Wiring Diagrams

Fast-Responset II
Industrial Generator Sets

Models:
20--200ROZJ
20--100REOZJ
40--180ROZJA
Controllers:
Decision-Makert 340
Decision-Makert 3+
Decision-Makert 3
Decision-Makert 1
Manual
Engine Gauge Box for Paralleling Switchgear

TP-5718 1/00b
 Introduction

This manual provides wiring diagrams for the At the time of print this manual applied to the model
20--200ROZJ, 20--100REOZJ, and 40--180 ROZJA numbers and specification (spec) numbers shown in the
John Deere engine-powered generator sets equipped Wiring Diagram Cross-Reference chart. On occasion
with one of the following controllers: this manual may apply to specs not listed in the Wiring
Diagram Cross-Reference chart.
D Decision-Makert340
D Decision-Makert3+ Information in this publication represents data available
D Decision-Makert3 at the time of print. Kohler Co. reserves the right to
D Decision-Makert1 change this publication and the products represented
D Manual without notice and without any obligation or liability
D Engine Gauge Box for Paralleling Switchgear whatsoever.
x:in:001:002

Service Assistance

Service Information Africa, Europe, Middle East

London Regional Office
Please contact a local authorized distributor/dealer for Langley, Slough, England
sales, service, or other information about Kohler Phone: (44) 1753-580-771
Generator Division products. Fax: (44) 1753-580-036
Australia
To locate a local authorized distributor/dealer inside Australia Regional Office
the U.S.A. and Canada Queensland, Australia
D Look on the product or in the information included with Phone: (617) 3893-0061
the product Fax: (617) 3893-0072
D Consult the Yellow Pages under the heading China
Generators— Electric China Regional Office
D Visit the Kohler Generator Division web site at Shanghai, People’s Republic of China
www.kohlergenerators.com Phone: (86) 21-6482 1252
D Call 1-800-544-2444 Fax: (86) 21-6482 1255
India, Bangladesh, Sri Lanka
To locate a local authorized distributor/dealer
India Regional Office
outside the U.S.A. and Canada
Bangalore, India
D Look on the product or in the information included
Phone: (91) 80-2284270
with the product
(91) 80-2284279
D Consult the telephone directory under the heading
Fax: (91) 80-2284286
Generators—Electric
Japan
D Visit the Kohler Generator Division web site at
Japan Regional Office
www.kohlergenerators.com
Tokyo, Japan
D Contact the nearest regional office
Phone: (813) 3440-4515
Fax: (813) 3440-2727
Latin America
Latin America Regional Office
Lakeland, Florida, U.S.A.
Phone: (941) 619-7568
Fax: (941) 701-7131
South East Asia
Singapore Regional Office
Singapore, Republic of Singapore
Phone: (65) 264-6422
Fax: (65) 264-6455

TP-5718 1/00 Introduction i

Product Information Engine Identification
Record the product identification information from the
Product identification numbers determine service parts. engine nameplate.
Record the product identification numbers in the spaces
Manufacturer
below immediately after unpacking the products so that
the numbers are readily available for future reference. Model Number
Record field-installed kit numbers after installing the Serial Number
kits.

Generator Set Identification Numbers

Record the product identification numbers from the
generator set nameplate(s).
Model Number
Specification Number
Serial Number

Accessory Number Accessory Description

ii Introduction TP-5718 1/00

 Wiring Diagrams

Use the Wiring Diagram Cross-Reference chart to Wiring Diagrams Reference chart to determine the
determine the wiring diagram version number for a wiring diagram numbers for your unit. Refer to the
given model number and spec number. Then find that generator set operation manual for controller type
version number and the controller type on the Controller identification if necessary.
x:in:003:002

Wiring Diagram Cross-Reference

Generator Set Generator Set Wiring Diagram
Model No. Hz Spec No. Version No.
20ROZJ 50/60 PA-189001-- (1, 2)*
30ROZJ 50/60 PA-189101-- (1, 2)*
40ROZJ 50/60 PA-189201-- (1, 2)*
50ROZJ 50/60 PA-189301-- (1, 2)*
60ROZJ 50/60 PA-189401-- (1, 2)*
80ROZJ 50/60 PA-189501-- (1, 2)*
100ROZJ 50/60 PA-189601-- (1, 2)*
125ROZJ 50/60 PA-189701--189719 (1, 2)*
125ROZJ 50/60 PA-189732, 189737 [
135ROZJ 50/60 PA-189721, 189722, 2
PA-189724--189731,
PA-189733--
135ROZJ 50/60 PA-189735-- [
150ROZJ 50/60 PA-189801--189826 (1, 2)*
150ROZJ 50/60 PA-189828--189831, 2
PA-189833--189840,
PA-189843--
150ROZJ 50/60 PA-189841, 189842, [
PA-189847, 189848--
180ROZJ 50/60 PA-189901--189937 (1, 2)*
180ROZJ 50/60 PA-189939--189942, 2
PA-189944--
200ROZJ 50/60 PA-189980-- 2

