Service parts for the 40ROZJ81
Grouped by system, with how many of each the parts manual calls for.
Fuel system
1 requiredPrices captured from merchant listings; some links are affiliate links. Confirm against your serial number before ordering.
Specifications
Ratings spec sheet not in our library yet — see the documents below.
Maintenance & consumables
| Item | Spec | Capacity | Part # | Interval | |
|---|---|---|---|---|---|
| Fuel filter | Secondary | 254471 | Amazon eBay $54.34 |
Service intervals
15| Item | Action | Hours | Months | Notes |
|---|---|---|---|---|
| System | Test | 1 hr | ToCI quarterly: exercise system under full load for 1 hour | |
| Battery | Test | 6 mo | Load-test battery at each semi-annual visit | |
| Coolant antifreeze | Change | 12 mo | NCCI/RCI: antifreeze change once per year during contract term | |
| Engine tune-up | Other | 12 mo | Annual: engine tune-up with parts | |
| Fuel filters | Change | 12 mo | Annual: change fuel filters | |
| Generator sets and associated systems | Inspect | 6 mo | Semi-annual inspection, testing and preventive maintenance (default unless Appendix A states otherwise) | |
| Load bank | Test | 12 mo | Annual four (4) hour load bank test / emergency service operation with four (4) hours full load test once per year | |
| Lube oil | Change | 12 mo | CMC/HCF: additional services on second visit - lube, oil and filter change | |
| Lube oil analysis | Test | 12 mo | Annual: lube oil analysis | |
| Oil | Change | 12 mo | NCCI/RCI: oil shall be changed once every 12 months | |
| Oil filter, fuel filter and air filter | Change | 12 mo | NCCI: change once every 12 months during the contract period | |
| Primary and bypass lube filters | Change | 12 mo | Annual: change primary and bypass lube filters | |
| Transfer switch | Lubricate | 12 mo | ToCI annual: check, clean and lubricate transfer switches and breakers | |
| Valve clearance | Adjust | 12 mo | ToCI annual: check valve clearance | |
| Water filters | Change | 12 mo | Annual: change water filters |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Service specifications
5| Type | Item | Value | Unit | Condition |
|---|---|---|---|---|
| Other | Exercise under full load | 1 | hour | ToCI quarterly |
| Other | Full load test duration | 4 | hours | Once per year |
| Other | Load bank data recording interval | 15 | minutes | During load bank test |
| Other | Load bank test load level | 80 | % of generator nameplate capacity | 4-hour resistive load bank test |
| Other | Load bank test profile | 2 hours at 50%, 1 hour at 75%, 1 hour at 100% | Annual four (4) hour load bank test |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Recommended fluids
| Fluid | Grade | Standard | Ambient | Capacity | Notes |
|---|---|---|---|---|---|
| Engine oil | meeting manufacturer's specs | Add crankcase oil (grade meeting manufacturer's specs) to correct level (SCI) |
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Procedures
11Automatic Transfer Switch Semi-Annual Service maintenance
- Verify proper operation of exerciser clock; adjust if necessary.
- Provide visual inspection of all contacts and connection points.
- Perform building load test if practical and inspect for proper transfer and re-transfer.
- Verify operation of all control lamps.
Battery and Battery Charger System Semi-Annual Service maintenance
- Clean all battery terminals; verify integrity of cables and connectors.
- Load-test battery.
- Measure specific gravity of each battery cell.
- Inspect electrolyte level and add fluid if necessary.
- Verify proper operation and float voltage of external battery charger.
- Verify and record output of engine alternator.
Controls Semi-Annual Service maintenance
- Verify and record output voltage and adjust voltage regulator, if necessary.
- Calibrate control meters.
- Verify and record output frequency and adjust governor, if necessary.
- Verify operation of all control panel lamps.
- Inspect for any loose connections, terminals or discoloration.
Coolant System Semi-Annual Service maintenance
- Inspect all clamps, verify condition of all hoses and identify any leaks.
- Verify proper operation of engine water jacket heater.
- Test coolant freeze point and verify coolant level.
- Test coolant additive package for proper corrosion inhibitors.
- Inspect belt condition and tension; correct as required.
- Inspect radiator core for visual blockage or obstructions.
- Inspect for proper operation of intake louvers.
- Verify proper operation of remote radiator and belt condition.
