Industrial Generator Sets

Models:

25--150 kW(GM-Powered Models)

Controllers:

Decision-Maker 550

Decision-Maker 3000

Decision-Maker 6000

TP-6799 5/11

Wiring Diagrams

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

TP-6799 5/11 3Introduction

Introduction

This manual provides wiring diagrams for the

25--150 kW (GM-powered) generator sets equipped

with one of the following controllers:

Decision-Maker 550

Decision-Maker 3000

Decision-Maker 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

requirements and conscientious service, please contact

your nearest Kohler distributor or dealer.

Consult the Yellow Pages under the heading

GeneratorsElectric.

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

TP-6799 5/114 Service Assistance

Notes

TP-6799 5/11 5Wiring 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 and the controller 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

GeneratorSet ModelNo. Hz

Generator SetSpec No.

WiringDiagramVersion 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 5/116 Wiring Diagrams

Controller Description Version 1-1 Page Version 1-2 Page

Decision-Maker 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-Maker 3000Controller

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.

TP-6799 5/11 7Wiring Diagrams

Controller Description Version 2 Page

Decision-Maker 550Controller

Point-to-Point Wiring Diagram

Sheet 1 GM77412A- 67

Sheet 2 GM77412B- 68

Sheet 3 GM77412C- 69

Sheet 4 GM77412D- 70

Schematic Diagram

Sheet 1 ADV-7965A- 29

Sheet 2 ADV-7965B- 30

Sheet 3 ADV-7965C- 31

Sheet 4 ADV-7965D- 32

Sheet 5 ADV-7965E- 33

Sheet 6 ADV-7965F- 34

Sheet 7 ADV-7965G- 35

Decision-Maker 3000Controller

Point-to-Point Wiring Diagram

Sheet 1 GM77413A- 71

Sheet 2 GM77413B- 72

Sheet 3 GM77413C- 73

Sheet 4 GM77413D- 74

Schematic Diagram

Sheet 1 ADV-7966A- 36

Sheet 2 ADV-7966B- 37

Sheet 3 ADV-7966C- 38

Sheet 4 ADV-7966D- 39

Sheet 5 ADV-7966E- 40

Sheet 6 ADV-7966F- 41

Alternator Reconnections

4-Lead ADV-5875A-M 9

12-Lead ADV-5875B-M 10

Controller Description Version 3 Page

Decision-Maker 550Controller

Point-to-Point Wiring Diagram

Sheet 1 GM77412A- 67

Sheet 2 GM77412B- 68

Sheet 3 GM77412C- 69

Sheet 4 GM77412D- 70

Schematic Diagram

Sheet 1 ADV-7965A- 29

Sheet 2 ADV-7965B- 30

Sheet 3 ADV-7965C- 31

Sheet 4 ADV-7965D- 32

Sheet 5 ADV-7965E- 33

Sheet 6 ADV-7965F- 34

Sheet 7 ADV-7965G- 35

Decision-Maker 3000Controller

Point-to-Point Wiring Diagram

Sheet 1 GM77413A- 71

Sheet 2 GM77413B- 72

Sheet 3 GM77413C- 73

Sheet 4 GM77413D- 74

Schematic Diagram

Sheet 1 ADV-7966A- 36

Sheet 2 ADV-7966B- 37

Sheet 3 ADV-7966C- 38

Sheet 4 ADV-7966D- 39

Sheet 5 ADV-7966E- 40

Sheet 6 ADV-7966F- 41

Decision-Maker 6000Controller

Point-to-Point Wiring Diagram

Sheet 1 GM79167A- 75

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 5/118 Controller Identification

Controller Identification

Decision-Maker 550 Controller

Decision-Maker 3000 Controller

Decision-Maker 6000 Controller

TP-67995/11

9WiringDiagrams

TP-67995/11

10

WiringDiagrams

TP-6799

5/11

11

WiringDiagrams

TP-6799

5/11

12

WiringDiagrams

TP-6799

5/11

13

WiringDiagrams

TP-6799

5/11

14

WiringDiagrams

TP-6799

5/11

15

WiringDiagrams

TP-6799

5/11

16

WiringDiagrams

TP-6799

5/11

17

WiringDiagrams

TP-6799

5/11

18

WiringDiagrams

TP-6799

5/11

19

WiringDiagrams

TP-67995/11

20

WiringDiagrams

TP-67995/11

21

WiringDiagrams

TP-67995/11

22

WiringDiagrams

TP-67995/11

23

WiringDiagrams

TP-67995/11

24

WiringDiagrams

TP-67995/11

25

WiringDiagrams

TP-67995/11

26

WiringDiagrams

TP-67995/11

27

WiringDiagrams

TP-67995/11

28

WiringDiagrams

TP-67995/11

29

WiringDiagrams

TP-67995/11

30

WiringDiagrams

TP-67995/11

31

WiringDiagrams

TP-67995/11

32

WiringDiagrams

TP-67995/11

33

WiringDiagrams

TP-67995/11

34

WiringDiagrams

TP-67995/11

35

WiringDiagrams

TP-67995/11

36

WiringDiagrams

TP-67995/11

37

WiringDiagrams

TP-67995/11

38

WiringDiagrams

TP-67995/11

39

WiringDiagrams

TP-67995/11

40

WiringDiagrams

TP-67995/11

41

WiringDiagrams

TP-67995/11

42

WiringDiagrams

TP-67995/11

43

WiringDiagrams

TP-67995/11

44

WiringDiagrams

TP-67995/11

45

WiringDiagrams

TP-67995/11

46

WiringDiagrams

TP-67995/11

47

WiringDiagrams

TP-67995/11

48

WiringDiagrams

TP-67995/11

49

WiringDiagrams

TP-67995/11

50

WiringDiagrams

TP-67995/11

51

WiringDiagrams

TP-67995/11

52

WiringDiagrams

TP-67995/11

53

WiringDiagrams

TP-6799

5/11

54

WiringDiagrams

TP-6799

5/11

55

WiringDiagrams

TP-6799

5/11

56

WiringDiagrams

TP-6799

5/11

57

WiringDiagrams

TP-6799

5/11

58

WiringDiagrams

TP-6799

5/11

59

WiringDiagrams

TP-6799

5/11

60

WiringDiagrams

TP-67995/11

61

WiringDiagrams

TP-67995/11

62

WiringDiagrams

TP-67995/11

63

WiringDiagrams

TP-67995/11

64

WiringDiagrams

TP-67995/11

65

WiringDiagrams

TP-67995/11

66

WiringDiagrams

TP-67995/11

67

WiringDiagrams

TP-67995/11

68

WiringDiagrams

TP-67995/11

69

WiringDiagrams

TP-67995/11

70

WiringDiagrams

TP-67995/11

71

WiringDiagrams

TP-67995/11

72

WiringDiagrams

TP-67995/11

73

WiringDiagrams

TP-67995/11

74

WiringDiagrams

TP-67995/11

75

WiringDiagrams

TP-67995/11

76

WiringDiagrams

TP-67995/11

77

WiringDiagrams

TP-67995/11

78

WiringDiagrams

TP-67995/11

79

WiringDiagrams

TP-67995/11

80

WiringDiagrams

TP-67995/11

81

WiringDiagrams

2011 by Kohler Co. All rights reserved.

TP-6799 5/11

KOHLER CO. Kohler, Wisconsin 53044Phone 920-457-4441, 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