ABBREVIATIONS

RENR7916-01
August 2006 ASR AIR SHUT-OFF RELAY GSC GENERATOR SET CONTROL

ATB AC TRANSFORMER BOX HET HIGH ENGINE TEMPERATURE

HIGH
COOLANT
TEMP
CR CONTROL RELAY HOT HIGH OIL TEMPERATURE
LOW
COOLANT
1 8 1 8 1 8 :A
TEMP
:B CTR CRANK TERMINATION RELAY KW KILOWATT
2 9 2 9 2 9

SLR/1
LOW
OIL
:C
PRESSURE 3 10 3 10 3 10 T
:D LCL LOW COOLANT LEVEL
T
108 108 EGR ELECTRONIC GOVERNOR RELAY
LOW
FUEL
4 11 4 11 4 11 4 33 :E
T11
LEVEL
5 12 5 12 5 12 FCR FUEL CONTROL RELAY
LOP LOW OIL PRESSURE
:A
SYSTEM
NOT IN 6 13 6 13 6 13 :B
AUTO
POT POTENTIOMETER

SLR/2
7 14 7 14 7 14 :C GFR GENSET FAULT RELAY
LOW
BATTERY
U U
:D
VOLTAGE
110 110 SCR SCREEN
6 34 :E GPHI GROUND POST HIGH
T13

SMR STARTER MOTOR RELAY

GPLO GROUND POST LOW

F32

:4/:L1
157
35
V V
18
157
(2A)
154
42 SYMBOLS
F33
LAMP W W (2A)
159 159 156
TEST :6/:L3 36 19 43

:2
FUSE POTENTIOMETER
ALARM ALARM :3 :1
SILENCE + SILENCE +

- - 3406, 3406C & 3456 Generator Set EMERGENCY STOP PUSHBUTTON

11 CHASSIS CUSTOMER TERMINAL

with EMCP II :10

PANEL LAMP
11 CHASSIS DC TERMINAL

Electrical System
R RELAY COIL
:2 8 CHASSIS AC TERMINAL
(FRONT) (REAR) (FRONT) (REAR) (FRONT) (REAR)
TRANZORB
28 DOOR TERMINAL
NOTE ON SYNC MODULE:
3406 Gen Set: 3406C Gen Set: 3456 Gen Set: SR4B Generator:
FOR 208V SYSTEM 108 & 110 SHOULD BE CONNECTED TO RESISTOR PIN D
FOR 240V SYSTEM 108 &
FOR 300V SYSTEM 108 &
110
110
SHOULD
SHOULD
BE
BE
CONNECTED
CONNECTED
TO
TO
RESISTOR PIN C
RESISTOR PIN B
C8G1-UP C2G1-UP C1G1-UP L5A1-UP SCREEN CABLE
58
CHASSIS TO DOOR DC SOCKET
FOR 380V SYSTEM 108 & 110 SHOULD BE CONNECTED TO RESISTOR PIN B
FOR 400V SYSTEM 108 &
FOR 415V SYSTEM 108 &
FOR 480V SYSTEM 108 &
110
110
110
SHOULD
SHOULD
SHOULD
BE
BE
BE
CONNECTED
CONNECTED
CONNECTED
TO
TO
TO
RESISTOR PIN B
RESISTOR PIN A
RESISTOR PIN A
C5G1-UP C3G1-UP L6B1-UP :1
R/1 RELAY CONTACT N/O 30
FOR 600V SYSTEM 108 & 110 SHOULD BE CONNECTED TO SINGLE RESISTOR
C4G1-UP L7A1-UP :3 ENGINE SOCKET

C2T1-UP J
CHASSIS TO DOOR AC SOCKET
:3
TERM. No. CONNECTION DESCRIPTION TERM. No. CONNECTION DESCRIPTION TERM. No. CONNECTION DESCRIPTION
PANEL LAMP SWITCH
1 WIRE No. 10 (GSC RM39) & HORN +VE 1 WIRE No. 10 (GSC RM39) & HORN +VE 1 WIRE No. 10 (GSC RM39) :2
2 WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK 2 WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK 2 WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK
POWER TERMINAL
3 JUMPER TO 10 3 LED 5 SWITCHED -VE INPUT 3 LED 5 SWITCHED -VE INPUT
4 JUMPER TO 11 4 LED 6 SWITCHED -VE INPUT 4 LED 6 SWITCHED -VE INPUT
5 NOT CONNECTED 5 LED 7 SWITCHED -VE INPUT 5 LED 7 SWITCHED -VE INPUT EARTH
6 LED 8 SWITCHED -VE INPUT GSC 40 WAY HARNESS CONNECTOR
6 NOT CONNECTED 6 LED 8 SWITCHED -VE INPUT
7 WIRE No. 30 (GSC RM27) & SILENCE SWITCH 7 WIRE No. 30 (GSC RM27) & SILENCE SWITCH 7 WIRE No. 30 (GSC RM27)
8 LOW FUEL LEVEL SWITCHED -VE INPUT 8 LED 1 SWITCHED -VE INPUT 8 LED 1 SWITCHED -VE INPUT
9 NOT CONNECTED 9 LED 2 SWITCHED -VE INPUT 9 LED 2 SWITCHED -VE INPUT :1 :2 GSC RELAY MODULE TERMINAL
10 LED 7 (SPARE) 10 LED 3 SWITCHED -VE INPUT :3
10 LED 3 SWITCHED -VE INPUT ENGINE CONTROL SWITCH
11 LED 8 (SPARE) 11 LED 4 SWITCHED -VE INPUT 11 LED 4 SWITCHED -VE INPUT PWM MODULE :4
:5 ATB TERMINAL
12 LAMP TEST -VE INPUT (IF REQUIRED) 12 LAMP TEST 12 LAMP TEST -VE INPUT (IF REQUIRED)
13 SILENCE SWITCH 13 SILENCE SWITCH 13 TERMINAL No. 13 ON 1st ALARM MODULE (ALM MUTE)
14 HORN -VE 14 HORN -VE 14 TERMINAL No. 14 ON 1st ALARM MODULE (HORN ON)

CIRCUIT BREAKER
3 2 1

9X9857
- - 69
:14 :3 :14 :8 SPARE FAULT INPUT (LED 1) HORN ON :14 :14 :8 SPARE FAULT INPUT (LED 1)
HORN
+ :10
LINK HORN
+ :9 SPARE FAULT INPUT (LED 2) :9 SPARE FAULT INPUT (LED 2)
Volume 1
SPARE FAULT INPUT (LED 7) -B S D +B
10 :4 10 :10 SPARE FAULT INPUT (LED 3) 10 :10 SPARE FAULT INPUT (LED 3)
4 :1 + LINK 4 :1 + FIRST 4 :1 + 2006 Caterpillar Printed in U.S.A.
30 DC :11 30 DC :11 SPARE FAULT INPUT (LED 4) 30 DC :11 SPARE FAULT INPUT (LED 4)
6 :7 - SPARE FAULT INPUT (LED 8) 6 :7 - ALARM 6 :7 -
:3 SPARE SHUTDOWN INPUT (LED 5) MODULE :3 SPARE SHUTDOWN INPUT (LED 5) All Rights Reserved
72 :4 SPARE SHUTDOWN INPUT (LED 6) :4 SPARE SHUTDOWN INPUT (LED 6)
:8 10 LOW FUEL LEVEL
SILENCE SILENCE :5 :5
LAMP SPARE SHUTDOWN INPUT (LED 7) SPARE SHUTDOWN INPUT (LED 7)
SWITCH :13 SWITCH :13 68
TEST :6 SPARE SHUTDOWN INPUT (LED 8) ALARM MUTE :13 :13 :6 SPARE SHUTDOWN INPUT (LED 8)
ALARM 90 20 :12 90 ALARM 90 20
17 :2 :12 38 LAMP TEST :2 17 ALARM DATALINK 17 :2 :12 38 LAMP TEST
DATALINK (IF REQUIRED) DATALINK
(IF REQUIRED)

(T11)

EMCP II (T12)
WIRE TABLE
ATB CIRCUIT
TERMINAL COLOR

-B
14
NO.

