RENR8077-01 December 2006

HIGH COOLANT TEMP

ABBREVIATIONS
ASR AIR SHUT-OFF RELAY GSC GENERATOR SET CONTROL

ATB

AC TRANSFORMER BOX

HET

HIGH ENGINE TEMPERATURE

CR

CONTROL RELAY

HOT

HIGH OIL TEMPERATURE

LOW COOLANT TEMP

LOW OIL PRESSURE

LOW FUEL LEVEL

SLR/2

SYSTEM NOT IN AUTO

1 2 3 4 5 6 7

8 9 10 11 12 13 14

1 2 3 4 5 6 7

8 9 10 11 12 13 14

1 2 3 4 5 6 7

8 9 10 11 12 13 14

108

T
33

108

:A :B :C :D :E
T11

SLR/1

CTR

CRANK TERMINATION RELAY

KW

KILOWATT

EGR

ELECTRONIC GOVERNOR RELAY

LCL

LOW COOLANT LEVEL

LOW BATTERY VOLTAGE

110

U
34

110

:A :B :C :D :E
T13

FCR

FUEL CONTROL RELAY

LOP

LOW OIL PRESSURE

GFR

GENSET FAULT RELAY

POT SCR

POTENTIOMETER SCREEN

GPHI

GROUND POST HIGH

GPLO

GROUND POST LOW

SMR

STARTER MOTOR RELAY

:4/:L1

157

V
35

V 18

157

F32 (2A) F33 (2A)

154

42

SYMBOLS
:2 :3 :1

LAMP TEST

:6/:L3

159

W
36

W 19

159

156

43

ALARM SILENCE

+ -

ALARM SILENCE

+ -

FUSE

POTENTIOMETER

(FRONT)

(REAR)

(FRONT)

(REAR)

(FRONT)

(REAR)
NOTE ON SYNC MODULE: FOR 208V SYSTEM 108 & FOR 240V SYSTEM 108 & FOR 300V SYSTEM 108 & FOR 380V SYSTEM 108 & FOR 400V SYSTEM 108 & FOR 415V SYSTEM 108 & FOR 480V SYSTEM 108 & FOR 600V SYSTEM 108 & 110 110 110 110 110 110 110 110 SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD BE BE BE BE BE BE BE BE CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED TO TO TO TO TO TO TO TO RESISTOR PIN D RESISTOR PIN C RESISTOR PIN B RESISTOR PIN B RESISTOR PIN B RESISTOR PIN A RESISTOR PIN A SINGLE RESISTOR

3406C & 3456 Generator Set with EMCP II+ Electrical System
3406C Gen Set: C2G1-UP C5G1-UP C8G1-UP 3456 Gen Set: C1G1-UP C2T1-UP C3G1-UP C4G1-UP SR4B Generator: L5A1-UP L6B1-UP L7A1-UP
R/1

EMERGENCY STOP PUSHBUTTON

11

CHASSIS CUSTOMER TERMINAL

PANEL LAMP :10 R :2 RELAY COIL

11

CHASSIS DC TERMINAL

CHASSIS AC TERMINAL

TRANZORB

28

DOOR TERMINAL

SCREEN CABLE :1 :3 RELAY CONTACT N/O

58

CHASSIS TO DOOR DC SOCKET

30

ENGINE SOCKET

J :3 PANEL LAMP SWITCH :2

TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTION DESCRIPTION WIRE No. 10 (GSC RM39) & HORN +VE WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK JUMPER TO 10 JUMPER TO 11 NOT CONNECTED NOT CONNECTED WIRE No. 30 (GSC RM27) & SILENCE SWITCH LOW FUEL LEVEL SWITCHED -VE INPUT NOT CONNECTED LED 7 (SPARE) LED 8 (SPARE) LAMP TEST -VE INPUT (IF REQUIRED) SILENCE SWITCH HORN -VE

TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTION DESCRIPTION WIRE No. 10 (GSC RM39) & HORN +VE WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK LED 5 SWITCHED -VE INPUT LED 6 SWITCHED -VE INPUT LED 7 SWITCHED -VE INPUT LED 8 SWITCHED -VE INPUT WIRE No. 30 (GSC RM27) & SILENCE SWITCH LED 1 SWITCHED -VE INPUT LED 2 SWITCHED -VE INPUT LED 3 SWITCHED -VE INPUT LED 4 SWITCHED -VE INPUT LAMP TEST SILENCE SWITCH HORN -VE

TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

CONNECTION DESCRIPTION WIRE No. 10 (GSC RM39) WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK LED 5 SWITCHED -VE INPUT LED 6 SWITCHED -VE INPUT LED 7 SWITCHED -VE INPUT LED 8 SWITCHED -VE INPUT WIRE No. 30 (GSC RM27) LED 1 SWITCHED -VE INPUT LED 2 SWITCHED -VE INPUT LED 3 SWITCHED -VE INPUT LED 4 SWITCHED -VE INPUT LAMP TEST -VE INPUT (IF REQUIRED) TERMINAL No. 13 ON 1st ALARM MODULE (ALM MUTE) TERMINAL No. 14 ON 1st ALARM MODULE (HORN ON)

CHASSIS TO DOOR AC SOCKET

POWER TERMINAL

EARTH

GSC 40 WAY HARNESS CONNECTOR

:1

PWM MODULE

:2 :3 :4 :5

GSC RELAY MODULE TERMINAL ENGINE CONTROL SWITCH ATB TERMINAL

1
9X9857

CIRCUIT BREAKER

HORN
4 6

+ 10 30

:14

:3 :10 :4 DC :11 :8

LINK SPARE FAULT INPUT (LED 7) LINK SPARE FAULT INPUT (LED 8) 72
10

HORN
4 6

+ 10 30

:14

:8 :9 :10 DC :11 :3 :4 :5 :6 :2 90

SPARE FAULT INPUT (LED 1) SPARE FAULT INPUT (LED 2) SPARE FAULT INPUT (LED 3) SPARE FAULT INPUT (LED 4) SPARE SHUTDOWN INPUT (LED 5) SPARE SHUTDOWN INPUT (LED 6) SPARE SHUTDOWN INPUT (LED 7) SPARE SHUTDOWN INPUT (LED 8)
17 ALARM

HORN ON

:14

69

:14

:8 :9 :10 DC :11 :3 :4 :5

SPARE FAULT INPUT (LED 1) SPARE FAULT INPUT (LED 2) SPARE FAULT INPUT (LED 3) SPARE FAULT INPUT (LED 4) SPARE SHUTDOWN INPUT (LED 5) SPARE SHUTDOWN INPUT (LED 6) SPARE SHUTDOWN INPUT (LED 7) 20 SPARE SHUTDOWN INPUT (LED 8)
38

Volume 1
-B S D +B

:1 + :7 -

:1 + :7 -

FIRST ALARM MODULE

4 6

10 30

:1 + :7 -

2006 Caterpillar All Rights Reserved

Printed in U.S.A.

