Wiring Diagrams

Industrial Generator Sets

Models:

650--1000REOZDB
1350--2000REOZDB
2500/2800REOZD
Controllers:
Decision-Maker!550
Decision-Maker!3+

TP-6216 10/06f
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
650--1000REOZDB, 1350--2000REOZDB, and 2500/
2800REOZD DDC/MTU engine-powered generator
sets equipped with the following controllers:
! Decision-Maker!550
! 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 set 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
! Consult the Yellow Pages under the heading (86) 10 6518 7952
Generators—Electric. Fax: (86) 10 6518 7955
! Visit the Kohler Power Systems website at East China Regional Office, Shanghai
KohlerPowerSystems.com. Phone: (86) 21 6288 0500
Fax: (86) 21 6288 0550
! 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
! Call toll free in the US and Canada 1-800-544-2444.
(91) 80 3366231
! Outside the US and Canada, call the nearest regional Fax: (91) 80 3315972
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
12, rue des Hauts Flouviers Latin America
94517 Thiais Cedex Latin America Regional Office
France Lakeland, Florida, USA
Phone: (33) 1 41 735500 Phone: (863) 619-7568
Fax: (33) 1 41 735501 Fax: (863) 701-7131

Asia Pacific
Power Systems Asia Pacific Regional Office
Singapore, Republic of Singapore
Phone: (65) 6264-6422
Fax: (65) 6264-6455

TP-6216 10/06 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
Controller Identification for controller type identification,
if necessary.

Wiring Diagram Cross-Reference

Model No. Hz Generator Set Spec No. Wiring Diagram Version No.
650REOZDB 50 GM30408-GA2, -GA12 1-1 or 1-2
750REOZDB 50 GM30408-GA4, -GA14 1-1 or 1-2
900REOZDB 50 GM30408-GA6, -GA16 2-1
1000REOZDB 50 GM30408-GA8, -GA18 2-1
1350REOZDB 50 GM24213-GA3 3-1
1350REOZDB 50 GM34995-GA2, -GA6 3-1
1500REOZDB 50 GM24213-GA6 3-1
1500REOZDB 50 GM34995-GA4, -GA8 3-1
1820REOZDB 50 GM24214-GA2 3-1
1820REOZDB 50 GM34996-GA2, -GA6 3-1
2000REOZDB 50 GM24214-GA4 3-1
2000REOZDB 50 GM34996-GA4, -GA8 3-1
2500REOZD 50 GM29817-GA3 4-1
2800REOZD 50 GM29817-GA4 4-1
650REOZDB 60 GM30408-GA1, -GA11 1-1 or 1-2
750REOZDB 60 GM30408-GA3, -GA13 1-1 or 1-2
800REOZDB 60 GM30408-GA9, -GA10 2-1
900REOZDB 60 GM30408-GA5, -GA15 2-1
1000REOZDB 60 GM30408-GA7, -GA17 2-1
1350REOZDB 60 GM24213-GA1 3-1
1350REOZDB 60 GM34995-GA1, -GA5 3-1
1500REOZDB 60 GM24213-GA4 3-1
1500REOZDB 60 GM34995-GA3, -GA7 3-1
1820REOZDB 60 GM24214-GA1 3-1
1820REOZDB 60 GM34996-GA1, -GA5 3-1
2000REOZDB 60 GM24214-GA3 3-1
2000REOZDB 60 GM34996-GA3, -GA7 3-1
2500REOZD 60 GM29817-GA1 4-1
2800REOZD 60 GM29818-GA2 4-1

4 Wiring Diagrams TP-6216 10/06

650/750REOZDB Controller Wiring Diagrams Reference
Controller Description Version 1-1 Page Version 1-2 Page
Decision-Maker!550
Point-to-Point Wiring Diagram
Sheet 1 GM34560A-B 52 GM34560A-C 53
Sheet 2 GM34560B-B 54 GM34560B-C 55
Schematic Diagram
Sheet 1 ADV-6934A-B 23 ADV-6934A-C 24
Sheet 2 ADV-6934B-B 25 ADV-6934B-C 26
Accessory Connections
Sheet 1 GM16088A-F 29 GM16088A-F 29
Sheet 2 GM16088B-F 30 GM16088B-F 30
Sheet 3 GM28632B-G 36 GM28632B-G 36
Sheet 4 GM28632C-G 37 GM28632C-G 37
Sheet 5 GM28632D-G 38 GM28632D-G 38
Sheet 6 GM28632E-G 39 GM28632E-G 39
Decision-Maker!3+
Point-to-Point Wiring Diagram
Sheet 1 GM34559A-B 48 GM34559A-C 49
Sheet 2 GM34559B-B 50 GM34559B-C 51
Schematic Diagram ADV-6933-C 21 ADV-6933-D 22
Accessory Connections
Sheet 1 328912A--G 60 328912A--G 60
Sheet 2 328912B--G 61 328912B--G 61
Sheet 3 328912C--G 62 328912C--G 62
Sheet 4 GM28631B-B 33 GM28631B-B 33
Sheet 5 GM28631C-B 34 GM28631C-B 34
Sheet 6 GM28631D-B 35 GM28631D-B 35
Alternator Reconnections ADV-5875C-G 11 ADV-5875C-G 11

Version 1-1 shows separate starter motor and starter solenoid with diode D2.
Version 1-2 shows integrated starter solenoid and starter motor with diode D2 removed.

