Wiring Diagrams

Industrial Generator Sets

Models:

500REOZVB
500REOZVC
550/600REOZV
550/600REOZVB

Controllers:
Decision-Makerr 3+
Decision-Makerr 3000
Decision-Makerr 550
Decision-Makerr 6000

TP-6777 10/11b

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

Introduction
This manual provides wiring diagrams for the
500REOZVB/C and 550/600REOZV/B generator sets
equipped with the following controllers:
D Decision-Makerr 3+
D Decision-Makerr 3000

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.

D Decision-Makerr 550
D Decision-Makerr 6000

Service Assistance
For professional advice on generator set power
requirements and conscientious service, please contact
your nearest Kohler distributor or dealer.
D Consult the Yellow Pages under the heading

GeneratorsElectric.
D Visit

the Kohler Power Systems website at

KohlerPower.com.

D Look at the labels and stickers on your Kohler product

or review the appropriate literature or documents

included with the product.
D Call toll free in the US and Canada 1-800-544-2444.
D Outside the US and Canada, 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

TP-6777 10/11

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

Introduction

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 Set
Model No.

Hz

Generator Set
Spec No.

Wiring Diagram
Version No.

500REOZVB

50/60

GM36226-GA5

500REOZVC

50/60

GM80027-GA1

550REOZV

60

GM59244-GA2

550REOZVB

60

GM80027-GA2

600REOZV

60

GM59244-GA1

600REOZVB

60

GM78621-GA1

Wiring Diagrams

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500REOZVB and 550/600REOZV Wiring

Diagrams Reference
Controller Description
Decision-Makerr 3+
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Schematic Diagram
Sheet 1
Sheet 2
Accessory Connections
Sheet 1
Sheet 2
Sheet 3
Sheet 3
Sheet 4
Decision-Makerr 550
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Schematic Diagram
Sheet 1
Sheet 2
Sheet 3
Accessory Connections
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Sheet 6
Decision-Makerr 6000
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Sheet 6
Accessory Connections
Sheet 1
Sheet 2
Schematic Diagram
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Engine Control
Alternator Reconnections
Pilot-Excited Permanent
Magnet Alternator

TP-6777 10/11

Version 1

Page

GM49815A-C
GM49815B-C
GM35943-D

35
36
32

ADV-7276-C
ADV-6957-B

11
8

328912A-H
328912B-H
GM28631B-B
GM28631C-B
GM28631D-B

55
56
25
26
27

GM37376A-D
GM37376B-D
GM35943-D

33
34
32

ADV-6961A-D
ADV-6961B-D
ADV-6957-B

9
10
8

GM16088A-H
GM16088B-H
GM28632B-J
GM28632C-J
GM28632D-J
GM28632E-J

23
24
28
29
30
31

GM72606AGM72606BGM72606CGM72606DGM72606EGM35943-D

38
39
40
41
42
32

GM78247A-A
GM78247B-A

44
45

ADV-7827AADV-7827BADV-7827CADV-7827DADV-6957-B

12
13
14
15
8

7746032-P60

57

ADV-5875D-M

500REOZVC and 550/600REOZVB Wiring

Diagrams Reference
Controller Description
Decision-Makerr 3000
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Schematic Diagram
Sheet 1
Sheet 2
Accessory Connections
Sheet 1
Sheet 2
Decision-Makerr 550
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Schematic Diagram
Sheet 1
Sheet 2
Sheet 3
Accessory Connections
Sheet 1
Sheet 2
Decision-Makerr 6000
Point-to-Point Wiring Diagram
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Sheet 6
Accessory Connections
Sheet 1
Sheet 2
Schematic Diagram
Sheet 1
Sheet 2
Sheet 3
Sheet 4
Sheet 5
Engine Control
Alternator Reconnections
Pilot-Excited Permanent
Magnet Alternator

Version 2

Page

GM79875AGM79875BGM35943-D

46
47
32

ADV-7940ADV-6957-B

18
8

GM67191-B
GM78246-

37
43

GM79876AGM79876BGM35943-D

48
49
32

ADV-7939AADV-7939BADV-6957-B

16
17
8

GM78247A-A
GM78247B-A

44
45

GM79877A-A
GM79877B-A
GM79877C-A
GM79877D-A
GM79877E-A
GM35943-D

50
51
52
53
54
32

GM78247A-A
GM78247B-A

44
45

ADV-7947A-A
ADV-7947B-A
ADV-7947C-A
ADV-7947D-A
ADV-6957-B

19
20
21
22
8

7746032-P60

57

ADV-5875D-M

Wiring Diagrams

Controller Identification

Decision-Makerr 3+, 16-Light Controller

Decision-Makerr 3000 Controller

Controller Identification

Decision-Makerr 550 Controller

Decision-Makerr 6000 Controller

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14

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Blue
Light Blue
Brown
Light Brown
Green
Grey
Orange
Pink
Red
Black
Purple
White
Yellow
Cable cross section = 0.75 mm2
unless otherwise stated.

BL
LBL
BN
LBN
GN
GR
OR
P
R
SB
VO
W
Y

Cable Colors

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.

57

Engine Control
7746032-P60

Wiring Diagrams

Sensor, fuel pressure

Sensor, piston cooling pressure
Sensor, coolant level
Sensor, water in fuel
J1587 (bus)
J1939 CAN (bus)
Stop button
Battery plus
Voltage after key
Battery minus
Connector block data bus
Sensor, oil level/oil temperature
Sensor, coolant temperature
Sensor, crankcase pressure
Extra stop
Relay socket
Main relay
Connector block B
Connector block A
Control module EMS 2
Sensor, air filter pressure and air temperature
Sensor, charge air pressure/charge air temperature
Sensor, oil pressure
Sensor, camshaft
Sensor, flywheel
Unit injector (cylinder 1--6)
Connector block
Main circuit breaker, 10 A
Relay preheating
Preheating
Diagnostic input
Alternator
Starter
Battery, 24 V
Connector block (not used)

Notes

58

Wiring Diagrams

TP-6777 10/11

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

TP-6777 10/11b
E 2010, 2011 by Kohler Co. All rights reserved.

Kohler Power Systems

Asia Pacific Headquarters
7 Jurong Pier Road
Singapore 619159
Phone (65) 6264-6422, Fax (65) 6264-6455