Kohler 125EOZDJ/EOZCJ User manual

TT-1644 11/14
INSTALLATION INSTRUCTIONS
Original Issue Date: 11/14
Model: 125/150EOZDJ/EOZCJ & 100/125EFOZDJ/EFOZCJ with
Decision-Makerr3500 Controllers
Market: Marine
Subject: Block Heater Kits GM89494-KP1 & GM89494-KP2
Introduction
The engine block heater kit heats engine coolant,
making starting easier and warmup quicker. The block
heater automatically turns on when coolant temperature
drops to 27_C(80_F) or below and turns off when
coolant temperature reaches 38_C (100_F).
Models Volts Amps Watts Kit No.
125EOZDJ/EOZCJ
100EFOZDJ/EFOZCJ
150EOZDJ/EOZCJ
125EFOZDJ/EFOZCJ
120
240
12.5
6.3
1500
1500
GM89494-KP1
GM89494-KP2
Figure 1 Kit Selection
Read the entire installation procedure before beginning
the installation. Perform the steps in the order shown.
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
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.
Hot coolant and steam.
Can cause severe injury or death.
Before removing the pressure cap,
stop the generator set and allow it to
cool. Then loosen the pressure cap
to relieve pressure.
WARNING
Allow the engine to cool. Release pressure from the
cooling system before removing the pressure cap. To
release pressure, cover the pressure cap with a thick
cloth and then slowly turn the cap counterclockwise to
the first stop. Remove the cap after pressure has been
completely released and the engine has cooled. Check
the coolant level at the tank if the generator set has a
coolant recovery tank.
Note: Air pockets often form in the engine water jacket
when the coolant system is refilled. Check the
coolant level in the coolant recovery tank after
each generator set operation and add coolant as
necessary until the level stabilizes. Check the
coolant at the interval specified in the service
schedule.
Note: Block heater damage. The block heater will fail
if the energized heater element is not immersed
in coolant. Fill the cooling system before turning
on the block heater. Run the engine until it is
warm, and refill the system to purge the air from
the system before energizing the block heater.

2TT-1644 11/14
Installation Procedure
1. Remove the generator set from service.
1.1 Press the generator set OFF/RESET button to
shut down the generator set.
1.2 Disconnect the power to the battery charger, if
equipped.
1.3 Disconnect the generator set engine starting
battery(ies), negative (--) lead first.
1.4 When the engine has cooled, remove the
pressure cap and open the drain valve(s). See the
Service Views in the operation manual for drain
valve location.
1.5 Drain the coolant into a suitable container.
Note: Dispose of all waste materials (engine oil, fuel,
filters, etc.) in an environmentally safe manner
and in accordance with all applicable laws.
2. Install the block heater.
Note: Apply pipe sealant to the threads of the hose
connectors.
2.1 Secure the block heater (352945 or 352946) and
mounting bracket (GM32987) to the skid using:
on the back side: 2 screws (M933-06020-60),
2 washers (X-25-40), and 2 hex nuts
(M6923-06-80). See Figure 2, Detail A.
on the front side: 2 screws (M933-06025-60),
2 washers (X-25-40), and 2 hex nuts
(M6923-06-80). See Figure 2, Detail A.
2.2 Remove the plug from the engine block and install
the adapter bushing (GM22991) and O-ring
(GM11694) as shown in Figure 2.
2.3 Install the street elbow (227642) as shown in
Figure 2.
2.4 Install the hose connector (X-582-1) into the end
of the hose (X-312-50).
2.5 Install the hose/hose connector into the street
elbow as shown in Figure 2. Secure the hose to
the street elbow using a hose clamp (X-426-12).
2.6 Connect the other end of the hose (X-312-50) to
the block heater inlet. Secure the hose to the inlet
using a hose clamp (X-426-12).
2.7 Remove the pipe plug from the engine block and
install an adapter bushing (273692), O-ring
(273693), and hose connector (X-582-1). See
Figure 2.
2.8 Connect the hose (X-312-17) to the hose
connector installed in step 2.7. Secure the hose to
the street elbow using a hose clamp (X-426-12).
2.9 Connect the other end of the hose (X-312-17) to
the block heater outlet using a hose clamp
(X-426-12) to secure.
2.10 Loop the block heater cord and secure it with a
cable tie.
2.11 Close the drain valve(s) on the engine block.
2.12 Fill the cooling system. See the specification
sheet for cooling system capacities.
Note: Use a coolant solution of 50% ethylene glycol to
provide freezing protection to --37_C(--34_F) and
overheating protection to 129_C (265_F). A
coolant solution with less than 50% ethylene
glycol can cause engine or component damage.
Do not use alcohol or methanol antifreeze or mix
them with the specified coolant.
Note: Do not add coolant to a hot engine. Wait until the
engine has cooled. Adding coolant to a hot
engine can cause the cylinder block or cylinder
head to crack.

