ABBREVIATIONS
RENR8077-03 June 2010
1 2 3 4 5 6 7
LOW OIL PRESSURE
LOW FUEL LEVEL
SYSTEM NOT IN AUTO
8 9 10 11 12 13 14
1 2 3 4 5 6 7
1 2 3 4 5 6 7
8 9 10 11 12 13 14
8 9 10 11 12 13 14
T
T
108
4
:A :B :C :D :E
108
33
LOW BATTERY VOLTAGE
U
U
110
6
:A :B :C :D :E
110
34
T13
LAMP TEST
ALARM SILENCE
+
19
159
F32 (2A) F33 (2A)
154
156
(FRONT)
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
GENERATOR SET CONTROL
ATB
AC TRANSFORMER BOX
HET
HIGH ENGINE TEMPERATURE
CR
CONTROL RELAY
HOT
HIGH OIL TEMPERATURE
CTR
CRANK TERMINATION RELAY
KW
KILOWATT
EGR
ELECTRONIC GOVERNOR RELAY
LCL
LOW COOLANT LEVEL
FCR
FUEL CONTROL RELAY
LOP
LOW OIL PRESSURE
GFR
GENSET FAULT RELAY
POT
POTENTIOMETER
GPHI
GROUND POST HIGH
SCR
SCREEN
GPLO
GROUND POST LOW
SMR
STARTER MOTOR RELAY
SYMBOLS
42
43
3406C & 3456 Generator Set with EMCP II+ Electrical System
-
(REAR)
GSC
:2
FUSE
(FRONT)
(REAR)
(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 &
TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
W
W 36
157
+
-
(FRONT)
18
35
159
:6/:L3
V
V
157
:4/:L1
ALARM SILENCE
AIR SHUT-OFF RELAY
T11
SLR/2
LOW COOLANT TEMP
SLR/1
HIGH COOLANT TEMP
ASR
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
110 110 110 110 110 110 110 110
SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD
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
3456 Gen Set: C1G1-UP C3G1-UP C4G1-UP C2T1-UP
EMERGENCY STOP PUSHBUTTON
PANEL LAMP
POTENTIOMETER
:1
11
CHASSIS CUSTOMER TERMINAL
11
CHASSIS DC TERMINAL
8
CHASSIS AC TERMINAL
:10 R
RELAY COIL
:2
TRANZORB
SR4B Generator: L5A1-UP L7A1-UP L6B1-UP
DOOR TERMINAL
28
SCREEN CABLE
58
RELAY CONTACT N/O
30
CHASSIS TO DOOR DC SOCKET
:1 R/1 :3
ENGINE SOCKET
J
CHASSIS TO DOOR AC SOCKET
:3
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)
TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
BE BE BE BE BE BE BE BE
3406C Gen Set: C2G1-UP C5G1-UP C8G1-UP C2Y1-UP
:3
PANEL LAMP SWITCH :2 POWER TERMINAL
EARTH
:1
:2 :3 :4 :5
PWM MODULE
2
GSC RELAY MODULE TERMINAL ENGINE CONTROL SWITCH ATB TERMINAL
CIRCUIT BREAKER
1 9X9857
3
GSC 40 WAY HARNESS CONNECTOR
SPARE FAULT INPUT (LED 3)
:11
SPARE FAULT INPUT (LED 4)
:3
SPARE SHUTDOWN INPUT (LED 5)
:3
SPARE SHUTDOWN INPUT (LED 5)
:4
SPARE SHUTDOWN INPUT (LED 6)
:4
SPARE SHUTDOWN INPUT (LED 6)
:5
SPARE SHUTDOWN INPUT (LED 7)
:5
SPARE SHUTDOWN INPUT (LED 7)
:6
SPARE SHUTDOWN INPUT (LED 8)
SPARE SHUTDOWN INPUT (LED 8) LAMP TEST (IF REQUIRED)
(T11)
ATB +
EMCP II+ ATB
(T12)
WIRE TABLE 27 26
+B
1
H21 H22 H23
LEVEL SWITCH (TOP VIEW)
84
H
HIG
PUMP RUN
LOWW LO
TERMINAL BOX
H HIG
15
18
LOW LEVEL FUEL SWITCH
LEVEL SWITCH (SIDE VIEW)
TERMINAL BOX
21
:3 PR/1 :1 20
HIGH LEVEL FUEL SWITCH
84
81
:6 PR/2
81
:7 SW4
NORMALLY OPEN
36
85
83
SW3
NORMALLY CLOSED
SW2
NORMALLY CLOSED
:2 MV :1 MOT. -VE SUPPLY
35 SW1
:2
+
PR :10
-
LOW LEVEL FUEL SWITCH
:3 PR/1 :1 20
LEVEL SWITCH (SIDE VIEW)
:3 PR/1 :1 20
HIGH LEVEL FUEL SWITCH
81
TERMINAL BOX
:6 :7
LEVEL SWITCH (SIDE VIEW)
85 :2 MV :1 MOT.
T1
35
:2
81 SW4
SW3
83
PR :10
NORMALLY OPEN
NORMALLY CLOSED
SW2
NORMALLY CLOSED
SW1
NORMALLY CLOSED
2
+ -
-VE SUPPLY
SW4
2
T11
T2
T12
T3
T13
NORMALLY OPEN
2
SW3
NORMALLY CLOSED
SW2
NORMALLY CLOSED
F22 (2A)
+
PR :10
-
2
13
COPPER BUSBAR
AC CIRCUIT
F22 (2A)
:13 AUX :14
24
203
208 23
10
203
208 PUMP STOP
12
51
52
52
53
53
80
80
82
82
T5
HI BK
J1-5 BR
16 GA BK BK
16 GA BK
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
1
3
5
13
6 mm
A1
2
2
208 211 131
2 .5 mm
204
:X1 PUMP TRIP/ STOP :X2
:X2
T6
HI BK
J1-6 BR
BK
PU
2
4
6
14
O/L 1
3
5
97
2
4
6
98
96
23 2 .5 mm FUEL PUMP
2 .5 mm
208 211 131
A1
1
3
5
13
2
4
6
14
O/L 1
3
5
97
2
4
72
NORMALLY OPEN
SW4
6
72
NORMALLY CLOSED
NORMALLY CLOSED
95
98
64
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
SW3
23 2 .5 mm
2
M 131
J2-1 J2-2 J2-3 J2-4 J2-5 J2-6
AC GND
18 GA GY
AC GND
VA AC VB AC VC AC
NSFORMERS, SFORMERS
17
11
72
10
CONNECT TO ALARM MODULE SPARE ALARM CHANNEL
2
30 77
65
30
30
77
SW2
72 72
26
28
77
45
CONNECT TO ALARM MODULE SPARE ALARM CHANNEL
FUEL PUMP
2 .5 mm
17
11
30
64
SW1
72
M 131
LED BLANK WATCHDOG LED +5V +12V SERIAL CLOCK SERIAL STROBE SERIAL DATA GROUND
RELAY BOARD
SEL GND SEL GND SEL GND
+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
29 30 31 32 33 34 35 36 37 38 39
-B
:9 :11
64 29
65 30
66 31
FUSED DC POSITIVE CAT DATA LINK
7
72
10
CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL
FUEL LEAK SWITCH
30
8
38 :2 GRR :10
65
3
LOW-LOW FUEL LEVEL SWITCH
30
SP2
4 31 32
10
1
D+
5
D-
14
CMS
:8
31
2
GRR/3 :9
3
12
22
16
6
:11 56
87 32
17
2
W2-1 W2-2 W2-3 W2-4 W2-5 W2-6 W2-7 W2-8
ALR/3 :8
REMOTE CONTACTS FOR GENERAL ALARM
3
2
24
2
W1-1 W1-2 W1-3 W1-4 W1-5 W1-6 W1-7 W1-8
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.
