Wiring Diagrams

Industrial Generator Sets

Models:

450REOZD-4
500--2000ROZD-4
Controllers:
Decision-Makert550
Decision-Makert340
Decision-Makert3+
Engine Gauge Box for Paralleling Switchgear

TP-6004 3/05i
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

2 TP-6004 3/05
 Introduction

This manual provides wiring diagrams for the Information in this publication represents data available
450REOZD-4 and 500--2000ROZD-4 Detroit Diesel at the time of print. Kohler Co. reserves the right to
engine-powered generator sets equipped with one of change this publication and the products represented
the following controllers: without notice and without any obligation or liability
D Decision-Makert550
whatsoever.
D Decision-Makert340
D Decision-Makert3+
D Engine Gauge Box for Paralleling Switchgear

Service Assistance
For professional advice on generator power China
requirements and conscientious service, please contact North China Regional Office, Beijing
your nearest Kohler distributor or dealer. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric Fax: (86) 10 6518 7955

D Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
D Look at the labels and stickers on your Kohler product India, Bangladesh, Sri Lanka
or review the appropriate literature or documents India Regional Office
included with the product Bangalore, India
Phone: (91) 80 3366208
D Call toll free in the US and Canada 1-800-544-2444 (91) 80 3366231
Fax: (91) 80 3315972
D Outside the US and Canada, call the nearest regional
office Japan, Korea
North Asia Regional Office
Headquarters Europe, Middle East, Africa Tokyo, Japan
(EMEA) Phone: (813) 3440-4515
Kohler Power Systems Fax: (813) 3440-2727
ZI Senia 122
Latin America
12, rue des Hauts Flouviers
Latin America Regional Office
94517 Thiais Cedex
Lakeland, Florida, USA
France
Phone: (863) 619-7568
Phone: (33) 1 41 735500
Fax: (863) 701-7131
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

TP-6004 3/05 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 and the controller type on the Controller
Wiring Diagrams Reference chart to determine the
wiring diagram numbers for your unit. Refer to the
generator set operation manual for controller type
identification, if necessary.

Wiring Diagram Cross-Reference

Wiring Wiring
Diagram Diagram
Generator Set Version Generator Set Version
Model No. Hz Spec No. No. Model No. Hz Spec No. No.
450REOZD-4 50 PA-197002 1-1 450REOZD-4 60 PA-197001 1-1
450REOZD-4 50 GM16974-GA2 1-2 or 1-3 450REOZD-4 60 GM16974-GA1 1-2 or 1-3
450REOZD-4 50 GM28476-GA2 1-3 450REOZD-4 60 GM28476-GA1 1-3
500ROZD-4 50 PA-197014 2-1 500ROZD-4 60 PA-197003 1-1
500ROZD-4 50 GM16975-GA2 2-2 or 2-3 500ROZD-4 60 GM16975-GA1 1-2 or 1-3
600ROZD-4 50 PA-197016 2-1 600ROZD-4 60 PA-197015 2-1
600ROZD-4 50 GM16976-GA2 2-2 or 2-3 600ROZD-4 60 GM16976-GA1 2-2 or 2-3
750ROZD-4 50 PA-197018 2-1 PA-197017,
750ROZD-4 60 2-1
PA-197038
750ROZD-4 50 GM16977-GA3 2-2 or 2-3
750ROZD-4 60 GM16977-GA1, 2 2-2 or 2-3
800ROZD-4 50 PA-197020 2-1
800ROZD-4 60 PA-197019 2-1
800ROZD-4 50 GM16978-GA2 2-2 or 2-3
800ROZD-4 60 GM16978-GA1 2-2 or 2-3
900ROZD-4 50 PA-197021 2-1
900ROZD-4 60 PA-197022 2-1
900ROZD-4 50 GM16979-GA2 2-2 or 2-3
GM16979-GA1,
1250ROZD-4 50 PA-132999 3-1 900ROZD-4 60 2-2 or 2-3
GM17864-GA1
1250ROZD-4 50 GM16797-GA2 3-2 or 3-3 1000ROZD-4 60 PA-197023 2-1
1250ROZD-4 50 GM21259-GA3 3-3 GM16980-GA1,
1000ROZD-4 60 2-2 or 2-3
1500ROZD-4 50 PA-132848 3-1 GM17865-GA1