13

27
T11 T11 BK

12

26
39
T12 T12 BK

11

25
38
(T13) T13 T13 BK

10

24
37
50 50 BK

23
36
9
61 61 BK

22
35
8
52 52 BK

34

21
7
53 53 BK
PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK

20
33
6
FUEL PUMPED FROM FREE STANDING BULK TANK GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK

19
32
5

RENR7916-01 VOL 1
TBC
FUEL SYSTEM No. 1

18
31
4
FUEL SYSTEM No. 3 FUEL SYSTEM No. 2

17
30
3

6
50

+B
51 51

61 ABBREVIATIONS
1 F23 1 F23
1
1 F23
1
GSC EMCP II
(2A) 84 DC CIRCUIT 1 (2A) DC CIRCUIT 52 IA - LINE A CURRENT
(2A) 84 DC CIRCUIT IB - LINE B CURRENT

LEVEL SWITCH LEVEL SWITCH 53 IC - LINE C CURRENT DISPLAY BOARD

(TOP VIEW) LEVEL SWITCH (TOP VIEW) VA - LINE A VOLTAGE W3-1
ALREADY KEYPAD SIG X7
FITTED AS ALREADY
(TOP VIEW) L1 L1
VB - LINE B VOLTAGE W3-2
KEYPAD SIG 36
STANDARD FITTED AS VC - LINE C VOLTAGE CPU BOARD KEYPAD PWR 1
W3-3
STANDARD EGC - ELECTRONIC GOVERNOR CONTROL W3-4
84 J2-1 J1-1
84
84
L3 L3 PP - PRE-LUBE PUMP +12V
J2-2 J1-2
+12V
KEYPAD SIG 1X
W3-5 KEYPAD
HI HI KEYPAD SIG 25
4 HIGGH- HIGGH- ASR - AIR SHUT-OFF RELAY GROUND GROUND W3-6
H HI H J2-3 J1-3 KEYPAD SIG X4
4 HIGGH-
16 H 80 80 CTR - CRANK TERMINATE RELAY SERIAL CLOCK
J2-4 J1-4
SERIAL CLOCK W3-7
16 KEYPAD PWR 2
FCR - FUEL CONTROL RELAY SERIAL DATA SERIAL DATA
SW4 CABLE SW4 CABLE J2-5 J1-5
GFR - GENSET FAULT RELAY KEYPAD PWR 1 KEYPAD PWR 1
SW4 CABLE 82 82 J1-1 J2-6 J1-6
SW3
PSR - PROGRAMMABLE SPARE RELAY MAG PU IN KEYPAD PWR 2 KEYPAD PWR 2
SW3 J1-2 J2-7 J1-7
84 SW2 ENTRY SW3
SW2 ENTRY RR - RUN RELAY MAG PU GND KEYPAD ROW 1 KEYPAD SIG 17
SW1 SW1 J2-8 J1-8
SW2 ENTRY J1-3

30 Page
PUMP 84 SMR - STARTING MOTOR RELAY KEYPAD ROW 2 KEYPAD SIG 36
SW1 H NC J2-9 J1-9
RUN HIG
H HIG J1-4
PUMP LOW PSR - PROGRAMMABLE SPARE RELAY IA IN LED BLANK LED BLANK
LOW HIG
H J2-10 J1-10
- RUN LOWW
- J1-5
LOWW LOW GEN - GENERATOR IB IN KEYPAD PWR 3 NC
LO - 84 LO J2-11 J1-11
LOWW J1-6
LO 21 I - CURRENT
J1-7
IC IN SERIAL STROBE
J2-12 J1-12
SERIAL STROBE LED BOARD
LOW TERMINAL BOX WATCHDOG LED WATCHDOG LED
15
TERMINAL BOX :3 :6
J1-8
COOLANT TEMP SNSR IN J2-13 J1-13
TERMINAL BOX LEVEL KEYPAD ROW 3 KEYPAD SIG 25 W1-1 W2-1
15 PR/1 PR/2 OIL PRESS. SNSR IN J2-14 J1-14 LED BLANK LED BLANK
FUEL J1-9 KEYPAD ROW 4 KEYPAD SIG X4 W1-2 W2-2
:1 :7 +V SNSR OUT J2-15 J1-15 WATCHDOG LED WATCHDOG LED
SWITCH J1-10 W1-3 W2-3
20 VA IN NC NC
J1-11 J2-16 J1-16 +5V +5V
ALREADY W1-4 W2-4
FITTED AS
LEVEL SWITCH ALREADY
HIGH 36
LEVEL SWITCH J1-12
VB IN +12V REG NC
+12V +12V
LEVEL SWITCH LEVEL 85 W1-5 W2-5
18
STANDARD (SIDE VIEW) FITTED AS (SIDE VIEW) J1-13
VC IN SERIAL CLOCK SERIAL CLOCK
FUEL W1-6 W2-6
18
(SIDE VIEW)
STANDARD
SWITCH
:2
MV 3-POLE
INTERNAL SCHEMATIC 8-PIN
J1-14
COOLANT LOSS IN
NC
SERIAL STROBE
LED DATA
W1-7 W2-7
SERIAL STROBE
SERIAL DATA
:1 MOT. FUSE BLOCK ATB TRANSFORMER EMCPII DEUTSCH
J1-15
J1-16
NC GROUND
W1-8 W2-8
GROUND
TERMINAL BOX TERMINAL BOX CONNECTOR
AC GND
VALVE J1-17
LOW
21
81
84
21
TERMINAL BOX 83
T1 T11
CHASIS GND
:3 T1 J1-1 J1-18
LEVEL LOW 81 35 VA NC
PR/1 :6 :3 H1 X1 J1-19
FUEL LEVEL CAT DATA LINK+
:1 PR/2 PR/1 J1-20

PRI
SWITCH 81 FUEL :2 CAT DATA LINK- +B
20 :7 :1 + J1-21
SWITCH 81 -VE SUPPLY
T2 T12 H2 X2 J1-2 NC
HIGH 20 PR VB J1-22 J3-1 J3-1
SW4 NORMALLY OPEN SW4 NORMALLY OPEN
- NC AC GND AC GND
LEVEL 36 HIGH
LEVEL
SW4 NORMALLY OPEN :10 J1-23
SPARE FAULT SW1 IN +12V
J3-2 J3-2
+12V RELAY BOARD
FUEL 85 T2 J1-24 J3-3 J3-3
SWITCH FUEL T3 T13 SPARE FAULT SW2 IN VB SEL VB SEL
SW3 NORMALLY CLOSED SW3 NORMALLY CLOSED H1 X1 J1-25 J3-4 J3-4
:2 SWITCH SW3 NORMALLY CLOSED 2 SPARE FAULT SW3 IN +12V +12V
2 J1-26 J3-5 J3-5 J1-1 1

PRI
MV NC VA SEL VA SEL +BAT. SW
J1-27 J3-6 J3-6 J1-2 2 29
H2 X2 J1-3 NC NC
83
SW2 NORMALLY CLOSED :1 MOT. SW2 NORMALLY CLOSED VC NC
J3-7 J3-7 +BAT. UNFUSED
J1-28 J1-3 3 30
VALVE 83 SW2 NORMALLY CLOSED NC VC SEL VC SEL CTR IN
35 -VE SUPPLY J1-29 J3-8 J3-8 J1-4 4 31
NC NC NC FCR IN
SW1 NORMALLY CLOSED 35 SW1 NORMALLY CLOSED J1-30 J3-9 J3-9 J1-5 5 32
NC EGC DRIVE EGC DRIVE ASR IN
SW1 NORMALLY CLOSED J1-31 J3-10 J3-10 J1-6 6 33
:2 SENSOR GND RR DRIVE RR DRIVE SMR IN
+ J1-32 J3-11 J3-11
:2 CTR DRIVE CTR DRIVE J1-7 7 34
PR + STOP SW IN
J3-12 J3-12 GFR IN
- J1-33 J1-8 8 35
:10 PR START/RUN SW IN ASR DRIVE ASR DRIVE RR2 IN
- J1-34 J3-13 J3-13 J1-9 9 36
:10 NC PSR DRIVE NC RR1 IN
J1-35 J3-14 J3-14 J1-10 10 37
ALM DATA OUT GFR DRIVE GFR DRIVE NC
HI T3 J1-4 J1-36 J3-15 J3-15 J1-11 11 38
2 IA SPARE DATA OUT SMR DRIVE SMR DRIVE NC
2 BK BR J1-37 J3-16 J3-16 J1-12 12 39
2 9-POLE NC FCR DRIVE FCR DRIVE
2 J3-17 J3-17 +BAT. FUSED OUT
TERMINAL J1-38 J1-13 13
+BAT. SW +BAT. SW

