Kohler 40EOZD User manual

INSTALLATION INSTRUCTIONS
TT-1501 9/12a
Original Issue Date: 9/09
Model: 40--180EOZD/EOZC and 33--150EFOZD/EFOZC
Market: Marine
Subject: Full Feature Panel Kits
Introduction
Installation of the Full Feature Panel kit allows generator
set starting/stopping from a location remote from the
generator set. The panel includes an illuminated DC
voltmeter, engine oil pressure gauge, coolant
temperature gauge, and hourmeter. See Figure 1 for kit
selection. Use these kits on generator sets equipped
with Decision-Makerr3+ controllers. See Figure 2 for
panel features.
Note: The installation of the Full Feature Panel requires
the control wiring kit GM51368-KP1 (33--99 kW)
or GM51368-KP2 (100--180 kW) unless
customer provided. See Figure 18.
Generator Set
Kit No.
Model Voltage
40EOZD/EOZC,
33EFOZD/EFOZC
12 GM51369-KP1
24 GM51369-KP2
55/65EOZD/EOZC,
40/50EFOZD/EFOZC
12 GM51369-KP3
24 GM51369-KP4
80/99EOZD/EOZC,
70/80EFOZD/EFOZC
12 GM51369-KP5
24 GM51369-KP6
125EOZD/EOZC,
100EFOZD/EFOZC
12 GM51369-KP7
24 GM51369-KP8
150EOZD/EOZC,
125EFOZD/EFOZC
12 GM51369-KP9
24 GM51369-KP10
180EOZD/EOZC,
150EFOZD/EFOZC
12 GM51369-KP11
24 GM51369-KP12
Figure 1 Kit Selection
The DC voltmeter measures the voltage of the starting
battery(ies). Check the battery manufacturer’s
recommendation for correct operating voltage.
The engine oil pressure gauge measures the engine
oil pressure. Refer to the following instructions for
locating the oil pressure sender.
Note: During the engine break-in period, the engine
sometimes produces high oil pressure readings.
Consult the service manual for specific values.
A-344404-T
1. Frequency meter
2. Voltmeter
3. Ammeter
4. Ammeter switch
5. On light
6. Start/stop switch
7. Hourmeter
8. Volt gauge
9. Temperature gauge
10. Oil pressure gauge
6789
10
1 2 3
4
5
Figure 2 Panel Features
The coolant temperature gauge measures the engine
coolant temperature. Refer to the following instructions
for locating the coolant temperature sender.
The hourmeter records the total generator set
operating hours for reference in maintenance
scheduling.
Note: For generator sets already in service, the
hourmeter on the controller will have
accumulated hours and, therefore, reflect a
different reading than the panel hourmeter. Use
the same hourmeter each time to schedule
maintenance.

2 TT-1501 9/12
Note: Depending upon the location, the Full Feature
Panel kits may require a Y connector and/or
harness kit. To ensure accuracy of the gauges
and meters, do not exceed 22.9 m (75 ft.) of
extension harnesses. See Figure 3.
Type Length Kit No. Refer to
Y connector —PA-344417 Figure 8
Pigtail 30.48 cm (12 in.) PA-344414 Figure 9
Extension
harness
4.6 m (15 ft.) PA-344415 Figure 10
7.6 m (25 ft.) PA-344416 Figure 10
Figure 3 Connector/Harness Kit Selection
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 connected equipment, disable the generator
set as follows: (1) Move the generator set master switch to the
OFF position. (2) Disconnect the power to the battery charger.
(3) Remove the battery cables, negative (--) lead first.
Reconnect the negative (--) lead last when reconnecting the
battery. Follow these precautions to prevent starting of the
generator set by an automatic transfer switch, remote
start/stop switch, or engine start command from a remote
computer.
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 in a
well-ventilated area away from 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 rigidlines. 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.
Installation Procedure
1. Remove the generator set from service.
1.1 Place the generator set master switch in the OFF
position.
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 panel kit.
2.1 Determine where in the wheelhouse or bridge to
mount the panel. The length of the wiring harness
and the panel size (including the mounting depth)
limits this decision. See Figure 4 for dimensions.
Allow 70 mm (2 3/4 in.) minimum mounting
clearance beyond the back of the panel. See
Figure 5 for the panel assembly wiring.
Notes:
Dimensions are in mm (in.)
Panel thickness is 4.8 mm (0.19 in.).
279.4 (11.0)
295.4 (11.63)
231.9 (9.13)
215.9 (8.5)
4 countersunk holes 4.4 (0.172) diameter
A-344404-T
Figure 4 Meter Panel Dimensions

