RTD MODULE

40-PIN CONNECTOR
RTD #1 - H RTD #1 - M RTD #1 - L RTD #1 - GND RTD #1 - SHIELD RTD #2 - H RTD #2 - M RTD #2 - L RTD #2 - GND RTD #2 - SHIELD RTD #3 - H RTD #3 - M RTD #3 - L RTD #3 - GND RTD #3 - SHIELD RTD #4 - H RTD #4 - M RTD #4 - L RTD #4 - GND RTD #4 - SHIELD RTD #5 - H RTD #5 - M RTD #5 - L RTD #5 - GND RTD #5 - SHIELD RTD #6 - H RTD #6 - M RTD #6 - L RTD #6 - GND RTD #6 - SHIELD RTD #7 - H RTD #7 - M RTD #7 - L RTD #7 - GND RTD #7 - SHIELD RTD #8 - H RTD #8 - M RTD #8 - L RTD #8 - GND RTD #8 - SHIELD 1 2 3 4 5 11 12 13 14 15 21 22 23 24 25 31 32 33 34 35 6 7 8 9 10 16 17 18 19 20 26 27 28 29 30 36 37 38 39 40 164 163 192 191 182 181 172 171

THERMOCOUPLE MODULE
RED

DISCREET I/O MODULE

40-PIN CONNECTOR
INPUT #1
124

CUSTOMER CONNECTIONS:

JUMPER PLUGS
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 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67

WIRE IDENT:-1 -2 x2

40-PIN CONNECTOR
112

THERMOCOUPLE #1

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

340 341 342 343 344 345 346 347 348 349 350 351 352 353 354 355 356 357 358 359

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

300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339

72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

INPUT 1 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW WARNING' INPUT 2 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW SHUTDOWN INPUT 3 DEFAULT SPN='COOLANT LEVEL LOW WARNING' INPUT 4 DEFAULT SPN='COOLANT LEVEL LOW SHUTDOWN' INPUT 5 DEFAULT SPN='AIR SHUTOFF DAMPER CLOSED' INPUT 6 DEFAULT SPN='GEN BREAKER CLOSED' INPUT 7 DEFAULT SPN='UTILITY BREAKER CLOSED' INPUT 8 DEFAULT SPN='ATS IN NORMAL POSITION' INPUT 9 DEFAULT SPN='ATS IN EMERGENCY POSITION' INPUT 10 DEFAULT SPN='SPARE' INPUT 11 DEFAULT SPN='SPARE' INPUT 12 DEFAULT SPN='SPARE'

RTD PT100 WHITE

THERMOCOUPLE #1 THERMOCOUPLE #2

CHANNEL1 DEFAULT SPN='EXHAUST GAS PORT 1 TEMP'

125 126

INPUT #2 INPUT #3

UENR3165 February 2012

SPARE BATTERY SPARE BATTERY SPARE BATTERY SPARE BATTERY SHUNT TRIP RELAY ETHER START RELAY COIL OPTIONS BATTERY + OPTIONS BATTERY +

AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12

113 114

THERMOCOUPLE #2 THERMOCOUPLE #3 THERMOCOUPLE #3

CHANNEL2 DEFAULT SPN='EXHAUST GAS PORT 2 TEMP'

127

INPUT #4 INPUT #5

RED
115

128

-6 -8 -55 -12 -30 -30 -37 -38 -55 x2 -55 x2 -59 -73 -77 -95 -96 -ES- x2 -EF1 -EF2 -CAN1-CAN1+ -SRN -93 -94 -M+ -M-MREF -S-SPD -D-SPD -SRN -G407 -G408 -G409 -57 -30 -64 -65 -66 -87 -88 -89 -81 -83 -84 -85 -90 -91 -92 -97 -98 -99 -CAN2+ -CAN2-SRN -231 -232 -233

CHANNEL3 DEFAULT SPN='EXHAUST GAS PORT 3 TEMP'

129 130

INPUT #6 INPUT #7

RTD PT100 WHITE

THERMOCOUPLE #4 THERMOCOUPLE #4

CHANNEL4 DEFAULT SPN='EXHAUST GAS PORT 4 TEMP'