:2 ALR :10
LOW FUEL LEVEL SWITCH
96
NORMALLY CLOSED
N
24
2
J1-7
211 209 210
211 209 210 N
204
A2 131
131
95
6 mm 2 46 131
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
IC
18 GA BR
J1-8
LED BOARD LED BLANK WATCHDOG LED +5V +12V SERIAL CLOCK SERIAL STROBE SERIAL DATA GROUND
RANGE SELECT JUMPER NOTE A
16 GA BK 16 GA BK
KEYPAD
NOTE: IF NO ALARM MODULE FITTED THEN RELAY WILL ACTIVATE ON SHUTDOWN ONLY.
PC
2 .5 mm
A2 131
131
204 PUMP RUN
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
18 GA GY
72
:95 O/L :96 :X1
IB
18 GA BR
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
PU
H HIG
:9
206
6 mm 2 46 131
PC
2
51
PU
2
131
204
131
50
BK 18 GA BK
6
2
:95 O/L :96
:X2
50
18 GA BK
5
PR/3 :11
2
206
PUMP RUN
50
IA
18 GA BR
12 205
:9 PR/3 :11
:X1 PUMP TRIP/ STOP :X2
203
21
2
205
:X1
H23
50
J1-4 BR
L
22
202
2.5 mm
203
H23
T4
HI BK
18 GA BK
AC SUPPLY CUSTOMER 100V TO 250V
23
K
L
22
18 GA RD
X2
205
K
21
H22
T1, T2 AND T3 ARE 15:1 POTENTIAL TRA T4, T5 AND T6 ARE 500:1 CURRENT TRAN
11 J
X1
VC
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
+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
W3-1 W3-2 W3-3 W3-4 W3-5 W3-6 W3-7
+B
CCM 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
24
205
202
LOW
SW3
H21
H22
207
6 mm
J
SW2
J1-3
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 LINK-
TERMINAL BOX
:97 O/L :98
202
AC SUPPLY CUSTOMER 100V TO 250V
11 PUMP STOP
SW1
2 .5 mm
202 10
F21 (6A)
2
:97 O/L :98
CABLE ENTRY
H21
M
mm 2.5
:13 AUX :14
6 mm 45 132
LOWW LO
13
207 M
SW4 2
VB
18 GA RD
X2
H2
10-POLE TERMINAL STRIP
2
J1-2 X1
H1
:2
VA
18 GA RD
X2
T2
NORMALLY CLOSED
AC CIRCUIT
F21 (6A)
H2
T3
HI HIGGHH
AC CIRCUIT
18 GA BK
8-PIN DEUTSCH CONNECTOR J1-1
X1
H2
SW1
AC CIRCUIT
6 mm 45 132
H1
18 GA BK
LEVEL SWITCH (TOP VIEW)
COPPER BUSBAR
T1 18 GA BK
H1
35
NORMALLY CLOSED
ATB + INTERNAL SCHEMATIC
3-POLE FUSE BLOCK
TERMINAL BOX
VALVE
83
H
PR/2
36
HIGH LEVEL FUEL SWITCH
TERMINAL BOX
21
VALVE
2
2
ALREADY FITTED AS STANDARD
18
21
LOW
IGH
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
HC5
ALREADY FITTED AS STANDARD
LOW LEVEL FUEL SWITCH
TERMINAL BOX
LOWW LO
84
82
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
HC3
15
LOW
ENTRY
82
ENTRY
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
HC4
LOW
SW1
SW3
+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
HC1
LOWW LO
SW1
SW2
80
KEYPAD SIG X7 KEYPAD ROW 2 KEYPAD PWR 1 KEYPAD SIG 1X KEYPAD ROW 3 KEYPAD ROW 4 KEYPAD PWR 2
CPU BOARD
HC2
PUMP RUN
SW2
SW3
80
CABLE
SW4
CABLE
SW4
ENTRY
53
HI HIGGHH
DISPLAY BOARD
2
SW1
SW3
SW2
16
CABLE
SW4
84
84 HI HIGGHH
4
GSC EMCP II+
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
HC0
16
52
84
HI HIGGHH
4
51
-
PRI
84
LEVEL SWITCH (TOP VIEW)
LEVEL SWITCH (TOP VIEW)
ALREADY FITTED AS STANDARD
IA IB IC VA VB VC EGC PP ASR CTR FCR GFR PSR RR SMR PSR GEN I
50
PRI
ALREADY FITTED AS STANDARD
DC CIRCUIT
(2A)
DC CIRCUIT
84
PRI
(2A)
PRI
1
ABBREVIATIONS
50
PRI
DC CIRCUIT
84
(2A)
50
1 F23
1
1 F23
PRI
1 F23
2 .5 mm
1
88 33
89 34
REMOTE CONTACTS FOR GENERATOR RUNNING
DC NEGATIVE
2
2
51
52
57 53
54
HARNESS CODE 18
55
33 CLR 23 SRV SCROLL SWITCH `SS'
:3 :2
MODE/ CLEAR SWITCH `MCS'
:1
:3 :6 :2
:4 :5
2
(Dimensions: 39 inches x 28 inches)
TBC
30 Page,
GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 2
FUEL PUMPED FROM FREE STANDING BULK TANK FUEL SYSTEM No. 3
BK BK BK BK BK BK BK BK BK BK
6
PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 1
COLOR
RENR8077-03 VOL 1 of 2
(T13)
T11 T12 T13 H21 H22 H23 50 51 52 53
25
T11 T12 T13 H21 H22 H23 50 51 52 53
24
CIRCUIT NO.