SILENCE SWITCH ALARM DATALINK

17

LOW FUEL LEVEL

:13 90 :2 :12 20
38

LAMP TEST

SILENCE SWITCH

:13 :12

ALARM MUTE

:13

68 ALARM DATALINK
17

LAMP TEST (IF REQUIRED)

DATALINK

90

:13 :2

:6 :12

LAMP TEST (IF REQUIRED)

EMCP II+ ATB

ATB +

(T11) (T12)

WIRE TABLE
13

(T13)

H21
1

H22 H23

1 F23 (2A) 84

DC CIRCUIT
ALREADY FITTED AS STANDARD

1 F23 (2A) 84

1 F23 (2A)

50

50

ABBREVIATIONS IA IB IC VA VB VC EGC PP ASR CTR FCR GFR PSR RR SMR PSR GEN I LINE A CURRENT LINE B CURRENT LINE C CURRENT LINE A VOLTAGE LINE B VOLTAGE LINE C VOLTAGE ELECTRONIC GOVERNOR CONTROL PRE-LUBE PUMP AIR SHUT-OFF RELAY CRANK TERMINATE RELAY FUEL CONTROL RELAY GENSET FAULT RELAY PROGRAMMABLE SPARE RELAY RUN RELAY STARTING MOTOR RELAY PROGRAMMABLE SPARE RELAY GENERATOR CURRENT

LEVEL SWITCH (TOP VIEW)

ALREADY FITTED AS STANDARD
HIG HHIG H SW4 SW3 H H IG

DC CIRCUIT
LEVEL SWITCH (TOP VIEW)

DC CIRCUIT
LEVEL SWITCH (TOP VIEW)

50 51 52

GSC EMCP II+

DISPLAY BOARD CPU BOARD
+12V GROUND SERIAL CLOCK SERIAL DATA KEYPAD PWR 1 KEYPAD PWR 2 KEYPAD ROW 1 KEYPAD ROW 2 LED BLANK KEYPAD PWR 3 SERIAL STROBE WATCHDOG LED KEYPAD ROW 3 KEYPAD ROW 4 NC +12V REG J2-1 J2-2 J2-3 J2-4 J2-5 J2-6 J2-7 J2-8 J2-9 J2-10 J2-11 J2-12 J2-13 J2-14 J2-15 J2-16 J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 +12V GROUND SERIAL CLOCK SERIAL DATA KEYPAD PWR 1 KEYPAD PWR 2 KEYPAD ROW 1 KEYPAD ROW 2 LED BLANK NC SERIAL STROBE WATCHDOG LED KEYPAD ROW 3 KEYPAD ROW 4 NC NC KEYPAD SIG X7 KEYPAD ROW 2 KEYPAD PWR 1 KEYPAD SIG 1X KEYPAD ROW 3 KEYPAD ROW 4 KEYPAD PWR 2 W3-1 W3-2 W3-3 W3-4 W3-5 W3-6 W3-7

84
4 16

84
HIG HHIG H SW4 SW3 H HIG HIG HHIG H SW4 SW3 H HIG

84
4 16

53 80 80 82

KEYPAD

CABLE ENTRY
PUMP RUN

CABLE ENTRY
84 :3 PR/1 :1
20
SW1 LOW LOW SW2

CABLE
82

PUMP RUN

84

SW1 LOW LOW

LOW LOW

LOW

LOW

LOW

15

TERMINAL BOX
15

TERMINAL BOX

LOW LEVEL FUEL SWITCH HIGH LEVEL FUEL SWITCH

21

:6 PR/2 :7
36

TERMINAL BOX

LED BOARD
LED BLANK WATCHDOG LED +5V +12V SERIAL CLOCK SERIAL STROBE SERIAL DATA GROUND W1-1 W1-2 W1-3 W1-4 W1-5 W1-6 W1-7 W1-8 W2-1 W2-2 W2-3 W2-4 W2-5 W2-6 W2-7 W2-8 LED BLANK WATCHDOG LED +5V +12V SERIAL CLOCK SERIAL STROBE SERIAL DATA GROUND

18

ALREADY FITTED AS STANDARD

LEVEL SWITCH (SIDE VIEW)

18

ALREADY FITTED AS STANDARD

LEVEL SWITCH (SIDE VIEW)

85 :2 MV :1 MOT. 83
35

LEVEL SWITCH (SIDE VIEW)

3-POLE FUSE BLOCK

ATB + INTERNAL SCHEMATIC

T11 18 GA BK H1 PRI T1 X1 J1-1 18 GA RD

8-PIN DEUTSCH CONNECTOR

LOW LEVEL FUEL SWITCH HIGH LEVEL FUEL SWITCH

21

TERMINAL BOX
:3 PR/1 :1
20

81 PR/2

84 :6 LOW LEVEL FUEL SWITCH HIGH LEVEL FUEL SWITCH

21

TERMINAL BOX
:3 PR/1 :1
20

VALVE

TERMINAL BOX

T1

VA

81 :2
SW4 NORMALLY OPEN

T2

T12 18 GA BK H2

81
SW4 NORMALLY OPEN

:7
36

81

+ -

X2

+B AC GND +12V VB SEL +12V VA SEL VA BUS SEL VC SEL VC BUS SEL EGC DRIVE RR DRIVE CTR DRIVE ASR DRIVE PSR DRIVE GFR DRIVE SMR DRIVE FCR DRIVE +BAT. SW +BAT. SW GROUND GROUND J3-1 J3-2 J3-3 J3-4 J3-5 J3-6 J3-7 J3-8 J3-9 J3-10 J3-11 J3-12 J3-13 J3-14 J3-15 J3-16 J3-17 J3-18 J3-19 J3-20 RANGE SELECT JUMPER NOTE A J3-1 J3-2 J3-3 J3-4 J3-5 J3-6 J3-7 J3-8 J3-9 J3-10 J3-11 J3-12 J3-13 J3-14 J3-15 J3-16 J3-17 J3-18 J3-19 J3-20 AC GND +12V VB SEL +12V VA SEL NC VC SEL NC EGC DRIVE RR DRIVE CTR DRIVE ASR DRIVE PSR DRIVE GFR DRIVE SMR DRIVE FCR DRIVE +BAT. SW +BAT. SW GROUND GROUND

PR :10

-VE SUPPLY

T3
SW4 NORMALLY OPEN

T13 18 GA BK H1 PRI T2 X1 J1-2 18 GA RD VB

85
SW3 NORMALLY CLOSED

RELAY BOARD
+BAT. SW +BAT. UNFUSED CTR IN FCR IN ASR IN SMR IN GFR IN RR2 IN RR1 IN PSR1 IN PSR2 IN +BAT. FUSED OUT EGC IN EGC N/O OUT FCR N/O OUT CTR N/O OUT CTR N/C OUT SMR N/O OUT ASR N/O OUT ASR N/C OUT SMR N/C OUT GFR N/O OUT RR1 N/C OUT RR2 N/O OUT PSR2 N/O OUT PSR1 N/C OUT FLYBACK GND -BAT. J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 J1-18 J1-19 J1-20 J1-21 J1-22 J1-23 J1-24 J1-25 J1-26 J1-27 J1-28 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

83
35

SW2

NORMALLY CLOSED

:2 MV :1 MOT. -VE SUPPLY VALVE

SW3

NORMALLY CLOSED

SW3

NORMALLY CLOSED

H2
SW2 NORMALLY CLOSED

X2

83
35

SW2

NORMALLY CLOSED

T3 H1 X1 PRI
SW1 NORMALLY CLOSED

J1-3 18 GA RD

VC

SW1

NORMALLY CLOSED

:2 PR :10

+ -

SW1

NORMALLY CLOSED

:2 PR :10

+ -

10-POLE TERMINAL STRIP H21 H22 H21 H22 H23 50 50 51 52 53 80 82 16 GA BK 16 GA BK 16 GA BK 18 GA BK 18 GA BK

H2

X2

HI BK PRI

T4 BR

J1-4 18 GA BR

IA

2
2

H23 50 50 51 52
HIG HHIG H

29 30 31 32 33 34 35 36 37 38 39

BK 18 GA BK HI BK PRI T5

PU

LEVEL SWITCH (TOP VIEW)

J1-5 BR 18 GA BR

IB

AC CIRCUIT

AC CIRCUIT

BK

PU

53 80

HI 16 GA BK BK PRI

T6 BR

J1-6 18 GA BR

IC

COPPER BUSBAR

AC CIRCUIT
13 M :13 AUX :14 202 10 J :97 O/L :98 203 11 PUMP STOP
23

6 mm 45 132

COPPER BUSBAR

SW4

F22 (2A)

F21 (6A)

AC CIRCUIT
13 M :13 AUX :14 :97 O/L :98 203 11 J PUMP STOP
23

6 mm 45 132
SW1 LOW LOW

F22 (2A)

F21 (6A)

SW2

SW3 H

CABLE ENTRY

82

BK

PU

J1-7 18 GA GY

AC GND

LOW

HIG

J1-8 18 GA GY T1, T2 AND T3 ARE 15:1 POTENTIAL TRA T4, T5 AND T6 ARE 500:1 CURRENT TRAN NSFORMERS, SFORMERS

AC GND

J2-1 J2-2 J2-3 J2-4 J2-5 J2-6

VA AC VB AC VC AC

SEL GND SEL GND SEL GND

207

207

TERMINAL BOX
24

24

NOTE A: THE RANGE SELECT JUMPER IS INSTALLED IN ALL CONTROLS TO SELECT THE DEFAULT 0-700V INPUT RANGE. REMOVAL OF THE JUMPER SELECTS 0-150V INPUT RANGE.