1500ROZD-4 50 GM16798-GA2 3-2 or 3-3 1250ROZD-4 60 PA-132998 3-1

1500ROZD-4 50 GM21259-GA6 3-3 1250ROZD-4 60 GM16797-GA1 3-2 or 3-3

1750ROZD-4 50 PA-132888 3-1 1250ROZD-4 60 GM21259-GA1, GA2 3-3

1750ROZD-4 50 GM16799-GA2 3-2 or 3-3 1500ROZD-4 60 PA-132847 3-1

1750ROZD-4 50 GM21260-GA2 3-3 1500ROZD-4 60 GM16798-GA1 3-2 or 3-3

2000ROZD-4 50 PA-132835 3-1 1500ROZD-4 60 GM21259-GA4, GA5 3-3

2000ROZD-4 50 GM16800-GA2 3-2 or 3-3 1750ROZD-4 60 PA-132887 3-1

2000ROZD-4 50 GM21260-GA4 3-3 1750ROZD-4 60 GM16799-GA1 3-2 or 3-3

1750ROZD-4 60 GM21260-GA1, GA5 3-3
2000ROZD-4 60 PA-132834 3-1
2000ROZD-4 60 GM16800-GA1 3-2 or 3-3
2000ROZD-4 60 GM21260-GA3, GA6 3-3

4 Wiring Diagrams TP-6004 3/05

450REOZD-4 (50/60 Hz) and 500ROZD-4 (60 Hz)
Controller Wiring Diagrams Reference
Controller Description Version 1-1 Page Version 1-2 Page Version 1-3 Page
Decision-Makert550 (190--600 Volt)
Point-to-Point Wiring Diagram
Sheet 1 — GM22218A 51 GM16925A-B 45
Sheet 2 — GM22218B 52 GM16925B-B 46
Schematic Diagram
Sheet 1 — ADV-6685A 28 ADV-6601A-B 22
Sheet 2 — ADV-6685B 29 ADV-6601B-B 23
Accessory Connections
Sheet 1 — GM16088A-F 34 GM16088A-F 34
Sheet 2 — GM16088B-F 35 GM16088B-F 35
Sheet 3 — GM16759B-C 42 GM16759B-C 42
Sheet 4 — GM16759C-C 43 GM16759C-C 43
Sheet 5 — GM16759D-C 44 GM16759D-C 44
Decision-Makert340
Point-to-Point Wiring Diagram
Sheet 1 361859A 70 — —
Sheet 2 361859B 71 — —
Schematic Diagram
Sheet 1 ADV-6466A 16 — —
Sheet 2 ADV-6466B 17 — —
Accessory Connections
Sheet 1 354246A-D 60 — —
Sheet 2 354246B-D 61 — —
Sheet 3 GM16758C-C 37 — —
Sheet 4 GM16758E-C 39 — —
Sheet 5 GM16758G-C 41 — —
Decision-Makert3+
Point-to-Point Wiring Diagram
Sheet 1 361858A-B 68 361858A-B 68 361858A-B 68
Sheet 2 361858B-B 69 361858B-B 69 361858B-B 69
Schematic Diagram
Sheet 1 ADV-6465A-C 14 ADV-6465A-C 14 ADV-6465A-C 14
Sheet 2 ADV-6465B-C 15 ADV-6465B-C 15 ADV-6465B-C 15
Accessory Connections
Sheet 1 328912A-G 57 328912A-G 57 328912A-G 57
Sheet 2 328912B-G 58 328912B-G 58 328912B-G 58
Sheet 3 328912C-G 59 328912C-G 59 328912C-G 59
Sheet 4 GM16758B-C 36 GM16758B-C 36 GM16758B-C 36
Sheet 5 GM16758D-C 38 GM16758D-C 38 GM16758D-C 38
Sheet 6 GM16758F-C 40 GM16758F-C 40 GM16758F-C 40
Engine Gauge Box for Paralleling Switchgear
Point-to-Point Wiring Diagram
Sheet 1 365262A 72 365262A 72 365262A 72
Sheet 2 365262B 73 365262B 73 365262B 73
Schematic Diagram
Sheet 1 ADV-6492A-A 20 ADV-6492A-A 20 ADV-6492A-A 20
Sheet 2 ADV-6492B-A 21 ADV-6492B-A 21 ADV-6492B-A 21
Alternator Reconnections (all models) ADV-5875C-F 9 ADV-5875C-F 9 ADV-5875C-F 9

Note: Version 1-1 uses the Decision-Makert340 controller.

Version 1-2 uses the Decision-Makert550 controller and DVR2000 voltage regulator.
Version 1-3 uses the Decision-Makert550 controller with integral voltage regulator.