TERMINAL
23
38
22
20
21
:12
20
:2
19
90
18
17
17
ALARM DATALINK
-B
DATALINK
:6
39
17 ALARM
:13
38
90
68
37
:2
:13
ALARM MUTE
Printed in U.S.A.
© 2010 Caterpillar All Rights Reserved
36
DC
35
:7 -
34
:1 +
33
10 30
+B
32
6
D
31
:12
4
FIRST ALARM MODULE
SPARE FAULT INPUT (LED 4)
S
30
:13
LAMP TEST (IF REQUIRED)
38
SPARE FAULT INPUT (LED 3)
:11
DC
Volume 1 of 2: 3406 with EMCP II+ -B
14
20
:12
SPARE FAULT INPUT (LED 2)
:10
:10
13
:2
SILENCE SWITCH
LAMP TEST
:7 -
:9
12
LOW FUEL LEVEL
10
:1 +
SPARE FAULT INPUT (LED 1)
SPARE FAULT INPUT (LED 2)
:14
11
72
30
6
:13 90
10
4
SPARE FAULT INPUT (LED 8)
:8
:9
HORN ON
10
LINK
:8
SILENCE SWITCH 17
:4 :11
DC
:14
SPARE FAULT INPUT (LED 1)
9
:7 -
+
69
:8
8
:1 +
:14
7
10
SPARE FAULT INPUT (LED 7)
-
6
:10 30
6
HORN
LINK
5
+
4
ALARM DATALINK
:3
4
:14
3
-
HORN
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
M VOLTS ADJUST POTENTIOMETER (1KW, 10 TURN) 80
G
T1
P1
P2
T2
S1 P1
S2 P2
CT1
T3
S1 P1
S2 P2
CT2
S1
S2
CT3
:2 :3
:1
N
L1 L2
72
10
L3
73
11
N
82
74
12
E
E
75
13
51
52
53
50
50
50
T1
T2
T3
101
76
14
REF. F14
1 A 8
L
9
10
B
97
82
55
93
52
53
50
LINK
LINK
T1
T2
T3
J1-5
H23 F11 (2A)
H21 F12 (2A)
H22 F13 (2A) T13
AC TRANSFORMER BOX (ATB)
101
101
T12
110
110
109
109
108
108
J1-2 T11
91
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.
LINK
J1-6
J1-3
92
H
91
51
J1-4
93
G
92
K
94
F
56
57
95
E
94
J1-7
81
15
J1-8
96
D
95
16
97
C
96 80
98
J1-1
2
84
16
MOT1
27
MOT2
28
30 31
82 35
36
NOT CONNECTED
5
2
27
5
4 29
1
5
5
3
25
26
18
67
15
99
61
12
14
63
90
43
5
1
35
13
217
5
18
1
I
RM 31
B+
470 ohm POT ST4
POST
RM 35
RM 33
RM 30
RM 2
RM 32
RM 1
RM 34
RM 36
FCR
6
218 P
52
Q
CCM+
CCM-
RM 23
17
99
8
90
34
63
35 ALARM
KW
45
F2 (10A)
CTR
F3 (10A)
F1 (10A)
F6 (10A)
RM 4
F4 (10A)
RM 6
RM 3
RM 8
FCR
51
7
50
F5 (10A)
F7 (10A)
RR
SMR
CTR
RM 12
RM 5
RM 7
36 SPARE
17 18 SPARE SPARE
D-
D+
D+
47
26
15
22
21
37
CCM-
SET OP6 SETPOINT SP17 TO 6 SET OP6 SETPOINT SP18 TO 7
GFR
ASR
203
+
19
30 RDM
-
D-
20
2
RM 15
RM 24
13
2
RM 17
RM 13
RM 16
39
20
41
38
37
RM 14
39
30
54
30 24
9
11
64 22
ATA+
65 23
ATA-
SCR
39
40
POST B-
RM 18 14
+ 1
RM 39
RM 21 26A
4
-
21
10
V-
2
V+
31
LOP 8
HET 7
9
207
+
D+ 131
-
DATA LINK
117
97
16 6
220
25
96 95
5 4
93
12
402
26
94
108
33
92
11
91
10 RM 22
110
34
6
2
6
37
6
3
37
157
35 5
159
36
37
6
LCL 13
24
23
22
SP1
43
5
62
41
J K L M N O
R S T U V W
202 203 205 207 131 117 220 402 108 110 157 159
8 9 10 11
F14 (10A)
2.5 mm
2.5 mm
CB2 (20A)
29
+
28 PS1
-
SMMS1/1
PS2
SMMS2/1
26
25
SM1
PS1
SM2
CB1 (60A) :30 1FCR/1 :87 :30 2FCR/1 :87
15
6 mm 2
11
PS2
FCS
23
24
PANEL LIGHT SWITCH
42
38
7 6
14 15 3 5
H
16 17
10
15
16
67
25
SP2
40
SP3
41
39
29 SP4
42
40
55
42
33
56
32
57
3
37 7
58
G
19
18
:3 :2
40
54
45
EMER. STOP
2 40
38
11
:11
20
41
30
34
17
26A
46
45
55
34
56
44
37
36
49
59
60
22
21
SP1 16
61
SP2
62
17
SP3
63
:1
19
18
30
6
:9 ALT
6
CHARGING ALTERNATOR 39
22
41
66
62
53
67
16
15
67
62
18
67
62
19
67
REF. L07
CHASSIS DOOR BODY
27
50
28
29
5
16
6
ASOR+
SD-PWR
SD-RTN
23A
22
4
10 23A
E
9
3
PANEL LIGHTS
OFF/RESET AUTO START COOLDOWN/STOP
7
CONTROL MODE SWITCH
57
P1/2
62
3 6 mm 2
:2 :3 :4 :5
SP4
9
10
25
8
CR/3
27
KEY REMOVABLE
9
37
F
30
30
57
38
9 8
ES-
EF1
59
EF2
4
E
12
E 7
8
2
E
E 2 2
11
12
2 2
2
ASOR+ 51
D
2
SD-PWR 52
SD-RTN
23A
53
8
23A 9
1
2
3 12 6
11
47
41
46
41
15
NOT CONNECTED
2
30
30
:10 CR :2
30 Page,
I
2
59