PRI
EMER STOP SW IN EGC IN
STRIP J1-39 J3-18 J3-18 J1-14 14
BK PU OFF/RESET SW IN +BAT. SW +BAT. SW EGC N/O OUT
J1-40 J3-19 J3-19
LEVEL SWITCH 50 50
AUTO. SW IN GROUND
J3-20 J3-20
GROUND FCR N/O OUT
J1-15
J1-16
15
16
GROUND GROUND
(TOP VIEW) HI T4 J1-5
IB
CTR N/O OUT
J1-17 17
51 51 RANGE CTR N/C OUT
AC CIRCUIT AC CIRCUIT
BK BR J1-18 18
SELECT SMR N/O OUT
J1-19 19

PRI
61 61 ASR N/O OUT
JUMPER
J1-20 20
BK PU NOTE A ASR N/C OUT
HI
52 52 J1-21 21
HIGGH- SMR N/C OUT
H J1-22 22
53 53 HI T5 J1-6
GFR N/O OUT
IC J2-1 J1-23 23
BK BR VA SEL RR1 N/C OUT
COPPER COPPER SW4 L1 L1 J2-2 J1-24 24
AC GND RR2 N/O OUT
BUSBAR BUSBAR
CABLE ENTRY J1-25 25

PRI
6 mm 2
6 mm 2 J2-3
45 45 VB SEL NC
132 132 SW3 L3 L3 BK PU J1-7 J2-4 J1-26 26
SW2 AC GND AC GND NC
J1-27 27
AC CIRCUIT F22
(2A)
F21
(6A) AC CIRCUIT F22
(2A)
F21
(6A)
SW1
HIG
H
80 80
J2-5
J2-6
VC SEL FLYBACK GND
-BAT.
J1-28 28
AC GND
LOW
- 82 82
LOWW J1-8 CHASSIS
LO
13 13 GND
207 207
M M T1 AND T2 ARE 30:1 POTENTIAL TRANSFO RMERS, NOTE A: THE RANGE SELECT JUMPER IS INSTALLED IN
T3, T4, AND T5 ARE 500:1 CURRENT TRA NSFORMERS ALL CONTROLS TO SELECT THE DEFAULT 0-700V
:13 :97 :13 :97 TERMINAL BOX INPUT RANGE. REMOVAL OF THE JUMPER SELECTS
AUX O/L AUX O/L -B
24 24 0-150V INPUT RANGE.
:14 :98 :14 :98
202 203 208 202 203 208
AC SUPPLY AC SUPPLY
10 11 10 11
CUSTOMER CUSTOMER
PUMP PUMP
J STOP 23 100V TO 250V J STOP 23 100V TO 250V NOTE:
IF NO ALARM MODULE FITTED THEN
205 205
RELAY WILL ACTIVATE ON SHUTDOWN ONLY.

K L K L 5
22 22 ALR/3
202 202 6
12 12 :8 :9
21 203 21 203
:2
205 205 :11
:9 :9 CONNECT TO ALARM MODULE SPARE ALR
17
PR/3 PR/3 72 72 :10 64 65 66
2

11 10
:11 :11 29 30 31
2.5 mm

mm

2
2.5

206 206
131 131 72 30
:95 6 mm 2 :95 6 mm 2 CONNECT TO ALARM MODULE SPARE REMOTE CONTACTS 10 1
46 46 26 3 FUSED DC 4
FOR GENERAL ALARM
NORMALLY OPEN SW4 77

CMS
O/L 131 O/L 131 77 POSITIVE
64 65 28 45 5
:96 :96 D+ 33 CLR
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO 31
CAT
204 ENTER DIRECTLY ONTO 204 ENTER DIRECTLY ONTO 23 SRV
30 DATA 14
6 mm 2 TERMINALS. 6 mm 2 TERMINALS. 72 30 7 LINK D-
2

:X1 :X1 :X1 :X1 32

204 208 211 131 204 208 211 131
2

PUMP PUMP
2 .5 mm

2 .5 mm

PUMP PUMP LOW :3 MODE/ :1 :3 :6 :4

TRIP/ A1 1 3 5 13 TRIP/
6 mm

A1 1 3 5 13
6 mm

RUN
STOP
RUN
STOP
NORMALLY CLOSED SW3 FUEL SCROLL
SWITCH
CLEAR
LEVEL 2 31 3 12 22 16 6 SWITCH
:X2 :X2 PC :X2 :X2 PC SWITCH 77 30 GRR/3 `SS' :2 :2 :5
`MCS'
8

2
:8 :9

HC1
HC0

HC2

HC3

HC4

HC5
A2 2 4 6 14 A2 2 4 6 14 2
FUEL 38
131 131 LEAK
131 131 CONNECT TO ALARM MODULE SPARE :11
SWITCH
NORMALLY CLOSED SW2 :2
2

O/L 1 3 5 97 95 O/L 1 3 5 97 95 72 17
72 56 57
11 GRR
2 .5 mm

2 .5 mm

10
87 88 89
:10 2
2 4 6 98 96 2 4 6 98 96 72 30 DC NEGATIVE 2 51 52 53 54 55
32 33 34
211 209 210 211 209 210 2
REMOTE CONTACTS HARNESS CODE 18
64 65 3
NORMALLY CLOSED SW1 FOR GENERATOR RUNNING
N N 17
SP2
23 24 23 24
72 30

LOW-LOW
2 .5 mm 2
2 .5 mm 2
2 .5 mm 2
2 .5 mm 2
FUEL
FUEL FUEL LEVEL
PUMP
M PUMP
M SWITCH
131 131
 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

4 POLE BREAKER OPTIONAL

METERING C.T.S
1
T1 L1 71 71
P1 P2 9 10
S1 S2 CT1 17
T2 L2 72 72 M
M P1 P2
10 11
G S1 S2 CT2
VOLTS ADJUST T3 P1 P2 L3 31
73 73
POTENTIOMETER :2 11 12
(1KW, 1 TURN) S1 S2 CT3
:3 :1 N N 25
80 82 74 74
12 13
E E
32
75 75
13 14

51 52 53 50 50 50 T1 T2 T3 101 33
76 76
14 15

1 REF.
18
F14 81 81
A 15 20
98 98
8 9 10 16 J1-8
L 1. IF THE FAULT SHUTDOWN INDICATOR IS 84
4
84 L
97
B
97
FLASHING THEN THE LINK SHOULD BE 16 21
J1-7 51 52 53 50 LINK LINK LINK
TEMPORARILY FITTED. THE GSC SETPOINTS 57 29
C MUST BE PROGRAMMED IN OFF/RESET WHEN MOT1 MOT1
96 96 27 23
J1-6 A FAULT SHUTDOWN IS ACTIVE. IF THE
T1 T2 T3
80 82 D FAULT ALARM INDICATOR IS FLASHING THE 58 30
95 95 H23 H21 H22 MOT2 MOT2
J1-5 101 101
GSC CAN BE PROGRAMMED WITH THE CONTROL 28 24
F11 F12 F13 2 SWITCH IN ANY POSITION.
E (2A) (2A) (2A) 63

