipment.
Hazardous voltage can cause
severe injury or death. Electrocution
is possible whenever electricity is
present. Open the main circuit
breakers 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 applicable codes
and standards. Never contact
electrical leads or appliances when
standing in water or on wet ground
because these conditions increase the
risk of electrocution.
Disconnecting the electrical load.
Hazardous voltage can cause
severe injury or death. Disconnect
the generator set from the load by
opening the line circuit breaker or by
disconnecting the generator set output
leads from the transfer switch and
heavily taping the ends of the leads.
High voltage transferred to the load
during testing may cause personal
injury and equipment damage. Do not
use the safeguard circuit breaker in
place of the line circuit breaker. The
safeguard circuit breaker does not
disconnect the generator set from the
load.

TP-6137 5/03IV Safety Precautions and Instructions
Short circuits. Hazardous
voltage/current can cause severe
injury or death. Short circuits can
cause bodily injury and/or equipment
damage.Do not contact electrical
connections with tools or jewelry while
making adjustments or repairs.
Remove all jewelry before servicing the
equipment.
Handling the capacitor. Hazardous
voltage can cause severe injury or
death. Electrical shock results from
touching the charged capacitor
terminals. Discharge the capacitor by
shorting the terminals together.
(Capacitor-excited models only)
Electrical backfeed to the utility.
Hazardous backfeed voltage can
cause severe injury or death.
Connect the generator set to the
building/marina electrical system only
through an approved device and after
the building/marina main switch is
opened. Backfeed connections can
cause severe injury or death to utility
personnel working on power lines
and/or personnel near the work area.
Some states and localities prohibit
unauthorized connection to the utility
electrical system. Install a
ship-to-shore transfer switch to prevent
interconnection of the generator set
power and shore power.
Testing live electrical circuits.
Hazardous voltage or current can
cause severe injury or death. Have
trained and qualified personnel take
diagnostic measurements of live
circuits. Use adequately rated test
equipment with electrically insulated
probes and follow the instructions of the
test equipment manufacturer when
performing voltage tests. Observe the
following precautions when performing
voltage tests: (1) Remove all jewelry.
(2) Stand on a dry, approved electrically
insulated mat. (3) Do not touch the
enclosure or components inside the
enclosure. (4) Be prepared for the
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 cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving rotor.
WARNING
Rotating parts.
Can cause severe injury or death.
Operate the generator set only when
all guards, screens, and covers are in
place.
WARNING
Airborne particles.
Can cause severe injury or
blindness.
Wear protective goggles and clothing
when using power tools, hand tools,
or compressed air.
WARNING
Tightening the hardware. Flying
projectiles can cause severe injury
or death. Loose hardware can cause
the hardware or pulley to release from
the generator set engine and can cause
personal injury. Retorque all
crankshaft and rotor hardware after
servicing. Do not loosen the crankshaft
hardware or rotor thrubolt when making
adjustments or servicing the generator
set. Rotate the crankshaft manually in
a clockwise direction only. Turning the
crankshaft bolt or rotor thrubolt
counterclockwise can loosen the
hardware.
Servicing the generator set when it
is operating. Exposed moving parts
can cause severe injury or death.
Keep hands, feet, hair, clothing, and
test leads away from the belts and
pulleys when the generator set is
running. Replace guards, screens, and
covers before operating the generator
set.
Sound shield removal. Exposed
moving parts can cause severe
injury or death. The generator set
must be operating in order to perform
some scheduled maintenance
procedures. Be especially careful if the
sound shield has been removed,
leaving the belts and pulleys exposed.
(Sound-shield-equipped models only)