24
30
20
65
10
16
30 25
17 48
34
45A
46
49
18
50
NOT CONNECTED
8
10
45
7
17
ES27
NOT CONNECTED
28
21
59 59
31
21
NOT CONNECTED
22 32
22
33
62T
67T
42
43
62
67T
16
15 14
16
67P
62P
18
67L
62L
13
44
45
20
21
19
15
67P
18
67L
62L
62
19 23
19
67O
67O
EF2
D-
D+
61
62
4
3
EF1
EF2
EF1
62O
24
22
62O
3
5
D
NOT CONNECTED
30
IF REQUIRED
FIT IF REQUIRED
59
C
30
30
46
1
12
11
46
3
5
34
3
64
72
59
C
7
EMER. STOP ON ENCLOSURE
62 1
B
2
4
2
B
67T A
16
15
67P
C
C
A
EF1
62 B
C
A
B
C
A
EF2
B
59 MAGNETIC PICK UP No.1
COOLANT TEMPERATURE
4 3
SMMS1
:86 1FCR :85
SMMS2
OIL PRESSURE
COOLANT LOSS IF REQUIRED
60
:86 2FCR :85
B
DIAGRAM-WIRING (EMCP II+)
8
6
SASV
SATS
235-0829
OIL TEMPERATURE CORE BALANCE CURRENT TRANSFORMER IF REQUIRED
IF REQUIRED
DIAGRAM-WIRING (ENGINE SCHEMATIC)
LOW FUEL LEVEL SWITCH
236-5745
30
A
A 2
2
IF REQUIRED
VOLUME 1 3406 WITH EMCP II+
FIT IF REQUIRED IF REQUIRED
18
K
AUX. ALARMS/SHUTDOWNS SWITCHED -VE
17
38
205
23
20
RM 19
GPLO RM 38 28
21
24
1
GPHI RM 27
19
RDM
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
SMR
1
20
D-
GENERATOR SET CONTROL (GSC)
F10 (10A)
2.5 mm 2 2
ATA-
202
21
19
RR
RM 9
1
2
(Dimensions: 39 inches x 28 inches)
31
29 23
21
19
437 CCM+
EGR
RENR8077-03 VOL 1 of 2
46
426
416
AVR
2
MOT2
L
21
32
31
RDM
CCM DATALINK
R448
BATTERY ISOLATOR SWITCH
MOT1
20
J 20
17
61
F
ATA+
84
15
D-
22
(OPTIONAL)
58
81
14
3
:2 KWR :10
48
SEE NOTE A
24V
57
76
13
D+
13
G
4
46
:8 :9 :10
AUTO START COOLDOWN/STOP
1
6 mm
18
75
12
OFF/RESET
P2/2
2
33
74
M
11
D-SPD
CONTROL MODE SWITCH
1
32
73
S-SPD
:6
1
25
72
10
24
J
1
31
71
32
37
H
17
29
30
80
1
71
9
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02)
G
T1
T1
T2
T2
T3
T3
N
N
E
E 406
E
3RD PHASE, FOR 480V USE TRANSFORMER
F42 (6A)
4
111B
REF. BBB
407
111A
B
158
B
157
B
N
NOTE: ADD FUSE F41, REMOVE LINK AND CONNECT WIRE 111A TO 3RD PHASE IF VOLTAGE IS 240V L-L
410 B
158
F41 (6A)
111
NEUTRAL, REFER TO BREAKER DRAWING
410
:1
402
402
:5
117 B
159A
159
159
:1 :3 UVT/1
BCR/1
:9
SPARE
:10
SPARE
:11
157
F32 (2A)
F40
178A
178A
117
N
N
E
E
POWER WIRING FROM GENERATOR
:C1
B
233
:14
231
:12
232
B
:11
N
E
E
111
BUS TRANSFORMER BOX (BTB+)
22
4
231
:11
:12
233
:13
:14
B12 17
98
2
:2 BCR :10
:86 EPIR :85
ETHER START SWITCH
2
220
:14
:1
:7
10
90
219
SECONDARY 120V AC L-L
:5 BKRR/1
3
:3 :4 BKKR/4 :12
WHITE
:13 BUSR :14
24
30
29
37
38
145
8
144
41
40
3
26A
6
:9 BUSR/1 :1
9
25
6
:87 :86 AIR ASOR SHUT-OFF :85 RELAY
SASV
37
35
2
3
FV
2
5
46
3406C
3 :2
ETHER START SWITCH
13
11
:13 BKRR :14
40
59
9
416
:6
426
46
206
58
MOT2 203
24
MOT2 201
201
203
NOTE B: CONNECT TO NEGATIVE ON STARTER MOTOR OR BATTERY ISOLATOR
M
CANOPY LIGHTING
UNIT INJECTOR (P91)
INLET AIR TEMPERATURE SENSOR (P89) (YELLOW SLEEVE)
TDC PROBE CONN (J26)
BACKUP SPEED/TIMING SENSOR (P44) GROUND TDC PROBE CONN (P26) ECM CONN (P2)
AIR SHUT-OFF OPTIONS
COOLANT TEMP SENSOR (P21) COOLANT FLOW SWITCH (P47)
B
OIL PRESSURE SENSOR (J22)
59
B
ACT+
BREAKER AUXILIARY/1 REF. A03 BREAKER DRAWING
ACTUATOR
SASV
ACTMPU-
3
1
4
2
3 2
5 7
6
1
2
:14 :13 :15
SASV - START AID SOLENOID VALVE SATS - START AID TEMPERATURE SWITCH
-VE SUPPLY
:11
35
FUEL TEMP SENSOR (P43) (BLACK SLEEVE)
:2 :1
SPEED ADJUST POTENTIOMETER (2K W, 10 TURN)
START AID OPTIONS
ENGINE LEFT SIDE
ATM PRESSURE SENSOR (J27)
36
3456 ENGINE COMPONENT LOCATIONS
Volume 2 of 2: 3456 with EMCP II+
Printed in U.S.A.