131 132

INPUT #8 INPUT #9

116 117

THERMOCOUPLE #5 THERMOCOUPLE #5 THERMOCOUPLE #6

CHANNEL5 DEFAULT SPN='EXHAUST GAS PORT 5 TEMP'

133

INPUT #10 INPUT #11

RED

SPARE BATTERY + SPARE BATTERY + ETHER START SOLENOID FUEL LEAK DETECT

AWG 12 AWG 12 AWG 12 AWG 12

118

134

RTD PT100 WHITE

THERMOCOUPLE #6 THERMOCOUPLE #7

CHANNEL6 DEFAULT SPN='EXHAUST GAS PORT 6 TEMP'

135

INPUT #12 INPUT COMMON #1

ETHER START SWITCH J1939 PRIMARY COMMUNICATION J1939 PRIMARY COMMUNICATION SHIELD
T1

AWG 12 AWG 12 AWG 12 AWG 12

136

120 OHM RESISTOR BETWEEN 27 & 29

119 120

THERMOCOUPLE #7 THERMOCOUPLE #8 THERMOCOUPLE #8

CHANNEL7 DEFAULT SPN='EXHAUST GAS PORT 7 TEMP'

137 138

INPUT COMMON #2 INPUT COMMON #3

RED

121

CHANNEL8 DEFAULT SPN='EXHAUST GAS PORT 8 TEMP'

139

INPUT COMMON #4 OUTPUT #1 (N/O)

RTD PT100 WHITE

THERMOCOUPLE #9 THERMOCOUPLE #9

140

CHANNEL9 DEFAULT SPN='EXHAUST GAS PORT 9 TEMP'

141

U
T4 T7

OUTPUT #1 (N/C) OUTPUT #1 (COM)

OUTPUT 1 DEFAULT SPN='COOLANT TEMP HIGH WARNING'

W (L3) T12 T6 LINK V (L2) T11 LINK
T9 T6

122 123

THERMOCOUPLE #10 THERMOCOUPLE #10 THERMOCOUPLE #11

142 143

CHANNEL10 DEFAULT SPN='EXHAUST GAS PORT 10 TEMP'

OUTPUT #2 (N/O) OUTPUT #2 (N/C)

MODBUS RS485 COMMUNICATION MODBUS RS485 COMMUNICATION MODBUS RS485 COMMUNICATION

AWG 12 AWG 12 AWG 12

120 OHM RESISTOR BETWEEN 41 & 42

CHASSIS DC TERMINAL RAIL

T9

T3

RTD TERMINAL STRIP

THERMOCOUPLE #11 THERMOCOUPLE #12 THERMOCOUPLE #12 THERMOCOUPLE #13 THERMOCOUPLE #13 THERMOCOUPLE #14 THERMOCOUPLE #14 THERMOCOUPLE #15 THERMOCOUPLE #15 THERMOCOUPLE #16 THERMOCOUPLE #16 THERMOCOUPLE #17 THERMOCOUPLE #17 THERMOCOUPLE #18 THERMOCOUPLE #18 THERMOCOUPLE #19 THERMOCOUPLE #19 THERMOCOUPLE #20 THERMOCOUPLE #20

THERMOCOUPLE TERMINAL STRIP

OUTPUT 2 DEFAULT SPN='OIL PRESSURE LOW WARNING'

SERIES STAR CONNECTION DIAGRAM (HIGH VOLTAGE WYE)

T10 T12

T11 T8

T5

OUTPUT #2 (COM) OUTPUT #3 (N/O) OUTPUT #3 (N/C) OUTPUT #3 (COM) OUTPUT #4 (N/O) OUTPUT #4 (N/C) OUTPUT #4 (COM) OUTPUT #5 (N/O) OUTPUT #5 (N/C) OUTPUT #5 (COM) OUTPUT #6 (N/O) OUTPUT #6 (N/C) OUTPUT #6 (COM) OUTPUT #7 (N/O) OUTPUT #7 (N/C) OUTPUT #7 (COM) OUTPUT #8 (N/O) OUTPUT #8 (N/C) OUTPUT #8 (COM)

