Wiring Diagrams

Industrial Generator Sets

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

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

TP-6799 1/17g
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- and PSI-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 Asia Pacific

requirements and conscientious service, please contact Power Systems Asia Pacific Regional Office
your nearest Kohler distributor or dealer. Singapore, Republic of Singapore
Phone: (65) 6264-6422
D Consult the Yellow Pages under the heading Fax: (65) 6264-6455
Generators—Electric.
China
D Visit
the Kohler Power Systems website at North China Regional Office, Beijing
KOHLERPower.com. Phone: (86) 10 6518 7950
(86) 10 6518 7951
D Look at the labels and decals on your Kohler product (86) 10 6518 7952
or review the appropriate literature or documents Fax: (86) 10 6518 7955
included with the product. East China Regional Office, Shanghai
Phone: (86) 21 6288 0500
D Call toll free in the US and Canada 1-800-544-2444. Fax: (86) 21 6288 0550
D Outside the US and Canada, call the nearest regional India, Bangladesh, Sri Lanka
office. India Regional Office
Bangalore, India
Headquarters Europe, Middle East, Africa Phone: (91) 80 3366208
(EMEA) (91) 80 3366231
Kohler Power Systems Netherlands B.V. Fax: (91) 80 3315972
Kristallaan 1
Japan, Korea
4761 ZC Zevenbergen
North Asia Regional Office
The Netherlands
Tokyo, Japan
Phone: (31) 168 331630
Phone: (813) 3440-4515
Fax: (31) 168 331631
Fax: (813) 3440-2727

TP-6799 1/17g Introduction 3

 Notes

4 Service Assistance TP-6799 1/17g


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
Wiring Diagrams
diagram numbers for your unit. Refer to Controller
Identification for controller type identification, if
necessary. Diagrams are arranged in alphanumeric
order on the following pages.

Wiring Diagram Cross-Reference

Generator Wiring
Set Model Generator Set Diagram
No. Hz Spec No. Version No.
25REZG 60 GM69415-GA7, -GA9, -GA11 1-1 or 1-2
25REZGB 60 GM66092-GA13, -GA14, -GA15 2
GM69415-GA8, -GA10, -GA12 1-1 or 1-2
30REZG 60
GM86748-GA1 1-2
30REZGB 60 GM66092-GA16, -GA17, -GA18 2
40REZG 60 GM66092-GA1, -GA3, -GA5 1-1 or 1-2
GM66092-GA2, -GA4, -GA6 1-1 or 1-2
45REZG 60
GM86752-GA1 1-2
50REZGB 60 GM79036-GA1, -GA2, -GA3 3
50REZGC 60 GM79037-GA8, -GA9, -GA10 4
GM79037-GA1, -GA2, -GA3 3
60REZGB 60
GM89957-GA1 3
80REZGD 60 GM81112-GA1, -GA4 3
80RZGD 60 GM81112-GA3, -GA6 3
100REZGD 60 GM81112-GA7, -GA9 5
100RZGD 60 GM81112-GA11, -GA12 5
125REZGB 60 GM77561-GA1, -GA2, -GA3 5
GM81460-GA1, -GA3, -GA7,
125REZGC 60 6
GM99493-GA1, -GA3, -GA7
GM81460-GA2, -GA4, -GA8,
125RZGC 60 6
GM99493-GA2, -GA4, -GA8
150REZGB 60 GM77562-GA1 5
GM80580-GA1, -GA3, -GA5,
150REZGC 60 6
GM99599-GA1, -GA3, -GA5
GM80580-GA2, -GA4, -GA6,
150RZGC 60 6
GM99599-GA2, -GA4, -GA6

TP-6799 1/17g Wiring Diagrams 5

25--45REZG Wiring Diagrams Reference
Controller Description Version 1-1 Page Version 1-2 Page
Decision-Makerr 550 Controller
Point-to-Point Wiring Diagram
Sheet 1 GM63941D--1 66 GM77410D--1 73
Sheet 2 GM63941D--2 67 GM77410D--2 74
Sheet 3 GM63941D--3 68 GM77410D--3 75
Sheet 4 GM35943D 65 GM35943D 65
Schematic Diagram
Sheet 1 ADV-7600F--1 14 ADV-7963C--1 23
Sheet 2 ADV-7600F--2 15 ADV-7963C--2 24
Sheet 3 ADV-7600F--3 16 ADV-7963C--3 25
Sheet 4 ADV-7600F--4 17 ADV-7963C--4 26
Sheet 5 ADV-7600F--5 18 ADV-7963C--5 27
Sheet 6 ADV-6957B 13 ADV-6957B 13
Accessory Connections
Accessories GM16088H--1 63 GM16088H--1 63
Remote Annunciator GM16088H--2 64 GM16088H--2 64
Decision-Makerr 3000 Controller
Point-to-Point Wiring Diagram
Sheet 1 GM73379B--1 70 GM77411G--1 76
Sheet 2 GM73379B--2 71 GM77411G--2 77
Sheet 3 GM73379B--3 72 GM77411G--3 78
Sheet 4 GM35943D 65 GM35943D 65
Schematic Diagram
Sheet 1 ADV-7834C--1 19 ADV-7964F--1 28
Sheet 2 ADV-7834C--2 20 ADV-7964F--2 29
Sheet 3 ADV-7834C--3 21 ADV-7964F--3 30
Sheet 4 ADV-7834C--4 22 ADV-7964F--4 31
Sheet 5 ADV-6957B 13 ADV-6957B 13
Accessory Connections
Sheet 1 GM67191B 69 GM78246C--1 87
Sheet 2 — GM78246C--2 88
Alternator Reconnections
4-Lead ADV-5875U--1 11 ADV-5875U--1 11
12-Lead ADV-5875U--2 12 ADV-5875U--2 12
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 1/17g

