Kohler 13EKOZD User manual

TT-1651 4/17a
INSTALLATION INSTRUCTIONS
Original Issue Date: 4/15
Model: 13EKOZD/11EFKOZD, 15EKOZD/13EFKOZD, 16.5/17.5/19.5/20EFKOZD,
20EKOZD/17.5-16.5EFKOZD, and 23EKOZD/20-19.5EFKOZD
Market: Marine
Subject: Sound Shield Kits with Front Connection Panel GM93548-KP1,
GM93548-KP2, GM93548-KP3, GM93548-KP4, GM95106-KP1, and
GM95106-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. See Figure 1 for kit
selection.
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 service and non-service side doors
(intake and discharge openings).
Model Kit Number
13EKOZD/11EFKOZD GM93548-KP1
15EKOZD/13EFKOZD GM93548-KP4
17.5/16.5EFKOZD GM93548-KP2
20EKOZD GM95106-KP1
20/19.5EFKOZD GM93548-KP3
23EKOZD GM95106-KP2
Figure 1 Sound Shield Kit Selection
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) 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.
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 fuel injection system, 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 fuel
system.

2TT-1651 4/17a
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.
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
Note: Read all safety precautions at the beginning of
this publication before performing 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 panel screws.
Note: Clearly mark all disconnected leads from
the controller with tape to simplify
reconnection.
1.5 Disconnect the following controller connectors.
See Figure 2. See the 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
1. P1 (35-pin) connector
2. P2 (14-pin) connector
3. P3 (8-pin) connector
4. P4 Ethernet connector
2
3
4
Figure 2 Decision-Makerr3500 Controller
1.6 Remove the controller. Save the hardware and
gasket to remount the controller into the sound
shield’s controller panel later.
1.7 Assemble the mounting brackets to the generator
drip tray as shown in Figure 3. Secure using the
screws (M933-08020-SS) and washers (X-25-139)
in the quantities specified in Figure 3.
1.8 Install the bushings (X-634-28 qty. 2) to the
alternator-end mounting bracket as shown in
Figure 3, item 5.

3
TT-1651 4/17a
GM89517-C
1
1. Mounting bracket, rear/alternator end (GM93411), screws
(M933-08020-SS qty. 2), and washers (X-25-139 qty. 2)
2. Side mounting bracket, non-service side (GM89786, or
GM90529, or GM90530, or GM93637), screws
(M933-08020-SS qty. 3), and washers (X-25-139 qty. 3)
3. Mounting bracket, engine end (GM93616), screws
(M933-08020-SS qty. 2), and washers (X-25-139 qty. 2)
4. Side mounting bracket, service side (GM89786, or
GM90529, or GM90530, or GM93637), screws
(M933-08020-SS qty. 3), and washers (X-25-139 qty. 3)
5. Round bushings (X-634-28 qty. 2) for customer load
leads.
2
3
4
5
Figure 3 Sound Shield Base Mounting Position
1.9 Remove and discard the belt guard brackets
(GM90741, GM90701, 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 panel (GM87127)
2. Alternator air-exhaust guard (GM90786)
2
Figure 5 End Bracket Components
1.11 Replace the existing end bracket panel with
alternator air intake duct (GM90676) and
alternator air intake duct (GM89976) using 4
screws (X-6216-1) and the existing hardware to
secure. See Figure 6.
GM89517-J
1
1. Alternator air intake duct (GM90676)
2. Alternator air intake duct (GM89976) and screws (X-6216-1
qty. 4)
3. U-channel (X-6047-14)
2
3
Figure 6 Alternator Air Duct Assembly

4TT-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.
SeeFigure7,item5.
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.

5
TT-1651 4/17a
2.6 Ground lead connection. Connect the lead
(LK-0616-1715) to the ground stud located inside
the junction box using nut (M6923-06-80), washer
(M125A-06-80), lock washer (X-22-12 qty. 2), and
screw (M933-06020-60). Route the lead under the
U-channel shown in Figure 6. Connect the other
end of the lead to the customer connection panel
location. See Figure 9.
2.7 Fuel line connections. See Figure 9 for fuel
supply and return connection locations.
2.8 Secure the U-channel (X-6047-14) as shown in
Figure 6.
1. Customer connestion panel (GM93558 or GM95124)
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 junction
box using nut (M6923-06-80), washer (M125A-06-80),
lock washer (X-22-12 qty. 2), and screw (M933-06020-60).
GM93548-J
3
45
6
7
2
9
1
8
Figure 9 Customer Connection Panel Connections
GM93548-J
1. New location for existing hose connector
2. Route harness (GM96427) from temperature sensor to engine
harness.
1
2
Figure 10 New Location for Existing Hose Connector