20REOZJ 50/60 PA-189029-- 2

30REOZJ 50/60 PA-189133-- 2
40REOZJ 50/60 PA-189229-- 2
50REOZJ 50/60 PA-189325-- 2
60REOZJ 50/60 PA-189423-- 2
80REOZJ 50/60 PA-189539-- 2
100REOZJ 50/60 PA-189641-- 2

40ROZJA 50/60 PA-189228-- 2]

60ROZJA 50/60 PA-189421-- 2]
80ROZJA 50/60 PA-189537-- 2]
100ROZJA 50/60 PA-189636-- 2]
125ROZJA 50/60 PA-189720, 189723 2]
125ROZJA 50/60 PA-189737-- 2w
150ROZJA 50/60 PA-189827, 189832 2]
150ROZJA 50/60 PA-189857-- 2w
180ROZJA 50/60 PA-189938, 189943 2]
180ROZJA 50/60 PA-189970-- 2w
* Use version 1 for serial no. below 363369. Use version 2 for serial no. 363369 and above.
[ See Wiring Diagram Manual TP-5807.
] All ROZJA models use the Decision-Makerä 1 controller with engine gauges and AC meters (12-lead alternator).
w All ROZJA models use the Decision-Makerä 1 controller with engine gauges and AC meters (4-lead alternator).

TP-5718 1/00 Introduction iii

 Controller Wiring Diagrams Reference
Controller Description Version 1 P. Version 2 P.
Decision-Makert t340
(12-Volt or 24-Volt Engine Electrical Systems)*
Point-to-Point Wiring Diagram
Sheet 1 — 347941A-J 26
Sheet 2 — 347941B-J 27
Schematic Diagram
Sheet 1 — ADV-6130A-J 10
Sheet 2 — ADV-6130B-J 11
Accessory Connections
Accessories — 354246A-D 28
Remote Annunciator Kit — 354246B-D 29
Decision-Makert t3+ and Decision-Makert t3
(12-Volt or 24-Volt Engine Electrical Systems)*
Point-to-Point Wiring Diagram
Sheet 1 327097-B 16 327153-L 20
Sheet 2 327098-B 17 —
Schematic Diagram
Sheet 1 ADV-5618-E 1 ADV-6002-E 7
Sheet 2 ADV-5619-J 3 —
Accessory Connections
Accessories 255828A-N 13 328912A-F 21
Remote Annunciator Kit, Sheet 1 255828B-N 14 328912B-F 22
Remote Annunciator Kit, Sheet 2 255828C-N 15 —
Decision-Makert t1 Controller
(12-Volt Engine Electrical Systems only)*
Point-to-Point Wiring Diagram
Standard and Standard with Engine Gauges — 347327-F 25
Expanded with Engine Gauges and AC Meters (12 Lead) — 347058-J 24
Expanded with Engine Gauges and AC Meters (4 Lead) — 360196-A 30
Schematic Diagram
Standard and Standard with Engine Gauges — ADV-6010-E 9
Expanded with Engine Gauges and AC Meters (12 Lead) — ADV-6008-G 8
Expanded with Engine Gauges and AC Meters (4 Lead) — ADV-6340- 12
Manual Controller
(12-Volt Engine Electrical Systems only)*
Point-to-Point Wiring Diagram
Sheet 1 327099-G 18 327099-H 19
Schematic Diagram
Sheet 1 ADV-5664-E 4 ADV-5664-F 5
Sheet 2 ADV-5665-G 6 —
Engine Gauge Box for Paralleling Switchgear
(12-Volt Engine Electrical Systems only)*
Point-to-Point Wiring Diagram
Sheet 1 — 342425-E 23
Schematic Diagram
Sheet 1 — ADV-5618-F 2
* Use generator set nameplate for engine electrical system voltage identification.
NOTE: Version 1 uses the Microprocessor Decision-Makerä 3 controller.
Version 2 uses the Microprocessor Decision-Makerä 3+ controller.

iv Introduction TP-5718 1/00

 t3 Controllers, Schematic Diagram, Sheet 1, ADV-5618-E
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 1

Engine Gauge Box for Paralleling Switchgear, Schematic Diagram, ADV-5618-F

2 Wiring Diagrams TP-5718 1/00

 t3 Controllers, Schematic Diagram, Sheet 2, ADV-5619-J
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 3

