Industrial Generator Sets

Models:

135--275RZD135--275RZDB

(Detroit Diesel Powered)

Controllers:Decision-Maker�550Decision-Maker�340

Decision-Maker�3+, 16-LightDecision-Maker�3+, 7-Light

TP-5720 1/07g

Wiring Diagrams

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

TP-5720 1/07 3Introduction

Introduction

This manual provides wiring diagrams for the

135--180RZD/RZDB Detroit Diesel Series 50 engine-

powered 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 andCanada, 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 1/074 Wiring Diagrams

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 SetModel No. Hz

Generator SetSpec No.

Wiring DiagramVersion 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

TP-5720 1/07 5Wiring Diagrams

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 1/076 Wiring Diagrams

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

TP-5720 1/07 7Controller Identification

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� 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.

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.

TP-5720 1/078 Controller Identification

Notes

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ADV5875B.DWG

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Notes

� 1996, 1997, 1999, 2001, 2004, 2005, 2007 by Kohler Co. All rights reserved.

TP-5720 1/07g

KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Web site www.kohlergenerators.comFax 920-459-1646 (U.S.A. Sales), Fax 920-459-1614 (International)For the nearest sales and service outlet in U.S.A. and CanadaPhone 1-800-544-2444

Kohler Power SystemsAsia Pacific Headquarters7 Jurong Pier RoadSingapore 619159Phone (65) 6264-6422, Fax (65) 6264-6455