TP-6137 5/03 VSafety Precautions and Instructions
Notice
NOTICE
This generator set has been
rewired from its nameplate voltage
to
246242
NOTICE
Voltage reconnection. Affix a notice
to the generator set after reconnecting
the set to a voltage different from the
voltage on the nameplate. Order
voltage reconnection decal 246242
from an authorized service
distributor/dealer.
NOTICE
Hardware damage. The engine and
generator set may use both American
Standard and metric hardware. Use
the correct size tools to prevent
rounding of the bolt heads 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 rating
and type (for example: 3AB or 314,
ceramic). Do not substitute clear
glass-type fuses for ceramic fuses.
Refer to the wiring diagram when the
ampere rating is unknown or
questionable.
NOTICE
Saltwater damage. Saltwater quickly
deteriorates metals. Wipe up saltwater
on and around the generator set and
remove salt deposits from metal
surfaces.

TP-6137 5/03VI Safety Precautions and Instructions
Notes

TP-6137 5/03 iIntroduction
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.
x:in:001:001
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.
x:in:001:003
Service Assistance
For professional advice on generator power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
DConsult the Yellow Pages under the heading
Generators—Electric
DVisit the Kohler Power Systems website at
KohlerPowerSystems.com
DLook at the labels and stickers on your Kohler product
or review the appropriate literature or documents
included with the product
DCall toll free in the US and Canada 1-800-544-2444
DOutside the US and Canada, call the nearest regional
office
Africa, Europe, Middle East
London Regional Office
Langley, Slough, England
Phone: [phone]
Fax: [phone]
Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: [phone]
Fax: [phone]
China
North China Regional Office, Beijing
Phone: [phone]
(86) 10 6518 7951
(86) 10 6518 7952
Fax: [phone]
East China Regional Office, Shanghai
Phone: [phone]
Fax: [phone]
India, Bangladesh, Sri Lanka
India Regional Office
Bangalore, India
Phone: [phone]
(91) 80 3366231
Fax: [phone]
Japan, Korea
North Asia Regional Office
Tokyo, Japan
Phone: [phone]
Fax: [phone]
Latin America
Latin America Regional Office
Lakeland, Florida, USA
Phone: [phone]
Fax: [phone]
X:in:008:001a

TP-6137 5/03ii Service Assistance
Notes

TP-6137 5/03 1Section 1 Specifications
Section 1 Specifications
1.1 General
This manual covers the operation, maintenance,
troubleshooting, and repair of the alternating current
marine generator sets.
Have an authorized service dealer/distributor perform
required servicing to assure your unit continues to meet
USCG requirements.
Please take a few moments to read this manual, then
carefully follow all service recommendations. Keep this
manual aboard your craft for future reference. See
Figure 1-1 for identification and location of components.
Your craft is equipped with a dependable 120 volt
(60 Hz) or 230 volt (50 Hz), single phase, alternating
current generator set.
The 4EOZ/3.5EFOZ models are powered by a
Farymann one-cylinder, direct water-cooled, four-cycle
diesel engine.
Kohler Co. develops all Kohlerrmarine generator set
ratings using accepted 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 (95.0)
Air requirements—combustion, L/min. (cfm) 436 (15.4) 363 (12.8)
Fuel consumption, Lph. (gph) at % load
25% 0.64 (0.17) 0.60 (0.16)
50% 1.02 (0.27) 0.96 (0.25)
75% 1.36 (0.36) 1.28 (0.34)
100% 1.70 (0.45) 1.60 (0.42)
Generator type 2 pole, rotating field
Coupling type Tapered hub
Excitation type Brushless exciter
Shaft RPM 3600 3000
Number of output leads 4 2
Voltage regulation model Capacitor type
Voltage regulation ±5%
Frequency regulation ±3%
Voltage 120 230
Amps @ 25 °C(77°F) 29.2/14.6 13.9
kW/kVA@25°C(77°F) 3.5 3.2
Phase (Hz) 1 (60 Hz) 1 (50 Hz)
Cold main field (rotor) resistance (ohms) 2.57
Cold stator resistance (ohms)
1--2 0.96 1.23
3--4 0.96 --
C1--C2 2.32 2.87
10--11 0.068 0.091