-B

208

AC SUPPLY CUSTOMER 100V TO 250V

202 10

208

AC SUPPLY CUSTOMER 100V TO 250V

205 K
22

205 L K
22

NOTE: IF NO ALARM MODULE FITTED THEN RELAY WILL ACTIVATE ON SHUTDOWN ONLY.
5

L 12 205 :9 mm 2.5 PR/3 :11

2

202
21

203

12 205 :9 2.5 mm PR/3 :11 206 :95 O/L :96 204

2 2 2

202
21

203

6 :2 ALR :10 2 131 6 mm 2 46 131 NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
2

ALR/3 :8 :9 :11 64
29

72 72 30
65

17

11

72

CONNECT TO ALARM MODULE SPARE

10

65
30

66
31

131

6 mm 2 46 131 NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS. 6 mm

206 :95 O/L :96 204 :X1 PUMP RUN :X2 :X1 PUMP TRIP/ STOP :X2

NORMALLY OPEN

SW4

64

77

26

28

77

CONNECT TO ALARM MODULE SPARE

45

REMOTE CONTACTS FOR GENERAL ALARM

FUSED DC POSITIVE CAT DATA LINK

4 31 32

10 D+ D-

1 5 14

:X1 PUMP RUN :X2

:X1 PUMP TRIP/ STOP :X2

2. 5 mm

2. 5 mm

204 A1 PC A2 131
2

208 211 131 1 3 5 13

204 A1 PC A2 131
2

208 211 131 1 3 5 13

72

30

30

CMS
2 31 HC0 3 HC1 12 HC2 22 HC3 16 HC4 6 HC5 2

33 CLR 23 SRV SCROLL SWITCH `SS' :3 :2 MODE/ CLEAR SWITCH `MCS' :1 :3 :6 :2 2 :4 :5

NORMALLY CLOSED

SW3

LOW FUEL LEVEL SWITCH FUEL LEAK SWITCH

6 mm

77

30

4 3 4

6 5 6

14 97 98 95 96 131

4 3 4

6 5 6

14 97 98 95 96

GRR/3 :8 :9 :11

38 :2 GRR :10 2

131

2 .5 mm

2 .5 mm

O/L 1 2

O/L 1 2

NORMALLY CLOSED

SW2
72 30
65

72

17

11

72

CONNECT TO ALARM MODULE SPARE

10

56

57 53 54 55

87
32

88
33

89
34

DC NEGATIVE

51

52

211 209 210 N N

211 209 210

NORMALLY CLOSED
23 2. 5 mm 24 2. 5 mm
2

SW1
LOW-LOW FUEL LEVEL SWITCH

64

3 17

23 2. 5 mm FUEL PUMP

24 2. 5 mm
2

SP2

REMOTE CONTACTS FOR GENERATOR RUNNING

HARNESS CODE 18

72

30

M
131

FUEL PUMP

M
131

30 Page

84

SW1

SW2

S W2

ENTRY

J1-1 J1-2 J1-3 J1-4 J1-5 J1-6 J1-7 J1-8 J1-9 J1-10 J1-11 J1-12 J1-13 J1-14 J1-15 J1-16 J1-17 J1-18 J1-19 J1-20 J1-21 J1-22 J1-23 J1-24 J1-25 J1-26 J1-27 J1-28 J1-29 J1-30 J1-31 J1-32 J1-33 J1-34 J1-35 J1-36 J1-37 J1-38 J1-39 J1-40

MAG PU IN MAG PU GND I NEUTRAL IN IA IN IB IN IC IN COOLANT TEMP SNSR IN OIL PRESS. SNSR IN +V SNSR OUT VA GEN IN VB GEN IN VC GEN IN COOLANT LOSS IN OIL TEMP SNSR IN AUTO SYNC AC GND VA BUS IN VC BUS IN CAT DATA LINK+ CAT DATA LINKCCM DATA LINK+ CCM DATA LINKSPARE FAULT SW1 IN SPARE FAULT SW2 IN SPARE FAULT SW3 IN SYNC CHECK SPEED ADJUST1 SPEED ADJUST2 SPARE FAULT SW4 IN RDM DATA OUT SENSOR GND STOP SW IN START/RUN SW IN KW RELAY OUT ALM DATA OUT SPARE DATA OUT CLOSE BREAKER OUT EMER STOP SW IN OFF/RESET SW IN AUTO. SW IN

RENR8077-01 VOL 1

PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 1

+B

FUEL PUMPED FROM FREE STANDING BULK TANK FUEL SYSTEM No. 3

GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 2

TBC

T11 T12 T13 H21 H22 H23 50 51 52 53

T11 T12 T13 H21 H22 H23 50 51 52 53

BK BK BK BK BK BK BK BK BK BK

12

11

39

10

38

37

36

34

35

33

32

31

30

17

18

19

20

21

22

23

24

25

26

27

TERMINAL

CIRCUIT NO.

COLOR

-B

14

17

16

15

14

13

12

11

10

4
4 POLE BREAKER OPTIONAL

METERING C.T.S T1
P1 S1 P1 S1 P1 S1 P2 S2 P2 S2 P2 S2

L1 CT1 CT2 CT3 L2 L3

71 72 73 74 75 76 81 84 MOT1 MOT2

71 72 73 74 75 76 81 84 MOT1 MOT2

10

M
VOLTS ADJUST POTENTIOMETER (1KW, 1 TURN) 80 :2 :3 :1

T2

17

10

11

T3 N

31 25

11

12 13

N
12

82 E E

32

13

14

51

52

53

50

50

50 1 REF. F14

T1

T2

T3

101
14

33

15

18 4

10

98 97 96 95 94 93 92 91

15

20

16

J1-8 J1-7 J1-6 J1-5 J1-4 J1-3 J1-2 T11 J1-1 108 108 51 52 53 50 LINK T1 H23 F11 (2A) LINK T2 H21 F12 (2A) LINK T3 H22 F13 (2A) T13 101 101 2

97 96 80 82 95 94 93
56

B C D E F G H

55

AC TRANSFORMER BOX (ATB)

1. IF THE FAULT SHUTDOWN INDICATOR IS FLASHING THEN THE LINK SHOULD BE TEMPORARILY FITTED. THE GSC SETPOINTS MUST BE PROGRAMMED IN OFF/RESET WHEN A FAULT SHUTDOWN IS ACTIVE. IF THE FAULT ALARM INDICATOR IS FLASHING THE GSC CAN BE PROGRAMMED WITH THE CONTROL SWITCH IN ANY POSITION.

