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4

TT-1651 4/17a

2.

Make connections.

1

GM89516-C

1. Save the existing hose connector.

2. Save the existing exhaust temperature sender.

3. Save the existing pipe plug.

4. Location of the existing tube tee and pressure switch.

5. Remove and discard the hose (X-312-4).

6. Remove and discard the exhaust tube (GM92557-1).

2

3

4

6

5

Figure 7

Remove the Existing Exhaust Tube

2.1

Exhaust connection.

Disconnect the lead to the

exhaust temperature sender. Remove the existing

exhaust tube (GM92557-1). See Figure 7, item 6.

Remove and save the exhaust temperature

sender, 90

_

hose connector, pipe plug, clamps,

pressure switch, and all hardware. Discard the

exhaust tube.

Remove and discard the short hose (X-312-4) that

connects to the hose connector and to the tee.

See Figure 7, item 5.

Remove and save the coverplate and hardware

and connect the new exhaust tube (GM92557-2 or

GM95109) at the location shown in Figure 8, item

1. Re-use the existing hardware and clamps and

re-install the hose connector, pipe plug, and

exhaust temperature sender. Reconnect the lead

to the exhaust temperature sender. Route the

harness (GM96427) from temperature sensor to

engine harness. See Figure 10 for the new

location of the hose connector.

Connect the hose (X-312-49) to the connector on

the new exhaust tube. Cut the hose 127 mm (5 in.)

from the end shown in Figure 8, item 4 and

connect it to the tee. Re-use the existing hose

clamps.

Re-install the existing coverplate and hardware at

the new location shown in Figure 8, item 2.

GM93548-A

1. Remove the existing coverplate and hardware and install the

new exhaust tube (GM92557-2 or GM95109) re-using the

existing hardware. Re-install the existing hose connector,

pipe plug, and exhaust temperature sender.

2. Relocate the existing cover plate and hardware at this location

3. Re-use the existing pressure switch, tube tee, and clamps

4. Hose (X-312-49). Cut hose 127 mm (5 in.) from the end to

assemble tee.

3

4

1

2

Figure 8

Install a New Exhaust Tube on the

Opposite Side

2.2

Customer connection panel.

Position the

customer connection panel (GM93558 or

GM95124) near the engine end of the generator

set. See Figure 9. However, do not final tighten the

panel. The panel will be final tightened in Section

5.

2.3

Seawater pump.

Connect the seawater hose

(X-373-30) to the inlet on the seawater pump and

secure with a hose clamp (X-426-12). Route the

hose through the insulated clamp (X-672-32).

Secure the clamp onto the tray. Connect the other

end of the hose to the seawater inlet on the

customer connection panel using a hose clamp

(X-426-12) to secure. See Figure 9.

2.4

Positive battery connection.

Connect the red,

positive battery cable (X-545-259) to the starter

motor. See Figure 9. The other end connects on to

the terminal on the customer connection panel.

2.5

Negative battery connection.

Connect the

black, negative battery cable (X-545-241 or

X-545-176) to the engine block. See Figure 9.

The other end connects to the terminal on the

customer connection panel.

Summary of Contents for 11EFKOZD

Page 1: ...idental 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 ...

Page 2: ...ming any work on the generator set Note Apply pipe sealant to the male threads of all pipe fittings before installation 1 Remove the generator set from service 1 1 Press the generator set master control OFF RESET button 1 2 Disconnect the generator set engine starting battery the negative lead first 1 3 Remove the junction box panel s as needed to access the wiring 1 4 Remove the four controller p...

Page 3: ...90701 and GM90702 to remove the belt guard GM90698 See Figure 4 1 Bracket belt guard GM90741 2 Bracket belt guard GM90702 3 Bracket belt guard GM90701 4 Wing screw and belt guard mounting hardware qty 3 5 Belt guard GM90698 3 2 1 4 4 5 Figure 4 Belt Guard 1 10 Remove and discard the end bracket panel GM87127 and alternator air exhaust guard GM90786 Save the hardware See Figure 5 1 1 End bracket pa...

