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This document, TT-1501, dated 9/09, describes the installation and features of Full Feature Panel Kits for Kohler generator sets, specifically models 40-180EOZD/EOZC and 33-150EFOZD/EFOZC, intended for the marine market. These kits enable remote starting and stopping of the generator set and provide essential operational information.
The Full Feature Panel Kit allows users to remotely monitor and control their Kohler generator set. It includes an illuminated DC voltmeter, an engine oil pressure gauge, a coolant temperature gauge, and an hourmeter. This remote panel is designed to work with generator sets equipped with Decision-Maker® 3+ controllers. The installation involves connecting the panel to the generator set via a wiring harness, installing current transformers, and integrating senders for oil pressure and coolant temperature.
The panel kits are available in various configurations depending on the generator set model and voltage. For example, GM51369-KP1 is for 40EOZD/EOZC and 33EFOZD/EFOZC models at 12V, while GM51369-KP2 is for the same models at 24V. The kits include a panel assembly, screws, nuts, current transformers (246886, 336314), a terminal block (266118), an oil pressure sender (GM51459), a coolant temperature sender (GM50536), a marker strip (344553), cable ties (X-468-3), and a 45° fitting (267428).
The panel dimensions are 295.4 mm (11.63 in.) wide by 231.9 mm (9.13 in.) high, with a panel thickness of 4.8 mm (0.19 in.). A minimum mounting clearance of 70 mm (2 3/4 in.) is required behind the panel. The wiring harnesses, such as PA-344415 (4.6 m / 15 ft.) and PA-344416 (7.6 m / 25 ft.), connect the remote panel to the generator set. The total length of extension harnesses should not exceed 22.9 m (75 ft.) to ensure accuracy of the gauges and meters.
Current transformer wiring varies based on the generator set's output voltage. For 120/240-volt connections, the generator set output leads pass through the current transformer once. For 480-volt connections, the output leads pass through the current transformer twice. The current transformers are installed with the "Dot" or "HI" mark facing the generator set output leads.
The DC voltmeter on the panel displays the voltage of the starting battery(ies), allowing users to monitor battery health. The engine oil pressure gauge provides real-time engine oil pressure readings. The coolant temperature gauge displays the engine coolant temperature, crucial for preventing overheating. The hourmeter records the total operating hours of the generator set, which is essential for scheduling maintenance.
The panel features a start/stop switch for remote control of the generator set. It also includes an "On" light to indicate operation. The ammeter switch allows selection between different meter scales for current readings. The panel's design integrates seamlessly with Decision-Maker® 3+ controllers, providing a comprehensive remote monitoring and control solution.
The hourmeter is a key maintenance feature, tracking generator set run time to facilitate adherence to scheduled maintenance intervals. The manual emphasizes the importance of using the same hourmeter (either on the controller or the remote panel) consistently for maintenance scheduling.
Installation involves specific steps for installing the coolant temperature and oil pressure senders. For 40EOZD/EOZC and 33EFOZD/EFOZC models, and 125-180EOZD/EOZC and 100-150EFOZD/EFOZC models, the installation involves removing a reducer bushing and petcock, coating the sender threads with pipe sealant, and inserting the coolant temperature sender into the engine block. For 55-99EOZD/EOZC and 40-80EFOZD/EFOZC models, an engine pipe plug is removed instead. The oil pressure sender is installed by removing an engine pipe plug, coating the threads of a 45° elbow and the sender with pipe sealant, and inserting them into the engine block.
The manual provides critical safety precautions, including disconnecting battery cables before working on the generator set (negative lead first) and disabling the generator set to prevent accidental starting. It also warns about explosive fuel vapors and the importance of proper fuel handling and system maintenance. After installation, the cooling system must be refilled with fresh coolant, ensuring all air is bled to prevent engine damage. The engine oil must also be replaced.
The control wiring kit (GM51368-KP1 for 33-99 kW or GM51368-KP2 for 100-180 kW) connects the remote panel to the main controller board, current transformers, and senders. Specific connections are detailed for leads C10, C11, C12, C13 (to TB12), 5A, N (to coolant temperature sender), 7C1, N (to oil pressure sender), N, 47 (to TB2), V0, V7, UP, LOW (to TB3), 70 (to TB10), 101, 102 (to voltmeter), and N/N (to ground).
Upon completion of installation, the generator set must be restored to service by checking the master switch position, reconnecting the battery (negative lead last), reconnecting the battery charger, and starting the generator set using both the controller and remote switches to verify correct function of the hourmeter and other panel features. Finally, the generator set should be stopped.
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