Kohler 99EOZDJ Bedienungsanleitung

TT-1604 5/16a

INSTALLATION INSTRUCTIONS

Original Issue Date: 9/13

Model: 99EOZDJ/80EFOZDJ

Market: Marine

Subject: Sound Shield Kit GM87198-KP2 and UMS Sound Shield Kit

GM88268-KP2

Introduction

The sound shield quiets operation of generator sets

used in marine applications. When installing the sound

shield, follow the installation procedure and observe the

safety precautions listed below.

Read the entire installation procedure before beginning

installation. Perform the steps in the order shown.

Take into consideration the minimum clearance for

vibration and cooling during operation. For sound

shielded units, allow 305 mm (12 inches) minimum

clearance for the left-rear door and front door (intake

and discharge openings).

Safety Precautions

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) 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.

Risk of fire.

Can cause severe injury or death.

Do not smoke or permit flames or

sparks near fuels or the fuel system.

WARNING

Servicing the fuel system. A flash fire can cause severe

injury or death. Do not smoke or permit flames or sparks near

the carburetor, fuel line, fuel filter, fuel pump, or other potential

sources of spilled fuels or fuel vapors. Catch fuels in an

approved container when removing the fuel line or carburetor.

Carbon monoxide.

Can cause severe nausea,

fainting, or death.

The exhaust system must be

leakproof and routinely inspected.

WARNING

Operating the generator set. Carbon monoxide can cause

severe nausea, fainting, or death. Be especially careful if

operating the generator set when moored or anchored under

calm conditions because gases may accumulate. If operating

the generator set dockside, moor the craft so that the exhaust

discharges on the lee side (the side sheltered from the wind).

Always be aware of others, making sure your exhaust is

directed away from other boats and buildings.

TT-1604 5/162

Hazardous voltage.

Can cause severe injury or death.

Operate the generator set only when

all guards and electrical enclosures

areinplace.

Moving parts.

WARNING

Short circuits. Hazardous voltage/current can cause

severe injury or death. Short circuits can cause bodily injury

and/or equipment damage.Do not contact electrical

connections with tools or jewelry while making adjustments or

repairs. Remove all jewelry before servicing the equipment.

Installation Procedure

See Figure 18 for the installed kit illustrations. Refer to

the generator set operation or service manual for items

not shown.

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 power to the battery charger, if

equipped.

1.3 Disconnect the generator set engine starting

battery, the negative (--) lead first.

Note: Before installing the sound shield,

disconnect and route the battery leads

through the holes provided in the skid.

1.4 Remove the junction box panel(s) as needed to

access the wiring.

1.5 Remove the four controller panel screws.

Note: Clearly mark all disconnected leads from

the controller with tape to simplify

reconnection.

1.6 Disconnect the following controller connectors.

See the corresponding wiring diagram found in

the operation manual for more details on wiring.

DP1 (35-pin) connector

DP2 (14-pin) connector

DP3 (8-pin) connector

DP4 Ethernet connector

DAny other external leads to the controller.

1. P3 (8-pin) connector

2. P2 (14-pin) connector

3. P1 (35-pin) connector

4. P4 Ethernet connector

GM86969A-

12 3

Figure 1 Decision-Maker3500 Controller

Connectors

TT-1604 5/16 3

1.7 Remove the controller. Save the hardware and

gasket to remount the controller into the sound

shield’s controller panel later in step 12.1.

1.8 Position the generator set onto the sound shield

base (GM87200) and secure the set with 4 bolts

(X-6238-3 or X-6238-11) and 4 washers

(X-25-37). See Figure 2.

For UMS Kit GM88268-KP2: Install two base

plates (GM89138) onto sound shield base

(GM87200).

GM87199-

Top View of Base

1. Engine end

2. Mounting hole locations

Figure 2 Sound Shield Base Mounting Position

1.9 Remove the end bracket cover. See Figure 3.

Save the mounting hardware and discard the

cover.

GM79560-

1. End bracket cover

Figure 3 End Bracket Cover

1.10 Remove the belt guard by removing the belt guard

brackets and hardware.

2. Construct the framework.

GM87198-

1. Rails (GM87713 qty. 4)

2. Internal rail (GM87544), bolts (X-6224-20 qty. 2), washers

(X-25-37 qty. 2), and nuts (X-6210-7 qty. 2)

3. Mounting bracket (GM86091), bolts (X-6224-20 qty. 4), and

nuts (X-6210-7 qty. 4) on each end of rail (GM87544)

4. Upper bulkhead (GM87203)

5. Internal rail (GM87545), mounting bracket (GM86091),

bolts (X-6224-20 qty. 3), and nuts (X-6210-7 qty. 3) on the

top of each rail

6. Extrusion mounting bracket (GM85876 qty. 3).

See Figure 6 for more detail.