25/30REZGB Wiring Diagrams Reference 50/60REZGB, 80REZGD, and 80RZGD
Wiring Diagrams Reference
Controller Description Version 2 Page
Decision-Makerr 3000 Controller Description Version 3 Page
Controller Decision-Makerr 550
Point-to-Point Wiring Diagram Controller
Sheet 1 GM77411G--1 76 Point-to-Point Wiring Diagram
Sheet 2 GM77411G--2 77 Sheet 1 GM77412D--1 79
Sheet 3 GM77411G--3 78 Sheet 2 GM77412D--2 80
Sheet 4 GM35943D 65 Sheet 3 GM77412D--3 81
Schematic Diagram Sheet 4 GM77412D--4 82
Sheet 1 ADV-7964F--1 28 Sheet 5 GM35943D 65
Sheet 2 ADV-7964F--2 29 Schematic Diagram
Sheet 3 ADV-7964F--3 30 Sheet 1 ADV-7965E--1 32
Sheet 4 ADV-7964F--4 31 Sheet 2 ADV-7965E--2 33
Sheet 5 ADV-6957B 13 Sheet 3 ADV-7965E--3 34
Accessory Connections Sheet 4 ADV-7965E--4 35
Sheet 1 GM78246C--1 87 Sheet 5 ADV-7965E--5 36
Sheet 2 GM78246C--2 88 Sheet 6 ADV-7965E--6 37
Alternator Reconnections Sheet 7 ADV-7965E--7 38
4-Lead ADV-5875U--1 11 Sheet 8 ADV-6957B 13
12-Lead ADV-5875U--2 12 Accessory Connections
Sheet 1 GM78247F--1 89
Sheet 2 GM78247F--3 91
Sheet 3 GM78247F--4 92
Decision-Makerr 3000
Controller
Point-to-Point Wiring Diagram
Sheet 1 GM77413E--1 83
Sheet 2 GM77413E--2 84
Sheet 3 GM77413E--3 85
Sheet 4 GM77413E--4 86
Sheet 5 GM35943D 65
Schematic Diagram
Sheet 1 ADV-7966D--1 39
Sheet 2 ADV-7966D--2 40
Sheet 3 ADV-7966D--3 41
Sheet 4 ADV-7966D--4 42
Sheet 5 ADV-7966D--5 43
Sheet 6 ADV-7966D--6 44
Sheet 7 ADV-6957B 13
Accessory Connections
Sheet 1 GM78246C--1 87
Sheet 2 GM78246C--2 88
Alternator Reconnections
4-Lead ADV-5875U--1 11
12-Lead ADV-5875U--2 12