TP-6137 5/032 Section 1 Specifications
1.3 Service Views
1. Cooling air inlet
2. On/off button
3. Hourmeter
4. Start button
5. Circuit breaker panel
6. Remote panel connector
7. Fuel inlet
8. Fuel return
9. Water outlet/exhaust outlet
10. Siphon break connection
11. Customer load lead access
12. Remote panel harness access
13. AC circuit breaker
14. Input fuse
15. Customer load lead access connection
16. Fuel injection pump
17. Oil fill
18. Oil drain valve and hose
19. Fuel filter
20. High engine water temperature 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. Anticorrosion zinc anode
37. Controller
38. Nameplate
ADV6652-
Service-Side View
Service-Side View
(Shown without sound shield doors and panels)
Engine-End View
1
23 4
6
7
89101112
13
14
15
18
19
21
24
25
26
28
32
37
36
22
38
35
5Circuit Breaker Panel
33
27
29
30
31
34
16
17
20
23
Figure 1-1 Service Views

TP-6137 5/03 3Section 1 Specifications
1.4 Engine
Generator Model 4EOZ 3.5EFOZ
Engine manufacturer Farymann Diesel
Engine model 18 W
Number of cylinders 1
Cylinder block material Cast iron
Cylinder head material Cast iron
Piston rings 2 compression/1 oil
Crankshaft material Stamped forging
Connecting rod material Aluminum
Governor Centrifugal, mechanical
Bore x stroke, mm (in.) 82 x 55 (3.23 x 2.17)
Displacement, L (cu. in.) 0.29 (17.7)
Compression ratio 20:1
Horsepower, 60/50 Hz 5.9 5.6
RPM, 60/50 Hz 3600 3000
Direction of rotation (as viewed from generator end) Counterclockwise
Lubrication system Pressure, trochoid pump
Lube oil capacity w/filter, 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 solenoid system Electric
Fuel feed pump Electric, solenoid type
Fuel pump priming Electric
Max. recommended fuel pump lift, m (ft.) 0.9 (3)
Thermostat, freshwater/seawater 75°C (167°F)/50°C (122°F)
Starter motor 12 volt
Intake/exhaust valve clearance (cold), mm (in.) 0.2 (0.008)
Inlet water line hose ID
(seawater pump inlet), mm (in.) 16 (5/8)
Outlet water line hose ID
(mixing elbow outlet), mm (in.) 51 (2.0)
Fuel inlet (fuel pump inlet) 1/4 NPT
Fuel return size type 1/4 NPT

TP-6137 5/034 Section 1 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)
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)
Flywheel/rotor hub nuts 25 (18.5)
Nut fixing the rotor 25 (18.5)
Stator screws 30 (22)
Alternator bracket screws 50 (37)
Engine bracket screws 50 (37)