55
94 94
J1-4 AC TRANSFORMER BOX T13
110 110
SP4
19

93
F
93
J1-3
(ATB) 5 42
26A
T12 25
56
G 109 109
92 92 4 26
J1-2 70A
57 26
H T11
91 91 108 108
K J1-1 3 K
7
RDM
18
30 31 32
80 82 50
CCM+
35 25
S-SPD
51
CCM-
NOT 36 26
CONNECTED D-SPD
52
37
SCR
27
OFF/RESET
AUTO :8 29
D+ 31
START :9 9
:6 COOLDOWN/STOP :10 46
54
J CONTROL 2
27 25 26 18 11 J
MODE SWITCH D-
64 39
ATA+ ATA+
P2/2 48
5 20 19 21 29 22

13 17 15 14 65 40
31 32 ATA- ATA-
1 5 61 99 90 63 CCM+ CCM- RDM D- D+ 30 23
1 3
43 35 5 6 52 50 51 7 41
SEE NOTE A 5 SCR
24

J
202 202
21 8
20 19 21
67 18 17 8 D+ D-
1 1 K
203 203
61 99 90 63 22 9
CCM+ CCM- RDM
L
I D- D+ 23
205 205 I
RM RM RM RM RM RM RM RM RM RM 10
B+ 34 35 36 21 22 30 19 20
470 ohm 31 35 30 33 2 1 32 34 36 23 M
POST FCR KW ALARM SPARE + - RDM + - 207 207
POT 24 11
CCM DATALINK DATA LINK
ST4 98 N
F2 F6 F1 F3 CTR F4 F5 F7 131 131
R448 (10A) (10A) (10A) (10A) (10A) (10A) (10A)
RR
GENERATOR SET CONTROL (GSC)
17
16
97
20 7
O
AVR LOW OIL PRESSURE 6
96 117 117
19 6
RM RM RM RM RM RM RM RM EMERGENCY STOP 95
4 8 3 6 12 5
5 7 9 HIGH WATER TEMPERATURE R
94 220 220
ENGINE OVERSPEED 4 25 14
93
FCR RR CTR SMR SMR LOW COOLANT LEVEL 12 S
92 402 402
OVERCRANK 11 26 15
1 GFR FAULT SHUTDOWN 91 T
F10 10 108 108
H FAULT ALARM 33 3 H
(10A)
1 RM
1 1 ASR 22 2 U
6 6 6 110 110
5 34 5
2
1 1 RM V
19 3 157 157
37 37 35 16
37
10
EGR W
AUX. ALARMS/SHUTDOWNS 159 159
36 17
SWITCHED -VE
GPHI GPLO
POST 6 37
RM RM RM RM RM RM RM RM RM RM RM + - V- V+ HET LOP LCL
6 mm 2 38 B- 1 2 31 9 7 8 13 23 24 25 39 40 33 32
27 15 24 17 16 13 14 28 18 21 39
3 7
2 13 39 38 41 20 30 21 22 SP1 SP2 SP3
17 14 10 55 56 57 58
2.5 mm 2 2 37 39 38 4 43 5 40 41 42
G 59 62 67 16 15 18 19 G
2

CB2 F14 CB1

2.5 mm

2.5 mm

PANEL :3
(20A) (10A) (60A)
RENR7916-01 VOL 1

LIGHT
29 SWITCH :1 :2 OFF/RESET
:30 15 11 23 24 38 :2 40 54 55 56 34 44 37 36 49 59
24 6 mm 2 60 61 62
1FCR/1 SP1 SP2 SP3 :3 AUTO
EMER. 45
2 21 22 :4 START
:87 STOP 16 17 18 7
+ 28 40 :5 COOLDOWN/STOP
:30
11 38 41 20 30 17 34 46 45 10 9 CONTROL MODE
PS1 SMMS1/1 PS2 SMMS2/1 2FCR/1
24V :11 SWITCH
:87 8 6 30 57
CR/3
- 25 26 27 :9 6
P1/2
(OPTIONAL) CHARGING
SM1 PS1 SM2 PS2 FCS ALT
ALTERNATOR
BATTERY 62 67 16 15 67 62 18 67 62 19 67 62
F ISOLATOR 22 39 41 66 53 F
16 30
SWITCH 30
3 57
KEY 6 mm 2 27 28 29 5 6 4 22 9 37 38
REMOVABLE REF. 50
10 9 PANEL 9
L07
LIGHTS EF1 EF2
ASOR+ SD-PWR SD-RTN 23A 23A 8 ES- 59
3
E
CHASSIS 4
30 Page

E 12
DOOR
E
BODY
7 8
2 2
E E
11
2 2 30
30
12
2 2 2 2

:10 1 2 3
CR
:2
3
ASOR+ SD-PWR SD-RTN 23A 23A 12 11 41 41 20 30 30 17 34 46 45A 45 10 8 ES- 59 21 22 62T 67T 16 15 67P 62P 18 67L 62L 19 67O 62O EF1 EF2 D- D+
51 52 53 8 9 6 47 46 15 16 10 65 25 48 49 50 18 17 7 27 28 59 31 32 33 42 43 14 13 44 45 20 21 19 23 24 22 61 62 4 3 5

D 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

2 30

IF REQUIRED FIT IF REQUIRED

59 64

C 30 30 46 11 12 46 34 3 59 72
C

1 3 5 7

EMER.
STOP
ON 62 67T 16 15 67P 62 EF1 EF2
ENCLOSURE 1 2 B A C C A B C A B C A B

B B
2 4 6 8
59
DIAGRAM-WIRING
SASV (EMCP II)
MAGNETIC
235-0744
COOLANT OIL
PICK UP No.1 TEMPERATURE PRESSURE COOLANT OIL
LOSS TEMPERATURE
4 CORE BALANCE
IF REQUIRED IF REQUIRED
3 60 CURRENT TRANSFORMER DIAGRAM-WIRING
IF REQUIRED
(ENGINE SCHEMATIC)
LOW

236-5745
:86 :86 FUEL
SMMS1 SMMS2 1FCR 2FCR SATS LEVEL
:85 :85 SWITCH

30
A A
2

2 IF REQUIRED
FIT IF REQUIRED
VOLUME 1
IF REQUIRED
3406 WITH EMCP II
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
 DC NEG.

DC POS.
202 201 201 202

NOTE: IF 4 POLE BREAKER FITTED

RENR7916-01
CHANGE N T0 202
4 POLE BREAKER OPTIONAL 4 POLE BREAKER OPTIONAL
August 2006
(SEE NOTE REF.A02) (SEE NOTE REF.A02) 2 39
T1 T1
2 38
T2 T2 T1 L1 T1 L1
G
T3 T3 POWER T2 L2 T2 L2
WIRING TO 204
BREAKER
N N POWER
WIRING FROM
T3 L3 POWER
WIRING FROM
T3 L3
:5 :2
GENERATOR GENERATOR
E E N N N N 6A FUSE

406 E E E E
E 3RD PHASE, FOR 480V USE TRANSFORMER 205
F42 117 117 POWER SUPPLY
(6A) B REFER TO BREAKER
4 REF. DRAWING
111B 407 BBB 2 :C1 2 :C11
2 2
24V DC 24V DC
O S ST SHUNT ST SHUNT
IF REQUIRED 6 6
5 TRIP 5 TRIP
:C2 :C12 :6 :4 :3 :1 NOTE:A 205 201 NOTE:B
117 :1 :4 402 402 OPEN SIGNAL
REFER TO BREAKER DRAWING
111A 107
GCR/1
B REFER TO BREAKER
BREAKER DRAWING 233 :14 231 :11 :12 Q/1 SPEED
REMOTE TERMS REMOTE TERMS
NOTE: ADD FUSE F41, FOR BREAKER
B
231 :12 FOR BREAKER
B
233 :13 :14 Q/2 LOWER/RAISE
157 N 158 410
REMOVE LINK AND
CONNECT WIRE 111A
F41
LINK
107
:6 :5
:5 OPEN & CLOSED B OPEN & CLOSED B
SWITCH MOT1 MOT2
(6A) CR/2 POSITIONS 232 :11 POSITIONS 232
TO 3RD PHASE IF ALR/2 B B
B B B B BREAKER BREAKER 205
VOLTAGE IS 240V L-L :6
AUXILIARY AUXILIARY
NOTE: 27 28
CLOSE SIGNAL
NEUTRAL, REFER TO 111
B
117 :1 :3 159A :1
UVT/1
:3 159 159
B REFER TO BREAKER
IF CONTROL PANEL IS SGCP THEN
SWITCH IS MOUNTED REMOTELY. MOT1 MOT2 6A FUSE
157 N 158 410 BREAKER DRAWING BCR/1 DRAWING