T0

T2V

T5

T8

T2 U (L1)

CUSTOMER LOAD CONNECTIONS

T10

T4

T7

95 96 97 98 99 100

OUTPUT 3 DEFAULT SPN='COOLANT TEMP LOW WARNING'

T1 N

T3

OUTPUT 4 DEFAULT SPN='GENERATOR CONTROL NOT IN AUTO'

U
T1

T7

101 OUTPUT 5 DEFAULT SPN='OIL PRESSURE LOW SHUTDOWN' 102 103 104 OUTPUT 6 DEFAULT SPN='COOLANT TEMP HIGH SHUTDOWN' 105 106
T12
T10

W (L3) T6 LINK V (L2)

T8 T11

T9

T3

PARALLEL STAR CONNECTION DIAGRAM (LOW VOLTAGE WYE)

T12

T4

T2

N
T0 T6

T5

T11 LINK

T5

T8

T2 U (L1)

CUSTOMER LOAD CONNECTIONS

C18 Generator Set with EMCP4.1/4.2 Electrical System

N1C1-UP N1D1-UP DKE1-UP M1P1-UP EKW1-UP M1Y1-UP M1Z1-UP
CT EARTH CT PHASE A CT PHASE B CT PHASE C CT NEUTRAL AWG 12 AWG 12 AWG 12 AWG 12 AWG 12

RS485 SERIAL ANNUNCIATOR + RS485 SERIAL ANNUNCIATOR RS485 SERIAL ANNUNCIATOR REF REMOTE START FROM ATS ATS REMOTE START FROM ATS COMMON SHUTDOWN RELAY - N/C COMMON SHUTDOWN RELAY - COMMON COMMON SHUTDOWN RELAY - N/O GENERATOR RUNNING RELAY - N/C GENERATOR RUNNING RELAY - COMMON GENERATOR RUNNING RELAY - N/O

AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12

120 OHM RESISTOR BETWEEN 62 & 63

T10

T4

T7

T1 N

J1939 SECONDARY COMMUNICATION J1939 SECONDARY COMMUNICATION SHIELD BREAKER AUX N/C BREAKER AUX COM BREAKER AUX N/O

AWG 12 AWG 12 AWG 12 AWG 12 AWG 12 AWG 12

107 OUTPUT 7 DEFAULT SPN='ENGINE OVERCRANK' 108 109 110 OUTPUT 8 DEFAULT SPN='ENGINE OVERSPEED' 111

T9

T3

GENERATOR LEAD WIRING

8-PIN CONNECTOR
BATT(+) BATT(-) 5 6 55 2 18 5 BATTERY POSITIVE(12-24V DC) BATTERY NEGATIVE (12-24VDC)

8-PIN CONNECTOR
BATT(+) BATT(-) CAN_H CAN_L SHIELD 64 1 4 2 3 5 55 2 CAN1 + CAN1 SHIELD 18 5 BATTERY POSITIVE(12-24V DC)

8-PIN CONNECTOR
BATT(+) BATT(-) BATTERY NEGATIVE (12-24VDC) 29 27 31 CAN_H CAN_L SHIELD 2 3 5 CAN2 + CAN2 SHIELD 1 4 55 2 18 BATTERY POSITIVE(12-24V DC) 5