Manual Controller, Schematic Diagram, Sheet 1, ADV-5664-E

4 Wiring Diagrams TP-5718 1/00

Manual Controller, Schematic Diagram, ADV-5664-F

TP-5718 1/00 Wiring Diagrams 5

Manual Controller, Schematic Diagram, Sheet 2, ADV-5665-G

6 Wiring Diagrams TP-5718 1/00

 t3 Controllers, Schematic Diagram, ADV-6002-E
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 7

Decision-Makerä1, Schematic Diagram, Expanded w/Engine Gauges and AC Meters (12-Lead), ADV-6008-G

8 Wiring Diagrams TP-5718 1/00

Decision-Makerä 1 Controller, Schematic Diagram, Standard and Standard w/Engine Gauges, ADV-6010-E

TP-5718 1/00 Wiring Diagrams 9

 t340 Controller, Schematic Diagram, Sheet 1, ADV-6130A-J
Decision-Makert

10 Wiring Diagrams TP-5718 1/00

 t340 Controller, Schematic Diagram, Sheet 2, ADV-6130B-J
Decision-Makert

TP-5718 1/00 Wiring Diagrams 11

 t1, Schematic Diagram, Expanded w/Engine Gauges and AC Meters (4-Lead), ADV-6340-
Decision-Makert

12 Wiring Diagrams TP-5718 1/00

 t3, Accessory Connections, Accessories, 255828A-N
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 13

 t3, Accessory Connections, Remote Annunciator Kit, Sheet 1, 255828B-N
t3+ and Decision-Makert
Decision-Makert

14 Wiring Diagrams TP-5718 1/00

 t3, Accessory Connections, Remote Annunciator Kit, Sheet 2, 255828C-N
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 15

 t3 Controllers, Point-to-Point Wiring Diagram, Sheet 1, 327097-B
t3+ and Decision-Makert
Decision-Makert

16 Wiring Diagrams TP-5718 1/00

 t3 Controllers, Point-to-Point Wiring Diagram, Sheet 2, 327098-B
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 17

Manual Controller, Point-to-Point Wiring Diagram, 327099-G

18 Wiring Diagrams TP-5718 1/00

Manual Controller, Point-to-Point Wiring Diagram, 327099-H

TP-5718 1/00 Wiring Diagrams 19

 t3 Controllers, Point-to-Point Wiring Diagram, 327153-L
t3+ and Decision-Makert
Decision-Makert

20 Wiring Diagrams TP-5718 1/00

 t3 Controllers, Accessory Connections, Accessories, 328912A-F
t3+ and Decision-Makert
Decision-Makert

TP-5718 1/00 Wiring Diagrams 21

 t3, Accessory Connections, Remote Annunciator Kit, 328912B-F
t3+ and Decision-Makert
Decision-Makert

22 Wiring Diagrams TP-5718 1/00

00

Engine Gauge Box for Paralleling Switchgear, Point-to-Point Wiring Diagram, 342425-E

TP-5718 1/00 Wiring Diagrams 23

Decision-Makerä1, Point-to-Point Wiring Diagram, Expanded w/Engine Gauges and AC Meters (12-Lead), 347058-J

24 Wiring Diagrams TP-5718 1/00

Decision-Makerä 1 Controller, Point-to-Point Wiring Diagram, Standard and Standard w/Engine Gauges, 347327-F

TP-5718 1/00 Wiring Diagrams 25

Decision-Makerä 340 Controller, Point-to-Point Wiring Diagram, Sheet 1, 347941A-J

26 Wiring Diagrams TP-5718 1/00

Decision-Makerä 340 Controller, Point-to-Point Wiring Diagram, Sheet 2, 347941B-J

TP-5718 1/00 Wiring Diagrams 27

 t 340 Controller, Accessory Connections, Accessories, 354246A-D
Decision-Makert

28 Wiring Diagrams TP-5718 1/00

 t 340 Controller, Accessory Connections, Remote Annunciator Kit, 354246B-D
Decision-Makert

TP-5718 1/00 Wiring Diagrams 29

Decision-Makerä1, Point-to-Point Wiring Diagram, Expanded w/Engine Gauges and AC Meters (4-Lead), 360196-A

30 Wiring Diagrams TP-5718 1/00

 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
Kohlerr Power Systems
Asia Pacific Headquarters
TP-5718 1/00b 7 Jurong Pier Road
Singapore 619159
E Kohler Co., 1996, 1998, 1999, 2000 All rights reserved. Phone (65)264-6422, Fax (65)264-6455