ABB MCCB ABB ACB

111 107 57 58
206
F40 117 178A 178A UV COIL SUPPLY

(6A)
B REFER TO BREAKER
DRAWING 4 POLE BREAKER OPTIONS MOT1 MOT2
203
:2 23 24

MOT1 MOT2
~
UVT
:10

F31 F32
203 201 201 203

3406, 3406C & 3456 Generator Set

(2A) (2A)
111 111
:8 SPARE 157 N 158 411 412 22 4 6
3456 3406C
NOTE A: CONNECT TO POSITIVE ON STARTER MOTOR

with EMCP II
:9 SPARE 27 1 7 GENERATOR NOTE B: CONNECT TO NEGATIVE ON STARTER MOTOR OR BATTERY ISOLATOR

SYNCHRONISING M
CANOPY LIGHTING
58

:10
3456 10
MOTOR

Electrical System
SPARE
:30
BUS LINK ES- 8
EPIR/1
1

TRANSFORMER B1 B2
28
:87
:11 SPARE
BOX B21 B22 ASOR+
F27 (16A)

(BTB+) F36
(2A)
F37
(2A) :1 MAN
23

:3 :2 AUTO
SPARE

J1-1 J1-2 J1-3 J1-4 B11 B12

ETHER
:86
EPIR
59
ASOR/1
:30
3406 Gen Set: 3406C Gen Set: 3456 Gen Set: SR4B Generator: UNIT INJECTOR (P91)
INLET AIR TEMPERATURE TDC PROBE CONN (J26)
217 218 98 START :87
:85 59 TURBO OUTLET PRESSURE SENSOR (P89)
:4 SPARE
17 2
2 SWITCH
1 :86 AIR
37
C8G1-UP C2G1-UP C1G1-UP L5A1-UP SENSOR (J23) (YELLOW SLEEVE)
ASOR SHUT-OFF
99 99
:5 SPARE
98 3
2
SASV
:85 RELAY 23A (OPTIONAL)
FLAP
VALVE
C5G1-UP C3G1-UP L6B1-UP BACKUP SPEED/TIMING
SENSOR (P44)
REF. BREAKER BREAKER REF. 2
GROUND
16 411 412 AAA OPEN
LAMP
CLOSED
LAMP
CCC
2
FV
C4G1-UP L7A1-UP
:6 SPARE 2
3 5
31 TDC PROBE
C2T1-UP
WHITE
RED

GREEN

BLACK
BROWN

6 6
CONN (P26)
2
30 10 26
2
19
-VE SUPPLY ECM CONN (P2)
SASV - START AID SOLENOID VALVE -VE SUPPLY
:2 146 SP4
BCR NOTE
:10 PT PRIMARY WIRE COLOURS 29 35 46
ALARM - WHITE = 240V AC 3 :2 PRIMARY SPEED/TIMING
:13 SILENCE :13
26
- GREEN
- BROWN
= 380V AC
= 480V AC 31 C 54
3406C ETHER
START
13
37 SENSOR (P20)
SECONDARY SWITCH :1
BLACK/WHITE

:14 - RED = 600V AC

:12
- BLACK = COMMON
120V AC L-L :5 :11
AIR SHUT-OFF OPTIONS
ORANGE

220 BKRR/1 BKRR/3 COOLANT TEMP

9 11
:2 :9 :3 3 25 :13 40
59
90 9 44 SENSOR (P21)
R 6 26A BKRR
:4
- + REF.
30 :9
:14
BKKR/4 BUSR/1 54
AAA 414 415 :2 :2 COOLANT FLOW
:12 :1
REF. BREAKER :13 ALR GCR SWITCH (P47)
:14 :1 :7 BBB OPEN
~
BUSR :10 :10 59
219 :14
OIL PRESSURE
24 29 30 145 144
10 30 2 2 B B
59 SENSOR (J22)
37 38 8 41 40 3
ENGINE RIGHT SIDE
3
ACT+ 1 4
90 10 30 BREAKER AUXILIARY/1 3
ACTUATOR 2
17 4 6 REF. A03 BREAKER DRAWING ACT- 2 3
REF. BREAKER SASV 4 FUEL TEMP
CCC CLOSE
MPU- SENSOR (P43)
5 13
43 :2 (BLACK SLEEVE)
MPU+ 7 35 ECM CONN (P1)
6 :1 :3
217 218
60 14
42
14 15
SATS
8 36 ATM PRESSURE ENGINE LEFT SIDE
9 SPEED ADJUST SENSOR (J27)
30 30 219 221 1 2
LINK POTENTIOMETER

Volume 2 3456 ENGINE COMPONENT LOCATIONS

10 (2K W, 10 TURN)
WOODWARD
:4 :5 :8 :10 :14 :13 :15 11 ELECTRONIC
SYNCHRONISE 2 12
LINK FUEL
MAGNETIC GOVERNOR
SWITCH -VE SUPPLY SASV - START AID SOLENOID VALVE PICK UP No.2 (ISOCHRONOUS) 2006 Caterpillar Printed in U.S.A.
:1 :6 :11
SATS - START AID TEMPERATURE SWITCH
416 426 437 All Rights Reserved
46 47 48 START AID OPTIONS GOVERNOR OPTION

EARTH FAULT RELAY OPTION

NEUTRAL EARTH LINK

ALTERNATOR TERMINAL BOX ALTERNATOR TERMINAL BOX
T1 AREP SHUNT PMG
T1 T1
TABLE: 1 SUPPLY - AUXILLARY WINDING SUPPLY 140V MAX 50/60HZ SUPPLY STATOR PMG
NOTE:A
T2 T2 50 HZ VOLTAGE WYE ST3 14
CORE 10/YELLOW 10/YELLOW
G G X2 X2
BALANCE TO 415/240V - (T2 380) 1/2 PHASE
T3 T3 C.T.
BREAKER 11/RED
400/230V - (T2 380) T1- T4 OR
T2 BOX J3 PMG
N1 N1 380/220V - (T2 380) 9/GREEN 9/GREEN T8 - T11 15
T3 50Hz 60Hz 10A FUSE X1 X1
N 220/127V - (T2 220) X2
E E 600V - (T2 220) 12/BLACK 16
E EXCITATION CEILING ADJUST Z2
Z1
NOTE: IF 4 POLE BREAKER FITTED P5
BT1 CHANGE N TO
4 POLE BREAKER OPTIONAL
X1
BT1 BT2 BT3 UNDER SPEED ADJUST
(SEE NOTE REF.A01) 60 HZ VOLTAGE WYE P4
RTD CORE BALANCE Z2
RTD RTD RTD PT100 CURRENT TRANSFORMER 480/277V - (T2 380) ST2
PT100 PT100 PT100 440/254V - (T2 380) STABILITY ADJUST 5

