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Industrial Generator Sets Models: 25--150REZG Controllers: Decision-Makerr 3000 Decision-Makerr 550 Decision-Makerr 3+ TP-6712 4/10a Wiring Diagrams

Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

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Page 1: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

Industrial Generator Sets

Models:

25--150REZG

Controllers:

Decision-Maker� 3000

Decision-Maker� 550

Decision-Maker� 3+

TP-6712 4/10a

Wiring Diagrams

Page 2: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

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

Engine Identification

Record the product identification information from the

engine nameplate.

Manufacturer

Model Designation

Serial Number

Controller Identification

Record the controller description from the generator set

operation manual, spec sheet, or sales invoice.

Controller Description

Page 3: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

TP-6712 4/10 3Introduction

Introduction

This manual provides wiring diagrams for the

25--150REZG generator sets equipped with one of the

following controllers:

� Decision-Maker� 3000

� Decision-Maker� 550

� Decision-Maker� 3+ (40--150REZG)

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 set 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

KohlerPower.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

3 rue de Brennus

93200 Saint Denis

France

Phone: (33) 1 49 178300

Fax: (33) 1 49 178301

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

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TP-6712 4/104 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.

Wiring Diagram Cross-Reference

Generator Set Model No. Hz Generator Set Spec No. Wiring Diagram Version No.

25REZG 50/60 GM69415-GA1,3,5,7,9,11 1

30REZG 50/60 GM69415-GA2,4,6,8,10,12 1

40REZG 50/60 GM66092-GA1,3,5 2

45REZG 50/60 GM66092-GA2,4,6 2

50REZG 50/60 GM66910-GA1,2,3 3

60REZG 50/60 GM66911-GA1,2,3 3

80REZG 50/60 GM66590-GA1,3,9 3

100REZG 50/60 GM66590-GA2,4,10 3

125REZG 50/60 GM65362-GA1,2,5 3

150REZG 50/60 GM64060-GA1 3

25/30REZG Wiring Diagrams Reference

Controller Description Version 1 Page

Decision-Maker� 550 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM63941A-D 28

Sheet 2 GM63941B-D 29

Sheet 3 GM63941C-D 30

Schematic Diagram

Sheet 1 ADV-7600A-D 11

Sheet 2 ADV-7600B-D 12

Sheet 3 ADV-7600C-D 13

Accessory Connections

Accessories GM16088A-H 26

Remote Annunciator Kit GM16088B-H 27

Decision-Maker� 3000 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM73379A-A 45

Sheet 2 GM73379B-A 46

Sheet 3 GM73379C-A 47

Schematic Diagram

Sheet 1 ADV-7834A-A 21

Sheet 2 ADV-7834B-A 22

Accessory Connections

Accessories GM67191-A 34

Alternator Reconnections

4-Lead ADV-5875A-L 9

12-Lead ADV-5875B-L 10

Page 5: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

TP-6712 4/10 5Wiring Diagrams

40/45REZG Wiring Diagrams Reference

Controller Description Version 2 Page

Decision-Maker� 550 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM63941A-D 28

Sheet 2 GM63941B-D 29

Sheet 3 GM63941C-D 30

Schematic Diagram

Sheet 1 ADV-7600A-D 11

Sheet 2 ADV-7600B-D 12

Sheet 3 ADV-7600C-D 13

Accessory Connections

Accessories GM16088A-H 26

Remote Annunciator Kit GM16088B-H 27

Decision-Maker� 3000 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM73379A-A 45

Sheet 2 GM73379B-A 46

Sheet 3 GM73379C-A 47

Schematic Diagram

Sheet 1 ADV-7834A-A 21

Sheet 2 ADV-7834B-A 22

Accessory Connections

Accessories GM67191-A 34

Decision-Maker� 3+ Controller

Point-to-Point Wiring Diagram

Sheet 1 GM63942A-D 31

Sheet 2 GM63942B-D 32

Sheet 3 GM63942C-D 33

Schematic Diagram

Sheet 1 ADV-7601A-C 14

Sheet 2 ADV-7601B-C 15

Accessory Connections

Accessories 328912A-H 48

Remote Annunciator Kit 328912B-H 49

Alternator Reconnections

4-Lead ADV-5875A-L 9

12-Lead ADV-5875B-L 10

Page 6: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

TP-6712 4/106 Wiring Diagrams

50--150REZG Wiring Diagrams Reference

Controller Description Version 3 Page

Decision-Maker� 550 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM70545A-C 38

Sheet 2 GM70545B-C 39

Sheet 3 GM70545C-C 40

Schematic Diagram

Sheet 1 ADV-7737A-B 16

Sheet 2 ADV-7737B-B 17

Sheet 3 ADV-7737CB 18

Accessory Connections

Accessories GM16088A-H 26

Remote Annunciator Kit GM16088B-H 27

Decision-Maker� 3000 Controller

Point-to-Point Wiring Diagram

Sheet 1 GM72401A-B 41

Sheet 2 GM72401B-B 42

Sheet 3 GM72401C-B 43

Sheet 4 GM72401D-B 44

Schematic Diagram

Sheet 1 ADV-7861A-B 23

Sheet 2 ADV-7861B-B 24

Sheet 3 ADV-7861C-B 25

Accessory Connections

Accessories GM67191-A 34

Decision-Maker� 3+ Controller

Point-to-Point Wiring Diagram

Sheet 1 GM70544A-C 35

Sheet 2 GM70544B-C 36

Sheet 3 GM70544C-C 37

Schematic Diagram

Sheet 1 ADV-7738A-B 19

Sheet 2 ADV-7738B-B 20

Accessory Connections

Accessories 328912A-H 48

Remote Annunciator Kit 328912B-H 49

Alternator Reconnections

4-Lead ADV-5875A-L 9

12-Lead ADV-5875B-L 10

Page 7: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

TP-6712 4/10 7Controller Identification

Controller Identification

Decision-Maker� 3000 Controller

Decision-Maker� 550 Controller

Decision-Maker� 3+, 16-Light Controller

Page 8: Wiring Diagrams - Kohler Power · 4 Wiring Diagrams TP-6712 4/10 Wiring Diagrams Use the Wiring Diagram Cross-Reference chart to determine the wiring diagram version number for a

TP-6712 4/108 Controller Identification

Notes

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TP-6712

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� 2009, 2010 by Kohler Co. All rights reserved.

TP-6712 4/10a

KOHLER CO. Kohler, Wisconsin 53044Phone 920-565-3381, Fax 920-459-1646For the nearest sales/service outlet in theUS and Canada, phone 1-800-544-2444KohlerPower.com

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