Wiring Diagrams

Industrial Generator Sets

Models:
25--150 kW
(GM-Powered Models)

Controllers:
Decision-Makerr 550
Decision-Makerr 3000
Decision-Makerr 6000

TP-6799 5/11
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
 Introduction

This manual provides wiring diagrams for the
25--150 kW (GM-powered) generator sets equipped
with one of the following controllers:
D Decision-Makerr 550
D Decision-Makerr 3000
D Decision-Makerr 6000 (100--150 kW)
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
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
KohlerPower.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
3 rue de Brennus
Latin America
93200 Saint Denis
Latin America Regional Office
France
Lakeland, Florida, USA
Phone: (33) 1 49 178300
Phone: (863) 619-7568
Fax: (33) 1 49 178301
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-6799 5/11 Introduction 3

 Notes

4 Service Assistance TP-6799 5/11


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 Wiring
Wiring Diagrams
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 Wiring
Set Model Generator Set Diagram
No. Hz Spec No. Version No.
25REZGB 60 GM69415-GA7, -GA9, -GA11 1-1 or 1-2
30REZGB 60 GM69415-GA8, -GA10, -GA12 1-1 or 1-2
40REZGB 60 GM66069-GA1, -GA3, -GA5 1-1 or 1-2
45REZGB 60 GM66069-GA2, -GA4, -GA6 1-1 or 1-2
50REZGB 60 GM79036-GA1, -GA2, -GA3 2
60REZGB 60 GM79037-GA1, -GA2, -GA3 2
80REZGD 60 GM81112-GA1, -GA4 2
80RZGD 60 GM81112-GA3, -GA6 2
100REZGD 60 GM81112-GA7, -GA9 3
100RZGD 60 GM81112-GA11, -GA12 3
125REZGB 60 GM77561-GA1, -GA2 3
150REZGB 60 GM77562-GA1 3
150REZGC 60 GM80580-GA1, -GA3 3
150RZGC 60 GM80580-GA2, -GA4 3

TP-6799 5/11 Wiring Diagrams 5

Controller Description Version 1-1 Page Version 1-2 Page
Decision-Makerr 550 Controller
Point-to-Point Wiring Diagram
Sheet 1 GM63941A-D 54 GM77410A- 61
Sheet 2 GM63941B-D 55 GM77410B- 62
Sheet 3 GM63941C-D 56 GM77410C- 63
Schematic Diagram
Sheet 1 ADV-7600A-E 11 ADV-7963A- 20
Sheet 2 ADV-7600B-E 12 ADV-7963B- 21
Sheet 3 ADV-7600C-E 13 ADV-7963C- 22
Sheet 4 ADV-7600D-E 14 ADV-7963D- 23
Sheet 5 ADV-7600E-E 15 ADV-7963E- 24
Accessory Connections
Accessories GM16088A-H 52 —
Remote Annunciator GM16088B-H 53 —
Decision-Makerr 3000
Controller
Point-to-Point Wiring Diagram
Sheet 1 GM73379A-B 58 GM77411A- 64
Sheet 2 GM73379B-B 59 GM77411B- 65
Sheet 3 GM73379C-B 60 GM77411C- 66
Schematic Diagram
Sheet 1 ADV-7834A-C 16 ADV-7964A- 25
Sheet 2 ADV-7834B-C 17 ADV-7964B- 26
Sheet 3 ADV-7834C-C 18 ADV-7964C- 27
Sheet 4 ADV-7834D-C 19 ADV-7964D- 28
Accessory Connections
Accessories GM67191-B 57 —
Alternator Reconnections
4-Lead ADV-5875A-M 9 ADV-5875A-M 9
12-Lead ADV-5875B-M 10 ADV-5875B-M 10
Note: Use Version 1-1 with Control and Harness Module Nos. GM69425-MA1, GM71696-MA3, GM71699-MA3, and
GM72450-MA1. Use Version 1-2 with Control and Harness Module Nos. GM77347-MA1, GM77348-MA1, GM77349-MA3,
and GM77350-MA3. The Module Nos. are listed on a nameplate decal located on the generator set controller or junction box.