TP-6004 3/05 Wiring Diagrams 5

500ROZD-4 (50 Hz) and 600--1000ROZD-4 (50/60 Hz)
Controller Wiring Diagrams Reference
Controller Description Version 2-1 Page Version 2-2 Page Version 2-3 Page
Decision-Makert550 (190--600 Volt)
Point-to-Point Wiring Diagram
Sheet 1 — GM22219A-A 53 GM16995A-B 47
Sheet 2 — GM22219B-A 54 GM16995B-B 48
Schematic Diagram
Sheet 1 — ADV-6686A 30 ADV-6602A-B 24
Sheet 2 — ADV-6686B 31 ADV-6602B-B 25
Accessory Connections
Sheet 1 — GM16088A-F 34 GM16088A-F 34
Sheet 2 — GM16088B-F 35 GM16088B-F 35
Sheet 3 — GM16759B-C 42 GM16759B-C 42
Sheet 4 — GM16759C-C 43 GM16759C-C 43
Sheet 5 — GM16759D-C 44 GM16759D-C 44
Decision-Makert340
Point-to-Point Wiring Diagram
Sheet 1 361354A-D 64 — —
Sheet 2 361354B-D 65 — —
Schematic Diagram
Sheet 1 ADV-6445A-C 12 — —
Sheet 2 ADV-6445B-C 13 — —
Accessory Connections
Sheet 1 354246A-D 60 — —
Sheet 2 354246B-D 61 — —
Sheet 3 GM16758C-C 37 — —
Sheet 4 GM16758E-C 39 — —
Sheet 5 GM16758G-C 41 — —
Decision-Makert3+
Point-to-Point Wiring Diagram
Sheet 1 361264A-G 62 361264A-G 62 361264A-G 62
Sheet 2 361264B-G 63 361264B-G 63 361264B-G 63
Schematic Diagram
Sheet 1 ADV-6393A-G 10 ADV-6393A-G 10 ADV-6393A-G 10
Sheet 2 ADV-6393B-G 11 ADV-6393B-G 11 ADV-6393B-G 11
Accessory Connections
Sheet 1 328912A-G 57 328912A-G 57 328912A-G 57
Sheet 2 328912B-G 58 328912B-G 58 328912B-G 58
Sheet 3 328912C-G 59 328912C-G 59 328912C-G 59
Sheet 4 GM16758B-C 36 GM16758B-C 36 GM16758B-C 36
Sheet 5 GM16758D-C 38 GM16758D-C 38 GM16758D-C 38
Sheet 6 GM16758F-C 40 GM16758F-C 40 GM16758F-C 40
Engine Gauge Box for Paralleling Switchgear
Point-to-Point Wiring Diagram
Sheet 1 361541A-D 66 361541A-D 66 361541A-D 66
Sheet 2 361541B-D 67 361541B-D 67 361541B-D 67
Schematic Diagram
Sheet 1 ADV-6467A-B 18 ADV-6467A-B 18 ADV-6467A-B 18
Sheet 2 ADV-6467B-B 19 ADV-6467B-B 19 ADV-6467B-B 19
Alternator Reconnections (all models) ADV-5875C-F 9 ADV-5875C-F 9 ADV-5875C-F 9

Note: Version 2-1 uses the Decision-Makert340 controller.

Version 2-2 uses the Decision-Makert550 controller and DVR2000 voltage regulator.
Version 2-3 uses the Decision-Makert550 controller with integral voltage regulator.