© 2010 Caterpillar All Rights Reserved
437
48
ECM CONN (P1)
:3
14
WOODWARD ELECTRONIC LINK FUEL GOVERNOR (ISOCHRONOUS)
12
MAGNETIC PICK UP No.2
13
LINK
11 2
3
42
9
ENGINE RIGHT SIDE
4
43
8
221
47
6A FUSE
TURBO OUTLET PRESSURE SENSOR (J23)
54
SYNCHRONIZE SWITCH :1
SR4B Generator: L5A1-UP L7A1-UP L6B1-UP
44
10 :4 :5 :8 :10
MOT2
PRIMARY SPEED/TIMING SENSOR (P20)
SATS 219
3456 Gen Set: C1G1-UP C3G1-UP C4G1-UP C2T1-UP
37
:1
15 30
MOT1
-VE SUPPLY
SASV - START AID SOLENOID VALVE
60
30
28
2
54
C
218
14
(OPTIONAL) FLAP VALVE
23A
MPU+ 217
3406C Gen Set: C2G1-UP C5G1-UP C8G1-UP C2Y1-UP
:30
59
NOTE:B
NOTE A: CONNECT TO POSITIVE ON STARTER MOTOR
GENERATOR SYNCHRONIZING MOTOR
59
2
2
BREAKER CLOSE
REF. CCC
(16A)
ASOR/1
2
:2 GCR :10
:2 ALR :10
30
4
7
1
:11 BKRR/3
:9
27
203
3406C & 3456 Generator Set with EMCP II + Electrical System
3406C
F27
201
SP4
31
415
414 BREAKER OPEN
30
10
17
REF. AAA REF. BBB
~
+
R
30
3
REF. CCC
205
NOTE:A
MOT2
MOT1
1
59
2
-VE SUPPLY
29
ORANGE
26
BREAKER CLOSED LAMP
19
146
BLACK/WHITE
:13
:1
205
2 26
NOTE PT PRIMARY WIRE COLORS - WHITE = 240V AC - GREEN = 380V AC - BROWN = 480V AC - RED = 600V AC = COMMON - BLACK
:3
MOT1
NOTE: IF CONTROL PANEL IS SGCP THEN SWITCH IS MOUNTED REMOTELY.
23
31
BLACK
10
GREEN
30
ALARM SILENCE
RED
6
BROWN
6
Q/2
BREAKER AUXILIARY
:30
99
BREAKER OPEN LAMP
REF. AAA
412
411
:4
SPEED LOWER/RAISE SWITCH
Q/1
232
:87
:1 MAN :2 AUTO
16
:6
:C12
EPIR/1
28
SPARE
205
24V DC SHUNT TRIP
ST
ASOR+
B11
6A FUSE
10 8
B22 F37 (2A)
204
:C11
3456
6
58
B2
B21 F36 (2A)
:2
MOT1
ES-
B1
:5
4 POLE BREAKER OPTIONS
111
202
202
38
57
3456
SPARE
-
N
201
201
ABB ACB
1
:13 :14 :12 :2
B
L3
39
202
2
23
SPARE
:6
B
BREAKER AUXILIARY
LINK
J1-1 J1-2 J1-3 J1-4 217 218 98
:5
B
L2
T3
6
5
REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
T2
2
2
24V DC SHUNT TRIP
ST
L1
2
:2 UVT :10
99
90
L3
:C2
B
SPARE
:4
L2
T3
6
412
411
158
B
UV COIL SUPPLY REFER TO BREAKER DRAWING
T2
T1
27
SPARE
:3
N
B
CLOSE SIGNAL REFER TO BREAKER DRAWING
L1
ABB MCCB 107
~ SPARE
REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
ALR/2 :6
:3
:1
OPEN SIGNAL REFER TO BREAKER BREAKER DRAWING
:5
CR/2
(6A)
:8
B
GCR/1 :6
107
LINK
:4
T1
2
S
117
107
111
F31 (2A)
POWER SUPPLY REFER TO BREAKER DRAWING
5
REFER TO BREAKER DRAWING N
B
POWER WIRING FROM GENERATOR
2
O
IF REQUIRED
157
117
117
POWER WIRING TO BREAKER
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02)
DC POS.
IF 4 POLE BREAKER FITTED CHANGE N T0
DC NEG.
NOTE:
RENR8077-03 June 2010
GOVERNOR OPTION
EARTH FAULT RELAY OPTION NEUTRAL EARTH LINK
T1
T2
G
NOTE:A
T2
G
T3
T3
N1
T2 T3 N E
N1
E
E NOTE:
BT1 BT2
163
3
3
172
181 3
P +
S -
Q
R
182
191
2
D +
3
P +
E -
S -
Q
R
D +
3
P +
E -
3
S -
Q
R
D +
3
1
6
74
5
7
75 30
2
1
3
74 30
6
5
30
75
7
75
2
1
3
74 30
6
NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.
2
164
163 P +
E 5
24V
2
S 2
2
+
24V -
192
2
G
164
+
2
171
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A01)
7
Q
1
3
R
3
6
D +
75
E -
14
75
75
CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL
13
T3
L3
N
N
E
E
5
37
THERMOCOUPLE RELAY
30
30
76
76
38
74
74
74
13
SP1
10
6 8
15
16 25
74
74
CONNECT TO ALARM MODULE SPARE ALARM CHANNEL
12
71
71
(T2 (T2 (T2 (T2 (T2
380) 380) 380) 220) 220)
33
76
14
76
A1
l
22
21
CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL
12
24
11
`EFU' A2 BENDER EARTH FAULT RELAY
30
8
k
30
8 31
73
14
10
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.
73
12
11
73
CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL SP2
SP1 1
71
9
71
U
CONNECT TO ALARM MODULE SPARE ALARM CHANNEL
U
T1
T7
10/YELLOW 1/2 PHASE T1- T4 OR T8 - T11
9/GREEN
12/BLACK
14
X2
PMG
15
X1
16
Z2
X1
UNDER SPEED ADJUST P4
Z2
ST2
STABILITY ADJUST P3
5
E+
R448
ST6
VOLTAGE ADJUST P2
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)
X1
X2
SUPPLY STATOR PMG
Z1
6
E-
110
+
CONNECTION TO EXCITER
NOTE:E
NOTE:F
W
3 2
NOTE:C
380
T1 S1 S2
POT 470ohm
NOTE:G
220
ST9
ST1
3ph
_
0
NOTE:D
NOTE:A 50/60 Hz SELECTION
EF2
17
16
-
9/GREEN
10A FUSE
V
J1
BLACK
W
BLACK
RFI UNIT
N
P1 QUADRATURE DROOP ADJUST
ST4
OPTIONAL RFI KIT CONNECTIONS
ALTERNATOR WINDING CONNECTIONS
U
J2 EF1
7
8
75
L2
2
30
32
T2
76
71
30
L1
-
75 30
T1
415/240V 400/230V 380/220V 220/127V 600V
60Hz
EXCITATION CEILING ADJUST P5
50 HZ VOLTAGE WYE
CORE BALANCE CURRENT TRANSFORMER
WHITE
WHITE
RED
RED
RED
RTD PT100
RTD PT100
WHITE
RTD PT100
WHITE
RTD PT100
NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.
