Kohler GM87026-KP1-WHT User manual

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INSTALLATION INSTRUCTIONS
Original Issue Date: 5/14
Model: 40EOZDJ/EOZCJ and 33/40EFOZDJ/EFOZCJ
Market: Marine
Subject: Oil Level Indicator Kits (GM87026-KP1-WHT and GM87026-KP1-G49)
Introduction
This kit contains an oil level gauge that mounts on the
skid and wiring to a remote indicator in the
Decision-Makert3500 controller or a
customer-supplied location. This instruction covers
installation of the oil level gauge and wiring to the
Decision-Makert3500 controller. Use the instructions
supplied with the oil level gauge for wiring the gauge to a
customer-provided light or alarm. See Figure 1 for kit
numbers.
Model Loose Kit Number
40EOZDJ/33EFOZDJ
40EFOZDJ GM87026-KP1-WHT
40EOZCJ/33EFOZCJ
40EFOZCJ GM87026-KP1-G49
Figure 1 Kit Selection
Read the entire installation procedure and compare the
kit parts with the parts list at the end of this publication
before beginning installation. Perform the steps in the
order shown.
Safety Precautions
Observe the following safety precautions while installing
the kit.
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 off/reset
button to shut down the generator set. (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.

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Installation Procedure
Note: Read all safety precautions at the beginning of
this publication before performing any work on
the generator set.
1. Remove the generator set from service.
1.1 Press the generator set OFF/RESET button to
shut down the generator set.
1.2 Disconnect the power to the battery charger, if
equipped.
1.3 Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
2. Install the oil level indicator kit.
Note: Apply pipe sealant to the threads of the hose
connectors.
2.1 Remove the oil drain plug and allow the oil to drain
completely. See the Service Views in the
operation manual for the oil drain location.
Note: Dispose of all waste materials (engine oil,
fuel, filter, etc.) in an environmentally safe
manner and in accordance with all
applicable laws.
2.2 Disconnect the oil drain hose from the oil drain
valve at the oil pan. Save the oil drain valve.
2.3 Secure the bracket (GM86335-WHT or
GM86335-G49) to the service side (right-hand
side) of the skid using 2 screws (M933-10025-60)
and 2 nuts (M6923-10-80). See Figure 2 for
bracket position.
2.4 Secure the oil level gauge (227257) to the bracket
using 4 mounts (241769), 4 lock washers
(X-22-12), and 4 nuts (X-6210-2).
Note: Use the upper set of holes in the mounting
bracket for assembly.
2.5 Install the coupling (X-567-1) into the oil gauge.
See Figure 2 for location.
2.6 Install the connector (X-582-5) into the back of the
oil level gauge.
2.7 Connect the pipe (X-209-2) to the bushing in the
oil pan.
2.8 Connect the pipe cross (X-207-7) to the pipe.
2.9 Connect the pipe plug (X-75-3) to the pipe cross
as shown in Figure 2, item 14.
2.10 Connect the hose connector (X-582-5) to the pipe
cross.
2.11 Secure the oil hose (X-422-18) to the hose
connector in the oil pan using a hose clamp
(X-426-12).
2.12 Place the restrictor plug (GM98574) in the other
end of the oil hose (X-422-18) and secure it to the
hose connector in the back of the oil gauge using a
hose clamp (X-426-12).
2.13 Cut the copper tubing at a slight angle at the
beginning of the arc. See Figure 2, item 1.
2.14 Attach one end of the hose (X-386-74) to the copper
tubing using a hose clamp (X-426-9) to secure.
Note: Place hose clamps 6 mm (0.25 in.) from
the hose end and tighten.
2.15 Position the existing oil drain valve at the position
shown in Figure 2, item 16.
2.16 Remove the existing plate and replace with a new
cover plate (GM47418-WHT or GM47418-G49)
reusing the existing hardware.
2.17 Insert the hose connector (X-582-38) into the hole
of the coverplate.
2.18 Attach the other end of the hose (X-386-74) to the
connector using a hose clamp (X-426-9) to
secure.
3. Replenish engine oil.
3.1 Replace the oil drain plug and refill the engine with
oil. See the operation manual for complete oil fill
instructions.
4. Wire the oil level gauge
4.1 See Figure 4 for wiring to the oil level gauge.
Note: Figure 4 shows a partial view of the wiring
diagram. For a complete wiring diagram, see the
generator operation manual.
4.2 If the generator set does not have a
Decision-Makert3500 controller, see the
instructions supplied with the oil level gauge for
wiring the gauge to a customer-provided light or
alarm.