TP-6137 5/03 5Section 2 Operation
Section 2 Operation
2.1 Prestart Checklist
To ensure continued satisfactory operation perform the
following checks or inspections before or at each
startup, as designated, and at the intervals specified in
the service schedule. In addition, some checks require
verification after the unit starts.
Air Inlets. Check for clean and unobstructed air inlets.
Air Shrouding. Check for securely installed and
positioned air shrouding.
Battery. Check for tight battery connections. Consult
the battery manufacturer’s instructions regarding
battery care and maintenance.
Exhaust System. Check for exhaust leaks and
blockages. Check the silencer and piping condition and
check for tight exhaust system connections.
Inspect the exhaust system components (exhaust
manifold, mixing elbow, exhaust line, hose clamps,
silencer, and outlet flapper) for cracks, leaks, and
corrosion.
DCheck the hoses for softness, cracks, leaks, or dents.
Replace the hoses as needed.
DCheck for corroded or broken metal parts and replace
them as needed.
DCheck for loose, corroded, or missing clamps.
Tighten or replace the hose clamps and/or hangers
as needed.
DCheck that the exhaust outlet is unobstructed.
DVisually inspect for exhaust leaks (blowby). Check
for carbon or soot residue on exhaust components.
Carbon and soot residue indicates an exhaust leak.
Seal leaks as needed.
DEnsure that the carbon monoxide detector(s) is (1) in
the craft, (2) functional, and (3) energized whenever
the generator set 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, or debris on or near the
generator set.
Seawater Pump Priming. Prime the seawater pump
before initial startup. To prime the pump: (1) close the
seacock, (2) remove the hose from the water-filter
outlet, (3) fill the hose and seawater pump with clean
water, (4) reconnect the hose to the water filter outlet,
and (5) open the seacock. Confirm seawater pump
operation on startup as indicated by water discharge
from the exhaust outlet.
2.2 Marine Inspection
Kohler Co. recommends that all boat owners have their
vessels—especially the exhaust system attached to the
generator set—inspected at the start of each boating
season by the local Coast Guard Auxiliary. If there is no
Coast Guard Auxiliary in the area, contact an authorized
Kohler distributor/dealer for the inspection.
2.3 Angular Operation
See Figure 2-1 for angular operation limits for units
covered in this manual.
Continuous
Intermittent—
3 minutes or less
25_30_
Maximum value for all directions
Figure 2-1 Angular Operation
m:op:001:004
2.4 Operation in European Union
Member Countries
This generator set is specifically intended and approved
for operation below the deck in the engine compartment.
Operation above the deck and/or outdoors would
constitute a violation of European Union Directive
2000/14/EC noise emission standard.

TP-6137 5/036 Section 2 Operation
2.5 Exercising the Generator Set
Operate the generator set under load once each week
for one hour with an operator present.
The operator should perform all of the prestart checks
before starting the exercise procedure. Start the
generator set according to the starting procedure in the
controller section of this manual. While the generator
set is operating, listen for a smooth-running engine and
visually inspect the generator set for fluid or exhaust
leaks.
x:op:001:005
2.6 Starting and Stopping
Procedure
Note: Opening seacock. Before starting the generator
set, open the seacock to allow cooling water
passage. Failure to do so could damage the
seawater pump impeller and cause serious
engine overheating damage.
Note: Transfer switch. Check that the marine
ship-to-shore transfer switch, if equipped, is in
the ship position.
Note: Close seacock if engine fails to start. If the
engine fails to start after the first attempt, close
the seacock before the next starting attempt.
Failure to close the seacock may cause seawater
to enter the exhaust piping, silencer, and/or
engine. A water-filled exhaust piping and
silencer may further hinder generator starting
and cause seawater entry into the engine
cylinder through the exhaust valve. Water
ingested into the engine may cause major engine
damage that the Kohler Co. warranty does not
cover.
Note: Close seacock if water enters the exhaust
system. If water enters the exhaust system,
close the seacock and drain the water from the
exhaust system at the silencer’s drain plug before
attempting to start the generator set. If excessive
cranking is a chronic problem, have the unit,
including the exhaust system, serviced by an
authorized Kohlerrdistributor/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 Kohlerrdistributor/ dealer
for repair. Failure to follow these guidelines may
result in starter motor burnout.
2.6.1 Controls and Indicators
The following table describes the controls and indicators
located at the controller. See Figure 2-2.
Name Description
On/Off Button Use this button to initiate the start
procedure or to stop the generator set.
Press the button to the ON position
before starting the generator set.
Press the button to the OFF position to
stop the generator set.
Start Button Use this button to start the generator
set. Press the start button to start the
generator set.
Hourmeter The meter records total generator set
operating hours for reference in
maintenance scheduling.
AC Circuit
Breaker
The circuit breaker trips when a fault
occurs in the output circuit. During
maintenance of craft or generator set
wiring, the circuit breaker disconnects
the generator set. Place the circuit
breaker(s) in the ON position to close
the circuit breaker. See Figure 1-1.
Oil Pressure
Lamp
The lamp illuminates (red) if the
generator set shuts down because of
low oil pressure.
Engine Lamp The lamp illuminates (red) if the
generator set shuts down because of
high engine temperature.
Exhaust Lamp The lamp illuminates (red) if the
generator set shuts down because of
high exhaust temperature.
Remote Start
Connectors
A 4-pin connector on the controller’s
side allows the connection of the
(optional) remote start/stop switch
and hourmeter panel kit.See
Figure 2-3.
A 25-pin connector underneath the
controller allows the connection of the
(optional) remote start/stop switch,
hourmeter, and indicator panel kit.
See Figure 2-3.