TABLE: 1
X2
11/RED
J3
50Hz
IF 4 POLE BREAKER FITTED CHANGE N TO
SUPPLY 140V MAX 50/60HZ
10/YELLOW
TO BREAKER BOX
BT3
RED
BT1
ST3
CORE BALANCE C.T.
PMG
SHUNT
SUPPLY - AUXILIARY WINDING
V
BLACK
U
NOTE:B
OR FOR 3 PHASE SENSING.
BLUE
AND R448
ALTERNATOR WINDING CONNECTIONS
N
. 7000 FRAME SIZE REQUIRES SPILT LINK - U
-
S2
- -
S1
P2
TI04
NOTE:H
P1
DIAGRAM - WIRING (R448)
N
T1 T4 T7 T10 T10 T12
T2
T4
N
T11
T5
T0
V T2
T8
N
T5 T8
T0
T12
T6
V
T11
T9 T6
THERMOCOUPLE RELAY OPTIONS W
T9
T3
W
SERIES STAR CONNECTION DIAGRAM
T3
AREP
PARALLEL STAR CONNECTION DIAGRAM
(HIGH VOLTAGE WYE)
NOTE:A ST3
(LOW VOLTAGE WYE)
10/YELLOW
W (L3) T12
T6
T9
T5
T8
LINK T11
HEATER OPTIONS
T4
T11
T9
T5
T8
V (L2) T2
T10
T1
T4
N
T7
60Hz
CUSTOMER LOAD CONNECTIONS
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
COPPER BUSBAR
F16 (2A)
F17 (6A) 136
131
SHOULD BE 25A SHOULD BE 16A BE 15A BE 10A 6 mm
F19 NOTE:A
F18 (4A)
6 mm
141
135
2
2
132
COPPER BUSBAR
45
CUSTOMER 100V TO 250V AC SUPPLY 131
F16 (2A)
F17 (6A)
6 mm
46
136
134
131
6 mm
2
2
132
HEATER IS HEATER IS IS FITTED IS FITTED
FITTED FUSE F19 FITTED FUSE F19 FUSE F19 SHOULD FUSE F19 SHOULD
COPPER BUSBAR
45
CUSTOMER 100V TO 250V AC SUPPLY 131
JACKET WATER JACKET WATER BLOCK HEATER BLOCK HEATER
ST2
6 mm
F19 NOTE:A
F18 (4A)
F16 (2A)
6 mm
46
136
135
131
2
132
R448
ST6
VOLTAGE ADJUST P2
110
NOTE:E
POT 470ohm
3ph
:4
:4
:4
CR/1 :1
CR/1 :1
CR/1 :1
45
141
135
137
134
131
137
135
131
J1
STATISME P2
P1 N
2
6 mm
N
110
230
2 .5 mm
2
N
NOTE:H
W 110
6 mm
2
TI04
U
BLUE
P2
ALTERNATOR WINDING CONNECTIONS
DIAGRAM - WIRING (R448 & R731) 400
230
400
6 mm
2
RFI UNIT
V
NOTE:I
V 110
6 mm
BLACK
S1
+
R731
230
2 .5 mm
2
W
BLACK
S1
U
BLACK
N
S2
_
OPTIONAL RFI KIT CONNECTIONS
ALTERNATOR WINDING CONNECTIONS
U
U
S2
400
6 mm
V
1
+
134
141
2
_
46
CONNECTION TO EXCITER
W
4
2
131
3
P1 QUADRATURE DROOP ADJUST
ST4
TENSION P1
2
137
NOTE:C
J2
470ohm POT
136
+
380
T1 S1 S2
NOTE:G
136
_
220
ST9
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
136
16
Z2
NOTE:B
0
134
141
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
6
E-
NOTE:D
CUSTOMER 100V TO 250V AC SUPPLY 131
PMG
15
X1
5
E+
SHOULD BE 25A SHOULD BE 16A BE 16A BE 10A 2
14
X2
X1
NOTE:F NOTE:A IF 120V IF 230V IF 120V IF 230V
9/GREEN
1/2 PHASE T1- T4 OR T8 - T11
Z2
ST1 NOTE:A IF 120V IF 230V IF 120V IF 230V
10/YELLOW
12/BLACK
N
GENERATOR LEADS
SUPPLY STATOR PMG
Z1
STABILITY ADJUST P3
T1
X1
X2
UNDER SPEED ADJUST P4
U (L1)
X2
9/GREEN
10A FUSE
EXCITATION CEILING ADJUST P5
T3
LINK
U (L1)
T7
T6 LINK
CUSTOMER LOAD CONNECTIONS
V (L2) T2
LINK T10
W (L3) T12
T3
SUPPLY 140V MAX 50/60HZ
11/RED
J3
50Hz
PMG
SHUNT
SUPPLY - AUXILIARY WINDING
4 3 141
137
134
131
:2 131
140
- 3
*
2
2
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
+
-
140
131
131
131
9
+ 1
2
36
(*)
:2 131
:A2
1
9
- 3
*
F15
36
(*) 2
2
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
134 :5
131
140
131
142 20
139 19
ALTERNATOR HEATER
+
-
140
131
131
131
131
131
9
ENGINE JACKET WATER HEATER
9
NOTE:A 50/60 Hz SELECTION NOTE:B REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448
:6
:4
CONSTANT VOLTAGE CHARGER
6 mm
F15
2
1
2 .5 mm
+ 1
ENGINE JACKET WATER HEATER
ALTERNATOR HEATER
CONSTANT VOLTAGE CHARGER
131
139 19
142 20
141 :3
HC :A2
:6
:4
131
:A1
2
:A2
137
135 :1
HC
HC
24V DC SUPPLY
131
:A1
:5
:3
2
:1
6 mm
135
131
:A1
2 .5 mm
137
2 1
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 . 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
TABLE: 2
TABLE: 1 50 HZ VOLTAGE WYE
50 HZ VOLTAGE WYE
415/240V 400/230V 380/220V 220/127V 600V
415/240V 400/230V 380/220V 220/127V 600V
-
(T2 (T2 (T2 (T2 (T2
380) 380) 380) 220) 220)
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)
(T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3
380) 380) 380) 220) 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
