Kohler 3.5EFOZ - 3.3 Lubrication System; Section 6 Cooling System

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TP-6137 5/03ii Service Assistance

Notes

Table of Contents

Product Identification Information2
Table of Contents3
Safety Precautions and Instructions5
Hot Parts8
Introduction11
Service Assistance11
Section 1 Specifications13
- General13
- Generator13
- Service Views14
- Engine15
- Torque Specifications16
Section 2 Operation17
- Prestart Checklist17
- Marine Inspection17
- Angular Operation17
- Operation in European Union Member Countries17
- Exercising the Generator Set18
- Starting and Stopping Procedure18
- Remote Panel Kits20
  - Remote Start/Stop Panel Kit20
  - Remote Panel Kit20
Section 3 Scheduled Maintenance21
- General21
- Service Schedule-3.5EFOZ and 4EOZ Models22
- Lubrication System24
- Battery26
- Generator Storage Procedure27
Section 4 Intake and Exhaust System29
- Air Intake Silencer/Filter29
- Exhaust System30
- Mixing Elbow30
Section 5 Fuel System31
- General31
- Fuel Specifications31
- Fuel Filter32
- Fuel Injector Nozzle33
- Excess Fuel Start Device35
- The Injection Pump's Fuel Starting Delivery Point36
- Fuel Pump Adjustment Timing37
- Fuel Pump and Gear Cover Installation37
- Bleeding the Fuel System38
- Governor39
Section 6 Cooling System43
- Direct Water Cooled43
- Thermostat44
- Seawater Pump and Impeller44
- Siphon Break45
- Anticorrosion Zinc Anode47
Section 7 Troubleshooting49
- General49
Section 8 Controller Troubleshooting53
- General54
- Engine Safety Shutdown Switches55
  - Low Oil Pressure (LOP) Shutdown55
  - High Water Temperature and High Exhaust Temperature Shutdown Switch55
- Operation Sequence57
- Troubleshooting59
Section 9 Generator Troubleshooting63
- General63
- Theory of Operation64
  - Brushless Generator Sets64
- Output Voltage and Frequency64
  - Voltage Rating and Rotation Speed64
  - Bearing64
- Rotor Test65
- Field Diode Test66
- Stator Test67
- Alternator Excitation68
Section 10 Generator and Engine Disassembly/Reassembly69
- Generator Alternator Disassembly69
- Generator Alternator Reassembly73
- Generator Engine Disassembly75
- Generator Engine Reassembly86
- Engine Component Dimensions and Wear100
Section 11 Wiring Diagrams103
- Wiring Diagram, Schematic104
- Wiring Diagram, Point-To-Point105
Appendix A Abbreviations107
Appendix B Common Hardware Application Guidelines109
Appendix C General Torque Specifications110
Appendix D Common Hardware Identification111
Appendix E Common Hardware List112

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