1 2 3 4 5 6 7 8 9 10 11 12 13 AWG 8 14 15

-50 -51 -52 -53 -101 -108 -209 -210 -142 -140 -131 -131 -143 -131 -131 -132 -132 -132 -133 -133 -133 -EARTH -EARTH

CT EARTH CT PHASE A CT PHASE B CT PHASE C CT NEUTRAL

AWG 12 AWG 12 AWG 12 AWG 12 AWG 12

CAN_H CAN_L SHIELD

2 4 3

CAN2 + CAN2 SHIELD

62 J1939 DATA LINK - HIGH 63 J1939 DATA LINK - LOW

J1939 DATA LINK - HIGH J1939 DATA LINK - LOW

N
62 63 64 J1939 DATA LINK - HIGH J1939 DATA LINK - LOW

L1

AWG 8

16 17 18

CHASSIS AC TERMINAL RAIL 3 WIRE 240V

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 AWG 8

-50 -51 -52 -53 -101 -108 -209 -210 -142 -140 -131 -131 -143 -131 -131 -132 -132 -132 -133 -133 -133 -EARTH -EARTH

16 17 18

CHASSIS AC TERMINAL RAIL 2 WIRE 240V

L2 AWG 8 CUSTOMER SUPPLY POWERS OPTIONAL JACKET WATER HEATER, BATTERY CHARGER, AND GENERATOR SPACE HEATER

19 20 21

L1 AWG 8 CUSTOMER SUPPLY POWERS OPTIONAL JACKET WATER HEATER, BATTERY CHARGER, AND GENERATOR SPACE HEATER

19 20 21

Failure Mode Identifier (FMI) Codes Description Data Valid but Above Normal Operational Range- Most Severe Level Data Valid but Below Normal Operational Range- Most Severe Level Data Erratic, Intermittent or Incorrect Voltage Above Normal or Shorted to High Source Voltage Below Normal or Shorted to Low Source Current Below Normal or Grounded Circuit Current Above Normal or Grounded Circuit Mechanical System Not Responding or Out of Adjustment Abnormal Frequency, Pulse Width or Period Abnormal Update Rate Abnormal Rate of Change Unexpected Engine Shutdown Bad Intelligent Device or Component Out of Calibration Special Instructions Data Valid But Above Normal Operational Range- Least Severe Level Data Valid But Above Normal Operational Range- Moderately Severe Level (Derate) Data Valid But Below Normal Operational Range- Least Severe Level Data Valid But Below Normal Operational Range- Moderately Severe Level (Derate) Received Network Data In Error Not Available or Condition Exists

T1

L1 L2 L3 N E 6 55 POWER WIRING FROM GENERATOR T1 T2 T3 N E

17

FMI 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 31

T1 L1 T2 L2 L3 N E
8

L1 L2 L3 N E

T2 POWER WIRING FROM GENERATOR T3 N E

POWER WIRING FROM GENERATOR

T3 N E

NOTES: WIRE SIZES ARE MAXIMUM TERMINAL CAPABILITIES. 208VAC IS ACCEPTABLE VOLTAGE FOR AC FEED, BUT THE JW HEATER WILL DERATE. DO NOT TURN ON AC POWER UNTIL FIELD TECHNICIAN HAS CHECKED WIRING. SEE SEPARATE DRAWINGS FOR INTERCONNECT POINTS ONTO OPTIONAL SHIP LOOSE ITEMS. SEE SEPARATE SHEET FOR THE LOCATION OF THE TERMINAL STRIP ON THE GENSET.

Volume 2 of 2: EMCP 4.1/4.2

2012 Caterpillar All Rights Reserved

55

TERMINAL BLOCK
Printed in U.S.A.

17

3 8

2 6

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

A1:

11:

P853 P854

:C1 ST :C2 24V DC SHUNT TRIP

4

2:

1:

2 C2/C12

:C1/C11* ST :C2/C12* 24V DC SHUNT TRIP

STR
10: 3:

STR/1

STR
A2: 14:

STR/1

REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS

65 67 66

231 233 232

:11 :13 BREAKER AUXILIARY

:12 :14

REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS

67 65 66

233 231 232

:14 :12 :11 BREAKER AUXILIARY

C2/C12 REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS

67 65 66

233 231 232

:14 :12 :11 BREAKER AUXILIARY

MCCB

* C1 & C2 CONNECTIONS ON T5 (630A) & T6 (800A) BREAKERS C11 & C12 CONNECTIONS ON T7 (1250A & 1600A) BREAKERS

MERLIN GERIN BREAKER

SPN Description Fuel Level (External Tank) Aftercooler Temperature Starting Air Pressure Fuel Pressure Fuel Filter Differential Pressure Fuel Level (Local Tank) Engine Oil Level Oil Filter Differential Pressure Engine Oil Pressure Crankcase Pressure Intake Manifold 1 Temperature Air Filter Differential Pressure Atmospheric Pressure Engine Coolant Temperature Engine Coolant Level Fire Extinguisher Pressure Battery Voltage (switch) Battery Charging System Voltage Battery Voltage Ambient Air Temperature Inlet Air Temperature Exhaust Temperature Fuel Temperature Engine Oil Temperature Turbo Oil Temperature Engine Speed Auxiliary Temperature 1 Auxiliary Temperature 2 Generator Rotating Diode Failure SCADA Data Link Fault Voltage Regulator Failure Primary Data Link (J1939 #1) Event Input Function #1 Event Input Function #2 Event Input Function #3 Event Input Function #4 Event Input Function #5 Event Input Function #6 Event Input Function #7 Event Input Function #8 Event Input Function #9 Event Input Function #10 Event Input Function #11 Event Input Function #12 Event Input Function #13 Event Input Function #14 Event Input Function #15 Event Input Function #16 Emergency Stop Switch Engine Derate Overridden Generator Bearing Temperature #1 Generator Bearing Temperature #2 Generator Winding Temperature #1 Generator Winding Temperature #2 Generator Winding Temperature #3 Intake Manifold 2 Temperature Intake Manifold 3 Temperature Intake Manifold 4 Temperature Engine Oil Temperature 2 Exhaust Gas Port 1 Temperature Exhaust Gas Port 2 Temperature Exhaust Gas Port 3 Temperature Exhaust Gas Port 4 Temperature Exhaust Gas Port 5 Temperature Exhaust Gas Port 6 Temperature Exhaust Gas Port 7 Temperature Exhaust Gas Port 8 Temperature Exhaust Gas Port 9 Temperature Exhaust Gas Port 10 Temperature Suspect Parameter Number (SPN) SPN SPN Description 38 52 82 94 95 96 98 99 100 101 105 107 108 110 111 137 158 167 168 171 172 173 174 175 176 190 441 442 612 625 628 639 701 702 703 704 705 706 707 708 709 710 711 712 713 714 715 716 970 971 1122 1123 1124 1125 1126 1131 1132 1133 1135 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 Exhaust Gas Port 11 Temperature Exhaust Gas Port 12 Temperature Exhaust Gas Port 13 Temperature Exhaust Gas Port 14 Temperature Exhaust Gas Port 15 Temperature Exhaust Gas Port 16 Temperature Exhaust Gas Port 17 Temperature Exhaust Gas Port 18 Temperature Exhaust Gas Port 19 Temperature Exhaust Gas Port 20 Temperature Main Bearing 1 Temperature (engine) Main Bearing 2 Temperature (engine) Main Bearing 3 Temperature (engine) Main Bearing 4 Temperature (engine) Main Bearing 5 Temperature (engine) Main Bearing 6 Temperature (engine) Main Bearing 7 Temperature (engine) Main Bearing 8 Temperature (engine) Main Bearing 9 Temperature (engine) Main Bearing 10 Temperature (engine) Main Bearing 11 Temperature (engine) Turbocharger 1 Compressor Inlet Temperature Turbocharger 2 Compressor Inlet Temperature Turbocharger 3 Compressor Inlet Temperature Turbocharger 4 Compressor Inlet Temperature Turbocharger 1 Turbine Inlet Temperature Turbocharger 2 Turbine Inlet Temperature Turbocharger 3 Turbine Inlet Temperature Turbocharger 4 Turbine Inlet Temperature Turbocharger 1 Turbine Outlet Temperature Turbocharger 2 Turbine Outlet Temperature Turbocharger 3 Turbine Outlet Temperature Turbocharger 4 Turbine Outlet Temperature Engine Auxiliary Coolant Temperature Accessory Data Link Fault (J1939 #2) Emergency Shutdown Override Mode Active Warning Ruptured Fuel Basin- Primary Tank Unexpected Engine Shutdown Engine Failure to Start Shutdown Battery 1 Temperature Battery 2 Temperature Intake Manifold 5 Temperature Intake Manifold 6 Temperature Right Exhaust Temperature Left Exhaust Temperature Generator Frequency Generator AC Voltage Generator AC Current Generator Reverse Power (kW) Generator Reverse Power (kVAr) Service Interval Warning Air Damper Closed ATS in Normal Position ATS in Emergency Position Battery Charger Failure Generator Breaker Closed Utility Breaker Closed Engine in Cooldown Generator Control Not in Automatic Warning Generator Breaker Failure to Open Utility Breaker Failure to Open Generator Breaker Failure to Close Utility Breaker Failure to Close Utility to Generator Transfer Failure Warning Generator to Utility Transfer Failure Warning Loss of Utility Earth Fault Earth Leakage SPN 1147 1148 1149 1150 1151 1152 1153
13 1 14 24 32