380) 380) 380) 220) 220) 220)
600V
-
- (T1,T2&T3 220)
(Dimensions: 39 inches x 28 inches)
AREP
T1 T1
30 Page,
ALTERNATOR TERMINAL BOX
RENR8077-03 VOL 2 of 2
ALTERNATOR TERMINAL BOX
17
16 1
1
14
13
12
11
10
8
7
6
5
4
3
2
METERING C.T.S 1
G
T1
P1
P2
T2
S1 P1
S2 P2
CT1
T3
S1 P1
S2 P2
CT2
S1
S2
CT3
N
L1
9
L2
10
L3 11
N 12
2
2.5 mm
CB1 (20A)
CB2 (60A)
CB3 (15A)
6 mm
+
L
SM1
BATTERY ISOLATOR SWITCH
PS1
SPEED ADJUST POTENTIOMETER (1K ,10 TURN)
ALT
B+
CHARGING ALTERNATOR
:1
KEY REMOVABLE
2
K
11
12
2
34
2
14
35
2
44
P91/J91 D789/WH 12 D790/OR 10 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
F723/PK F724/PU
26
36
43
8
9
10
FUEL INJECTOR (128-8510)
S-SPD
D
CYL NO.5
CYL NO.4
CYL NO.3
CYL NO.2
55
+B -B
10
82
P20/J20 BK F724/PU 1 WH F723/PK 2
I
+5V SIGNAL RETURN
J23/P23 OR A GN C YL B
+5V SIGNAL RETURN
N940/BU 994/GY N941/YL
67
53
15
50
LINK
LINK
T3
J1-5
H21 F12 (2A)
H22 F13 (2A) T13
AC TRANSFORMER BOX (ATB)
T12
T11 J1-1
110
110
109
109
108
108
2
RM 31
POST
2
27
5
5 48
RM 35
1
5
3
15
99
12
14
63
90
43
5
SEE NOTE A
17
61
35
RM 33
RM 30
RM 2
RM 32
RM 1
F6 (10A)
CTR
F3 (10A)
F1 (10A)
RM 34
F4 (10A)
RM 6
RM 3
RM 8 RR
SMR
CTR
RM 12
25
6
218 P
52
Q
RM 36
RM 23
17
99
8
90
34
63
35 ALARM
KW
45
46
26
18
CCM+
CCM-
51
7
50
F5 (10A)
F7 (10A)
17 18 SPARE SPARE
26
15
RM 5
RM 7
22
21
37
CCM-
E
RM 15
2
RM 24
13
2
RM 17
RM 13
RM 16
39
RM 14 20
41
38
37
39
GPLO RM 38 28 30
RM 9
SET OP6 SETPOINT SP17 TO 6 SET OP6 SETPOINT SP18 TO 7
POST B-
RM 18 14
+ 1
RM 39
RM 21 26A
4
-
21
10
V-
2
11
23
24
PANEL LIGHT SWITCH
42
38
38
11
:11
20
41
30
34
17
46
45
19
30 RDM
-
27
2
E
2 4 6 6 5 4 3 2 1 + -
ANALOG SNSR POWER (+5V) ATMOSPHERIC PRESS. SNSR RETURN 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 SPEED CONTROL (S) SPEED CONTROL (D)
D COOLANT FLOW SW
C
B
22
2
29
F709/BU
ASOR+
F700/BU 5
E799/BR
+
97
10
:2
24
23 SP1
62
40
95 26
94
4
93
12
33
91
10 RM 22
15
16
67
25
SP2
40
SP3
41
39
29 SP4
42
40
55
42
131 117 220 402 108
34
6
2
6
37
6
37
157
5 36
3
37
35
110
159
L M N O
R S T U V W
203 205 207 131 117 220 402 108 110 157 159
8 9 10 11
I
7 6
14 15 3 5
H
16 17
10
33
56
32
57
41
66
54
55
34
56
44
37
36
49
59
60
22
SP1 16
62
53
G
61
SP2
62
17
SP3
63
:1
:2 :3 :4 :5
SP4 19
18
67
16
15
67
62
18
67
62
19
67
PANEL LIGHTS
22
OFF/RESET AUTO START COOLDOWN/STOP
7
CONTROL MODE SWITCH
57
P1/2
62 16
3
37 7
58
30
9
3
19
18
9
37
F
30
30
57
38
9 8
ES-
EF1
59
EF2
12
7
29
40
F722/OR 28
F716/WH 39
F721/GY
30
30 2
J3/P3 F717/YL
8
E
D-
892/BR
2
41
:10 CR :2
41 ASOR+
45
35
37
36
SD-PWR
51
SD-RTN
52
10
53
8
1
2
3
3
23A
12 6
9
11
47
41
46
41
15
30
20
65
10
16
30 25
17 48
34
45
49
45A 18
17
46 50
8
10 7
ES27
28
21
59 59
31
22 32
33
62T
67T
42
43
45A 21
NOT CONNECTED
412/BU
16
15 14
13
NOT CONNECTED
22
67P
62P
18
67L
62L
44
45
20
21
19
18
67L
62L
19 23
19
67O
67O
EF2
D-
D+
61
62
4
3
EF1
EF2
EF1
62O
24
22
62O
5
D
J3/P3 10
S-SPD
12
E966/YL F725/WH
21
998/BR 997/OR 993/BR F703/GY
SEE NOTE A 38
F720/GN
32
31
997/OR
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
4
AP-
2
998/BR
AP+
A700/OR 19
A745/WH
12
11
46
34
ATAFP ATA+
F703/GY
10
A
1
3
5
7 10
2
23A
D+
D
32
24
D-
E
EMER. STOP ON ENCLOSURE
65 30
22 64 23
29
AP-
AP+
A
C
B
A
82
78
80
ATA-
145-3850
ATA+
2
C
A
B
C
A
EF2
B
REF B3
H
2
4
ST4 R448 AVR
8
6
MAGNETIC PICK UP No.1
J
:86 SR :85
4
AIR SHUT-OFF SOLENOID ASOS
FP
2
SMMS1
B CDVR
2
OIL TEMPERATURE
REF A11
CORE BALANCE CURRENT TRANSFORMER IF REQUIRED
59
2
REF B3
COOLANT LOSS
1
SASV
LOW FUEL LEVEL SWITCH
NOTE B: VOLTS ADJUST CONNECTION WHEN USING A CDVR REGULATOR
A
IF REQUIRED
VOLUME 2 3456 WITH EMCP II+
FIT IF REQUIRED
2
15
14
13
12
11
REF B10
SMMS2
30
16
10
NOTE A: VOLTS ADJUST CONNECTION WHEN USING A R448 REGULATOR
2
C
C
234-3205
82
72
59
1
2 B
DIAGRAM-WIRING (ENGINE SCHEMATIC)
56
DIAGRAM-WIRING (ENGINE HARNESS) EF1
20 XT
55
54
B
SERVICE CONNECTOR
P+
80
FIT IF REQUIRED
P+
11
20
56
64