RENR7916-01 VOL 2
T1 L1 E+
380/220V - (T2 380) P3 CONNECTION
WHITE

240/139V - (T2 220) 6 _ + TO EXCITER

T2 L2
R448
WHITE

WHITE

WHITE

RED

E-
220/127V - (T2 220)
RED

RED

RED

G 208/120V - (T2 220) ST6

163 164 T3 L3 VOLTAGE ADJUST 0
3 3 600V - (T2 220) P2 NOTE:D
+ N N
3 110
24V + NOTE:G
2 24V NOTE:A
- E E ST9 220 3 W OPTIONAL RFI KIT CONNECTIONS
2 50/60 Hz SELECTION ALTERNATOR
- ST1
NOTE: NOTE: NOTE:B NOTE:E NOTE:C 2 WINDING
WIRE DIRECTLY ONTO NOTE:F 380 V
171 172 181 182 191 192 WIRE DIRECTLY ONTO
163 164 3 2 REMOVE LINK FOR REMOTE VOLTAGE ADJUSTMENT POTENTIOMETER OR FOR 3 PHASE SENSING. CONNECTIONS
RELAY TERMINALS. RELAY TERMINALS. POT T1 BLACK
3 2 3 2 3 2 NOTE:C W
P S Q R D E 3ph 470ohm S1 S2 J1
37 38 REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448 U ALTERNATOR
P S Q R D E P S Q R D E P S Q R D E + - + - THERMOCOUPLE NOTE:D J2 WINDING
+ - + - + - + - + - + - RELAY
ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK - . 7000 FRAME SIZE REQUIRES SPILT LINK - - BLACK
2 1 3 6 5 7 EF1 EF2
RFI UNIT V
NOTE:E CONNECTIONS
2 1 3 6 5 7 2 1 3 6 5 7 2 1 3 6 5 7 P1 N
71 76 CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL ST9 - AREP AND SHUNT - FULL LINK - . PMG SPLIT LINK - -
74 75 74 75 74 75 10 k l 22 21 24 12 ST4 QUADRATURE DROOP ADJUST BLACK
6 A1 NOTE:F U
30 30 30 11 30 ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT - - NOTE:B
30 30 30 30 30 30 8 30 `EFU' 8
8 8 A2
14 73
31
73 73 NOTE:G BLUE
BENDER 12 N
11 FIT 5VA TRANSFORMER FOR 600V OPERATION
EARTH FAULT RELAY
32
CONNECT TO ALARM MODULE SPARE CONNECT TO ALARM MODULE SPARE NOTE:H
33
75 75 75 75 75 76 76 76 76 OPTION TI04 FOR PARALLEL OPERATION.
14 13 15 14
U
P2
SP2 S2
17

30 Page
S1 TI04 NOTE:H
SP1 SP1
16 16 P1
CONNECT TO ALARM MODULE SPARE CONNECT TO ALARM MODULE SPARE
74 74 74
13
74
25
74
12 71 71
10
71
1

9
71
U
T1 U T7
N
DIAGRAM - WIRING (R448)
T1

T4

T7
T10
T2
T4
T10
N T11 T5
V N
T5

T12
T0 T8 T2
T8
V
T12 T0
T11
T6

T9
T6

THERMOCOUPLE RELAY OPTIONS T9

T3
W W T3
AREP SHUNT PMG
SUPPLY - AUXILLARY WINDING SUPPLY 140V MAX 50/60HZ SUPPLY STATOR PMG
SERIES STAR CONNECTION DIAGRAM PARALLEL STAR CONNECTION DIAGRAM NOTE:A
(HIGH VOLTAGE WYE) (LOW VOLTAGE WYE) ST3 10/YELLOW 10/YELLOW 14
X2 X2
1/2 PHASE
11/RED
T1- T4 OR
J3 PMG
9/GREEN 9/GREEN T8 - T11 15
50Hz 60Hz 10A FUSE X1 X1
X2
W (L3) W (L3) 12/BLACK 16
EXCITATION CEILING ADJUST Z2
T12 T6 T9 T12 T6 T9 Z1
T3 T3 P5
LINK LINK
V (L2) CUSTOMER V (L2) CUSTOMER X1
T11 T5 T8 T11 T5 T8
UNDER SPEED ADJUST
LOAD LOAD
HEATER OPTIONS LINK
T2
CONNECTIONS
LINK
T2
CONNECTIONS
P4
ST2 Z2
U (L1) U (L1) STABILITY ADJUST 5
T10 T4 T7 T10 T4 T7 P3 E+
T1 T1 CONNECTION
_ TO EXCITER
6 +
N N R448 E-
ST6 NOTE:B
VOLTAGE ADJUST 0
P2 NOTE:D
GENERATOR LEADS 110
NOTE:C 3
W
ST9 220 OPTIONAL RFI KIT CONNECTIONS
ALTERNATOR
ST1
NOTE:E 2 WINDING
NOTE:F 380 V
CONNECTIONS
NOTE:A NOTE:A POT T1 BLACK
W
IF 120V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 25A IF 120V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 25A 3ph 470ohm S1 S2 J1 1
IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A U ALTERNATOR
IF 120V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 15A IF 120V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 16A J2 WINDING
BLACK
IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A 4 RFI UNIT V
CONNECTIONS
P1 N
COPPER BUSBAR 6 mm 2
132 COPPER BUSBAR 6 mm 2
132 COPPER BUSBAR 6 mm 2
132 ST4 QUADRATURE DROOP ADJUST BLACK
45 45 45 U
CUSTOMER CUSTOMER CUSTOMER _ U
100V TO 250V 100V TO 250V 100V TO 250V P2 BLUE
F16 F17 F18 F19 F16 F17 F16 F18 F19
S2 N
(2A) (6A) (4A) NOTE:A AC SUPPLY (2A) (6A) AC SUPPLY (2A) (4A) NOTE:A AC SUPPLY
6 mm 2
131 6 mm 2
131 6 mm 2
131 +
46 46 46 S1 TI04 NOTE:H
136 131 135 141 134 136 131 135 136 131 141 134
STATISME P1
NOTE:G P2
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO N
ENTER DIRECTLY ONTO ENTER DIRECTLY ONTO ENTER DIRECTLY ONTO
6 mm 2 TERMINALS. 6 mm 2 TERMINALS. 6 mm 2 TERMINALS.
S2 S1

136 136 136 470ohm _ +

NOTE:I
POT

:4 :4 :4
TENSION
P1
CR/1
:1
CR/1
:1
CR/1
:1 R731 DIAGRAM - WIRING (R448 & R731)
137 131 135 141 134 137 131 135 137 131 141 134
U V W
2

2
2

2
2

2
2 .5 mm

2 .5 mm

400

110

230

400

230
230

400

110

110

N
6 mm

6 mm

6 mm
6 mm

6 mm

4
3
NOTE:A 2
137 131 135 141 134 137 131 135 137 131 141 134
50/60 Hz SELECTION
1 TABLE: 1 TABLE: 2
:A1 :1 :3 :5 :A1 :1 :A1 :3 :5 NOTE:B
HC HC HC REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448 50 HZ VOLTAGE WYE 50 HZ VOLTAGE WYE
:A2 :2 :4 :6 :A2 :2 :A2 :4 :6 NOTE:C
415/240V - (T2 380) 415/240V - (T1,T2&T3 380)
131 131 140 142 139 131 131 140 131 131 142 139 REFERENCE TABLE 2 FOR CONNECTION BETWEEN ALTERNATOR AND R731
NOTE:D 400/230V - (T2 380) 400/230V - (T1,T2&T3 380)
20 19 20 19
ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK - . 7000 FRAME SIZE REQUIRES SPILT LINK - - . 380/220V - (T2 380) 380/220V - (T1,T2&T3 380)
NOTE:E 220/127V - (T2 220) 220/127V - (T1,T2&T3 220)
ST9 - AREP AND SHUNT - FULL LINK - . PMG SPLIT LINK - - . 600V - (T2 220) 600V - (T1,T2&T3 220)
NOTE:F
ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT . 60 HZ VOLTAGE WYE 60 HZ VOLTAGE WYE
ALTER- ENGINE ALTER- ENGINE
NOTE:G 480/277V - (T2 380) 480/277V - (T1,T2&T3 380)
CONSTANT NATOR JACKET CONSTANT NATOR JACKET
HEATER WATER HEATER WATER
REMOVE FOR OPTIONAL VOLTAGE ADJUST POT. 440/254V - (T2 380) 440/254V - (T1,T2&T3 380)
VOLTAGE CHARGER VOLTAGE CHARGER
HEATER HEATER NOTE:H 380/220V - (T2 380) 380/220V - (T1,T2&T3 380)
F15
2