ACB

Related Electrical Service Manuals Title EMCP 3 Systems Operation/ Troubleshooting/ Testing and Adjusting Form Number RENR7902

CONNECTOR PINOUTS FOR HARNESS 269-8103

160-7689 9X-4391
23 31 39 47 57 70

155-2264

CONNECTOR PINOUTS FOR HARNESS 258-4700

160-7689
CONTROL RELAY CR
8 7 6 5
13 23 31 1 14 24 32 40 48 58

1154 1155 1156 1157 1158 1159 1160 1161 1162 1163 1164 1165 1166 1167 1172 1173 1174 1175 1180 1181 1182 1183 1184 1185 1186 1187 1212 1231 1237 1239 1383 1664 1800 1801 1802 1803 2433 2434 2436 2440 2448 2452 2456 2648 4000 4001 4002 4003 4004 4005 4006 4007 4009 4010 4011 4012 4015 4016 4017 4028 4029

14 13 12 11 10

28 27 26 25 24 23 22 42 41 40 39 38 37 36 56 55 54 53 52 51 50

21 20 19 18 17 16 15 35 34 33 32 31 30 29 49 48 47 46 45 44 43 63 62 61 60 59 58 57

1 2 3 4

103-0213

128-2312
41 55

10 1A 55

2 10 3

40 48 58

10 11 12 13 14

D E F G H A J C B

90

70 69 68 67 66 65 64

55

15 16 17 18 19 20 21 29 30 31 32 33 34 35 43 44 45 46 47 48 49 57 58 59 60 61 62 63

22 23 24 25 26 27 28 36 37 38 39 40 41 42 50 51 52 53 54 55 56 64 65 66 67 68 69 70

16 0

39 47 57

90

90

160 160

CAN 1CAN 1+

2 55

26

ECM (J1) PLUG POSITION NO: 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 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 WIRE INDENT 1 1 D+ DSCR n/a 10 n/a n/a 20 2 2 n/a n/a 41 n/a 45 n/a n/a 18 n/a n/a 19 n/a n/a n/a 8 ESn/a n/a 21 22 SCR n/a SSPD DSPD SCR n/a CAN1+ CAN1SCR n/a n/a n/a n/a 11 12 17 34 46 n/a n/a n/a 78 80 82 n/a n/a 59 n/a EF1 EF2 n/a 72 30 n/a n/a n/a n/a SCR

GENERATOR PLUG 70 WAY POSITION NO: 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 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 WIRE INDENT n/a n/a n/a n/a n/a n/a n/a D+ Dn/a n/a n/a n/a n/a n/a n/a n/a 20 n/a n/a 8 ES45 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a CAN1n/a n/a n/a n/a n/a 41 n/a n/a n/a n/a n/a n/a n/a B+ n/a CAN1+ n/a B+ B+ n/a n/a n/a n/a n/a n/a n/a 2 n/a 2 n/a 2 SSPD n/a DSPD n/a 10

E /STOP PLUG 8 WAY POSITION NO: 1 2 3 4 5 6 7 8 WIRE INDENT 17 30 12 11 46 2 34 4

ELECTRONIC CONTROL MODULE (ECM) P1

GENERATOR RECEPTACLE

200

50

20

30

20

0 16 160 160

6 8 10

70

120

30
0 16 160 160

23A 30 37

340

EMCP 3 PLUG PIN 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 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 WIRE 97 90 MSRN M+ n/a 101 n/a 110 n/a 109 n/a 108 99 92 n/a n/a n/a n/a n/a n/a n/a n/a 98 91 38 55 94 62 19 51 6 36 CAN 137 93 62 16 50 55 55 SRN 55 72 73 62 52 41 n/a CAN 1+ 14 55 77 18 57 15 53 2 n/a n/a 55 CAN 2+ SRN CAN 22 22 21 96 95 17