20 SCR
8
46
20 31
9
30
30
39
ATA+
E794/YL
451/BR E965/BU F717/YL
40
ATA-
E793/BU
14
55
41
J3/P3
993/BR
SEE NOTE B
ES54
15
235-0745
8
F710/BR
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
DIAGRAM-WIRING (EMCP II+)
D-SPD
F704/OR
30
17
207
92
11
9
4
23A
25
96
5
205
K
202
D+
6
F704/OR F702/GN
-
6
203
J
53
SD-RTN
893/GN
A745/WH A746/PK A747/GY 994/GY A751/YL C967/BU E799/BR F700/BU F701/BR 995/BU
20
16
202
D+
52
SD-PWR
7
N944/PU
SD-RTN
11
4 3
N940/BU N941/YL F714/PK
SD-PWR
54
9
:3
6
ASOR+
GROUND STUD
A
39
102/RD
L983/WH L984/OR L985/YL A706/GY A705/BU A704/GN A703/BR A702/PU A701/GY F723/PK F724/PU
20
6
10
F702/GN J1/P1 BKUP SP/TMG SNSR 18 SPARE 32 37 DIGITAL SNSR RETURN 29 ANALOG SNSR PWR (5V) 36 ANALOG SNSR RETURN 30 SPARE 31 38 SPARE 20 SPARE 27 STARTING AID 25 SPARE 15 GROUND LEVEL SHUTDOWN (NO) 2 GROUND LEVEL SHUTDOWN (NC) 8 SPARE 22 DIGITAL SNSR POWER (+8V) 35 ENG. RTDR SEL. SW (LO/MED/HI) 24 SPARE 34 START/RUN/STOP 2 13 SPARE 21 SPARE 28 ETHER START VALVE RELAY 40 10 SPARE 11 BACKUP SPEED / TIMING SNSR (-) 12 START/RUN/STOP 1 14 16 SPARE 17 ENG. RETARDER SEL. SW (MED) 19 SPARE 23 +BAT. (UNSWITCHED)(NOTE B) 4 +BAT. (SWITCHED) 6 J1939 SHIELD 26 SPARE 39 SPARE 33 ATA DATA LINK - 1 ATA DATA LINK + 7 CAT DATA LINK - 3 CAT DATA LINK + 9 -BAT. 5
28
D-
DATA LINK
3
150/OR
23 24
6
22
21
6
LCL 13
22
21
10
25
8
CR/3
26A
LOP 8
HET 7
9
5
45
EMER. STOP
2
V+
31
43
59
15
31
30 24
AUX. ALARMS/SHUTDOWNS SWITCHED -VE
17
38
19
RDM
50
GPHI RM 27
20
D-
RM 19
1
INJECTOR COMMON 1 & INJECTOR COMMON 3 & INJECTOR COMMON 5 & INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR TDC PROBE TDC PROBE
D+ 21
D+
+
EGR
BODY
MOT2
29 23
21
19
D-
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
ASR
E
MOT1
L
21
32
31
RDM
GENERATOR SET CONTROL (GSC)
ENG OIL PR SNSR (161-9926)
DOOR
84
20
J
19
RR
GFR
FUEL PRESSURE SNSR (194-6725)
58
29
437 CCM+
36 SPARE
F10 (10A)
E
57
81
15
D-
47
426
416
SMR
ATMOSPHERIC PRESS. (161-9926)
CHASSIS
MOT2
4
76
14
K
13
217
5
18
FCR
FCR
FUEL TEMP SNSR (102-2240)
MOT1
18
75
13
3
20
13
1
TURBO OUTLET PRESS. (194_6724)
REF. L07
84
33
74
12
4
:2 KWR :10
J3/P3
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
28
81
32
46
:9
ECM
27
76
5
CCM DATALINK
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
F
16
75
25
73
M
11
D+
1
RM 4
+5V SIGNAL RETURN
101
101
J1-2
91
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.
LINK
T2
61
P47/J47 COOLANT FLOW SWITCH 412/BU 1 (NOT USED) N944/PU 2
G
101
REF. G14
COOL. TEMP SNSR (102-2240)
+5V SIGNAL RETURN
J49/P49 OR A N940/BU GN C A745/WH YL B N941/YL
T3
H23 F11 (2A)
1
F2 (10A)
+5V SIGNAL RETURN
P43/J43 OR A N940/BU WH A751/YL C BK B N941/YL
T2
22
BKUP SP/TMG SNSR (4P-7610)
+5V SIGNAL RETURN
J22/P22 OR A GN C YL B
52
PRIM. SP/TMG SNSR (4P-7610)
SIGNAL (-) SIGNAL (+)
P21/J21 OR N940/BU A WH 995/BU C BK N941/YL B
T1
:8 :9 :10
P2/2
470 ohm POT ST4
B+
J27/P27 OR N940/BU A WH A747/GY C BK N941/YL B
H
50
T1
CONTROL MODE SWITCH
32
30 31
INLET AIR TEMP SNSR (107-8618)
SIGNAL (-) SIGNAL (+)
P44/J44 BK E965/BU 1 WH E966/YL 2
N940/BU A746/PK N941/YL
50
J1-6
J1-3
92
H
AUTO START COOLDOWN/STOP
30
AVR +5V SIGNAL RETURN
74
31
72
OFF/RESET 80
1
P89/J89 OR A N940/BU WH C C967/BU BK B N941/YL
73
17
10
57
56
R448
P26/J26 F723/PK 1 F724/PU 2
72
71
1
:6
CYL NO.1
93
G
51
J1-4
82
SPEED CONTROL S
CYL NO.6
80
94
F
92
J1-7
95
E
93
33
42
2
D-SPD
L983/WH L984/OR L985/YL A706/GY A705/BU A704/GN A703/BR A702/PU A701/GY F700/BU F701/BR E799/BR
50
J1-8
96
D
91
RETARDER SOLENOIDS NOT USED
(Dimensions: 39 inches x 28 inches)
96
82
16
97
C
95
13
3
30 Page,
80
:3
:1
94
2
RENR8077-03 VOL 2 of 2
:3
98
B
97
:2
6 mm 2
12
J
A
:2
2
53
1
VOLTS ADJUST POTENTIOMETER (1K, 1 TURN)
25
(OPTIONAL)
52
14
SR/1 :87
SMMS1/1
-
51
40
:30 PS1
2
1
71
E
E
13
A+
24V
1
4 POLE BREAKER OPTIONAL
2
6 mm
9
1
2
1
M
15
10
9
8
7
6
5
4
3
2
1
