Service Parts Marine Generator Sets Models: 3.
Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Numbering System Significance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 How to Find Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This manual lists service replacement parts for 4 kW generator sets. At the time of print this manual applied to the generator set specification (spec) numbers listed in the Specification Number Index. On occasion this manual may apply to specs not listed in the Specification Number Index. Information in this publication represents data available at the time of print. Kohler Co.
Specification Number Index Group Title Group No. 1 2 3 4 5 6 7 8 9 10 11 12 13 VARIATION NUMBER Spec. No. 3.5EFOZ GM20642-SA1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 14 15 16 17 18 19 20 21 22 4EOZ GM20641-SA1 Group Title Group No. VARIATION NUMBER Spec No. 3.
Group 1: Crankcase 6138_1 Item 1 2 3 4 5 7 10 11 12 13 14 15 16 17 18 19 20 Part Number GM24007 GM23884 GM23885 GM23886 GM23870 GM23934 GM23955 GM23927 GM23965 GM23973 # # GM23925 GM23937 # # # Description Crankcase Assembly Stud, Cylinder Block Stud, Cylinder Block Stud, Crankcase Switch, Oil Pressure Gasket, Crankcase O-ring, 99 x 3 mm Housing, Main Bearing Retainer, Ring Seal, Oil, 60 x 80 x 8 mm Nut, Hex Head, M8 Washer, Tooth, 18 mm Pump Assembly, Oil Gasket, Oil Pump Washer, Split, 6 mm ID Screw,
Group 2: Crankshaft and Piston 6138_2 4 TP-6138 5/02
Group 2: Crankshaft and Piston Item 1 3 4 5 6 7 8 8 8 9 9 9 10 11 12 12 12 13 15 16 17 18 19 20 21 22 24 25 26 27 Part Number GM24009 GM23954 GM23893 GM23946 GM23891 GM23879 GM23942 GM23943 GM23944 GM24000 GM24001 GM24002 GM23975 GM23945 GM23906 GM23907 GM23908 GM23974 GM24010 GM24006 GM23983 GM23874 GM23926 GM23883 GM23890 GM23882 # GM23997 GM23953 GM24011 Quantity Variation No. Description Crankshaft Assembly O-ring, 32 x 2 mm Ring, Angle Washer, Spring, 52 x 36 x 1.
Group 3: Cylinder Head 6138_3 6 TP-6138 5/02
Group 3: Cylinder Head Item 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 47 48 49 50 52 53 54 Part Number GM24012 GM23921 GM23941 GM23878 GM23990 GM23876 GM23964 GM23947 GM23895 GM24005 GM23877 GM23894 GM23911 GM23948 GM23951 GM23967 # # GM23872 GM23919 GM23918 GM23889 # GM23902 GM23962 GM23903 GM23904 GM23905 GM23991 GM23972 GM23971 # # GM23987 GM23956 # # GM23932 GM23920 # GM23989 GM23890 # GM23914 GM23981 # # GM23931 GM23912 GM24
Group 4: Gear Timing and Cover 6138_4 8 TP-6138 5/02
Group 4: Gear Timing and Cover Item 1 3 4 8 9 10 11 12 13 14 17 18 19 20 21 24 25 26 26 26 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 40 42 43 44 45 46 47 53 55 56 57 58 59 60 61 62 Part Number GM23923 GM23933 GM23976 # GM23887 GM23958 GM24003 GM23929 GM23968 GM24013 GM23938 GM23977 # # GM24004 GM24008 # GM23993 GM23994 GM23995 GM23996 GM23939 GM23901 GM23896 # # GM23897 GM23900 GM23898 GM23899 GM23875 GM23957 # GM23922 GM23936 GM23940 GM23966 GM23960 GM23873 GM23924 GM23880 GM23975 GM23917 GM23961 # # G
Group 5: Speed Control Shaft 6138_5 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Part Number GM23949 GM23916 GM23888 GM23992 # GM23952 GM23871 GM23953 GM23950 GM23986 GM23984 # # GM23913 Description Spring, Torsion Return Arm, Governor Screw, Adjustment Tab, Locking Nut, Hex Head, M6 Retainer Shaft, Speed Control O-ring, 10 x 2.2 mm Spring, Torsion Return Plate, Control Lever Washer, Tooth, 8 mm Nut, Hex Head, M8 Bolt Quantity Variation No. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 # Common hardware; procure locally.
