Industrial Generator Sets

Models:

500REOZVB500REOZVC

550/600REOZV550/600REOZVB

Controllers:

Decision-Maker 3+

Decision-Maker 3000

Decision-Maker 550

Decision-Maker 6000

TP-6777 10/11b

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

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

TP-6777 10/11 3Introduction

Introduction

This manual provides wiring diagrams for the

500REOZVB/C and 550/600REOZV/B generator sets

equipped with the following controllers:

Decision-Maker 3+

Decision-Maker 3000

Decision-Maker 550

Decision-Maker 6000

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-6777 10/114 Wiring 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

Generator SetModel No. Hz

Generator SetSpec No.

Wiring DiagramVersion No.

500REOZVB 50/60 GM36226-GA5 1

500REOZVC 50/60 GM80027-GA1 2

550REOZV 60 GM59244-GA2 1

550REOZVB 60 GM80027-GA2 2

600REOZV 60 GM59244-GA1 1

600REOZVB 60 GM78621-GA1 2

TP-6777 10/11 5Wiring Diagrams

500REOZVB and 550/600REOZV Wiring

Diagrams Reference

Controller Description Version 1 Page

Decision-Maker 3+

Point-to-Point Wiring Diagram

Sheet 1 GM49815A-C 35

Sheet 2 GM49815B-C 36

Sheet 3 GM35943-D 32

Schematic Diagram

Sheet 1 ADV-7276-C 11

Sheet 2 ADV-6957-B 8

Accessory Connections

Sheet 1 328912A-H 55

Sheet 2 328912B-H 56

Sheet 3 GM28631B-B 25

Sheet 3 GM28631C-B 26

Sheet 4 GM28631D-B 27

Decision-Maker 550

Point-to-Point Wiring Diagram

Sheet 1 GM37376A-D 33

Sheet 2 GM37376B-D 34

Sheet 3 GM35943-D 32

Schematic Diagram

Sheet 1 ADV-6961A-D 9

Sheet 2 ADV-6961B-D 10

Sheet 3 ADV-6957-B 8

Accessory Connections

Sheet 1 GM16088A-H 23

Sheet 2 GM16088B-H 24

Sheet 3 GM28632B-J 28

Sheet 4 GM28632C-J 29

Sheet 5 GM28632D-J 30

Sheet 6 GM28632E-J 31

Decision-Maker 6000

Point-to-Point Wiring Diagram

Sheet 1 GM72606A- 38

Sheet 2 GM72606B- 39

Sheet 3 GM72606C- 40

Sheet 4 GM72606D- 41

Sheet 5 GM72606E- 42

Sheet 6 GM35943-D 32

Accessory Connections

Sheet 1 GM78247A-A 44

Sheet 2 GM78247B-A 45

Schematic Diagram

Sheet 1 ADV-7827A- 12

Sheet 2 ADV-7827B- 13

Sheet 3 ADV-7827C- 14

Sheet 4 ADV-7827D- 15

Sheet 5 ADV-6957-B 8

Engine Control 7746032-P60 57

Alternator Reconnections

Pilot-Excited Permanent

Magnet AlternatorADV-5875D-M 7

500REOZVC and 550/600REOZVB Wiring

Diagrams Reference

Controller Description Version 2 Page

Decision-Maker 3000

Point-to-Point Wiring Diagram

Sheet 1 GM79875A- 46

Sheet 2 GM79875B- 47

Sheet 3 GM35943-D 32

Schematic Diagram

Sheet 1 ADV-7940- 18

Sheet 2 ADV-6957-B 8

Accessory Connections

Sheet 1 GM67191-B 37

Sheet 2 GM78246- 43

Decision-Maker 550

Point-to-Point Wiring Diagram

Sheet 1 GM79876A- 48

Sheet 2 GM79876B- 49

Sheet 3 GM35943-D 32

Schematic Diagram

Sheet 1 ADV-7939A- 16

Sheet 2 ADV-7939B- 17

Sheet 3 ADV-6957-B 8

Accessory Connections

Sheet 1 GM78247A-A 44

Sheet 2 GM78247B-A 45

Decision-Maker 6000

Point-to-Point Wiring Diagram

Sheet 1 GM79877A-A 50

Sheet 2 GM79877B-A 51

Sheet 3 GM79877C-A 52

Sheet 4 GM79877D-A 53

Sheet 5 GM79877E-A 54

Sheet 6 GM35943-D 32

Accessory Connections

Sheet 1 GM78247A-A 44

Sheet 2 GM78247B-A 45

Schematic Diagram

Sheet 1 ADV-7947A-A 19

Sheet 2 ADV-7947B-A 20

Sheet 3 ADV-7947C-A 21

Sheet 4 ADV-7947D-A 22

Sheet 5 ADV-6957-B 8

Engine Control 7746032-P60 57

Alternator Reconnections

Pilot-Excited Permanent

Magnet AlternatorADV-5875D-M 7

TP-6777 10/116 Controller Identification

Controller Identification

Decision-Maker 3+, 16-Light Controller

Decision-Maker 3000 Controller

Decision-Maker 550 Controller

Decision-Maker 6000 Controller

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WiringDiagrams

1.Sensor,fuelpressure

2.Sensor,pistoncoolingpressure

3.Sensor,coolantlevel

4.Sensor,waterinfuel

5.J1587(bus)

6.J1939CAN(bus)

7.Stopbutton

8.Battery

plus

9.Voltageafterkey

10.Battery

minus

11.Connectorblockdatabus

12.Sensor,oillevel/oiltemperature

13.Sensor,coolanttemperature

14.Sensor,crankcasepressure

15.Extrastop

16.Relaysocket

17.Mainrelay

18.ConnectorblockB

19.ConnectorblockA

20.ControlmoduleEMS2

21.Sensor,airfilterpressure

andairtemperature

22.Sensor,chargeairpressure/chargeairtemperature

23.Sensor,oilpressure

24.Sensor,camshaft

25.Sensor,flywheel

26.Unitinjector(cylinder1--6)

27.Connectorblock

28.Maincircuitbreaker,10A

29.Relaypreheating

30.Preheating

31.Diagnosticinput

32.Alternator

33.Starter

34.Battery,24V

35.Connectorblock(notused)

Cable

Colors

BL

Blue

LBL

LightBlue

BN

Brown

LBN

LightBrown

GN

Green

GR

Grey

OR

Orange

PPink

RRed

SB

Black

VO

Purple

WWhite

YYellow

Cablecrosssection=0.75mm2

unlessotherwisestated.

EngineControl

7746032-P60

TP-6777

10/11

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WiringDiagrams

Notes

2010, 2011 by Kohler Co. All rights reserved.

TP-6777 10/11b

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