F15
2

1 36 140 1 36 140 OPTION TI04 FOR PARALLEL OPERATION. WITHOUT 3 PHASE SENSING CONNECT TO S1 AND S2 ON R448 ONLY. STANDARD POSITION ON PHASE U.
+ 1 + 1
2

+ + 240/139V - (T2 220) 240/139V - (T1,T2&T3 220)

2 .5 mm

2 .5 mm

(*) (*) 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).
6 mm

6 mm

24V DC 220/127V - (T2 220) 220/127V - (T1,T2&T3 220)

SUPPLY
131 131 131 NOTE:I
2 2 -
131 131
9 9 2 2 -
131 131 131
9 9 208/120V - (T2 220) 208/120V - (T1,T2&T3 220)
- 3 - 3 FIT 2 x 5VA TRANSFORMERS FOR 600V OPERATION
600V - (T2 220) 600V - (T1,T2&T3 220)

* FOR 5A CHARGER FIT (6A) FUSE * FOR 5A CHARGER FIT (6A) FUSE
FOR 10A CHARGER FIT (10A) FUSE FOR 10A CHARGER FIT (10A) FUSE
 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

4 POLE BREAKER OPTIONAL

1
1 1
METERING C.T.S
1
2 T1 L1 71 71
P1 P2 9 10
1 1
S1 S2 CT1 17
T2 L2 72 72 M
M P1 P2
10 11
6 mm 2
G S1 S2 CT2
T3 P1 P2 L3 31
73 73
11 12
2.5 mm 2 S1 S2 CT3
N N 25
74 74
12 13

2
CB1 CB3 CB2 E E

2.5 mm

2.5 mm
32
(20A) (15A) (60A) 75 75
13 14

24 6 mm 2 51 52 53 50 50 50 T1 T2 T3 101 33
A+ 76 76
14 15
+ 40 1 REF.
18
:30 VOLTS ADJUST G14 81 81
A 15 20
PS1 SMMS1/1 PS2 SMMS2/1 SR/1 POTENTIOMETER 98
24V 16 J1-8
L :87 (1K, 1 TURN) 1. IF THE FAULT SHUTDOWN INDICATOR IS 84
4
84 L
97
B
97
FLASHING THEN THE LINK SHOULD BE 16 21
- 25 26 SPEED ADJUST
POTENTIOMETER
:2 J1-7 51 52 53 50 LINK LINK LINK
TEMPORARILY FITTED. THE GSC SETPOINTS 57 29
(OPTIONAL) CHARGING (1K ,10 TURN) :3 :1 C MUST BE PROGRAMMED IN OFF/RESET WHEN MOT1 MOT1
SM1 PS1 SM2 PS2 B+ ALT
ALTERNATOR 80 82
96 96
J1-6 A FAULT SHUTDOWN IS ACTIVE. IF THE
27 23
BATTERY :1 :3 T1 T2 T3
ISOLATOR D FAULT ALARM INDICATOR IS FLASHING THE 58 30
95 95 H23 H21 H22 MOT2 MOT2
SWITCH
:2
J1-5 101 101
GSC CAN BE PROGRAMMED WITH THE CONTROL 28 24
F11 F12 F13 2 SWITCH IN ANY POSITION.
KEY 6 mm 2 E (2A) (2A) (2A)
REMOVABLE 94 94
J1-4 AC TRANSFORMER BOX T13
110 110
29
31
9

IF REQUIRED 12 13 14 26 8 9 10 93
F
93
J1-3
(ATB) 5
46
54
T12 11
G 109 109
92 92 4
11 34 35 36 33 J1-2
2 2
2 2 H T11
91 91 108 108
K J1-1 3 K
12 80 82
2 2 44 43 42

3 2 1

P91/J91
L983/WH 12 D789/WH FUEL INJECTOR 55 56 57
L984/OR 10 D790/OR (128-8510)
L985/YL 8 D791/YL SPEED CONTROL
A706/GY 6 A706/GY
A705/BU 5 A705/BU
A704/GN 4 A704/GN
A703/BR 3 A703/BR S D +B -B OFF/RESET
A702/PU 2 A702/PU 80 82 AUTO :8
A701/GY 1 A701/GY D+

S-SPD

D-SPD
F700/BU 11 D786/BR 10 30 START :9
F701/BR 9 D787/GN :6 COOLDOWN/STOP :10
E799/BR 7 D788/BK CYL CYL CYL CYL CYL CYL
J NO.6 NO.5 NO.4 NO.3 NO.2 NO.1 CONTROL 2
27 25 26 18 J
30 31 32 MODE SWITCH D-

RETARDER SOLENOIDS
NOT USED
1
470 ohm P2/2 48
5 20 19 21

POT 13 17 15 14
31 32
ST4 1
1 3
5 61 99 90 63 CCM+ CCM- RDM D- D+ J
F723/PK
P26/J26
1 F723/PK R448 SEE NOTE A 5
43 35 5 6 52 50 51 7 21
202 202
8
F724/PU 2 F724/PU K
P89/J89 AVR 203 203
N940/BU A OR +5V 22 9
INLET AIR TEMP SNSR
C967/BU C WH SIGNAL
(107-8618) L
N941/YL B BK RETURN 67 20 19 21 205 205
1 18 17 8 D+ D- 23 10
P20/J20 1
F724/PU 1 BK SIGNAL (-) 61 99 90 63 M
PRIM. SP/TMG SNSR CCM+ CCM- RDM 207 207
F723/PK 2 WH SIGNAL (+) 24 11
I (4P-7610)
RM RM RM RM RM D- D+ I
RM RM RM RM RM N
B+ 34 35 36 21 22 30 19 20 131 131
P44/J44 31 35 30 33 2 1 32 34 36 23 20
POST KW ALARM SPARE + - RDM + - 7
E965/BU 1 BK SIGNAL (-) FCR
BKUP SP/TMG SNSR
E966/YL 2 WH SIGNAL (+) CCM DATALINK DATA LINK O
(4P-7610)
117 117
F3 CTR 98 19 6
F2 F6 F1 F4 F5 F7 17
RR
N940/BU
P21/J21
A OR +5V
COOL. TEMP SNSR
(10A) (10A) (10A) (10A) (10A) (10A) (10A) GENERATOR SET CONTROL (GSC) 16
97
220
R
220
995/BU C WH SIGNAL 96 25 14
(102-2240) LOW OIL PRESSURE
N941/YL B BK RETURN 6
RM RM RM RM RM RM RM RM EMERGENCY STOP 95 S
J23/P23 4 6 12 5 402 402
8 3 5 7 9 HIGH WATER TEMPERATURE 26 15
N940/BU A OR +5V 94
TURBO OUTLET PRESS. ENGINE OVERSPEED 4
A746/PK C GN SIGNAL T
(194_6724) 93 108 108
N941/YL B YL RETURN LOW COOLANT LEVEL 33 3
FCR RR CTR SMR SMR 12
J27/P27 OVERCRANK 92
11 U
N940/BU A OR +5V ATMOSPHERIC PRESS. GFR FAULT SHUTDOWN 110 110
91 34
A747/GY C WH SIGNAL (161-9926) 10 5
H F10
N941/YL B BK RETURN FAULT ALARM H
(10A)
RM V
J22/P22 157 157
ASR 22 2 35 16
N940/BU A OR +5V 6 6 6
ENG OIL PR SNSR 5
994/GY C GN SIGNAL W
(161-9926)
N941/YL B YL RETURN 159 159
RM 36 17
P43/J43 REF. 50 19 3
37 37 37
N940/BU A OR +5V L07 10
FUEL TEMP SNSR
A751/YL C WH SIGNAL EGR
(102-2240)
N941/YL B BK RETURN AUX. ALARMS/SHUTDOWNS
E SWITCHED -VE
J49/P49 CHASSIS GPHI GPLO
N940/BU A OR +5V POST 6 37
FUEL PRESSURE SNSR E RM RM RM RM RM RM RM RM RM RM RM + - V- V+ HET LOP LCL
A745/WH C GN SIGNAL DOOR 38 B- 1 2 31 9 7 8 13 23 24 25 39 40 33 32
(194-6725) 27 15 24 17 16 13 14 28 18 21 39
N941/YL B YL RETURN 3 7
E
BODY 2 13 39 38 41 20 30 21 22 SP1 SP2 SP3
P47/J47 17 14 10 55 56 57 58
412/BU 1 COOLANT FLOW SWITCH 2 37 39 38 4 43 5 40 41 42
G N944/PU 2 (NOT USED) 62 67 16 15 18 19 G
59