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GM87026-
1. Cut copper tubing at a slight angle at the beginning of the arc.
2. See Oil Level Alarm Mounting View.
3. Coupling (X-567-1)
4. Screws (M933-10025-60 qty. 2) and nuts (M6923-10-80 qty. 2)
5. Mounts (241769 qty. 4)
6. Oil level gauge (227257). Assemble to the upper set of holes
as shown.
7. High level indicator adjust
8. Low level indicator adjust
9. Washers (X-22-12 qty. 4) and nuts (X-6210-2 qty. 4)
10. Oil level bracket (GM86335-WHT or GM86335-G49)
11. Hose (X-422-18) and hose clamps (X-426-12 qty. 2)
12. Hose connector (X-582-5)
13. Pipe (X-209-2). Attach to oil pan on engine.
14. Pipe plug (X-75-3)
15. Pipe cross (X-207-7)
16. Position existing oil drain valve in this position.
17. Restrictor plug (GM98574)
18. Hose connector (X-582-5)
19. Hose (X-386-74) and hose clamps (X-426-9 qty. 2)
20. Cover plate (GM47418-WHT or GM47418-G49). Remove
and discard the existing plate and use existing hardware.
21. Hose connector (X-582-38)
4
3
2
1
11
12
5
6
10
98
7
13
14
15 16 18
19
20
21
Oil Level Alarm
Mounting View
17
Figure 2 Installed Kit

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5. Restore the generator set to service.
5.1 Check that the generator set is OFF.
5.2 Reconnect the generator set engine starting
battery, negative (--) lead last.
5.3 Reconnect power to the battery charger, if
equipped.
6. Program the low oil level shutdown.
6.1 Check the dipstick to verify the oil level as full.
With the engine running and warm, adjust the high
and low oil level indicators to approx. 12.7 mm
(0.50 in.) from the full level. See Figure 2 for
adjustment locations.
6.2 Using SiteTecht, under the Programmable
Digital Input 110 parameter, change the settings
to the following:
Digital Input Enabled: On
Digital Input Logic: Active Close
Digital Input Event: Engine Oil Level
Low Shutdown*
Digital Input Delay: 5 s
Digital Input Inhibit Delay: 30 s
* Engine Oil Level Low Shutdown will be displayed for either low or
high oil level.
Note: For more information on SiteTecht,see
TP-6701tSiteTech Software Operation
Manual.
Figure 3 Programmable Digital Input 110 Parameter
(in SiteTecht)
Parts List
Oil Level Indicator Kits
Kits: GM87026-KP1-WHT and GM87026-KP1-G49
Qty. Description Common Parts
1Gauge, oil level 227257
4Mount, controller 241769
1Cover, plate
for Kit GM87026-KP1-WHT
for Kit GM87026-KP1-G49
GM47418-WHT
GM47418-G49
1Bracket,
for Kit GM87026-KP1-WHT
for Kit GM87026-KP1-G49
GM86335-WHT
GM86335-G49
2Nut, hex (10 mm) M6923-10-80
2Screw, hex cap M933-10025-60
1 Cross, pipe (1/2 in. NPT) X-207-7
1Pipe (1/2 in. NPT x 1.19 in.) X-209-2
4Washer, lock
(0.262 in. ID x 0.743 in. OD)
X-22-12
1Hose (0.25 in. ID x 17 in.) X-386-74
1Hose (0.50 in. ID x 9.25 in.) X-422-18
2Clamp, hose (0.69/1.25 in.) X-426-12
2Clamp, hose (0.25/0.70 in.) X-426-9
1Coupling X-567-1
1Connector, hose X-582-38
2Connector, hose X-582-5
4Nut X-6210-2
1Plug, pipe X-75-3
1Restrictor plug GM98574

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1. Oil level gauge
1
See the full wiring diagram in the operation manual.
GM86969B-D
Figure 4 Wiring for Oil Level Gauge (Typical)

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Notes

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Notes

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KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
Availability is subject to change without notice. Kohler Co. reserves the
right to change the design or specifications without notice and without any
obligation or liability whatsoever. Contact your local Kohlerrgenerator
set distributor for availability.
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