16

21 29 23 30 24

57

27

58

28

29

110

110

31 54

46

T12

92
57

109

109

11

4
29

ATA+

64 22 65 23

ATA+

39

K
30 31 35 32

91

3
30

ATA-

ATA-

40

80

82 S-SPD D-SPD

24

SCR

41

NOT CONNECTED

36

37

OFF/RESET AUTO START COOLDOWN/STOP CONTROL MODE SWITCH :8 :9 :10

2

D+

:6

5 :2 KWR :10
13 17 15 14

27

25

26

18

D20 19 21

P2/2
1
1 3

5
48

12 217
6

13 218 P Q
52 50

5 5

61
43

99
35

90
5

63

CCM+
51

CCM7

RDM

31

32

D-

D+
21 22

202 203 205 207 131 117 220 402 108 110 157 159

J K L M N O

202 203 205 207 131 117 220 402 108 110 157 159

SEE NOTE A

8 9 10 11 7 6

67

1 61

18

17

45

46

47

D+ CCM+ CCMRDM 19 + 20 -

D-

20

19

21

23 24

99 34

90 35 ALARM

63 36 SPARE 17 18 SPARE SPARE

416

426

437 DD+
20

470 ohm POT ST4

B+ POST

RM 31

RM 35

RM 30

RM 33

RM 2 FCR

RM 1

RM 32

RM 34

RM 36

RM 23

15

26

37

21 +

22 -

KW

30 RDM

CCM DATALINK F2 (10A) F6 (10A) F1 (10A) F3 (10A) CTR F4 (10A) F5 (10A) F7 (10A) RR

DATA LINK
19

R448
AVR

GENERATOR SET CONTROL (GSC)

LOW OIL PRESSURE EMERGENCY STOP HIGH WATER TEMPERATURE ENGINE OVERSPEED OVERCRANK (SPARE 1) LOW COOLANT LEVEL HIGH OIL TEMPERATURE (SPARE 2) SPARE 3 FAULT SHUTDOWN FAULT ALARM

16 6 5 4 12 11 10 RM 22 RM 19

97 96 95 94 93 92 91
34 26 33 25

R S T U V W

14 15 3 5 16 17

RM 4 FCR
1

RM 8 RR

RM 3 CTR

RM 6 SMR SMR

RM 12

RM 5

RM 7

RM 9

GFR F10 (10A)

SET OP6 SETPOINT SP17 TO 6 SET OP6 SETPOINT SP18 TO 7

H
1
1

ASR

35 5 36

1 EGR GPHI RM 27 2
2 37

37

37

37

10

6 mm 2.5 mm 2

RM 15 13

RM 24 39

RM 17
39

RM 16 38

RM 13 41
38

RM 14 20

GPLO RM 38 28 30 17

AUX. ALARMS/SHUTDOWNS SWITCHED -VE POST BRM 18 14 RM 21 26A RM 39 10

43

+ 1 21 59

22

V-

31

V+

HET 7

LOP 8

LCL 13

6 23 SP1
5 40

37
7

24 SP2
41

25 SP3
42

29 SP4
42

39 55

40 56

33 57

32 58

G
2

62

67

16

15

18

19

2.5 mm

2.5 mm

RENR8077-01 VOL 1

CB2 (20A) 24

F14 (10A) 29 :30 1FCR/1 :87 :30 2FCR/1 :87

CB1 (60A) 6 mm 2 40 :11 CR/3 :9 ALT CHARGING ALTERNATOR

22 39 41 66 53 15 11 23 24 38 42

PANEL LIGHT SWITCH

45

:3 :2
40 54 55 56 34 44 37 36 49 59 60 61 62 63

:1 SP4
19

+ 24V (OPTIONAL) PS1 SMMS1/1 PS2 SMMS2/1

28

EMER. STOP 11
8

SP1
16

SP2
17

SP3
18

21 9

22

:2 :3 :4 :5 30
6

OFF/RESET AUTO START COOLDOWN/STOP

38

41

20

30

17

34

26A
25

46

45
6

10

CONTROL MODE SWITCH

25

26

27 FCS

P1/2
30

57

BATTERY ISOLATOR SWITCH KEY REMOVABLE

SM1

PS1

SM2

PS2

62

67

16

15

67

62

18

67

62

19

67

62
16

3 6 mm 2 REF. L07 50
27 28 29 5 6 4 22 9 37 38

30

57

30 Page, B&W

10 ASOR+ SD-PWR SD-RTN 23A 23A

4

PANEL LIGHTS

9 8 ES59 EF1 EF2

CHASSIS DOOR BODY 2 2

E E E

12

E
2 2
11

E
2 2 2 2 30 30

12

:10 CR :2 ASOR+
51

SD-PWR
52

SD-RTN
53

23A
8

23A
9

3 12
6 47

11
46

41
15

41
16

20
10

30
65

30
25

17
48

34
49

46
50

45A
18

45
17

10
7

8
27

ES28

59
59

21
31

22
32 33

62T
42

67T
43

16
14

15
13

67P
44

62P
45

18
20

67L
21

62L
19

19
23

67O
24

62O
22

EF1
61

EF2
62

D4

D+
3 5

D
NOT CONNECTED NOT CONNECTED NOT CONNECTED NOT CONNECTED

21

22

62

67T

16

15

67P

62

18

67L

62L

19

67O

62O

EF1

EF2

NOT CONNECTED

30

IF REQUIRED
59

FIT IF REQUIRED
64

30

30

46

11

12

46

34

59

72

EMER. STOP ON ENCLOSURE

62 1 2 B

67T A

16 C

15 C

67P A

62 B C A B C A B

EF1

EF2

8
59 SASV MAGNETIC PICK UP No.1 4 3 60 LOW FUEL LEVEL SWITCH COOLANT TEMPERATURE OIL PRESSURE COOLANT LOSS IF REQUIRED OIL TEMPERATURE IF REQUIRED CORE BALANCE CURRENT TRANSFORMER IF REQUIRED

DIAGRAM-WIRING (EMCP II+)

235-0829
DIAGRAM-WIRING (ENGINE SCHEMATIC)

SMMS1 30 2 2

SMMS2

:86 1FCR :85

:86 2FCR :85

SATS

236-5745
A

IF REQUIRED

FIT IF REQUIRED IF REQUIRED

VOLUME 1 3406 WITH EMCP II+

8 7 6 5 4 3 2 1

18

17

16

15

14

13

12

11

10

DC NEG.

DC POS.

NOTE:

IF 4 POLE BREAKER FITTED CHANGE N T0 4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02) T1 T2 T1 T2 T3 N E 406 POWER WIRING TO BREAKER T1 T2 POWER WIRING FROM GENERATOR T3 N E 117 117
B

4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02)

RENR8077-01 December 2006

L1 L2 L3 N E

202

201 202

201

202

39

2
L1 L2 L3 N E POWER WIRING FROM GENERATOR T1 T2 T3 N E

38
204 6A FUSE 205

T3 N E

:5

:2

E 4

F42 (6A) 111B IF REQUIRED 407

3RD PHASE, FOR 480V USE TRANSFORMER REF. BBB O S

POWER SUPPLY REFER TO BREAKER DRAWING

2 5

2 6

:C1 ST :C2 24V DC SHUNT TRIP

2 5

2 6

:C11 ST :C12 Q/1 Q/2 24V DC SHUNT TRIP

REFER TO BREAKER DRAWING 157

B

111A 410
B

107

117

:1

:4

402

402

GCR/1 :6 CR/2 :5 :5 ALR/2 :6 159A :1 :3 UVT/1 159 159

B

OPEN SIGNAL REFER TO BREAKER BREAKER DRAWING

:6 SPEED LOWER/RAISE SWITCH

NOTE: IF CONTROL PANEL IS SGCP THEN SWITCH IS MOUNTED REMOTELY.
27

:4

:3

:1 MOT2

NOTE:A

205

201

NOTE:B

N
B B

158

NOTE: ADD FUSE F41, REMOVE LINK AND CONNECT WIRE 111A TO 3RD PHASE IF VOLTAGE IS 240V L-L

F41 (6A)

