Kohler GM79104-KP1 User manual

TT-1567 5/12a
INSTALLATION INSTRUCTIONS
Original Issue Date: 2/11
Model: 20-200 kW Generator Sets (with Fast-ResponsetX Alternators)
Market: Industrial and Marine
Subject: Generator Strip Heater Kits GM79104-KP1 and GM79104-KP2
Introduction
The generator strip heater kit heats the unit in cold
climates and helps prevent condensation from forming
in the alternator.
Read the entire installation procedure and compare the
kit parts with the parts list in this publication before
beginning installation. Perform the steps in the order
shown.
Always observe applicable local and national electrical
codes.
Special Tools and Equipment
The following items are necessary for installing the kit.
D110--120-volt or 220--240-volt, 50/60 Hz, 15-amp
utility power supply outlet or electrical box in close
proximity to the generator set.
DPermabondrMM-128 (red) thread adhesive or
equivalent.
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
Permabondris a registered trademark of Permabond Engineering
Adhesives Ltd.
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.
(Decision-Makerr550 Controller)
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) Press the generator set off/reset
button to shut down the generator set. (2) Disconnect the
power to the battery charger, if equipped. (3) Remove the
battery cables, negative (--) lead first. Reconnect the negative
(--) lead last when reconnecting the battery. Follow these
precautions to prevent the starting of the generator set by the
remote start/stop switch.
(Decision-Makerr3000 and 6000 Controllers)
Hazardous voltage.
Will cause severe injury or death.
Disconnect all power sources before
opening the enclosure.
DANGER
Hazardous voltage.
Can cause severe injury or death.
Operate the generator set only when
all guards and electrical enclosures
areinplace.
Moving parts.
WARNING

2 TT-1567 5/12a
Grounding electrical equipment. Hazardous voltage can
cause severe injury or death. Electrocution is possible
whenever electricity is present. Ensure you comply with all
applicable codes and standards. Electrically ground the
generator set and related equipment and electrical circuits.
Turn off the main circuit breakers of all power sources before
servicing the equipment. Never contact electrical leads or
appliances when standing in water or on wet ground because
these conditions increase the risk of electrocution.
Connecting the battery and the battery charger.
Hazardous voltage can cause severe injury or death.
Reconnect the battery correctly, positive to positive and
negative to negative, to avoid electrical shock and damage to
the battery charger and battery(ies). Have a qualified
electrician install the battery(ies).
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
1. Remove the generator set from service.
1.1 Place the generator set master switch to the
OFF/RESET position (Decision-Makerr550).
OR
Press the generator set master control
OFF/RESET button (Decision-Makerr3000 or
6000).
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 heater kit.
2.1 Remove enclosure panels as needed to access
generator set.
2.2 Remove the junction box panels as needed to
access the alternator end bracket and stator.
2.3 Disconnect generator set from load by opening
line circuit breaker or disconnecting output leads
from the transfer switch and heavily taping lead
ends.
2.4 Connect installer-supplied AC leads to strip
heaters. Installation must conform to applicable
local and national electrical codes. Position lead
terminals perpendicular to strip heater. See
Figure 1.
2.5 Place one flat washer (M125A-05-80) onto each
screw (M933-05020-60).
2.6 Apply general purpose thread adhesive to screw
threads. Use PermabondrMM-128 (red) or
equivalent.
2.7 Assemble the screws (M933-05020-60), flat
washers (M125A-05-80), and strip heaters
(GM79574 or GM85733) to the existing holes in
the stator shell as shown in Figure 1. Position
the strip heaters with the AC terminals closest to
the end bracket. Torque the screws to 5.8 Nm
(4.3 in. lbs.). Do not over-tighten the hardware.
2.8 Use a rag to wipe up any excess thread
adhesive.
2.9 Open circuit breaker to AC power source. With
installer-supplied leads and terminals, connect
strip heaters to AC voltage source using
appropriate wiring diagram in Figure 2.
Installation must conform to applicable local and
national electrical codes.
2.10 Replace junction box side panels.
2.11 Replace enclosure panels as needed.
2.12 Close circuit breaker to AC power source.
2.13 Reconnect generator set to load by closing line
circuit breaker or reconnecting output leads to
transfer switch.
3. Restore power to the generator set.
3.1 Place the generator set master switch to the
OFF/RESET position (Decision-Makerr550
only).
3.2 Reconnect the generator set engine starting
battery, negative (--) lead last.
3.3 Reconnect power to the battery charger, if
equipped.
Parts List
Strip Heater Kits
Kits: GM79104-KP1 GM79104-KP2
Qty. Description Part Number Part Number
2 Heater, strip GM79574
(100 W each)
GM85733
(85 W each)
4Screw, M5 x 20 M933-05020-60 M933-05020-60
4 Washer, M5 M125A-05-80 M125A-05-80
Permabondris a registered trademark of Permabond Engineering
Adhesives Ltd.

TT-1567 5/12a 3
GM79104-C
Note: Dimensions shown are in mm (inches).
GM79104-KP1: 133.4 (5.25) REF
GM79104-KP2: 108.4 (4.27) REF
Figure 1 Heater Kit Installation
GM79104-C
110--120 Volt Connection Diagram 220--240 Volt Connection Diagram
Strip Heater
110--120 Volt AC
Power Supply
220--240 Volt AC
Power Supply
Strip Heater Strip Heater Strip Heater
Figure 2 Heater Kit Wiring Diagrams