TT-1501 9/12 3
A-344404-T
Figure 5 Panel Electrical Connections, Back View
2.2 Connect the 24-pin connector from the remote
extension harness to the 24-pin connector on the
remote full feature panel.
2.3 Mount the full feature panel using four screws (not
supplied).
2.4 Use rubber grommets and cable ties to protect
and secure the wiring harness. The installation
must conform to USCG Regulations Title 33CFR
Parts 183.425 through 183.460.
3. Install the current transformers.
3.1 Remove the screws from the junction box panel
and remove the panel.
3.2 Mount the TB12 terminal block (266118) and the
marker strip (344553) in the junction box using two
screws (X-51-11) and two nuts (X-6210-4).
Note: Place all current transformers with the Dot
or HI mark toward the generator set output
leads.
3.3 For generator sets with 120/240-volt connections,
place the generator set output leads through the
current transformer one turn. For generator sets
with 480-volt connections, route the generator set
output leads through the current transformer two
turns.
3.4 Connect the white and black leads from the
current transformers to the terminal block (TB12)
as shown in Figure 6.
3.5 Make current transformer connections as shown
in Figure 6 through Figure 13.
GM51639D-
See Figure 11
or Figure 12
Figure 6 Current Transformer Wiring to TB12
Terminal Block

4 TT-1501 9/12
ADV7903-
Figure 7 Remote Panel Options for Generator Sets Equipped with Decision-Makerr3+ Controllers
344417-C
Figure 8 Optional Y Connector (Kit PA-344417)

TT-1501 9/12 5
249935-K
Note: Underlined coded terminals are located at connector end of harness.
Figure 9 Optional Pigtail, 12 in. (PA-344414)
344501-P
PA-344415
4.6 m (15 ft.) Extension Harness
PA-344416
7.6 m (25 ft.) Extension Harness
Note: Underlined coded terminals are located at connector end of harness.
Figure 10 Optional Extension Harness, 15 ft. or 25 ft. (PA-344415 and PA-344416)

6 TT-1501 9/12
GM51639D, E-
View A-A
From
View A-A.
See the
full wiring
diagram
in the
operation
manual.
See the
full wiring
diagram
in the
operation
manual.
From
View A-A.
See the
full wiring
diagram
in the
operation
manual.
From
View A-A.
Figure 11 40EOZD/EOZC and 33EFOZD/EFOZC Models—Current Transformer Wiring for Units Equipped with
Decision-Makerr3+ Controllers (consult the operation manual for the full wiring diagram)

TT-1501 9/12 7
GM51352C, D-B
See the
full wiring
diagram
in the
operation
manual.
From
View A-A.
View A-A
See the
full wiring
diagram
in the
operation
manual.
From
View A-A.
See the
full wiring
diagram
in the
operation
manual.
From
View A-A.
Figure 12 55--180EOZD/EOZC and 40--150EFOZD/EFOZC Models—Current Transformer Wiring for Units
Equipped with Decision-Makerr3+ Controllers (consult the operation manual for the full wiring
diagram)

8 TT-1501 9/12
ADV-5875-L
Figure 13 Generator Set Reconnection

TT-1501 9/12 9
4. Install the coolant temperature and oil
pressure senders.
4.1 Drain the engine oil and coolant. See the
operation manual for more information regarding
oil and coolant drain locations. Dispose of the oil
and coolant in an environmentally safe manner.
4.2 For 40EOZD/EOZC & 33EFOZD/EFOZC and
125--180EOZD/EOZC & 100--150EFOZD/EFOZC
Models:
4.2.1 Remove and discard the reducer bushing
(X-202-47) and petcock (X-256-3). See
Figure 14 or Figure 17.
4.2.2 Coat the threads of coolant temperature
sender (GM50536) with pipe sealant.
4.2.3 Insert the coolant temperature sender into
the engine block where the reducer
bushing and petcock was located. See
Figure 14 or Figure 17.
4.3 For 55--99EOZD/EOZC & 40--80EFOZD/EFOZC
Models:
4.3.1 Remove and discard the engine pipe plug.
SeeFigure15orFigure16.
4.3.2 Coat the threads of the coolant
temperature sender (GM50536) with pipe
sealant.
4.3.3 Insert the coolant temperature sender into
the engine block where the engine pipe
plug was located. See Figure 15 or
Figure 16.
4.4 Close the coolant drain(s).
4.5 Fill the cooling system with fresh coolant. Follow
the instructions in the operation manual.
Note: Pay special attention to the coolant level.
After the coolant has been drained, allow
time for a complete refill of the engine
water jacket. Check the coolant level as
prescribed in the prestart checklist of the
operation manual.
Note: Engine Damage! Failure to bleed air from
the coolant system may cause
overheating and subsequent engine
damage.
4.6 Remove and discard the engine’s pipe plug at the
location shown in Figure 14, Figure 15,
Figure 16, or Figure 17.
Note: 99 kW units and below: Located on the
non-service side, left-most oil fitting under the
starter.
100 kW units and above: Located on the
service side, under the engine fuel filters (tucked
slightly behind the closed crankcase canister’s
mounting bracket).
4.7 Coat the threads of the 45_elbow (267428) and oil
pressure sender (GM51459) with pipe sealant.
4.8 Insert the 45_elbow and the oil pressure sender
where the pipe plug was located. See Figure 14,
Figure 15, Figure 16, or Figure 17.
4.9 Replace the engine oil.
2
1
JK-250000B-T
1. Remove pipe plug and install 45_elbow (267428) and oil
pressure sender (GM51459)
2. Remove reducer bushing and petcock and install coolant
temperature sender (GM50536)
Figure 14 Sender Location (40EOZD/EOZC and
33EFOZD/EFOZC Models)
JL-250000B-U
1. Remove pipe plug and install coolant temperature
sender (GM50536)
2. Remove pipe plug and install 45_elbow (267428) and
oil pressure sender (GM51459)
1
2
Figure 15 Sender Location, Typical
(55--65EOZD/EOZC and
40--50EFOZD/EFOZC Models)