LINK

107

REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS

B B B

233 231 232

:14 :12 :11 BREAKER AUXILIARY

REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS

B B B

231 233 232

:11 :13

:12 :14

MOT1 MOT1
58 28

BREAKER AUXILIARY

205

157

158

410

NEUTRAL, REFER TO BREAKER DRAWING

111

117
B

:1

:3 BCR/1

CLOSE SIGNAL REFER TO BREAKER DRAWING

MOT2
206

6A FUSE

ABB MCCB
111 107 F40 (6A) 117 178A 178A
B

ABB ACB
57

UV COIL SUPPLY REFER TO BREAKER DRAWING

4 POLE BREAKER OPTIONS

23

MOT1
24

MOT2
203

:2 UVT :10

MOT1
3456
27 1

MOT2
203 201 201 203

F31 (2A)

F32 (2A) 411 412

111

111
22 4 6

:8 :9 :10 :11 :3 :4 :5 :6

SPARE

157

158

SPARE

SPARE

SPARE

BUS TRANSFORMER BOX (BTB+)

J1-1 J1-2 J1-3 J1-4 217 218 98

LINK B1 B21 F36 (2A) B11 B22 F37 (2A) B12

17 2

B2

SPARE

SPARE

SPARE

98
16

411 GREEN WHITE RED BROWN

412 BLACK

SPARE

30

10 :2 BCR :10
26

26

BLACK/WHITE

ORANGE

90

:13 :14 :12 :2 :14 +

ALARM SILENCE

:13

NOTE PT PRIMARY WIRE COLOURS - WHITE = 240V AC - GREEN = 380V AC - BROWN = 480V AC - RED = 600V AC - BLACK = COMMON

146

SECONDARY 120V AC L-L BKRR/1

:5 :9 BKRR/3

:11 :3 :4 BKKR/4 :12 :9 BUSR/1 :1 144

40 3 3 25 9

220 30 R

219

10

30

90
17 4

10
6

30 REF. CCC BREAKER CLOSE

217 14

218 15

30

30

219

221

:4 :5 :8 :10

SYNCHRONISE SWITCH
:1 :6 426 437

:14 :13 :15 2 -VE SUPPLY SASV - START AID SOLENOID VALVE SATS - START AID TEMPERATURE SWITCH MAGNETIC PICK UP No.2

:11

416

46

47

48

ALTERNATOR TERMINAL BOX T1 T2

T3 N1 E

BT1 RTD PT100

BT2 RTD PT100

BT3 RTD PT100 WHITE RTD PT100

T1 CORE BALANCE CURRENT TRANSFORMER

L1 L2 L3 N E

E+

WHITE

WHITE

WHITE

RED

T2

RED

RED

RED

163
3 2 + 24V NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.

164
3 2

G
+ 24V -

T3 N E

VOLTAGE ADJUST P2

ST6

R448

E0 110

CONNECTION TO EXCITER

NOTE:D

NOTE:A 50/60 Hz SELECTION NOTE:B REMOVE LINK FOR REMOTE VOLTAGE ADJUSTMENT POTENTIOMETER NOTE:C REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) NOTE:D ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK NOTE:E ST9 - AREP AND SHUNT - FULL LINK - . PMG SPLIT LINK NOTE:F ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT NOTE:G FIT 5VA TRANSFORMER FOR 600V OPERATION NOTE:H OPTION TI04 FOR PARALLEL OPERATION. OR FOR 3 PHASE SENSING. AND R448 . 7000 FRAME SIZE REQUIRES SPILT LINK - - J2

NOTE:G 3 NOTE:C 2 W V U N RFI UNIT BLACK BLACK BLUE V U N ALTERNATOR WINDING CONNECTIONS OPTIONAL RFI KIT CONNECTIONS

NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.

ST1

ST9

220 380 J1

171

172 3 2 E 5 75 30 30 7

181

182 3 2 E 5 75 30 30 7

191

192 3 2 E 5 75 30 30 7

163 P +
2

164 Q R
D +

3 E 5 76

2
37 38

NOTE:F 3ph POT 470ohm

NOTE:E T1 S1 S2

BLACK

W ALTERNATOR WINDING CONNECTIONS

P +
2

S 1 74

D +

P +
2

S 1 74

D +

P +
2

S 1 74

D +

S 1 71

THERMOCOUPLE RELAY 7 10 30

EF1

EF2 12 11 14 30 73
8
31

30
8

30

30

6 8 8

A1

22

21

24

CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL

ST4

P1 QUADRATURE DROOP ADJUST

75

75

75

14

75

32

CONNECT TO ALARM MODULE SPARE 75

13

76

76

15

76

33

CONNECT TO ALARM MODULE SPARE

14

`EFU' A2 BENDER EARTH FAULT RELAY

NOTE:B

12

73

11

73

76

U S2 S1

P2

TI04 P1

NOTE:H

16

SP1 74
25

CONNECT TO ALARM MODULE SPARE 74

12

16

SP1 CONNECT TO ALARM MODULE SPARE 71

1

74

74

74

13

71

71

10

71

T1

U
T1 T4 T7

N
T7

DIAGRAM - WIRING (R448)

T10 T10 T12 T4 T2

T11 T8

T5

T0

V T2
T12

N
T0 T6

T5 T8 T11

T9

THERMOCOUPLE RELAY OPTIONS

W

T6

T3

T9

T3

AREP
NOTE:A
ST3 J3

SHUNT
SUPPLY 140V MAX 50/60HZ X2 10/YELLOW 1/2 PHASE T1- T4 OR T8 - T11 X2

PMG
SUPPLY STATOR PMG 14 PMG

SERIES STAR CONNECTION DIAGRAM (HIGH VOLTAGE WYE)

PARALLEL STAR CONNECTION DIAGRAM (LOW VOLTAGE WYE)

SUPPLY - AUXILLARY WINDING 10/YELLOW 11/RED

10A FUSE

50Hz
W (L3) T12 LINK T6 T9 T3 V (L2) T2 U (L1) T1 N T12 T6 LINK T11 LINK T10 T4 T7 T1 N T5 T8 T2 U (L1) T9 T3 V (L2) W (L3)

60Hz

9/GREEN
X2

X1

9/GREEN

X1 Z2

15 16

EXCITATION CEILING ADJUST P5

12/BLACK
Z1 X1 ST2 Z2 E+

HEATER OPTIONS

T11 LINK T10

T5

T8

CUSTOMER LOAD CONNECTIONS

CUSTOMER LOAD CONNECTIONS

UNDER SPEED ADJUST P4 STABILITY ADJUST P3

T4

T7

5 6
_ +

GENERATOR LEADS
NOTE:A IF 120V IF 230V IF 120V IF 230V NOTE:A IF 120V IF 230V IF 120V IF 230V 132 COPPER BUSBAR CUSTOMER 100V TO 250V AC SUPPLY 131
46

VOLTAGE ADJUST P2

ST6

R448

E0 110 ST9 220 380 J1

CONNECTION TO EXCITER

NOTE:B NOTE:C
3

NOTE:D

W ALTERNATOR WINDING CONNECTIONS

OPTIONAL RFI KIT CONNECTIONS

ST1

NOTE:F
JACKET WATER JACKET WATER BLOCK HEATER BLOCK HEATER HEATER IS HEATER IS IS FITTED IS FITTED FITTED FUSE F19 FITTED FUSE F19 FUSE F19 SHOULD FUSE F19 SHOULD SHOULD BE 25A SHOULD BE 16A BE 15A BE 10A 6 mm
2

NOTE:E T1 S1 S2

2 1 4

V U N

JACKET WATER JACKET WATER BLOCK HEATER BLOCK HEATER COPPER BUSBAR

HEATER IS HEATER IS IS FITTED IS FITTED

FITTED FUSE F19 FITTED FUSE F19 FUSE F19 SHOULD FUSE F19 SHOULD

SHOULD BE 25A SHOULD BE 16A BE 16A BE 10A

2

3ph
J2

POT 470ohm

BLACK

W ALTERNATOR WINDING CONNECTIONS

COPPER BUSBAR

45

6 mm

132

45

6 mm

132

ST4
45

P1 QUADRATURE DROOP ADJUST

U S2 S1 STATISME P2 S2 S1

RFI UNIT

BLACK BLACK BLUE

V U N

F16 (2A) 136

F17 (6A) 131 135

F18 (4A)

F19 NOTE:A 141 134

6 mm

F16 (2A) 136

F17 (6A) 131 135

6 mm

CUSTOMER 100V TO 250V AC SUPPLY 131

46

F16 (2A) 136 131

F18 (4A)

F19 NOTE:A 141 134

6 mm

CUSTOMER 100V TO 250V AC SUPPLY 131

46

_ +

P2

TI04 P1 N

NOTE:H

NOTE:G
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS. 136 136 NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS. 136 NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.