TP-6799 1/17g Wiring Diagrams 7

50REZGC Wiring Diagrams Reference Controller Description Version 5 Page
Decision-Makerr 3000
Controller Description Version 4 Page Controller
Decision-Makerr 3000 Point-to-Point Wiring Diagram
Controller
Sheet 1 GM77413E--1 83
Point-to-Point Wiring Diagram Sheet 2 GM77413E--2 84
Sheet 1 GM77413E--1 83 Sheet 3 GM77413E--3 85
Sheet 2 GM77413E--2 84 Sheet 4 GM77413E--4 86
Sheet 3 GM77413E--3 85 Sheet 5 GM35943D 65
Sheet 4 GM77413E--4 86 Schematic Diagram
Sheet 5 GM35943D 65 Sheet 1 ADV-7966D--1 39
Schematic Diagram Sheet 2 ADV-7966D--2 40
Sheet 1 ADV-7966D--1 39 Sheet 3 ADV-7966D--3 41
Sheet 2 ADV-7966D--2 40 Sheet 4 ADV-7966D--4 42
Sheet 3 ADV-7966D--3 41 Sheet 5 ADV-7966D--5 43
Sheet 4 ADV-7966D--4 42 Sheet 6 ADV-7966D--6 44
Sheet 5 ADV-7966D--5 43 Sheet 7 ADV-6957B 13
Sheet 6 ADV-7966D--6 44 Accessory Connections
Sheet 7 ADV-6957B 13 Sheet 1 GM78246C--1 87
Accessory Connections Sheet 2 GM78246C--2 88
Sheet 1 GM78246C--1 87 Decision-Makerr 6000
Sheet 2 GM78246C--2 88 Controller
Alternator Reconnections Point-to-Point Wiring Diagram
4-Lead ADV-5875U--1 11 Sheet 1 GM79167G--1 93
12-Lead ADV-5875U--2 12 Sheet 2 GM79167G--2 94
Sheet 3 GM79167G--3 95
100REZGD, 100RZGD, and 125/150REZGB Sheet 4 GM79167G--4 96
Wiring Diagrams Reference Sheet 5 GM35943D 65
Schematic Diagram
Controller Description Version 5 Page Sheet 1 ADV-8018F--1 45
Sheet 2 ADV-8018F--2 46
Decision-Makerr 550
Controller Sheet 3 ADV-8018F--3 47
Point-to-Point Wiring Diagram Sheet 4 ADV-8018F--4 48
Sheet 1 GM77412D--1 79 Sheet 5 ADV-8018F--5 49
Sheet 2 GM77412D--2 80 Sheet 6 ADV-8018F--6 50
Sheet 3 GM77412D--3 81 Sheet 7 ADV-6957B 13
Sheet 4 GM77412D--4 82 Accessory Connections
Sheet 5 GM35943D 65 Sheet 1 GM78247F--2 90
Schematic Diagram Sheet 2 GM78247F--3 91
Sheet 1 ADV-7965E--1 32 Alternator Reconnections
Sheet 2 ADV-7965E--2 33 4-Lead ADV-5875U--1 11
Sheet 3 ADV-7965E--3 34 12-Lead ADV-5875U--2 12
Sheet 4 ADV-7965E--4 35
Sheet 5 ADV-7965E--5 36
Sheet 6 ADV-7965E--6 37
Sheet 7 ADV-7965E--7 38
Sheet 8 ADV-6957B 13
Accessory Connections
Sheet 1 GM78247F--1 89
Sheet 2 GM78247F--3 91
Sheet 3 GM78247F--4 92

8 Wiring Diagrams TP-6799 1/17g

125/150REZGC and 125/150RZGC Wiring Diagrams Reference
Controller Description Version 6 Page Controller Description Version 6 Page
Decision-Makerr 550 Decision-Makerr 6000
Controller Controller
Point-to-Point Wiring Diagram Point-to-Point Wiring Diagram
Sheet 1 GM89756C--1 100 Sheet 1 GM89757C--1 103
Sheet 2 GM89756C--2 101 Sheet 2 GM89757C--2 104
Sheet 3 GM89756C--3 102 Sheet 3 GM89757C--3 105
Sheet 4 GM35943D 65 Sheet 4 GM35943D 65
Schematic Diagram Schematic Diagram
Sheet 1 ADV-8561C--1 55 Sheet 1 ADV-8562C--1 59
Sheet 2 ADV-8561C--2 56 Sheet 2 ADV-8562C--2 60
Sheet 3 ADV-8561C--3 57 Sheet 3 ADV-8562C--3 61
Sheet 4 ADV-8561C--4 58 Sheet 4 ADV-8562C--4 62
Sheet 5 ADV-6957B 13 Sheet 5 ADV-6957B 13
Accessory Connections Accessory Connections
Sheet 1 GM78247F--1 89 Sheet 1 GM78247F--2 90
Sheet 2 GM78247F--3 91 Sheet 2 GM78247F--3 91
Sheet 3 GM78247F--4 92
Alternator Reconnections
Decision-Makerr 3000 4-Lead ADV-5875U--1 11
Controller
12-Lead ADV-5875U--2 12
Point-to-Point Wiring Diagram
Sheet 1 GM89520C--1 97
Sheet 2 GM89520C--2 98
Sheet 3 GM89520C--3 99
Sheet 4 GM35943D 65
Schematic Diagram
Sheet 1 ADV-8557C--1 51
Sheet 2 ADV-8557C--2 52
Sheet 3 ADV-8857C--3 53
Sheet 4 ADV-8557C--4 54
Sheet 5 ADV-6957B 13
Accessory Connections
Sheet 1 GM78246C--1 87
Sheet 2 GM78246C--2 88

TP-6799 1/17g Wiring Diagrams 9

Controller Identification

Decision-Makerr 550 Controller Decision-Makerr 3000 Controller

Decision-Makerr 550 Controller with Decision-Makerr 6000 Controller

Keyswitch

10 Controller Identification TP-6799 1/17g

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 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
TP-6799 1/17g 7 Jurong Pier Road
Singapore 619159
E 2011, 2012, 2013, 2014, 2016, 2017 by Kohler Co. All rights reserved. Phone (65) 6264-6422, Fax (65) 6264-6455