Cooling System Semi-Annual Service (SCI) maintenance
- Visual inspection of Radiator/Heat exchanger for leaks, damage and obstructions.
- Add coolant to correct level.
- Inspect radiator cap, gasket and sealing surface.
- Visual inspection of water pump and cooling system gaskets for leaks.
- Inspect belts for cracking and fraying.
- Check water jacket heater for proper operation and adjust thermostat setting as needed.
- Check belt tension.
- Inspect flexible water connections for cracking, leaks and pliability.
- Inspect pulleys for excessive wear.
- Analyze coolant for proper antifreeze percentage.
- Analyze coolant conditioner level and add supplemental coolant additive as needed.
- Tighten hose clamps as needed.
- Lubricate fan drive with bearing lubricant.
Engine Semi-Annual Service maintenance
- Verify and record oil pressure and water temperature.
- Test all safety shutdown circuits and alarms (overspeed, overcrank, low oil pressure, high water temp, low coolant level).
- Inspect air intake system (air filter, crankcase breather, turbocharger).
- Inspect muffler system and drain condensation trap; verify rain cap operation.
- Inspect engine starting system; verify cable integrity and connections.
- Inspect exhaust flex coupling and piping for leaks and proper connection.
- Check for abnormal vibration or noise.
- Inspect spark plugs, plug wires and distributor.
Fuel System Semi-Annual Service maintenance
- Inspect all fuel lines and hoses for leaks and general condition.
- Inspect day tank and float assembly for proper operation and leaks.
- Inspect fuel pump for leaks.
- Verify proper operation of governor and governor linkage.
- Check fuel level in primary supply tank.
- Drain water and sediment from fuel filter and fuel supply tanks.
Generator Semi-Annual Service maintenance
- Inspect and lubricate generator end bell bearing.
- Inspect brushes, brush holders and commutators.
- Inspect cooling screen and general condition of alternator.
- Inspect for abnormal vibration.
- Verify connections and insulation condition.
- Verify proper operation of shunt trip on mainline circuit breaker.
Lubrication System Semi-Annual Service (SCI) maintenance
- Add crankcase oil (grade meeting manufacturer's specs) to correct level.
- Inspect oil heater for proper operation and leaks.
- With engine running, check for excessive crankcase blow-by.
- Visually inspect front and rear crankshaft seals and lubrication system gaskets for leaks.
- Check crankcase breather, inspect hose and connections.
- Take oil sample and perform oil analysis.
Optional Load Bank Testing maintenance
- Perform 4-hour resistive load bank test at 80% of generator nameplate capacity.
- Record all performance data at fifteen minute intervals including oil pressure, water temperature, voltage and frequency.
- Identify proper operation of fuel system, cooling system and overall condition of engine/generator set.
- Load bank testing shall be performed with no interruption to the normal power supply.
Starting System Semi-Annual Service (SCI) maintenance
- Check electrolyte level and add as needed.
- Check and record battery charger amperage.
- Check battery charger and adjust float rate for optimum battery performance and life.
- With engine running, check and record alternator for proper charge rate.
- Check for proper cranking termination upon engine start.
- Clean lead acid battery terminals and apply corrosion inhibitor.
- Tighten battery cable connections as needed.
- Inspect and tighten starter motors, connections and wiring.
Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.
Common questions
What fuel filter fits the Kohler 40ROZJ81?
The Kohler 40ROZJ81 uses fuel filter part number 254471.
Parts
4model family| Part # | Description | Qty | System | |
|---|---|---|---|---|
| 1000ROZD71-351890 | Generator - 1000ROZD71, Serial No. 351890, Main Compound | Generator | buy | |
| 12V149TI-12E0010387 | Power Unit - 12V149TI, Serial No. 12E0010387, Main Compound | Power unit | buy | |
| 6059T402728 | Power Unit - 4 cylinder, Serial No. 6059T402728, Correctional Camp | Power unit | Amazon eBay | |
| 80ROZJ81-338593 | Generator - 80ROZJ81, Serial No. 338593, Correctional Camp | Generator | Amazon eBay |
Compiled from this model's family documentation — may include parts for closely-related variants. Confirm the exact part for your serial number. See the full parts catalog to search and cross-reference.
Available documents
Service manual — OT906706 RC (Ohio Department of Administrative Services (DAS), General Services Division, Office of State Purchasing)
This page was generated from the 1 manufacturer document above by automated extraction; every figure shown is copied from one of them. How the data is compiled.