TT-1644 11/14 3
GM89494-
1
1. Block heater (352945 or 352946)
2. Bracket (GM32987)
3. Front side: screws (M933-06025-60 qty. 2), washers (X-25-40
qty. 2), and hex nuts (M6923-06-80 qty. 2)
4. Back side: screws (M933-06020-60 qty. 2), washers (X-25-40
qty. 2), and hex nuts (M6923-06-80 qty. 2)
5. Remove and discard pipe plug supplied with engine.
Install adapter bushing (273692), O-ring (273693), and hose
connector (X-582-1).
6. Hose (X-312-17) and hose clamps (X-426-12 qty. 2)
7. Hose (X-312-50) and hose clamps (X-426-12 qty. 2)
8. Hose connector (X-582-1)
9. Street elbow (227642)
10. Remove and discard plug supplied with engine.
Install O-ring (GM11694) and adapter bushing (GM22991).
2
3
4
5
6
78
9
10
Figure 2 Block Heater(Installed Kit)
3. Restore the generator set to service.
3.1 Check that the generator set is OFF.
3.2 Reconnect the generator set engine starting
battery, negative (--) lead last.
3.3 Reconnect power to the battery charger, if
equipped.
3.4 Test run the generator set for a few minutes to
check for coolant leaks and to purge air from the
system.
3.5 Stop the generator set. After allowing the engine
to cool, correct any leakage.
Note: Purge trapped air to prevent block heater
element failure. See the operation manual.
3.6 Recheck the coolant level. After draining the
cooling system, allow time for all air cavities in the
system to refill. Add coolant as necessary.
3.7 Connect the block heater electrical plug to the
power outlet.
Note: The inlet of the block heater is lower than the
outlet. The inlet hose should be cooler than the
outlet hose when the block heater is operating.

4TT-1644 11/14
Parts List
Block Heater Kits
Kits: GM89494-KP1 and GM89494-KP2
Qty. Description
Common
Parts
Unique Parts
GM89494-KP1 GM89494-KP2
1Block heater 352945 352946
1Elbow, street
(45_x1/2in.NPT) 227642
1Adapter, bushing
(1/2--14 NPT ID thread,
1 5/8--12 UN--2B OD thread) 273692
1O-ring (1.475 in. ID) 273693
1O-ring (15.3 mm ID) GM11694
1Bushing, adapter
(1/2--14 NPT ID thread,
M18--1.50 OD thread) GM22991
1Bracket, block heater GM32987
4Nut, hex (6 mm) M6923-06-80
2Screw, hex cap
(M6 x 20 mm) M933-06020-60
2Screw, hex cap
(M6 x 25 mm) M933-06025-60
4Washer, plain
(0.281 ID x 0.625 in. OD) X-25-40
1Hose (0.63 in. ID x 17 in.) X-312-17
1Hose (0.63 in. ID x 26 in.) X-312-50
4Clamp, hose (0.69/1.25 in.) X-426-12
2Connector, hose
(5/8 in. x 1/2 in. NPT) X-582-1
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.
2014 by Kohler Co. All rights reserved.