7. LH bulkhead (GM87205)

8. RH bulkhead (GM87204)

9. Internal rail (GM87545), mounting bracket (GM86091),

bolts (X-6224-20 qty. 4), and nuts (X-6210-7 qty. 4) on the

top of the rail.

10. Corner extrusion mounting brackets (GM85875 qty. 4).

See Figure 5 for more detail.

11. Internal rail (GM87543), mounting brackets (GM86091

qty. 2), bolts (X-6224-20 qty. 8), and nuts (X-6210-7 qty. 8)

Figure 4 Sound Shield Framework Installation

2.1 Cut foam (GM87549 or GM88912) to length and

insert into four rails (GM87713). save remaining

foam for later.

2.2 Secure the rails (GM87713 qty. 4) to each corner

using the mounting bracket and hardware

identified in Figure 5.

TT-1604 5/164

2.3 Position the internal rails (GM87545 qty. 2) at the

location shown in Figure 4 using the mounting

bracket and hardware identified in Figure 6.

Position a mounting bracket (GM86091) to the top

of each internal rail using three bolts (X-6224-20)

and three nuts (X-6210-7) per bracket. See

Figure 14 for more detail.

2.4 Position the internal rail (GM87545) at the location

shown in Figure 4 using the mounting bracket and

hardware identified in Figure 6.

Position a mounting bracket (GM86091) to the top

of the internal rail using four bolts (X-6224-20) and

four nuts (X-6210-7). See Figure 14 for more

detail.

Note: Do not final tighten at this time.

GM86396A-

1. Bolt (X-6238-3 or X-6238-11 qty. 4) and washer (X-25-37

qty. 4)

2. Bolt (X-6224-20 qty. 8), nut (X-6210-7 qty. 8), and washer

(X-25-37 qty. 8)

3. Corner extrusion mounting bracket (GM85875 qty. 4)

Figure 5 Corner Extrusion Mounting Bracket

Installation (Corner Rails to Base, 4 Places)

GM86396A-

1. Extrusion mounting bracket (GM85876 qty. 3)

2. Bolt (X-6224-20 qty. 6), nut (X-6210-7 qty. 6), and washer

(X-25-37 qty. 6)

3. Bolt (X-6238-3 or X-6238-11 qty. 6) and washer (X-25-37

qty. 6)

Figure 6 Extrusion Mounting Bracket Installation

(Rails to Base, 3 Places)

2.5 Position the LH and RH bulkheads (GM87204 and

GM87205) as shown in Figure 4 (items 7 and 8).

Secure the bottom of the bulkheads to the existing

skid using a screw (M933-06020-60), washer

(X-25-40) and nut (M6923-06-80) for each

bulkhead.

Secure the sides of the bulkheads to the two

internal rails using a bolt (X-6224-20), washer

(X-25-37), and nut (X-6210-7) for each bulkhead.

2.6 Position the upper bulkhead (GM87203) as

shown in Figure 4 (item 4).

Secure the bottom of the upper bulkhead to the LH

and RH bulkheads using two screws

(M933-06020-60), two washers (X-25-40) and two

nuts (M6923-06-80) for each bulkhead.

Secure the sides of the upper bulkhead to the

internal rails using a bolt (X-6224-20), washer

(X-25-37), and nut (X-6210-7) for each side rail.

TT-1604 5/16 5

2.7 Position the internal rail (GM87544) as shown in

Figure 4 (item 2).

Secure the internal rail to the upper bulkhead panel

using two bolts (X-6224-20), two washers

(X-25-37), and two nuts (X-6210-7).

On each end of the internal rail, secure a mounting

bracket (GM86091) using four bolts (X-6224-20)

and four nuts (X-6210-7) per bracket. See

Figure 14 for more detail.

2.8 Position the internal rail (GM87543) as shown in

Figure 4 (item 11).

Secure the internal rail to the corner rail using a

mounting bracket (GM86091), four bolts

(X-6224-20) and four nuts (X-6210-7). See

Figure 14 for more detail.

Secure the other end of the internal rail to the rail

using a mounting bracket (GM86091), four bolts

(X-6224-20) and four nuts (X-6210-7). See

Figure 14 for more detail.

Note: Do not final tighten at this time.

3. Attach the foam and seal on bulkhead.

DAttach the foam and seal to the bulkhead as shown

in Figure 7 for standard sound shield kit or Figure 8

for UMS sound shield kit.

