Wiring Diagrams Industrial Generator Sets Models: 135-275RZD 135-275RZDB (Detroit Diesel Powered) Controllers: Decision-Maker 550 Decision-Maker 340 Decision-Maker 3+, 16-Light Decision-Maker 3+, 7-Light TP-5720 1/07g
Product Identification Information Product identification numbers determine service parts. Record the product identification numbers in the spaces below immediately after unpacking the products so that the numbers are readily available for future reference. Record field-installed kit numbers after installing the kits. Generator Set Identification Numbers Record the product identification numbers from the generator set nameplate(s). Model Designation Specification Number Serial Number Accessory Number Accessory Description Controller Identification Record the controller description from the generator set operation manual, spec sheet, or sales invoice. Controller Description Engine Identification Record the product identification information from the engine nameplate. Manufacturer Model Designation Serial Number
Introduction This manual provides wiring diagrams for the 135--180RZD/RZDB Detroit Diesel Series 50 enginepowered generator sets and 200--275RZD/RZDB Detroit Diesel Series 60 engine-powered generator sets equipped with one of the following controllers: Decision-Maker 550 Decision-Maker 340 Decision-Maker 3+ Information in this publication represents data available at the time of print. Kohler Co. reserves the right to change this publication and the products represented without notice and without any obligation or liability whatsoever. Service Assistance For professional advice on generator power requirements and conscientious service, please contact your nearest Kohler distributor or dealer. Consult the Yellow Pages under the heading Generators Electric. Visit the Kohler Power Systems website at KohlerPowerSystems.com. Look at the labels and stickers on your Kohler product or review the appropriate literature or documents included with the product. Call toll free in the US and Canada 1-800-544-2444. Outside the US and Canada, call the nearest regional office. Headquarters Europe, Middle East, Africa (EMEA) Kohler Power Systems ZI Senia 122 12, rue des Hauts Flouviers 94517 Thiais Cedex France Phone: (33) 1 41 735500 Fax: (33) 1 41 735501 Asia Pacific Power Systems Asia Pacific Regional Office Singapore, Republic of Singapore Phone: (65) 6264-6422 Fax: (65) 6264-6455 China North China Regional Office, Beijing Phone: (86) 10 6518 7950 (86) 10 6518 7951 (86) 10 6518 7952 Fax: (86) 10 6518 7955 East China Regional Office, Shanghai Phone: (86) 21 6288 0500 Fax: (86) 21 6288 0550 India, Bangladesh, Sri Lanka India Regional Office Bangalore, India Phone: (91) 80 3366208 (91) 80 3366231 Fax: (91) 80 3315972 Japan, Korea North Asia Regional Office Tokyo, Japan Phone: (813) 3440-4515 Fax: (813) 3440-2727 Latin America Latin America Regional Office Lakeland, Florida, USA Phone: (863) 619-7568 Fax: (863) 701-7131 TP-5720 1/07 Introduction 3
Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a given model number and spec number. Then find that version number, the controller type, and the alternator type on the Wiring Diagrams Reference chart to determine the wiring diagram numbers for your unit. Refer to Controller Identification for controller type identification, if necessary. Refer to the generator set nameplate for the alternator type. A wound field alternator is identified with a W as the last digit. Example: Gen. Model 4S11W. Wiring Diagram Cross-Reference Generato Set Model No. Hz Generator Set Spec No. Wiring Diagram Version No. 135RZD 50/60 PA-194006, 7, 10, 49, 51 1-1 135RZD 50/60 GM16893-GA1, 2 1-2 135RZDB 50/60 GM16893-GA1, 2 1-2 150RZD 50/60 PA-194011, 12, 15, 20, 33--35, 38, 59, 61, 65 1-1 150RZD 50/60 GM16894-GA1, 2, 3 1-2 150RZDB 50/60 GM16894-GA1, 2, 3 1-2 180RZD 50/60 PA-194045--48, 63, 67, 71 1-1 180RZD 50/60 GM16895-GA1, 2 1-2 180RZDB 50/60 GM16895-GA1, 2 1-2 200RZD 50/60 PA-194245--49, 80, 82, 84 2-1 200RZD 50/60 GM16896-GA1, 2 2-2 200RZDB 50/60 GM16896-GA1, 2 2-2 230RZD 50/60 PA-194256--59, 90, 92, 94 2-1 230RZD 50/60 GM16897-GA1, 2 2-2 230RZDB 50/60 GM16897-GA1, 2 2-2 250RZD 50/60 PA-194265--69, 300, 302 2-1 250RZD 50/60 GM16898-GA1, 2 2-2 250RZDB 50/60 GM16898-GA1, 2 2-2 275RZD 50/60 PA-194235, 75--79, 306, 308 2-1 275RZD 50/60 GM16899-GA1, 2 2-2 275RZDB 50/60 GM16899-GA1, 2 2-2 Note: Versions 1-1 and 2-1 use the Decision-Maker 340 controller Versions 1-2 and 2-2 use the Decision-Maker 550 controller The RZDB models have wound field or permanent magnet alternator options 4 Wiring Diagrams TP-5720 1/07