6 Wiring Diagrams TP-6004 3/05

1250--2000ROZD-4 Controller Wiring Diagrams Reference
Controller Description Version 3-1 Page Version 3-2 Page Version 3-3 Page
Decision-Makert550 (190--600 Volt)
Point-to-Point Wiring Diagram
Sheet 1 — GM22219A-A 53 GM16995A-B 47
Sheet 2 — GM22219B-A 54 GM16995B-B 48
Schematic Diagram
Sheet 1 — ADV-6686A 30 ADV-6602A-B 24
Sheet 2 — ADV-6686B 31 ADV-6602B-B 25
Accessory Connections
Sheet 1 — GM16088A-F 34 GM16088A-F 34
Sheet 2 — GM16088B-F 35 GM16088B-F 35
Sheet 3 — GM16759B-C 42 GM16759B-C 42
Sheet 4 — GM16759C-C 43 GM16759C-C 43
Sheet 5 — GM16759D-C 44 GM16759D-C 44
Decision-Makert550 (1905--4160 Volt)
Point-to-Point Wiring Diagram
Sheet 1 — GM22220A 55 GM17689A-C 49
Sheet 2 — GM22220B 56 GM17689B-C 50
Schematic Diagram
Sheet 1 — ADV-6687A 32 ADV-6611A-C 26
Sheet 2 — ADV-6687B 33 ADV-6611B-C 27
Decision-Makert340
Point-to-Point Wiring Diagram
Sheet 1 361354A-D 64 — —
Sheet 2 36135BA-D 65 — —
Schematic Diagram
Sheet 1 ADV-6445A-C 12 — —
Sheet 2 ADV-6445B-C 13 — —
Accessory Connections
Sheet 1 354246A-D 60 — —
Sheet 2 354246B-D 61 — —
Sheet 3 GM16758C-C 37 — —
Sheet 4 GM16758E-C 39 — —
Sheet 5 GM16758G-C 41 — —
Decision-Makert3+
Point-to-Point Wiring Diagram
Sheet 1 361264A-G 62 361264A-G 62 361264A-G 62
Sheet 2 361264B-G 63 361264B-G 63 361264B-G 63
Schematic Diagram
Sheet 1 ADV-6393A-G 10 ADV-6393A-G 10 ADV-6393A-G 10
Sheet 2 ADV-6393B-G 11 ADV-6393B-G 11 ADV-6393B-G 11
Accessory Connections
Sheet 1 328912A-G 57 328912A-G 57 328912A-G 57
Sheet 2 328912B-G 58 328912B-G 58 328912B-G 58
Sheet 3 328912C-G 59 328912C-G 59 328912C-G 59
Sheet 4 GM16758B-C 36 GM16758B-C 36 GM16758B-C 36
Sheet 5 GM16758D-C 38 GM16758D-C 38 GM16758D-C 38
Sheet 6 GM16758F-C 40 GM16758F-C 40 GM16758F-C 40
Engine Gauge Box for Paralleling Switchgear
Point-to-Point Wiring Diagram
Sheet 1 361541A-D 66 361541A-D 66 361541A-D 66
Sheet 2 361541B-D 67 361541B-D 67 361541B-D 67
Schematic Diagram
Sheet 1 ADV-6467A-B 18 ADV-6467A-B 18 ADV-6467A-B 18
Sheet 2 ADV-6467B-B 19 ADV-6467B-B 19 ADV-6467B-B 19
Alternator Reconnections (all models) ADV-5875C-F 9 ADV-5875C-F 9 ADV-5875C-F 9

Note: Version 3-1 uses the Decision-Makert340 controller.

Version 3-2 uses the Decision-Makert550 controller and DVR2000 voltage regulator.
Version 3-3 uses the Decision-Makert550 controller with integral voltage regulator.

TP-6004 3/05 Wiring Diagrams 7

Controller Identification

Decision-Makert 550 Controller Decision-Makert 3+, 16-Light Controller

D Audiovisual annunciation with NFPA 110 Level 1
capability.
D Programmable microprocessor logic and digital
display features.
D Alternator safeguard circuit protection.
D 12- or 24-volt engine electrical system capability.
D Remote start, remote annunciation, and remote
communication options.
D Audiovisual annunciation with NFPA 110 Level 1
capability.
D Microprocessor logic, AC meters, and engine
gauge features.
D 12- or 24-volt engine electrical system capability.
D Remote start, prime power, and remote
annunciation options.

Engine Gauge Box for Paralleling

Switchgear (not shown)

Decision-Makert 340 Controller

D Audiovisual annunciation with NFPA 110 Level 1
capability.
D Programmable microprocessor logic and digital
display features.
D 12- or 24-volt engine electrical system capability.
D Remote start, prime power, remote annunciation, and
remote communication options.

8 Controller Identification TP-6004 3/05

TP-6004 3/05 Wiring Diagrams 9
10 Wiring Diagrams TP-6004 3/05
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12 Wiring Diagrams TP-6004 3/05
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14 Wiring Diagrams TP-6004 3/05
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16 Wiring Diagrams TP-6004 3/05
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18 Wiring Diagrams TP-6004 3/05
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20 Wiring Diagrams TP-6004 3/05
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22 Wiring Diagrams TP-6004 3/05
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24 Wiring Diagrams TP-6004 3/05
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26 Wiring Diagrams TP-6004 3/05
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28 Wiring Diagrams TP-6004 3/05
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30 Wiring Diagrams TP-6004 3/05
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32 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 33
34 Wiring Diagrams TP-6004 3/05
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36 Wiring Diagrams TP-6004 3/05
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38 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 39
40 Wiring Diagrams TP-6004 3/05
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42 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 43
44 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 45
46 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 47
48 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 49
50 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 51
52 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 53
54 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 55
56 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 57
58 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 59
60 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 61
62 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 63
64 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 65
66 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 67
68 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 69
70 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 71
72 Wiring Diagrams TP-6004 3/05
TP-6004 3/05 Wiring Diagrams 73
 Notes

74 Wiring Diagrams TP-6004 3/05

 KOHLER CO. Kohler, Wisconsin 53044
Phone 920-565-3381, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPowerSystems.com
Kohler Power Systems
Asia Pacific Headquarters
TP-6004 3/05i 7 Jurong Pier Road
Singapore 619159
E 1998, 1999, 2000, 2001, 2002, 2005 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455