GENERATOR RECEPTACLE 70 WAY PIN 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 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 WIRE 1 1 D+ DSRN n/a 10 3 23A n/a 2 2 15 16 41 41 45 n/a 62 18 n/a n/a 19 n/a 30 n/a 8 ESn/a n/a 21 22 SRN n/a SSPD DSPD YEL SRN CAN 1+ CAN 1SRN n/a n/a n/a n/a n/a n/a 17 34 46 n/a n/a n/a 78 80 82 n/a n/a 59 n/a EF1 EF2 n/a 72 30 n/a n/a n/a n/a SRN

SERVICE CONNECTOR PIN A B D E F G H J WIRE 55 2 D+ DCAN 1CAN 1+ n/a n/a

SERVICE CONNECTOR RECEPTACLE

20
0 16 160 160

38 55 59

108 30 109 110

12 0 120 120 0 16 160 160

ETHER START
59 2

73 77

SPLICE(2)

ES20 ES16 0
0 16 160 160

30

95 96

116

EF2 30 50
1 19 90 0

110 SPLICE(7) SPLICE(5) SPLICE(4) SPLICE(3)

EF1 SCN

51 52

CONTROL PANEL

115

305

300

105

128

567

190

385

593

379

47

220

12 0 120 120

10

CAT DIGITAL VOLTAGE REGULATOR

2

0 19 190 190 190 19 0

CAN1CAN1+ SCN CAN1CAN1+

90

ETHER START
ES2 80 570 80 2

PANEL LIGHT SWITCH

1A 9

160

372 72

78 80

FUEL LEVEL
2

30 1790 30 1500 EF2 EF1

82

ANALOG VOLTAGE REGULATOR

CAN1CAN1+

440 40

260 131

PANEL LIGHT
9

80

80

20

93 94

2 2 4 10 EARTH
2 2.5mm

SPLICE(6)

R
30

19

L
180 180 180 200 245 165 200 200 200 210 180 1 B+

OIL TEMPERATURE

MAGNETIC PICKUP
100 200

2.5mm

17 14 45 30 30 200 30 120 120 120 46 30 101 80 140 140 140 OPTION CHASSIS ETH 78 100 250
160-7689
58 48 40 32 24 14 1 70 57 47 39 31 23 13

25

SCN DSPD
16 0
0 16 160

2 8mm

1 310 310

2 8mm

DOOR STUD ETH

SSPD

100 100 100

70

200 CONTROLLER ETH

25

428 SPLICE(1) 2198 143

2 8mm

40 1
2.5mm
2

STARTER MOTOR

30 57 53
12 0 120 120

E/STOP

34

50

40 20
1 16 60 0

2 8mm

55 10

90

TERMINAL BOX
2 8mm

180 180 180 180 30

2 8mm

0 16 160

ETH 2
2 8mm

108

VOLTAGE 82 ADJUST

90 91 CHASSIS ETH ETH TERM 50

1 16 60 0

40 2

92
0 16 160 160 160 16 0

A-10 B

ALTERNATOR
8mm
2

130

360

613

97 98 99 SCN

30

B-2 C-18

180 100
SPLICE 50 SPLICE 62 SPLICE 10 SPLICE 30 SPLICE 108

COOLANT LOSS
NOTE A: UNLESS OTHERWISE SPECIFIED ALL WIRE SIZES 1.5mm/16 AWG
1595

600
SPLICE 55 SPLICE 2 SPLICE 41 SPLICE 1 SPLICE 17

100

CAN2+ CAN2-

EMCP CONNECTOR ALL WIRES SIZES 1.5mm/16 AWG UNLESS OTHERWISE STATED

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 269-8103

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 258-4700

20 Page,

CORE BALANCE CURRENT TRANSFORMER

E/STOP

30 200

ALARM BUZZER
2

1 19 90 0

570

30

60

36

SCN
0 19 190 190

M+ M-

21

22

E/STOP

200

(Dimensions: 39 inches x 24 inches)