6 Wiring Diagrams TP-6799 5/11

Controller Description Version 2 Page Controller Description Version 3 Page
Decision-Makerr 550 Decision-Makerr 550
Controller Controller
Point-to-Point Wiring Diagram Point-to-Point Wiring Diagram
Sheet 1 GM77412A- 67 Sheet 1 GM77412A- 67
Sheet 2 GM77412B- 68 Sheet 2 GM77412B- 68
Sheet 3 GM77412C- 69 Sheet 3 GM77412C- 69
Sheet 4 GM77412D- 70 Sheet 4 GM77412D- 70
Schematic Diagram Schematic Diagram
Sheet 1 ADV-7965A- 29
Sheet 1 ADV-7965A- 29
Sheet 2 ADV-7965B- 30
Sheet 2 ADV-7965B- 30
Sheet 3 ADV-7965C- 31
Sheet 3 ADV-7965C- 31
Sheet 4 ADV-7965D- 32
Sheet 4 ADV-7965D- 32
Sheet 5 ADV-7965E- 33
Sheet 5 ADV-7965E- 33 Sheet 6 ADV-7965F- 34
Sheet 6 ADV-7965F- 34 Sheet 7 ADV-7965G- 35
Sheet 7 ADV-7965G- 35
Decision-Makerr 3000
Decision-Makerr 3000 Controller
Controller Point-to-Point Wiring Diagram
Point-to-Point Wiring Diagram Sheet 1 GM77413A- 71
Sheet 1 GM77413A- 71 Sheet 2 GM77413B- 72
Sheet 2 GM77413B- 72 Sheet 3 GM77413C- 73
Sheet 3 GM77413C- 73 Sheet 4 GM77413D- 74
Sheet 4 GM77413D- 74 Schematic Diagram
Schematic Diagram Sheet 1 ADV-7966A- 36
Sheet 1 ADV-7966A- 36 Sheet 2 ADV-7966B- 37
Sheet 2 ADV-7966B- 37 Sheet 3 ADV-7966C- 38
Sheet 3 ADV-7966C- 38 Sheet 4 ADV-7966D- 39
Sheet 4 ADV-7966D- 39 Sheet 5 ADV-7966E- 40
Sheet 6 ADV-7966F- 41
Sheet 5 ADV-7966E- 40
Sheet 6 ADV-7966F- 41 Decision-Makerr 6000
Controller
Alternator Reconnections
Point-to-Point Wiring Diagram
4-Lead ADV-5875A-M 9 Sheet 1 GM79167A- 75
12-Lead ADV-5875B-M 10 Sheet 2 GM79167B- 76
Sheet 3 GM79167C- 77
Sheet 4 GM79167D- 78
Sheet 5 GM79167E- 79
Sheet 6 GM79167F- 80
Sheet 7 GM79167G- 81
Schematic Diagram
Sheet 1 ADV-8018A- 42
Sheet 2 ADV-8018B- 43
Sheet 3 ADV-8018C- 44
Sheet 4 ADV-8018D- 45
Sheet 5 ADV-8018E- 46
Sheet 6 ADV-8018F- 47
Sheet 7 ADV-8018G- 48
Sheet 8 ADV-8018H- 49
Sheet 9 ADV-8018I- 50
Sheet 10 ADV-8018J- 51
Alternator Reconnections
4-Lead ADV-5875A-M 9
12-Lead ADV-5875B-M 10

TP-6799 5/11 Wiring Diagrams 7

Controller Identification

Decision-Makerr 550 Controller

Decision-Makerr 3000 Controller

Decision-Makerr 6000 Controller

8 Controller Identification TP-6799 5/11

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TP-6799 5/11
E 2011 by Kohler Co. All rights reserved.
KOHLER CO. Kohler, Wisconsin 53044
Phone 920-457-4441, Fax 920-459-1646
For the nearest sales/service outlet in the
US and Canada, phone 1-800-544-2444
KohlerPower.com
Kohler Power Systems
Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455