GM87198-E

1. Foam (GM87548 qty. 2)

2. Foam (GM87223-12)

3. Foam (GM87223-14)

4. Seal (X-6422-38)

5. Foam (GM87223-15)

6. Foam (GM87223-13)

Figure 7 Foam and Seal Installation for Standard

Sound Shield Kit GM87198-KP2

Follow below method to attach foam pieces for

the UMS sound shield kit:

3.1 Apply adhesive (GM96475) to the foam pieces

shown in Figure 8.

3.2 Stick the insulating hanger stud (GM96473) onto

the adhesive at equal distances.

3.3 Install the foam piece and allows the stud to

protrude through foam piece.

3.4 Install a washer (GM96474) and cap (GM55130)

over the protruding stud.

GM88268-C

1. Foam (GM88911 qty. 2)

2. Foam (GM88894-24)

3. Foam (GM88894-26)

4. Foam (GM88894-28)

5. Seal (X-6422-38)

6. Foam (GM88894-29)

7. Foam (GM88894-27)

8. Foam (GM88894-25)

Figure 8 Foam and Seal Installation for UMS Sound

Shield Kit GM88268-KP2

TT-1604 5/166

4. Connect the fuel lines.

4.1 Connect the fuel-inlet line (GM86395) to the fuel

inlet on the engine.

4.2 Remove the fuel fitting from the fuel-return

connection point (nonservice side of the unit).

4.3 Connect the straight union fitting (X-695-2) to the

fuel-return connection point.

4.4 Connect the fuel-return line (GM86395) to the

straight union fitting installed in step 4.3.

4.5 Secure the fuel return line to the left side of the

engine using a hose clamp (X-672-32) and

existing hardware and torque to 15 Nm (11 ft. lbs).

SeeFigure9.

GM87198E-B

1. Clamp (X-672-32)

Figure 9 Fuel Return Line Connections

4.6 Bleed the air from the fuel system according to the

procedure provided in the engine operation

manual.

5. Connect the seawater hose.

5.1 Connect the seawater hose (X-6014-133) to the

seawater inlet on the engine and secure with a

hose clamp (X-426-16).

GM87198-E

1. Hose (GM92876) and hose clamp (X-426-7). Attach hose to

air cleaner inlet.

2. Flex fuel line (GM86395), clamp (X-672-32) and straight

union (X-695-2). Attach to fuel return on engine.

3. Bulkhead connection panel (GM87238 or GM88933).

4. Flex fuel line (GM86395). Attach to fuel inlet on engine.

5. Hose (X-6014-133) and hose clamps (X-426-16 qty. 2).

Attach to seawater inlet on engine.

Figure 10 Internal Connections

GM87198-E

1. Clamp (X-672-33), washer (X-25-40), screw

(M933-06025-60), and nut (M6923-06-80)

Figure 11 Seawater Inlet Clamp Location

5.2 Secure the seawater inlet hose as shown in

Figure 11 using a clamp (X-672-33), screw

(M933-06025-60), washer (X-25-40), and nut

(M6923-06-80).

6. Connect the air cleaner hose

6.1 Position the air cleaner hose (GM92876) through

the upper bulkhead as shown in Figure 10 (Item 1)

and secure the hose to the air cleaner inlet using a

hose clamp (X-426-7).

7. Install the bulkhead connection panel.

7.1 Connect the fuel-inlet line to the fuel-inlet opening

on the bulkhead connection panel.

TT-1604 5/16 7

7.2 Connect the fuel-return line to the fuel-return

opening on the bulkhead connection panel.

7.3 Connect the seawater hose to the seawater

connection on the bulkhead connection panel and

secure with a hose clamp (X-426-16).

7.4 Secure the bulkhead connection panel (GM87238

or GM88933) to the corner rails (GM87713) using

brackets (GM86091 qty. 2), bolts (X-6224-20

qty. 4), and nuts (X-6210-7 qty. 4). See Figure 12.

8. Top rails and Bracket Installation

8.1 Cut foam (GM87549 or GM88912) to length and

insert into the rails (GM87712 qty. 2 and GM87715

qty. 2). See Figure 14.

8.2 Position the rails (GM87712 qty. 2 and GM87715

qty. 2) as shown in Figure 13.

8.3 Attach the brackets (GM86091 qty. 5) to the

service side rail (GM87715) using the hardware

specified at the locations shown in Figure 14.

8.4 Attach the brackets (GM86091 qty. 4) using the

hardware specified at the locations shown in

Figure 14.