TP-6137 5/03 7Section 2 Operation
1
26
1. Hourmeter
2. On/Off button
3. Oil pressure lights
4. Engine temperature lights
5. Exhaust temperature lights
6. Start button
3
4
5
Figure 2-2 Controls and Indicators
1
1. 4-pin connector
2. 25-pin connector
2
Figure 2-3 Remote Panel Connections
2.6.2 Starting the Generator Set
The following table describes the actions required to
start the generator set.
S
t
e
p
A
c
t
i
o
n
Step
A
ction
1Fuel shutoff valve
Open the manual fuel shutoff valve, if equipped.
2Initiate Starting
Press the controller on/off button to the ON position.
Note: The controller’s oil pressure, engine, and
exhaust lamps illuminate.
3Starting
Hold the generator set controller start button until the
generator set starts. Green LEDs indicate good
water engine and exhaust temperature
performance.
Note: If the start button is pressed before a normal
start procedure, an electrical device disconnects the
starter pinion.
2.6.3 Stopping the Generator Set
The following table describes the actions required to
stop the generator set.
S
t
e
p
A
c
t
i
o
n
Step
A
ction
1Cooldown
Run the generator set at no load for 5 minutes to
ensure adequate engine cooldown.
2Stopping
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.
3Fuel shutoff valve
Close the manual fuel shutoff valve, if equipped.
2.6.4 Engine Safety Shutdown Switches
The engine is protected by 3 shutdown switches which
automatically reset when the engine failure is corrected.
The engine safety shutdown switches become
functional when the unit comes up to speed, AC voltage
is available, and after a 3--5 second time delay.
The engine will shut down when:
DThe engine oil pressure is 0.3--0.7 bar (30--70 kPa) or
less.
DThe engine water temperature is 78--83_C
(172--181_F) or higher.
DThe water temperature in the mixer elbow is
94--100_C (201--212_F) or higher
Note: The low oil pressure switch is not a low oil level
shutdown. Check the oil level regularly to protect
against engine damage from low oil level.

TP-6137 5/038 Section 2 Operation
2.6.5 Circuit Protection
The AC circuit breaker trips when a fault is detected in
the output circuit. After correcting the fault, reset the AC
circuit breaker by placing in the ON position. See
Figure 1-1 for circuit breaker location.
Note: Replace the 25-amp fuse installed in the control
box after a fault. See Figure 1-1 for the fuse
location. Unit is now ready for restart.
2.7 Remote Panel Kits
Remote start/stop panels allow starting or stopping the
generator set from a remote location.
2.7.1 Remote Start/Stop Panel Kit
The remote start/stop panel includes an hourmeter and
start/stop switch. The generator set includes a 4-pin
connector 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
23
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
The remote panel kit includes a start button, an on/off
button, an hourmeter to record total generator set
operating hours, an engine oil pressure light, an engine
water temperature light, and an exhaust gas light. Order
additional extension harnesses for panel connection to
the 25-pin connector.
GM20768-
1
26
1. Hourmeter
2. On/Off button
3. Oil pressure lights
4. Engine temperature lights
5. Exhaust temperature lights
6. Start button
3
4
5
Figure 2-6 Remote Panel Features