6TT-1651 4/17a
3. Construct the framework.
3.1 Position the sound shield rails (GM89784-2 qty. 4)
as shown in Figure 11 using the corner bracket
and hardware identified in Figure 12.
1. Sound shield rails (GM89784-2 qty. 4)
GM89517-C
1
Figure 11 Rail Framework
1. Carriage bolt (X-6224-20 qty. 4) and hex. nut (X-6210-7 qty. 4)
2. Corner bracket (GM74790 qty. 4)
3. Screw (M933-08020-SS qty. 8) and hex. nut (M6923-08-80
qty. 8)
GM89517-C
1
2
3
Figure 12 Bottom Corner Bracket Assembly
(4 Places)
Note: Create corner assemblies by sliding the rail
bracket(s) into the end of each rail
groove/channel. Position the rail bracket in place
and 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
Figure 14.
3.3 See Figure 14 and Figure 15 for mounting bracket
locations.
1. Panel mounting bracket (GM77222 qty. 7), carriage bolt
(X-6224-20 qty. 7), and hex. nut (X-6210-7 qty. 7)
2. Corner connector (GM74137 qty. 4)
3. Carriage bolt (X-6224-20 qty. 12) and hex. nut (X-6210-7 qty.
12)
4. Panel mounting bracket (GM82181),
carriage bolt (X-6224-20), and hex. nut (X-6210-7)
1
GM89517-C
23
4
Figure 14 Top Corner Connector Assembly
(4 Places)

7
TT-1651 4/17a
Bracket Location
on Service Side
Bracket Location
on Non Service Side
Bracket Location
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)
11
2
Figure 15 Mounting Bracket Location in Top Rails

8TT-1651 4/17a
4. Install the roof.
4.1 Install a panel mounting bracket (GM77222 qty. 3)
onto the service-side rail and secure with a
carriage bolt (X-6224-20 qty. 3), and a hex. nut
(X-6210-7 qty. 3). See Figure 16 and Figure 17.
4.2 Use 3 wing nuts (X-276-9) to secure the sound
shield roof (GM89898, or GM90510, or GM90519,
or GM93642) to the panel mounting bracket. See
Figure 16.
GM89548-A
1. Wing nut (X-276-9 qty. 3)
2. Panel mounting bracket (GM77222 qty. 3), carriage bolts
(X-6224-20 qty. 3), and hex. nut (X-6210-7 qty. 3)
2
1
Figure 16 Sound Shield Roof Assembly to Top Rail
1
GM89517-C
1. Panel mounting bracket (GM77222 qty. 3), carriage bolts
(X-6224-20 qty. 3), and hex. nut (X-6210-7 qty. 3)
Bracket Location
on Service Side
Figure 17 Panel Mounting Bracket Location for Roof
5. Install the doors/panels.
5.1 Align the pins to the holes in the mounting
bracket/base and install the controller panel
(GM89881) on the service side of the unit. Secure
the top of the panel to the top rail using 2 screws
(M7985A-05020-20) and 2 washers
(M125A-05-08). Install the decal (GM93648) on
the panel. See Figure 19.
5.2 Align the pins to the holes in the mounting
bracket/base and install the door (GM93560) 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 the holes in the mounting
bracket/base and install the door (GM89877, or
GM90507, or GM90516, or GM93640) on the non
service side of the unit. See Figure 19. Secure
the top of the panel using 3 screws
(M7985A-05020-20) and 3 washers
(M125A-05-08).
5.5 Align the pins to the holes in the mounting
bracket/base and install the door (GM89867, or
GM90504, or GM90513, or GM93638) on the
service side of the unit. See Figure 19.
5.6 Align the pins to the holes in the mounting
bracket/base and install the door (GM93562) on
the engine end of the unit. See Figure 19.
GM93548-A
Figure 18 Sound Shield
6. Restore the generator set to service.
6.1 Reconnect the connectors that were
disconnected in step 1.5. Position the controller
into the controller panel and secure using the
existing hardware and gasket (removed in step
1.6.
6.2 Check that the generator set master switch is in
the OFF position.
6.3 Reconnect the generator set engine starting
battery, the negative (--) lead last.