10 TT-1501 9/12
JM-250000B-V
1. Remove pipe plug and install coolant temperature
sender (GM50536)
2. Remove pipe plug and install 45_elbow (267428) and
oil pressure sender (GM51459)
1
2
Figure 16 Sender Location, Typical
(80--99EOZD/EOZC and
70--80EFOZD/EFOZC Models)
JY-250000B-S
1. Remove pipe plug and install oil pressure sender
(GM51459)
2. Remove reducer bushing and petcock and install
coolant temperature sender (GM50536)
1
2
Figure 17 Sender Location, Typical
(125--180EOZD/EOZC and
100--150EFOZD/EFOZC Models)
5. Connect the control wiring kit:
GM51368-KP1 (33--99 kW) or
GM51368-KP2 (100--180 kW)
Note: See Figure 18.
5.1 Connect the 24-pin (P1) connector from the
control wiring kit to the 24-pin connector on the
remote extension harness.
5.2 Connect leads C10, C11, C12, and C13 from the
control wiring kit to the TB12 (current transformer)
terminal block. See Figure 6.
5.3 Connect leads 5A and N from the control wiring kit
to the new coolant temperature sender (installed
in Section 4).
5.4 Connect leads 7C1 and N from the control wiring
kit to the new oil pressure sender (installed in
Section 4).
5.5 Make the remaining control wiring connections:
5.5.1 Lead N connects to the main controller
board’s TB2 terminal strip at location 3.
5.5.2 Lead 47 connects to the main controller
board’s TB2 terminal strip at location 4.
5.5.3 Leads V0, V7, UP, and LOW connect to the
TB3 terminal strip (located inside the
controller).
5.5.4 Lead 70 connects to the TB10 terminal
strip (located inside the junction box).
5.5.5 Leads 101 and 102 connect to the
controller’s voltmeter.
5.5.6 Leads N/N (eyelet terminal) connect to the
controller’s ground location.

TT-1501 9/12 11
GM51264-B
GM51352-B
See the
full wiring
diagram
in the
operation
manual.
Figure 18 Control Wiring Connections (Typical)

12 TT-1501 9/12
6. Restore the generator set to service.
6.1 Check that the generator set master switch is in
the OFF position.
6.2 Reconnect the generator set engine starting
battery, negative (--) lead last.
6.3 Reconnect power to the battery charger, if
equipped.
6.4 Start the generator set using the controller switch
and the remote switch. Monitor the hourmeter for
correct function.
6.5 Stop the generator set.
Parts List
Full Feature Panel Kits
Kits: GM51369-KP1, GM51369-KP2, GM51369-KP3, GM51369-KP4, GM51369-KP5, GM51369-KP6
Qty. Description
Common
Parts
Unique Parts
GM51369-KP1 GM51369-KP2 GM51369-KP3 GM51369-KP4 GM51369-KP5 GM51369-KP6
1 Panel assembly,
control GM51370-1 GM51370-2 GM51370-3 GM51370-4 GM17001 GM17004
2 Screw, RHM,
8-32 x 3 X-51-11
2 Nut, whiz, 8-32 X-6210-4
3Transformer 246886 246886 336314 336314 246886 246886
1Block, terminal 266118
1Sender, oil pressure GM51459
1 Sender, coolant
temperature GM50536
1Strip, marker 344553
1 Tie, cable nylon X-468-3
1 Fitting, 45°267428
Kits: GM51369-KP7, GM51369-KP8, GM51369-KP9, GM51369-KP10, GM51369-KP11, GM51369-KP12
Qty. Description
Common
Parts
Unique Parts
GM51369-KP7 GM51369-KP8 GM51369-KP9 GM51369-KP10 GM51369-KP11 GM51369-KP12
1 Panel assembly,
control GM17002 GM17005 GM17003 GM17006 GM51370-5 GM51370-6
2 Screw, RHM,
8-32 x 3 X-51-11
2 Nut, whiz, 8-32 X-6210-4
3Transformer 246886
1Block, terminal 266118
1Sender, oil pressure GM51459
1 Sender, coolant
temperature GM50536
1Strip, marker 344553
1 Tie, cable nylon X-468-3
1 Fitting, 45°267428