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Kohler 175EFOZDJ / 35EFKOZD — Installation Procedure

Installation · Decision-Maker 3500 controller

For the Kohler 175EFOZDJ / 35EFKOZD, from the Kohler service manual.

Applies to: Kohler 175EFOZDJ, Kohler 35EFKOZD

Before you start

  • Accidental starting can cause severe injury or death. Disconnect battery cables before working on generator set; remove negative lead first and reconnect it last.
  • Do not cut or splice the harness; do not select a longer harness.

Procedure

  1. Remove generator set from service: press OFF/RESET, disconnect battery charger, disconnect starting batteries negative lead first.
  2. Remove junction box cover/panels as needed to access controller wiring.
  3. Remove four controller panel screws and mark all disconnected controller leads with tape.
  4. Disconnect P1 35-pin, P2 14-pin, P3 8-pin, P4 Ethernet, and any other external controller leads.
  5. Remove controller; save mounting hardware and gasket.
  6. Place new controller gasket GM88990 and remote circuit board mounting panel GM96382 in controller opening; studs face into junction box.
  7. Secure remote circuit board mounting panel using existing hardware removed in step 2.4.
  8. Place two spacers X-712-13 on each of the eight studs on back of mounting panel.
  9. Place remote interconnect circuit board assembly GM96419 on eight studs and secure with hex nut X-70-12 at each stud.
  10. Connect existing engine harness connectors to back of remote interconnect circuit board assembly.
  11. Connect remote controller harness GM96428 to front of remote circuit board mounting panel.
  12. For 40-200EOZDJ/33-175EFOZDJ sound-shielded units, install sound shield panel GM95799, gasket GM88990, four screws, four washers, and bushing X-634-29; route harness through opening.
  13. Connect other end of controller harness to remote Decision-Maker 3500 controller, reusing existing controller gasket.
  14. Secure wiring with rubber grommets and cable ties; conform to USCG CFR Title 33 Parts 183.425 through 183.460.
  15. Replace removed panels; verify set OFF, reconnect battery negative lead last, reconnect battery charger, start and verify metering, then stop.

Specs & values

  • 12 m (40 ft.) harness

Full service-parts list: Kohler 175EFOZDJ →, Kohler 35EFKOZD →

Source: Kohler service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.

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