470ohm POT TENSION P1

NOTE:I

:4 CR/1 :1 137
2

:4 CR/1 :1 131 135

2

:4 CR/1 :1 131
2

R731 U
400 110 400 230

DIAGRAM - WIRING (R448 & R731)

W
400 230 110 N

141
2

134

137

135

137
2

131
2

141 2. 5 mm
2

134

V
230 110

2. 5 mm

6 mm

6 mm

6 mm

6 mm

6 mm

4 3
137 :A1 HC :A2 131 131 :2 140 :4 142 20 :6 139 19 131 :1 135 :3 141 :5 HC :A2 131 131 :2 140 134 137 :A1 131 :1 HC :A2 131 131 :4 142 20 :6 139 19 135 137 :A1 131 :3 141 :5 134

NOTE:A 50/60 Hz SELECTION NOTE:B REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448 NOTE:C REFERENCE TABLE 2 FOR CONNECTION BETWEEN ALTERNATOR AND R731 NOTE:D ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK - . 7000 FRAME SIZE REQUIRES SPILT LINK - - . NOTE:E ST9 - AREP AND SHUNT - FULL LINK - . PMG SPLIT LINK - - . NOTE:F ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT .

2 1 TABLE: 1 50 HZ VOLTAGE WYE 415/240V 400/230V 380/220V 220/127V 600V (T2 (T2 (T2 (T2 (T2 380) 380) 380) 220) 220) TABLE: 2 50 HZ VOLTAGE WYE 415/240V 400/230V 380/220V 220/127V 600V (T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3 380) 380) 380) 220) 220)

CONSTANT VOLTAGE CHARGER 2. 5 mm + 1 24V DC SUPPLY - 3 1 F15 (*) 2 2

2

ALTERNATOR HEATER 140 131

2

6 mm

131

131

- 3

131

131

131

131

131

6 mm

(*)

2. 5 mm

36

ENGINE JACKET WATER HEATER + 1

CONSTANT VOLTAGE CHARGER 1 F15 36 + 140

2

ALTERNATOR HEATER
2

ENGINE JACKET WATER HEATER

NOTE:G REMOVE FOR OPTIONAL VOLTAGE ADJUST POT. NOTE:H OPTION TI04 FOR PARALLEL OPERATION. WITHOUT 3 PHASE SENSING CONNECT TO S1 AND S2 ON R448 ONLY. STANDARD POSITION ON PHASE U. FOR CT PARALLEL OPERATION ON PHASE V - MODIFY R731 VOLTAGE SENSING AS FOLLOWS - U(R731) -> V(ALT) . V(R731) -> W(ALT) . W(R731) -> U(ALT). NOTE:I FIT 2 x 5VA TRANSFORMERS FOR 600V OPERATION

60 HZ VOLTAGE WYE 480/277V - (T2 380) 440/254V - (T2 380) 380/220V - (T2 380) 240/139V - (T2 220) 220/127V - (T2 220) 208/120V - (T2 220) 600V - (T2 220)

60 HZ VOLTAGE WYE 480/277V - (T1,T2&T3 440/254V - (T1,T2&T3 380/220V - (T1,T2&T3 240/139V - (T1,T2&T3 220/127V - (T1,T2&T3 208/120V - (T1,T2&T3 600V

380) 380) 380) 220) 220) 220)

- (T1,T2&T3 220)

FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE

FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE

30 Page

17

SP2

RENR8077-01 VOL 2

:1

:7

REF. AAA REF. BBB

414 BREAKER OPEN :13 BUSR :14

415

24
37

29
38

30
8

145
41

ALTERNATOR TERMINAL BOX T1 T2

BT1

3406C
7

3456

58

10 ES28

:30 EPIR/1 :87 ASOR+ F27

1 (16A) 23

3406C & 3456 Generator Set with EMCP II + Electrical System

3406C Gen Set: C2G1-UP C5G1-UP C8G1-UP 3456 Gen Set: C1G1-UP C2T1-UP C3G1-UP C4G1-UP SR4B Generator: L5A1-UP L6B1-UP L7A1-UP

NOTE A: CONNECT TO POSITIVE ON STARTER MOTOR

GENERATOR SYNCHRONISING MOTOR

NOTE B: CONNECT TO NEGATIVE ON STARTER MOTOR OR BATTERY ISOLATOR

CANOPY LIGHTING

:1 MAN :2 AUTO ETHER START SWITCH

:86 EPIR :85

59

:30 ASOR/1 :87 :86 AIR ASOR SHUT-OFF :85 RELAY 2

UNIT INJECTOR (P91) TURBO OUTLET PRESSURE SENSOR (J23) BACKUP SPEED/TIMING SENSOR (P44)

59
1

37 23A (OPTIONAL) FLAP VALVE FV

5

INLET AIR TEMPERATURE SENSOR (P89) (YELLOW SLEEVE)

TDC PROBE CONN (J26)

99 REF. AAA BREAKER OPEN LAMP 31 BREAKER CLOSED LAMP

99 REF. CCC
3

SASV 2

GROUND TDC PROBE CONN (P26) ECM CONN (P2)

2
19

2 SASV - START AID SOLENOID VALVE -VE SUPPLY

-VE SUPPLY

SP4
29 35 C 46

31

54

3406C
40

ETHER START SWITCH

3 :2 :1

13

37

PRIMARY SPEED/TIMING SENSOR (P20)

AIR SHUT-OFF OPTIONS

COOLANT FLOW SWITCH (P47)

6 :2 ALR :10 2

26A :2 GCR :10 2

B

:13 BKRR :14

11 9

59

44

COOLANT TEMP SENSOR (P21)

54

59 B

59 ACT+ SASV ACTUATOR ACTMPUMPU+ 60 SATS 1 2 8 9 10 11 12 LINK WOODWARD ELECTRONIC LINK FUEL GOVERNOR (ISOCHRONOUS) 3 2
4 3
13

OIL PRESSURE SENSOR (J22)

3 4 5 6 7 1 2

ENGINE RIGHT SIDE

FUEL TEMP SENSOR (P43) (BLACK SLEEVE)

BREAKER AUXILIARY/1 REF. A03 BREAKER DRAWING

43

35
14

:2 :1 :3

ECM CONN (P1)

42

36

SPEED ADJUST POTENTIOMETER (2K W, 10 TURN)

ATM PRESSURE SENSOR (J27)

ENGINE LEFT SIDE

Volume 2
2006 Caterpillar All Rights Reserved

3456 ENGINE COMPONENT LOCATIONS

Printed in U.S.A.

START AID OPTIONS

GOVERNOR OPTION

EARTH FAULT RELAY OPTION

NEUTRAL EARTH LINK

T1
TABLE: 1
CORE BALANCE C.T.