Group 6: Fuel Lines 6138_6 Item 1 2 3 4 5 6 7 8 9 10 11 Part Number GM23999 GM23982 GM23959 GM23978 GM23892 GM23980 GM23988 GM23998 GM24072 GM24099 # X-6288-1 Description Line, Return Fuel Bolt, Banjo Union Washer, Copper, 8 mm ID Washer, Copper, 8 mm ID Connector Washer, Copper, 12 mm ID Clamp, Fuel Line Pipe, Fuel Injector Solenoid, Shutoff Bolt, Banjo Union Eye, Fuel Supply Line Quantity Variation No. 1 1 2 1 3 1 4 1 1 1 1 1 # Common hardware; procure locally.
Group 7: Flywheel 6138_7 Item Part Number 1 GM23928 2 GM23881 Description Flywheel Gear Quantity Variation No. 1 1 1 # Common hardware; procure locally.
Group 8: Starter Motor 6138_8 Item 1 2 3 4 5 6 7 8 9 10 11 Part Number GM23910 # GM24083 GM24109 # GM24097 GM23909 GM23969 GM23970 # # Description Starter Assembly, 12 Volt Screw, Hex Head Cap, M8 x 20 Plate, Connecting Spacer Washer, Tooth, 8 mm ID Housing, Flywheel Bushing Stud, M10 x 25 Stud, M10 x 25 Washer, Spring, 10 mm ID Nut, Hex Head, M10 Quantity Variation No. 1 1 4 1 3 4 1 1 3 1 4 4 # Common hardware; procure locally.
Group 9: Exhaust System 6138_9 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Part Number GM24074 # # # GM24021 GM24120 GM24103 GM24512 GM24119 GM24063 GM24051 # # GM23935 # GM24124 Description Tube, Mixing Washer, Plain, 8 mm ID Washer, Split, 8 mm ID Screw, Hex Head Cap, M8 x 55 Clamp, Hose Hose Nipple Hose Adapter, Rubber Tube Hose Switch, Temperature Alarm Washer, Tooth, 3 mm ID Screw, Round Phillips Head, M3 X 6 Gasket Plug, Cap, 1/8 Hose Quantity Variation No.
Group 10: Oil Cooler and Lines 6138_10 Item 1 2 3 4 5 6 7 8 9 10 11 12 Part Number GM24114 GM24112 # # GM24021 GM24121 GM24104 GM24122 GM24118 GM24116 GM24027 GM24102 Description Element, Oil Cooler Elbow Washer, Tooth, 6 mm ID Screw, Hex Head Cap, M6 x 30 Clamp, Hose Hose Tube Hose Hose Hose Adapter, Rubber Hose Tube Quantity Variation No. 1 1 2 6 6 8 1 1 1 1 1 3 1 # Common hardware; procure locally.
Group 11: Seawater Pump Note: Item 1, Seawater pump does not include items 2 and 5. 6138_11 Item 1 2 3 4 5 6 7 8 9 Part Number GM24052 GM24106 GM24032 GM24053 # GM24031 GM20852 GM24054 # Description Pump Assembly, Seawater Shaft, Seawater Pump Seal Housing, Seawater Pump Screw, Hex Head Cap, M5 x 40 O-ring Impeller Cover, Seawater Pump Screw, Hex Head, M4 x 8 Quantity Variation No. 1 1 1 1 1 3 1 1 1 4 # Common hardware; procure locally.
Group 12: Oil Draining Lines 6138_12 Item 1 2 3 4 5 6 7 8 9 Part Number GM24143 GM23980 GM24142 GM24141 GM24020 GM24117 GM24111 GM24113 GM24513 Description Bushing, Reducer Washer, Copper, 12 mm ID Eye, Banjo Union Bolt, Banjo Union Clamp, Hose Hose, Oil Draining Adapter, Rubber Hose Plug, M8 x 10 Clip, hose Quantity Variation No. 1 1 2 1 1 2 1 1 1 1 # Common hardware; procure locally.
Group 13: Fuel Filter and Pump 6138_13 Item 1 2 3 4 5 6 7 8 9 10 11 12 Part Number GM24125 GM24020 GM20850 GM24126 GM24055 # # # GM24127 GM24025 GM24024 # Description Hose, Fuel Clamp, Hose Filter, Fuel Hose, Fuel Supply Pump, Fuel Washer, Plain, 6 mm ID Washer, Split, 6 mm ID Screw, Hex Head, M6 x 16 Hose, Fuel Return Adapter, Fuel Hose Connector, Fuel Hose Plug, 1/4 NPT Quantity Variation No. 1 1 8 1 2 1 2 2 2 1 2 2 2 # Common hardware; procure locally.