TP-6216 10/06 Wiring Diagrams 5

800--1000REOZDB Controller Wiring Diagrams Reference
Controller Description Version 2-1 Page
Decision-Maker!550
Point-to-Point Wiring Diagram
Sheet 1 GM28374A-J 31
Sheet 2 GM28374B-J 32
Schematic Diagram
Sheet 1 ADV-6805A-H 12
Sheet 2 ADV-6805B-H 13
Accessory Connections
Sheet 1 GM16088A-F 29
Sheet 2 GM16088B-F 30
Sheet 3 GM28632B-G 36
Sheet 4 GM28632C-G 37
Sheet 5 GM28632D-G 38
Sheet 6 GM28632E-G 39
Decision-Maker!3+
Point-to-Point Wiring Diagram
Sheet 1 GM30909A-G 46
Sheet 2 GM30909B-G 47
Schematic Diagram ADV-6886-F 20
Accessory Connections
Sheet 1 328912A--G 60
Sheet 2 328912B--G 61
Sheet 3 328912C--G 62
Sheet 4 GM28631B-B 33
Sheet 5 GM28631C-B 34
Sheet 6 GM28631D-B 35
Alternator Reconnections ADV-5875C-G 11

6 Wiring Diagrams TP-6216 10/06

1350--2000REOZDB Controller Wiring Diagrams Reference
Controller Description Version 3-1 Page
Decision-Maker!550 (380--600 V)
Point-to-Point Wiring Diagram
Sheet 1 GM28374A-J 31
Sheet 2 GM28374B-J 32
Schematic Diagram
Sheet 1 ADV-6805A-H 12
Sheet 2 ADV-6805B-H 13
Accessory Connections
Sheet 1 GM16088A-F 29
Sheet 2 GM16088B-F 30
Sheet 3 GM28632B-G 36
Sheet 4 GM28632C-G 37
Sheet 5 GM28632D-G 38
Sheet 6 GM28632E-G 39
Decision-Maker!550 (3300/4160 V)
Point-to-Point Wiring Diagram
Sheet 1 GM28739A-F 40
Sheet 2 GM28739B-F 41
Schematic Diagram
Sheet 1 ADV-6814A-F 14
Sheet 2 ADV-6814B-F 15
Decision-Maker!3+ (380--600 V)
Point-to-Point Wiring Diagram
Sheet 1 GM30909A-G 46
Sheet 2 GM30909B-G 47
Schematic Diagram ADV-6886-F 20
Accessory Connections
Sheet 1 328912A--G 60
Sheet 2 328912B--G 61
Sheet 3 328912C--G 62
Sheet 4 GM28631B-B 33
Sheet 5 GM28631C-B 34
Sheet 6 GM28631D-B 35
Decision-Maker!3+ (3300/4160 V)
Point-to-Point Wiring Diagram
Sheet 1 GM35961A-B 56
Sheet 2 GM35961B-B 57
Schematic Diagram ADV-6886-F 20
Alternator Reconnections ADV-5875C-G 11

TP-6216 10/06 Wiring Diagrams 7

2500/2800REOZD Controller Wiring Diagrams Reference
Controller Description Version 4-1 Page
Decision-Maker!550 (380--600 V)
Point-to-Point Wiring Diagram
Sheet 1 GM30090A-B 42
Sheet 2 GM30090B-B 43
Schematic Diagram
Sheet 1 ADV-6844A-B 16
Sheet 2 ADV-6844B-B 17
Accessory Connections
Sheet 1 GM16088A-F 29
Sheet 2 GM16088B-F 30
Sheet 3 GM28632B-G 36
Sheet 4 GM28632C-G 37
Sheet 5 GM28632D-G 38
Sheet 6 GM28632E-G 39
Decision-Maker!550 (3300 V, 4160 V, and 6600 V)
Point-to-Point Wiring Diagram
Sheet 1 GM30091A-B 44
Sheet 2 GM30091B-B 45
Schematic Diagram
Sheet 1 ADV-6848A-B 18
Sheet 2 ADV-6848B-B 19
Decision-Maker!550 (11--13.8 kV)
Point-to-Point Wiring Diagram
Sheet 1 GM39844A-- 58
Sheet 2 GM39844B-- 59
Schematic Diagram
Sheet 1 ADV-7044A- 27
Sheet 2 ADV-7044B- 28
Alternator Reconnections ADV-5875C-G 11

8 Wiring Diagrams TP-6216 10/06

 Controller Identification

Decision-Maker! 550 Controller Decision-Maker! 3+, 16-Light 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.
! 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-6216 10/06 Controller Identification 9

 Notes

10 Controller Identification TP-6216 10/06

TP-6216 10/06 Wiring Diagrams 11
12 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 13
14 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 15
16 Wiring Diagrams TP-6216 10/06
 B

TP-6216 10/06 Wiring Diagrams 17

18 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 19
20 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 21
22 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 23
24 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 25
26 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 27
28 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 29
30 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 31
32 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 33
34 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 35
36 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 37
38 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 39
40 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 41
42 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 43
44 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 45
46 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 47
48 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 49
50 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 51
52 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 53
54 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 55
56 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 57
58 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 59
60 Wiring Diagrams TP-6216 10/06
TP-6216 10/06 Wiring Diagrams 61
62 Wiring Diagrams TP-6216 10/06
 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-6216 10/06f 7 Jurong Pier Road
Singapore 619159
! 2003, 2004, 2005, 2006 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455