AREP
NOTE:A
ST3 J3

SHUNT
SUPPLY 140V MAX 50/60HZ X2 10/YELLOW 1/2 PHASE T1- T4 OR T8 - T11 X2

PMG
SUPPLY STATOR PMG 14 PMG

SUPPLY - AUXILLARY WINDING 10/YELLOW 11/RED

10A FUSE

50 HZ VOLTAGE WYE

T3 N1 E NOTE: IF 4 POLE BREAKER FITTED CHANGE N TO

T2 T3 N E

TO BREAKER BOX

415/240V 400/230V 380/220V 220/127V 600V

(T2 (T2 (T2 (T2 (T2

380) 380) 380) 220) 220)

50Hz EXCITATION CEILING ADJUST P5 UNDER SPEED ADJUST P4 STABILITY ADJUST P3

ST2

60Hz

9/GREEN
X2

X1

9/GREEN

X1 Z2

15 16

12/BLACK
Z1 X1 Z2

4 POLE BREAKER OPTIONAL (SEE NOTE REF.A01)

60 HZ VOLTAGE WYE 480/277V - (T2 380) 440/254V - (T2 380) 380/220V - (T2 380) 240/139V - (T2 220) 220/127V - (T2 220) 208/120V - (T2 220) 600V - (T2 220)

17

16
1
1

15
1

14

13

12

11

10

4
4 POLE BREAKER OPTIONAL

METERING C.T.S 1 T1 T2
P1 S1 P1 S1 P1 S1 P2 S2 P2 S2 P2 S2

L1 CT1 CT2 CT3 L2 L3

71 72 73 74 75 76 81 84 MOT1 MOT2

71 72 73 74 75 76 81 84 MOT1 MOT2

10

M
2.5 mm
2 2

6 mm

17

10

11

T3 N

31 25

11

12 13

N
12

2.5 mm

2.5 mm

CB1 (20A) 24

CB3 (15A) A+ :30

CB2 (60A) 6 mm 40 VOLTS ADJUST POTENTIOMETER (1K, 1 TURN) SPEED ADJUST POTENTIOMETER (1K ,10 TURN) :1 :3 :2 6 mm 2 80 :2 :3 :1 82
2

E
13

32

14

51

52

53

50

50

50 1 REF. G14

T1

T2

T3

101
14

33

+ 24V PS1 SMMS1/1 PS2 SMMS2/1

15

18 4

SR/1 :87

A B C D E F G H

98 97 96 95 94 93 92 91

15

20

16

J1-8 J1-7 J1-6 J1-5 J1-4 J1-3 J1-2 T11 J1-1 108 108 51 52 53 50 LINK T1 H23 F11 (2A) LINK T2 H21 F12 (2A) LINK T3 H22 F13 (2A) T13 101 101 2

(OPTIONAL) BATTERY ISOLATOR SWITCH KEY REMOVABLE

25

26

97 96 95 94

SM1

PS1

SM2

PS2

B+

ALT

CHARGING ALTERNATOR

IF REQUIRED 2 2 2
11

12

13

14

26

8 33

10

93 92 91

AC TRANSFORMER BOX (ATB)

1. IF THE FAULT SHUTDOWN INDICATOR IS FLASHING THEN THE LINK SHOULD BE TEMPORARILY FITTED. THE GSC SETPOINTS MUST BE PROGRAMMED IN OFF/RESET WHEN A FAULT SHUTDOWN IS ACTIVE. IF THE FAULT ALARM INDICATOR IS FLASHING THE GSC CAN BE PROGRAMMED WITH THE CONTROL SWITCH IN ANY POSITION.

16

21 29 23 30 24

57

27

58

28

29

110

110

31 54

46

T12

2 2

34

35

36

109

109

11

12

44 3 2

43 1

42

80

82

L983/WH L984/OR L985/YL A706/GY A705/BU A704/GN A703/BR A702/PU A701/GY F700/BU F701/BR E799/BR

P91/J91 12 D789/WH 10 D790/OR D791/YL 8 A706/GY 6 A705/BU 5 A704/GN 4 A703/BR 3 A702/PU 2 A701/GY 1 D786/BR 11 D787/GN 9 7 D788/BK

FUEL INJECTOR (128-8510)

SPEED CONTROL
S S-SPD D D-SPD +B -B

55

56

57

OFF/RESET 80 82 :6
30

10

CYL NO.6

CYL NO.5

CYL NO.4

CYL NO.3

CYL NO.2

CYL NO.1
1

AUTO START COOLDOWN/STOP CONTROL MODE SWITCH

:8 :9 :10
2

D+

30 31

32

5 :2 KWR :10
13 17 15 14

27

25

26

18

D20 19 21

RETARDER SOLENOIDS NOT USED

470 ohm POT ST4

P2/2
1
1 3

5
48

12 217
6

13 218 P Q
52 50

F723/PK F724/PU

P26/J26 1 F723/PK 2 F724/PU

R448
AVR

5 5

61
43

99
35

90
5

63

CCM+
51

CCM7

RDM

31

32

D-

D+
21 22

202 203 205 207 131 117 220 402 108 110 157 159

J K L M N O

202 203 205 207 131 117 220 402 108 110 157 159

SEE NOTE A

8 9 10 11 7 6

P89/J89 OR N940/BU A WH C967/BU C BK N941/YL B P20/J20 BK F724/PU 1 WH F723/PK 2 P44/J44 BK E965/BU 1 WH E966/YL 2 P21/J21 OR N940/BU A WH 995/BU C BK N941/YL B N940/BU A746/PK N941/YL J23/P23 OR A GN C YL B

+5V SIGNAL RETURN SIGNAL (-) SIGNAL (+)

INLET AIR TEMP SNSR (107-8618)

67

1 61 B+ RM 31 RM 35 RM 30 RM 33 RM 2 FCR F2 (10A) F6 (10A) F1 (10A) F3 (10A) CTR F4 (10A) F5 (10A) RM 1 RM 32 RM 34 RM 36 RM 23 34 KW

18

17

45

46

47

D+ CCM+ CCMRDM 19 + 20 -

D-

20

19

21

23 24

PRIM. SP/TMG SNSR (4P-7610)

99

90 35 ALARM

63 36 SPARE 17 18 SPARE SPARE

416

426

437 DD+
20

15

26

37

21 +

22 -

SIGNAL (-) SIGNAL (+)

BKUP SP/TMG SNSR (4P-7610)

POST

30 RDM

CCM DATALINK F7 (10A) RR

DATA LINK
19

+5V SIGNAL RETURN +5V SIGNAL RETURN +5V SIGNAL RETURN +5V SIGNAL RETURN +5V SIGNAL RETURN +5V SIGNAL RETURN

COOL. TEMP SNSR (102-2240)

GENERATOR SET CONTROL (GSC)

LOW OIL PRESSURE EMERGENCY STOP HIGH WATER TEMPERATURE ENGINE OVERSPEED OVERCRANK (SPARE 1) LOW COOLANT LEVEL HIGH OIL TEMPERATURE (SPARE 2) SPARE 3 FAULT SHUTDOWN FAULT ALARM

16 6 5 4 12 11 10 RM 22 RM 19

97 96 95 94 93 92 91
34 26 33 25

R S T U V W

14 15 3 5 16 17

RM 4
TURBO OUTLET PRESS. (194_6724)

RM 8 RR

RM 3 CTR

RM 6 SMR SMR

RM 12

RM 5

RM 7

RM 9

FCR
ATMOSPHERIC PRESS. (161-9926)

J27/P27 OR N940/BU A WH A747/GY C BK N941/YL B N940/BU 994/GY N941/YL J22/P22 OR A GN C YL B

GFR F10 (10A) ASR

SET OP6 SETPOINT SP17 TO 6 SET OP6 SETPOINT SP18 TO 7

ENG OIL PR SNSR (161-9926)

35 5 36

P43/J43 OR N940/BU A WH A751/YL C BK N941/YL B J49/P49 OR A N940/BU GN C A745/WH YL B N941/YL

FUEL TEMP SNSR (102-2240)