135-180RZD/RZDB Wiring Diagrams Reference Controller Description Version 1-1 Page Version 1-2 Page Decision-Maker 550 Point-to-Point Wiring Diagram Sheet 1 GM17422A-D 32 Sheet 2 GM17422B-D 33 Wound Field Alternator GM35944-C 39 Permanent Magnet Alternator GM35943-B 38 Schematic Diagram Sheet 1 ADV-6607A-C 20 Sheet 2 ADV-6607B-C 21 Wound Field Alternator ADV-6958-A 27 Permanent Magnet Alternator ADV-6957-26 Accessory Connections Accessories GM16088A-F 30 Remote Annunciator Kit GM16088B-F 31 Decision-Maker 340 Point-to-Point Wiring Diagram Sheet 1 347942A-G 44 Sheet 2 347942B-D 45 Schematic Diagram Sheet 1 ADV-6132A-E 14 Sheet 2 ADV-6132B-B 15 Sheet 3 ADV-6132C-B 16 Sheet 4 ADV-6132D-C 17 Accessory Connections Accessories 354246A-D 46 Remote Annunciator Kit 354246B-D 47 Decision-Maker 3+ Point-to-Point Wiring Diagram Sheet 1 328614A-H 40 GM14230A-C 28 Sheet 2 328614B-H 41 GM14230B-C 29 Wound Field Alternator GM35942-J 37 Permanent Magnet Alternator GM35941-E 36 Schematic Diagram Sheet 1 ADV-6082A-F 12 ADV-6572A-C 18 Sheet 2 ADV-6082B-F 13 ADV-6572B-C 19 Wound Field Alternator ADV-6956-E 25 Permanent Magnet Alternator ADV-6955-A 24 Accessory Connections Accessories 328912A-G 42 328912A-G 42 Remote Annunciator 14-Relay Kit 328912B-G 43 328912B-G 43 Alternator Reconnections Permanent Magnet/Wound Field Alternators, 4-Lead ADV-5875A-H 9 ADV-5875A-H 9 Permanent Magnet Alternator ADV-5875B-H 10 ADV-5875B-H 10 Wound Field Alternator 11 ADV-5875C-H 11 Note: Version 1-1 uses the Decision-Maker 340 controller Version 1-2 uses the Decision-Maker 550 controller Diagram 328614 replaces 328615 Diagram ADV-6082 replaces ADV-6083 The RZDB models have wound field or permanent magnet alternator options TP-5720 1/07 Wiring Diagrams 5
200-275RZD/RZDB Wiring Diagrams Reference Controller Description Version 2-1 Page Version 2-2 Page Decision-Maker 550 Point-to-Point Wiring Diagram Sheet 1 GM17423A-D 34 Sheet 2 GM17423B-D 35 Wound Field Alternator GM35944-C 39 Permanent Magnet Alternator GM35943-B 38 Schematic Diagram Sheet 1 ADV-6608A-C 22 Sheet 2 ADV-6608B-C 23 Wound Field Alternator ADV-6958-A 27 Permanent Magnet Alternator ADV-6957-26 Accessory Connections Accessories GM16088A-F 30 Remote Annunciator Kit GM16088B-F 31 Decision-Maker 340 Point-to-Point Wiring Diagram Sheet 1 347942A-G 44 Sheet 2 347942B-D 45 Schematic Diagram Sheet 1 ADV-6132A-E 14 Sheet 2 ADV-6132B-B 15 Sheet 3 ADV-6132C-B 16 Sheet 4 ADV-6132D-C 17 Accessory Connections Accessories 354246A-D 46 Remote Annunciator Kit 354246B-D 47 Decision-Maker 3+ Point-to-Point Wiring Diagram Sheet 1 328614A-H 40 GM14230A-C 28 Sheet 2 328614B-H 41 GM14230B-C 29 Wound Field Alternator GM35942-J 37 Permanent Magnet Alternator GM35941-E 36 Schematic Diagram Sheet 1 ADV-6082A-F 12 ADV-6572A-C 18 Sheet 2 ADV-6082B-F 13 ADV-6572B-C 19 Wound Field Alternator ADV-6956-E 25 Permanent Magnet Alternator ADV-6955-A 24 Accessory Connections Accessories 328912A-G 42 328912A-G 42 Remote Annunciator 14-Relay Kit 328912B-G 43 328912B-G 43 Alternator Reconnections 200--275 kw Permanent Magnet Alternator ADV-5875B-H 10 ADV-5875B-H 10 200--275 kw Wound Field Alternator 11 ADV-5875C-H 11 Note: Version 2-1 uses the Decision-Maker 340 controller Version 2-2 uses the Decision-Maker 550 controller Diagram 328614 replaces 328615 Diagram ADV-6082 replaces ADV-6083 The RZDB models have wound field or permanent magnet alternator options 6 Wiring Diagrams TP-5720 1/07
Controller Identification Decision-Maker 550 Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Programmable microprocessor logic and digital display features. Alternator safeguard circuit protection. 12- or 24-volt engine electrical system capability. Remote start, remote annunciation, and remote communication options. Decision-Maker 3+, 16-Light Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Microprocessor logic, AC meters, and engine gauge features. 12- or 24-volt engine electrical system capability. Remote start, prime power, and remote annunciation options. Decision-Maker 340 Controller Audiovisual annunciation with NFPA 110 Level 1 capability. Programmable microprocessor logic and digital display features. 12- or 24-volt engine electrical system capability. Remote start, prime power, remote annunciation, and remote communication options. TP-5720 1/07 Controller Identification 7
Notes 8 Controller Identification TP-5720 1/07
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10 Wiring Diagrams ADV5875B.DWG TP-5720 1/07
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48 Wiring Diagrams Notes TP-5720 1/07
TP-5720 1/07g 1996, 1997, 1999, 2001, 2004, 2005, 2007 by Kohler Co. All rights reserved. KOHLER CO. Kohler, Wisconsin 53044 Phone 920-565-3381, Web site www.kohlergenerators.com Fax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International) For the nearest sales and service outlet in U.S.A. and Canada Phone 1-800-544-2444 Kohler Power Systems Asia Pacific Headquarters 7 Jurong Pier Road Singapore 619159 Phone (65) 6264-6422, Fax (65) 6264-6455