PANEL :3
RENR7916-01 VOL 2

LIGHT
SWITCH :2 :1 :2 OFF/RESET
15 11 23 24 38 40 54 55 56 34 44 37 36 49 59 60 61 62
SP1 SP2 SP3 :3 AUTO
EMER. 45
2 21 22 :4 START
STOP 16 17 18 7
:5 COOLDOWN/STOP
11 38 41 20 30 17 34 46 45 10 9 CONTROL MODE
:11 SWITCH
8 6 30 57
CR/3
:9 6
P1/2
J3/P3
62 67 16 15 67 62 18 67 62 19 67 62
F 22 39 41 66 53 F
1 16 30
ECM 3
30
57
2 27 28 29 6 4 22 9 37 38
J2/P2 10 9 PANEL 9
INJECTOR COMMON 1 & 2 5 L983/WH LIGHTS EF1 EF2
INJECTOR COMMON 3 & 4 17 L984/OR
ASOR+ SD-PWR SD-RTN 10A 23A 8 ES- 59
22 3
INJECTOR COMMON 5 & 6 27 L985/YL ASOR+
INJECTOR 6 34 A706/GY 4
INJECTOR 5 28 A705/BU
30 Page

3 52 12
INJECTOR 4 22 A704/GN SD-PWR
INJECTOR 3 18 A703/BR
INJECTOR 2 12 A702/PU
INJECTOR 1 6 A701/GY 5 53
TDC PROBE + 39 F723/PK SD-RTN
TDC PROBE - 4 F724/PU 7 8
UNUSED 10 7
UNUSED 40 D+
E ANALOG SNSR POWER (+5V) 36 N940/BU E
UNUSED 30 N941/YL
INLET AIR TEMP SNSR 2 F714/PK 6
D-
+V ENG SP/TMG 1 30 30
COOLANT FLOW SW COMMON 29 N944/PU
PRIM. SP/TMG SNSR 37
FUEL PRESSURE SNSR 14 A745/WH 2 2
TURBO OUTLET PRESS. 23 A746/PK
ATMOSPHERIC PRESS. SNSR 20 A747/GY
29
ENG OIL PRESS. SNSR 8 994/GY 41
FUEL TEMP SNSR 3 A751/YL :10 1 2 3
INLET AIR TEMPERATURE SNSR 9 C967/BU CR
SOLENOID COMMON 7 E799/BR 40
41 :2
ENGINE RETARDER (MED/HI) SOL 13 F700/BU
ENGINE RETARDER (LO/HI) SOL 19 F701/BR 3
COOLANT TEMPERATURE SNSR 15 995/BU 28 ASOR+ SD-PWR SD-RTN 10 23A 12 11 41 41 20 30 30 17 34 45 45A 46 10 8 ES- 59 21 22 62T 67T 16 15 67P 62P 18 67L 62L 19 67O 62O EF1 EF2 D- D+
UNUSED 26 45
UNUSED 24 F704/OR 35 36 37 51 52 53 8 9 6 47 46 15 16 10 65 25 48 49 17 18 50 7 27 28 59 31 32 33 42 43 14 13 44 45 20 21 19 23 24 22 61 62 4 3 5
THROTTLE POSITON SNSR 31 F702/GN
UNUSED 25 39
D 45A
UNUSED 38 NOT CONNECTED D
UNUSED 11 NOT 21 22 18 67L 62L 19 67O 62O EF1 EF2
COOLANT FLOW SW 16 412/BU CONNECTED
UNUSED 21
UNUSED 32
UNUSED 33
UNUSED 35 10
2 30 S-SPD

J1/P1 12
BKUP SP/TMG SNSR 18 E966/YL D-SPD
UNUSED 32 F725/WH
UNUSED 37
21
DIGITAL SNSR RETURN 29 998/BR 8 SEE NOTE A SEE NOTE B
ANALOG SNSR PWR (5V) 36 997/OR
ANALOG SNSR RETURN
UNUSED
30
31
993/BR
F703/GY 38
DIAGRAM-WIRING
ES- 54 55 56 54 55 56
UNUSED
UNUSED
38
20 F718/BU (EMCP II)
UNUSED 27 F706/PU

234-3202
C STARTING AID 25 F720/GN
41
C
UNUSED 15 N942/OR 80 82 78 80 82
GROUND LEVEL SHUTDOWN (NO) 2 F715/PU
32 40
GROUND LEVEL SHUTDOWN (NC) 8 F716/WH 30 46 11 12
UNUSED 22 F707/WH
ATA- 30 46 34
DIAGRAM-WIRING
DIGITAL SNSR POWER (+8V) 35 A700/OR 64
ENG. RTDR SEL. SW (LO/MED/HI) 24 F719/BR 31
ATA+
39 4
10
A (ENGINE SCHEMATIC)
UNUSED 34 F709/BU 1 3 5 7
234-3205
ENG. RETARDER SEL. SW (HI) 13 F722/OR 72
UNUSED 21 F705/PK 10 23A 59
15 2
UNUSED 28 F708/YL AP- 2 B
ETHER START VALVE RELAY 40 F710/BR
UNUSED 10
451/BR 14 20 EF1 EF2 DIAGRAM-WIRING
UNUSED 11 AP+ EMER.
BACKUP SPEED / TIMING SNSR (-)
UNUSED
12
14
E965/BU
F717/YL 31
D+
D
STOP
1 2 C A B C A B (ENGINE HARNESS)
UNUSED 16

145-3850
9 ON
UNUSED 17 450/YL 20
ENG. RETARDER SEL. SW (MED) 19 F721/GY SCR D- ENCLOSURE
UNUSED 23 N943/BR 24 32 E ST4
B 8 CDVR B
+BAT. (UNSWITCHED)(NOTE B) 4 102/RD P+ REF R448
+BAT. (SWITCHED) 6 150/OR 65 AVR
J1939 SHIELD 26 A234/BK ATA- B3
ATA-
UNUSED 39 F712/GY 19 22 30 H
FP
UNUSED 33 F711/GN 2 4 6 8 2 10
ATA DATA LINK - 1 E793/BU 64 MAGNETIC
ATA DATA LINK + 7 E794/YL 11 ATA+ ATA+ PICK UP No.1 COOLANT OIL
23 29 J REF REF
CAT DATA LINK - 3 892/BR LOSS TEMPERATURE
CAT DATA LINK + 9 893/GN A11 B10
1 CORE BALANCE
-BAT. 5 229/BK AIR SHUT-OFF
SERVICE SOLENOID 59
CURRENT TRANSFORMER
IF REQUIRED
CONNECTOR
:86
4 SR NOTE A: VOLTS ADJUST CONNECTION WHEN USING A R448 REGULATOR
ASOS SASV LOW
:85 FUEL NOTE B: VOLTS ADJUST CONNECTION WHEN USING A CDVR REGULATOR
2 LEVEL
GROUND STUD 20
REF SWITCH
2
B3
20 P+ XT AP- AP+ FP
A SMMS1 SMMS2 A
2
2

30
B A C B A C
IF REQUIRED
FIT IF REQUIRED
VOLUME 2
3456 WITH EMCP II
2
17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1