9
TT-1651 4/17a
1
7
1. Roof (GM89898, or GM90510, or GM90519, or GM93642)
2. Alternator-end (rear) door (GM93560)
3. Decal, caution (GM93648)
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
5GM93548-J
3
Figure 19 Roof, Panel, and Door Identification

10 TT-1651 4/17a
Sound Shield Parts List
Kits: GM93548-KP1, GM93548-KP2, GM93548-KP3, and GM93548-KP4
Qty. Description Common Parts
Unique Parts
GM93548-KP1 GM93548-KP2 GM93548-KP3 GM93548-KP4
4Corner, sound shield GM74137
4Bracket, sound shield corner
(1 x 1.6 in.) GM74790
10 Bracket, sound shield panel
mounting (1.1 x 1.8 in.) GM77222
1Bracket, sound shield mounting GM93616
2Rail, sound shield GM89784-1
4Rail, sound shield GM89784-2
1Door, front (engine end) GM93562
1Panel, RH (service side, controller) GM89881
1 Duct, alternator air intake GM89976
1Bracket, panel mounting GM82181
1 Duct, alternator air intake GM90676
1Panel, customer connection GM93558
1Door, rear (alternator end) GM93560
1Bracket, mounting GM93411
1Tube, front mixing GM92557-2
1 Lead, ground LK-0616-1715
9Washer, plain (#5 screw size) M125A-05-80
8Nut, hex (8 mm) M6923-08-80
9Screw, 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
3Nut, wing (1/4--20) X-276-9
1Hose X-312-49
2Clamp, hose (0.69/1.25 in.) X-426-12
1Cable, battery (positive, red) X-545-259
1 Cable, battery (negative, black) X-545-241
1Hose, coolant X-373-30
2Bushing X-634-28
1Clamp, insulated (1.06 in.) X-672-32
1U-channel X-6047-14
4Screw, Phillips hex crimptite X-6216-1
27 Bolt, carriage X-6224-20
1Decal, caution GM93648
1Harness, extension GM96427
1Washer, plain M125A-06-80
1Nut, hex (6mm) M6923-06-80
1Screw, hex cap (M6 x 20 mm) M933-06020-60
2Washer, lock (.262 in. ID x.743 in.
OD)
X-22-12
27 Nut, flange spiralock (5/16-18) X-6210-7
1Door, RH (service side) GM89867 GM90504 GM90513 GM93638
1Door, LH (non service side) GM89877 GM90507 GM90516 GM93640
1Roof GM89898 GM90510 GM90519 GM93642
2Rail, sound shield GM89784-3 GM89784-4 GM89784-5 GM89784-9
2Bracket, mounting (side) GM89786 GM90529 GM90530 GM93637

11
TT-1651 4/17a
Kits: GM95106-KP1 and GM95106-KP2
Qty. Description Common Parts
Unique Parts
GM95106-KP1 GM95106-KP2
4Corner, sound shield GM74137
4Bracket, sound shield corner
(1 x 1.6 in.) GM74790
10 Bracket, sound shield panel mounting
(1.1 x 1.8 in.) GM77222
1Bracket, sound shield mounting GM93616
2Rail, sound shield GM89784-1
4Rail, sound shield GM89784-2
1Door, front (engine end) GM93562
1Panel, RH (service side, controller) GM89881
1 Duct, alternator air intake GM89976
1Bracket, panel mounting GM82181
1 Duct, alternator air intake GM90676
1Panel, customer connection GM95124
1Door, rear (alternator end) GM93560
1Bracket, mounting GM93411
1Tube, front mixing GM95109
1 Lead, ground LK-0616-1715
9Washer, plain (#5 screw size) M125A-05-80
8Nut, hex (8 mm) M6923-08-80
9Screw, 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
3Nut, wing (1/4--20) X-276-9
1Hose X-312-49
2Clamp, hose (0.69/1.25 in.) X-426-12
1Cable, battery (positive, red) X-545-259
1 Cable, battery (negative, black) X-545-176
1Hose, coolant X-373-30
2Bushing X-634-28
1Clamp, insulated (1.06 in.) X-672-32
1U-channel X-6047-14
4Screw, Phillips hex crimptite X-6216-1
27 Bolt, carriage X-6224-20
1Decal, caution GM93648
1Harness, extension GM96427
1Washer, plain M125A-06-80
1Nut, hex (6mm) M6923-06-80
1Screw, hex cap (M6 x 20 mm) M933-06020-60
2Washer, lock (.262 in. ID x.743 in. OD) X-22-12
27 Nut, flange spiralock (5/16-18) X-6210-7
1Door, RH (service side) GM90504 GM90513
1Door, LH (non service side) GM90507 GM90516
1Roof GM90510 GM90519
2Rail, sound shield GM89784-4 GM89784-5
2Bracket, mounting (side) GM90529 GM90530

12 TT-1651 4/17a
KOHLER CO., Kohler, Wisconsin 53044 USA
Phone [phone], Fax [phone]
For the nearest sales and service outlet in the
US and Canada, phone [phone]
KOHLERPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone [phone], Fax [phone]
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 Kohlerrgenerator
set distributor for availability.
2015, 2017 by Kohler Co. All rights reserved.