Group 14: Air Intake Filter 6138_14 Item 1 2 3 4 5 6 7 8 9 10 11 12 13 Part Number GM24073 # # # GM20848 # # # # # GM24144 GM24022 GM23935 Description Screen, Air Intake Washer, Plain , 8 mm ID Washer, Split , 8 mm ID Screw, Hex Head, M8 x 25 Screen Washer, Plain, 5 mm ID Washer, Split, 5 mm ID Screw, Hex Head, M5 x 12 Washer, Tooth, 5 mm ID Screw, Hex Head, M5 x 25 Hose, Air Intake Clamp, Hose Gasket Quantity Variation No. 1 1 2 2 2 1 2 2 2 6 6 1 1 1 # Common hardware; procure locally.
Group 15: Gasket Set 6138_15 20 TP-6138 5/02
Group 15: Gasket Set Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Part Number GM24014 GM23934 GM23955 GM23937 GM23954 GM23953 GM23941 GM23962 GM23956 GM23932 # GM23931 GM23933 GM23939 GM23979 GM23958 GM23938 GM23977 GM23957 GM23936 GM23940 GM23960 GM23961 GM23930 GM23959 GM23963 GM23935 GM23981 GM23980 GM24029 Description Set, Gasket Gasket, Crankcase O-ring, 99 x 3 mm Gasket, Oil Pump O-ring, 32 x 2 mm O-ring, 10 x 2.
Group 16: Base and Mounting 6138_16 22 TP-6138 5/02
Group 16: Base and Mounting Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Part Number GM24080 GM24044 # # # # GM24047 GM24078 GM24110 GM24046 # # # # GM24079 # GM24056 # # GM24084 # GM24115 GM24139 Description Tray Vibromount Washer, Plain Washer, Split, 8 mm ID Nut, Hex Head , M8 Screw, Hex Head, M10 x 70 Ring, Rubber Bracket, Engine Right Spacer Bushing, Rubber Washer, Plain, 10 mm ID Washer, Split, 10 mm ID Nut, Hex Head, M10 Screw, Hex Head, M8 x 40 Bracket, Engine Left Washer, Toot
Group 17: Sound Shield 6138_17 24 TP-6138 5/02
Group 17: Sound Shield Part Item 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 35 36 Number GM24159 GM24145 GM24148 GM24146 GM24147 GM24019 # GM24095 GM24094 GM24089 GM24077 GM24160 GM24035 GM24088 GM24090 GM24087 GM24082 # # # GM24158 GM24086 GM24076 GM24081 GM24075 GM24096 # # GM24039 GM24041 GM24042 GM24037 GM24022 GM24123 GM24107 GM24108 GM24048 Items Not Shown GM24017 GM24018 GM24049 GM24050 GM24128 GM24129 GM24130 GM24130 GM24131 GM24132 GM24133 GM24
Group 18: Generator and Mounting 6138_18 26 TP-6138 5/02
Group 18: Generator and Mounting Item 1 2 3 4 5 6 7 8 9 10 11 11 12 13 14 15 16 17 18 19 20 21 22 23 23 24 25 26 Part Number GM24070 GM24085 GM24100 # # GM24101 GM24065 GM24066 GM24151 GM24033 GM24149 GM24150 GM24028 GM20853 # # GM24030 GM24091 # # # # # # # # # # Quantity Variation No.
Group 19: Controller and Mounting 6138_19 28 TP-6138 5/02
Group 19: Controller and Mounting Item 1 X-506-68 2 X-506-46 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 Part Number GM24098 GM24015 GM24016 GM24093 # # GM24040 GM20851 GM24062 GM24061 GM20849 # # # # GM24067 GM24092 # # # # # # # # # GM24060 GM24059 GM24064 GM24057 GM24058 GM24157 GM24153 GM24154 GM24155 GM24045 GM24036 GM24038 GM24071 # # # GM24068 # # GM24043 Quantity Variation No.