REF. L07

50 EGR AUX. ALARMS/SHUTDOWNS SWITCHED -VE POST BRM 18 14 RM 21 26A RM 39 10

43

37

37

37

10

CHASSIS
FUEL PRESSURE SNSR (194-6725)

E E E 2
2

DOOR BODY

GPHI RM 27
37

RM 15 13

RM 24 39

RM 17
39

RM 16 38

RM 13 41
38

RM 14 20

GPLO RM 38 28 30 17

+ 1 21 59

22

V-

31

V+

HET 7

LOP 8

LCL 13

6 23 SP1
5 40

37
7

24 SP2
41

25 SP3
42

29 SP4
42

39 55

40 56

33 57

32 58

P47/J47 COOLANT FLOW SWITCH 412/BU 1 (NOT USED) N944/PU 2

62

67

16

15

18

19

RENR8077-01 VOL 2

ABBREVIATION ALT ALTERNATOR CB CIRCUIT BREAKER DIG DIGITAL CIS CUSTOMER IGNITION SWITCH ECM ELECTRONIC CONTROL MODULE NC NO CONNECTION PWM PULSE WIDTH MODULATION SM STARTING MOTOR SMMS START MOTOR MAG SWITCH

15

11

23

24

38

42

PANEL LIGHT SWITCH

45

:3 :2
40 54 55 56 34 44 37 36 49 59 60 61 62 63

:1 SP4
19

EMER. STOP 11
8

SP1
16

SP2
17

SP3
18

21 9

22

:2 :3 :4 :5 30
6

OFF/RESET AUTO START COOLDOWN/STOP

:11 CR/3 :9

38

41

20

30

17

34

26A
25

46

45
6

10

CONTROL MODE SWITCH

P1/2
30

57

J3/P3

ECM
INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 INJECTOR 6 INJECTOR 5 INJECTOR 4 INJECTOR 3 INJECTOR 2 INJECTOR 1 TDC PROBE + TDC PROBE UNUSED UNUSED ANALOG SNSR POWER (+5V) UNUSED INLET AIR TEMP SNSR +V ENG SP/TMG COOLANT FLOW SW COMMON PRIM. SP/TMG SNSR FUEL PRESSURE SNSR TURBO OUTLET PRESS. ATMOSPHERIC PRESS. SNSR ENG OIL PRESS. SNSR FUEL TEMP SNSR INLET AIR TEMPERATURE SNSR SOLENOID COMMON ENGINE RETARDER (MED/HI) SOL ENGINE RETARDER (LO/HI) SOL COOLANT TEMPERATURE SNSR UNUSED UNUSED THROTTLE POSITON SNSR UNUSED UNUSED UNUSED COOLANT FLOW SW UNUSED UNUSED UNUSED UNUSED J2/P2 5 17 27 34 28 22 18 12 6 39 4 10 40 36 30 2 1 29 37 14 23 20 8 3 9 7 13 19 15 26 24 31 25 38 11 16 21 32 33 35 J1/P1 18 32 37 29 36 30 31 38 20 27 25 15 2 8 22 35 24 34 13 21 28 40 10 11 12 14 16 17 19 23 4 6 26 39 33 1 7 3 9 5

22

39

41

66

53

62

67

16

15

67

62

18

67

62

19

67

62
16

3
2 27 28 29 6 4 22 9 37 38

30

57

30 Page, B&W

10
L983/WH L984/OR L985/YL A706/GY A705/BU A704/GN A703/BR A702/PU A701/GY F723/PK F724/PU N940/BU N941/YL F714/PK N944/PU A745/WH A746/PK A747/GY 994/GY A751/YL C967/BU E799/BR F700/BU F701/BR 995/BU F704/OR F702/GN J3/P3
29 22

ASOR+ ASOR+

SD-PWR

SD-RTN

10

23A
4

PANEL LIGHTS

9 8 ES59 EF1 EF2

SD-PWR

52

12

5 7

SD-RTN D+ D-

53 7 8

E
30 2 2 30

41

40 28

41 45 45A ASOR+
35 36 37 51

:10 CR :2 SD-PWR
52

SD-RTN
53

10
8

23A
9

3 12
6 47

11
46

41
15

41
16

20
10

30
65

30
25

17
48

34
49

45
17

45A
18

46
50

10
7

8
27

ES28

59
59

21
31

22
32 33

62T
42

67T
43

16
14

15
13

67P
44

62P
45

18
20

67L
21

62L
19

19
23

67O
24

62O
22

EF1
61

EF2
62

D4

D+
3 5

39

412/BU J3/P3
10 12

NOT CONNECTED

21

22

NOT CONNECTED

18

67L

62L

19

67O

62O

EF1

EF2

S-SPD D-SPD 8 SEE NOTE A SEE NOTE B

56 54 55 56

BKUP SP/TMG SNSR UNUSED UNUSED DIGITAL SNSR RETURN ANALOG SNSR PWR (5V) ANALOG SNSR RETURN UNUSED UNUSED UNUSED UNUSED STARTING AID UNUSED GROUND LEVEL SHUTDOWN (NO) GROUND LEVEL SHUTDOWN (NC) UNUSED DIGITAL SNSR POWER (+8V) ENG. RTDR SEL. SW (LO/MED/HI) UNUSED ENG. RETARDER SEL. SW (HI) UNUSED UNUSED ETHER START VALVE RELAY UNUSED UNUSED BACKUP SPEED / TIMING SNSR (-) UNUSED UNUSED UNUSED ENG. RETARDER SEL. SW (MED) UNUSED +BAT. (UNSWITCHED)(NOTE B) +BAT. (SWITCHED) J1939 SHIELD UNUSED UNUSED ATA DATA LINK ATA DATA LINK + CAT DATA LINK CAT DATA LINK + -BAT.

E966/YL F725/WH 998/BR 997/OR 993/BR F703/GY F718/BU F706/PU F720/GN N942/OR F715/PU F716/WH F707/WH A700/OR F719/BR F709/BU F722/OR F705/PK F708/YL F710/BR 451/BR E965/BU F717/YL 450/YL F721/GY N943/BR 102/RD 150/OR A234/BK F712/GY F711/GN E793/BU E794/YL 892/BR 893/GN 229/BK

DIAGRAM-WIRING (EMCP II+)

21

38

235-0745
DIAGRAM-WIRING (ENGINE SCHEMATIC)
C
82

ES54 55 41 40

J3/P3
32

ATAATA+ APAP+ 20

30
4

30

46

11

12

46

34

FIT IF REQUIRED
64

80

82

78

80

234-3205
DIAGRAM-WIRING (ENGINE HARNESS)

31 15 14

39

10

7
10 23A 59

72

20
31

EF1 D+
D

EF2

145-3850
ST4 R448 AVR

SCR
8

24 65 22 64 23

32

D-

EMER. STOP ON ENCLOSURE

P+ ATAFP ATA+
30

REF B3

B
CDVR

19

ATA-

F703/GY

11

29

ATA+

MAGNETIC PICK UP No.1 AIR SHUT-OFF SOLENOID ASOS

1

COOLANT LOSS

OIL TEMPERATURE CORE BALANCE CURRENT TRANSFORMER IF REQUIRED

2 REF A11

10 REF B10

SERVICE CONNECTOR
20 20 P+ XT APAP+ FP REF B3 2 B 30 2 A C B A C

:86 SR :85

59 SASV 2
2

GROUND STUD

LOW FUEL LEVEL SWITCH

NOTE A: VOLTS ADJUST CONNECTION WHEN USING A R448 REGULATOR NOTE B: VOLTS ADJUST CONNECTION WHEN USING A CDVR REGULATOR

30

SMMS1 2

SMMS2

IF REQUIRED

FIT IF REQUIRED

VOLUME 2 3456 WITH EMCP II+

7 6 5 4 3 2 1

17

16

15

14

13

12

11

10