Page 4: ...ing hose clamps Re install the existing coverplate and hardware at the new location shown in Figure 8 item 2 GM93548 A 1 Remove the existing coverplate and hardware and install the new exhaust tube GM92557 2 or GM95109 re using the existing hardware Re install the existing hose connector pipe plug and exhaust temperature sender 2 Relocate the existing cover plate and hardware at this location 3 Re...

Page 5: ...2 Opening for exhaust tube 3 Lead LK 0616 1715 4 Battery cable X 545 259 Attach positive battery cable to the starter motor 5 Hose clamps X 426 12 qty 2 Attach seawater inlet hose to inlet on the seawater pump 6 Hose X 373 30 7 Battery cable X 545 241 or X 545 176 Attach negative battery cable to the engine block 8 Insulated clamp X 672 32 9 Attach lead to the ground stud located inside of the jun...

Page 6: ...secure with the corner connector or bracket and hardware specified in Figure 12 and Figure 14 1 Rails GM89784 1 qty 2 2 Rails GM89784 3 or GM89784 4 or GM89784 5 or GM89784 9 qty 2 GM89517 C 2 1 Figure 13 Top Rail Framework 3 2 Position the top rails GM89784 1 qty 2 and GM89784 3 or GM89784 4 or GM89784 5 or GM89784 9 qty 2 as shown in Figure 13 using the corner bracket and hardware identified in ...

Page 7: ...on on Engine End Bracket Location on Alternator End 1 GM93548 A GM89517 C 1 Panel mounting bracket GM77222 qty 7 carriage bolt X 6224 20 qty 7 and hex nut X 6210 7 qty 7 2 Panel mounting bracket GM82181 carriage bolt X 6224 20 and hex nut X 6210 7 1 1 2 Figure 15 Mounting Bracket Location in Top Rails ...

Page 8: ...93560 on the alternator end of the unit See Figure 19 Secure the top of the door to the top rail using 2 screws M7985A 05020 20 and 2 washers M125A 05 08 5 3 Use the existing hardware on the customer connection panel GM93558 or GM95124 to secure it to the mounting bracket base See Figure 19 Secure the top of the panel using 2 screws M7985A 05020 20 and 2 washers M125A 05 08 5 4 Align the pins to t...

Page 9: ...93648 4 Controller service side panel GM89881 5 Service side RH door GM89867 or GM90504 or GM90513 or GM93638 6 Engine end front door GM93562 7 Customer connection panel GM93558 or GM95124 8 Non service side LH door GM89877 or GM90507 or GM90516 or GM93640 2 4 6 8 5 GM93548 J 3 Figure 19 Roof Panel and Door Identification ...

Page 10: ... 05 80 8 Nut hex 8 mm M6923 08 80 9 Screw pan head machine M5 x 20 mm M7985A 05020 20 18 Screw hex cap M8 x 20 mm M933 08020 SS 10 Washer plain 0 344 ID x 0 75 in OD X 25 139 3 Nut wing 1 4 20 X 276 9 1 Hose X 312 49 2 Clamp hose 0 69 1 25 in X 426 12 1 Cable battery positive red X 545 259 1 Cable battery negative black X 545 241 1 Hose coolant X 373 30 2 Bushing X 634 28 1 Clamp insulated 1 06 in...

Page 11: ...M125A 05 80 8 Nut hex 8 mm M6923 08 80 9 Screw pan head machine M5 x 20 mm M7985A 05020 20 18 Screw hex cap M8 x 20 mm M933 08020 SS 10 Washer plain 0 344 ID x 0 75 in OD X 25 139 3 Nut wing 1 4 20 X 276 9 1 Hose X 312 49 2 Clamp hose 0 69 1 25 in X 426 12 1 Cable battery positive red X 545 259 1 Cable battery negative black X 545 176 1 Hose coolant X 373 30 2 Bushing X 634 28 1 Clamp insulated 1 ...

Page 12: ... Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone 65 6264 6422 Fax 65 6264 6455 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 Kohlerr generator set distributor for availability 2015 2017 by Kohler Co All rights reserv...

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