Group 20: Control Panel 6138_20 Item 1 2 3 4 5 6 7 8 9 10 Part Number GM24161 # GM24069 GM24156 GM24152 # # GM24034 GM24156 GM24514 Description Panel, Control Screw, Flat Phillips Head, M3 x 12 Connector Connector to Remote Start/Stop Switch Harness Connector to Remote Control Panel Harness Nut, Hex Head, M3 Screw, Special Head, M3 x 12 Grommet Control Box Harness GM34930 Connector to Remote Start/Stop Switch Harness Fuse, 0.63 Amp Quantity Variation No.
Group 21: Siphon Break and Lines 6138_21 TP-6138 5/02 Item Part Number 1 2 3 4 5 PA-229928 GM24021 GM24105 GM24023 GM24035 Description Kit, Siphon Break Clamp, Hose Connection, Hose Hose Grommet Quantity Variation No.
Group 22: Literature Item 1 2 3 4 5 6 7 8 Part Number TP-5620 TP-6069 TP-6134 TP-6137 TP-6138 TP-6143 TP-6149 TP-6163 Quantity Variation No. 1 Description Safety Precautions, Marine I/M 3.5-150EOZ/EFOZ, Marine O/M 3.5EFOZ/4EOZ, Marine S/M 4EOZ/3.5EFOZ, Marine P/C 4EOZ/3.5EFOZ Farymann 18W O/M Farymann 18W Warranty, 4EOZ/3.5EFOZ, Marine S/M Farymann 18W (903.04.08 1.5) 1 1 1 1 1 1 1 1 Paint and Miscellaneous Parts Paint, White, Gallon Paint, White, Spray Can Paint, White, .75 oz.
Appendix A Abbreviations The following list contains abbreviations that may appear in this publication. A, amp ABDC AC A/D ADC adj. ADV AHWT AISI ALOP alt. Al ANSI AO API approx. AR AS ASE ASME assy. ASTM ATDC ATS auto. aux. A/V avg. AVR AWG AWM bat. BBDC BC BCA BCI BDC BHP blk. blk. htr. BMEP bps br. BTDC Btu Btu/min. C cal. CARB CB cc CCA ccw. CEC cert.
k K kA KB kg kg/cm2 kilo (1000) kelvin kiloampere kilobyte (210 bytes) kilogram kilograms per square centimeter kgm kilogram-meter kilograms per cubic meter kg/m3 kHz kilohertz kJ kilojoule km kilometer kOhm, kW kilo-ohm kPa kilopascal kph kilometers per hour kV kilovolt kVA kilovolt ampere kVAR kilovolt ampere reactive kW kilowatt kWh kilowatt-hour kWm kilowatt mechanical L liter LAN local area network L x W x H length by width by height lb.
Appendix B Common Hardware Application Guidelines Use the information below and on the following pages to identify proper fastening techniques when no specific reference for reassembly is made. Bolt/Screw Length: When bolt/screw length is not given, use Figure 1 as a guide. As a general rule, a minimum length of one thread beyond the nut and a maximum length of 1/2 the bolt/screw diameter beyond the nut is the preferred method. Steps for common hardware application: 1.
Appendix C General Torque Specifications Use the following torque specifications when service literature instructions give no specific torque values. The charts list values for new plated, zinc phosphate, or oiled threads. Increase values by 15% for nonplated threads. All torque values are +0%/--10%. American Standard Fasteners Torque Specifications Size Assembled into Aluminum Grade 2 or 5 Assembled into Cast Iron or Steel Torque Measurement Grade 2 Grade 5 Grade 8 8-32 Nm (in. lb.) 1.
Appendix D Common Hardware Identification Screw/Bolts/Studs Nuts Hardness Grades Head Styles Nut Styles American Standard Hex Head or Machine Head Hex Head Grade 2 Hex Head or Machine Head with Washer Lock or Elastic Grade 5 Flat Head (FHM) Square Grade 8 Round Head (RHM) Cap or Acorn Grade 8/9 (Hex Socket Head) Pan Head Wing Hex Socket Head Cap or Allent Head Cap Washers Metric 5.
Appendix E Common Hardware List The Common Hardware List lists part numbers and dimensions for common hardware items. American Standard Part No. Dimensions Part No. Dimensions Part No. Dimensions Type Hex Head Bolts (Grade 5) Hex Head Bolts, cont.
Metric Hex head bolts are hardness grade 8.8 unless noted. Part No. Dimensions Part No. Dimensions Part No.
KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Fax 920-459-1646 For the nearest sales/service outlet in the US and Canada, phone 1-800-544-2444 KohlerPowerSystems.com TP-6138 5/02 E 2002 by Kohler Co. All rights reserved.