1. Brackets (GM86091 qty. 2), bolts (X-6224-20 qty. 4), and

nuts (X-6210-7 qty. 4)

2. Bulkhead connection panel (GM87238 or GM88933)

GM87198-

Figure 12 Secure Bulkhead Connection Panel to

Corner Rails

GM87198-

1. Rail (GM87712 qty. 2). See Figure 14 for bracket location.

2. Rail (GM87715 qty. 2)

3. Corner (GM86035 qty. 4) and screw (X-67-141 qty. 24)

Figure 13 Top Rail and Bracket Installation

8.5 Secure the corners (GM86035 qty. 4) to the rails

as shown in Figure 13 using six screws

(X-67-141) per corner.

8.6 Position the corner foam (GM87547 or GM88910)

as shown in Figure 14. Install three foam pieces

per corner.

TT-1604 5/168

GM87198-B

1. Bracket (GM86091), bolts (X-6224-20 qty. 2), and nuts

(X-6210-7 qty. 2)

2. Bracket (GM86091), bolts (X-6224-20 qty. 4), and nuts

(X-6210-7 qty. 4)

3. Bracket (GM86091), bolts (X-6224-20 qty. 3), and nuts

(X-6210-7 qty. 3)

4. Wing nut (X-276-9) installed when installing alternator roof.

5. Wing nut (X-276-9) installed when installing controller panel.

6. Wing nut (X-276-9) installed when installing exhaust panel.

7. Wing nut (X-276-9) installed when installing engine roof.

8. Foam (GM87549 or GM88912). Insert foam into all rails. Cut

to fit.

9. Corner foam (GM87547 or GM88910 qty. 12). Install three

per corner.

111

444

Figure 14 Bracket Location/Installation

TT-1604 5/16 9

9. Corner Cover Installation

GM87198-

1. Corner cover (GM86036 qty. 4) and pan head machined

screws (M965A-06020-20 qty. 12)

Figure 15 Corner Covers

9.1 Position the corner covers (GM86036 qty. 4) as

shown in Figure 15 using 3 pan head machined

screws (M965A-06020-20) per corner cover.

10. Install the roofs.

GM87198-

1. Alternator roof (GM87234 or GM88929)

2. Engine roof (GM87228 or GM88925)

Figure 16 Roofs

10.1 Position the alternator roof (GM87234 or

GM88929) and engine roof (GM87228 or

GM88925) onto the sound enclosure as shown in

Figure 16.

Attach the alternator roof to the mounting brackets

in the top rail and secure using four wing nuts

(X-276-9). See Figure 14 for more detail.

Attach the engine roof to the mounting brackets in

the top rail and secure using three wing nuts

(X-276-9). See Figure 14 for more detail.

Note: Final tighten all hardware.

TT-1604 5/1610

11. Install the remaining doors.

11.1 Align the pins with the holes in the bulkhead

connection panel and install the rear door

(GM87237 or GM88932) on the alternator end of

the unit. See Figure 17 (item 1).

11.2 Align the pins with the holes in the base and install

the LH alternator panel (GM87236 or GM88931)

on the nonservice, alternator side of the unit. See

Figure 17 (item 2).

11.3 Align the pins with the holes in the base and install

the exhaust panel (GM87227 or GM88924) on the

nonservice side of the unit See Figure 17 (item 3).

Attach the top of the exhaust panel to the

mounting brackets in the top rail and secure using

two wing nuts (X-276-9). See Figure 14 for more

detail.

11.4 Align the pins with the holes in the base and install

the LH panel (GM87226 or GM88923) on the

nonservice side, engine end of the unit. See

Figure 17 (item 4).

11.5 Align the pins with the holes in the base and install

the front panel (GM87225 or GM88922) on the

engine end of the unit. See Figure 17 (item 5).

11.6 Align the pins with the holes in the base and install

the RH panel (GM87224 or GM88921) to the

service side, engine end of the unit. See

Figure 17 (item 6).

11.7 Align the pins with the holes in the base and install

the RH alternator panel (GM87230 or GM88927)

to the service side, alternator end of the unit. Place

decal (GM93648) on RH alternator panel. See

Figure 17 (item 7).

11.8 Position the controller panel (GM87232) as

shown in Figure 17 and attach to the mounting

brackets in the top rail and secure using two wing

nuts (X-276-9). See Figure 14 for more detail.

12. Restore the generator set to service.

12.1 Reconnect the leads that were disconnected in

step 1.6. Position the controller into the controller

panel and secure using the existing hardware and

gasket(removedinstep1.7).

12.2 Check that the generator set master switch is in

the OFF position.

12.3 Reconnect the generator set engine starting

battery, the negative (--) lead last.

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