D+ D-

UENR3165 VOL 2 of 2

260 260 0 26 0 26

0 19 0 19 190 0 16 0 16

6
CORE BALANCE CURRENT TRANSFORMER IF REQUIRED
T1 T2

1
AREP
SUPPLY - AUXILIARY WINDING NOTE:A
ST3

11

133

SHUNT
SUPPLY 140V MAX 50/60HZ X2 10/YELLOW 1/2 PHASE T1- T4 OR T8 - T11 X1 Z2 X2

PMG
SUPPLY STATOR PMG 14

133

21

20 55 132

10/YELLOW 11/RED
J3

132
PMG

18

17 :11 :8
M2 2P 16A

4 POLE BREAKER OR POWER TERMINAL STRIP (PTS) OPTIONAL

POLARITY MARKS METERING C.T.s L1 S1 S1 S1 S2 S2 S2 CT1 CT2 CT3 L2 L3 N E
EXCITATION CEILING ADJUST P5
ST2

133
M1 2P 6A MCB

132 :3 :4

50Hz

60Hz

10A FUSE

9/GREEN
X2

X1

9/GREEN

15 16

:1 :2

:1 :2

:3 :4

CR/3 MCB

12/BLACK
Z1

T3 N E

F
CAN 2 SERVICE CONNECTOR
A 55 2
10 3

X1 Z2

STABILITY ADJUST P3

5
E+

LOCAL ANNUNCIATOR
55 2 ANNUNCIATOR # 1 P16 J16 1 BATT + 1 2 3 2 3 4 5 6 BATT TABLE: 1 VOLTAGE ADJUST P2
ST6

R448
NOTE:D

E0 110 ST9 220 380 J1

CONNECTION TO EXCITER OPTIONAL RFI KIT CONNECTIONS

141

AH2

137

134

138

NOTE:B

:5
NOTE:C
3 BLACK W ALTERNATOR WINDING CONNECTIONS BLACK RFI UNIT BLACK U BLUE N W ALTERNATOR WINDING CONNECTIONS

EF2 18 14 55 30 5 7 1 22 21 24 12 13 14 73 30 14 20 EF1 61 62

EF1
51 MAGNETIC PICK UP No.1 52 53 50 T1 F1 (2A) 2 T2 F2 (2A) T3 F3 (2A) 101

:A1

:3 :4 JW1

:5 :6 JW2

REMOTE ANNUNCIATOR
ANNUNCIATOR # 1 BATT + J16 P16 1 1 2 3 4 5 6 2 3 4 5 6 G407 G408 G409 55 2 18 5

B D SERVICE CONNECTOR E C H J

18 5

CR/2 :6

HC
:A2

EARTH FAULT RELAY 8 9 2 EF1 25 EF2 26

EF2 GENERATOR RECEPTACLE 1030213 GENERATOR PLUG 9X4391 EF2 EF1

NEUTRAL EARTH LINK

NC CAN2 SRN CAN2 CAN2 +

50 HZ VOLTAGE WYE 415/240V 400/230V 380/220V 220/127V 600V (T2 (T2 (T2 (T2 (T2 380) 380) 380) 220) 220)

ST1

NOTE:F 3ph
J2

NOTE:E T1 S1 S2

SRN CAN2+ CAN2-

64 63 62

SRN CAN2CAN2+

4 5 6

T1

POT 470ohm

1 4

BATT -

AH1

AH2

108
CORE BALANCE C.T.

109

110

101

NC RS-485+

BREAKER T2 T3 N E

1 REF. B05 21 GEN CONN. 70 WAY 22

ST4
_

P1 QUADRATURE DROOP ADJUST

U

2 ENGINE HEATER

RS-485RS-485 REF

GEN CONN. 70 WAY

31
21

32
22

33

41

42

43

29

27

31

62

63

64

35

36

37

1
1

120 OHMS

120 OHMS

120 OHMS

E
CAN2M+ MMREF

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)

P2 S2
+

ALTERNATOR HEATER
NOTE:H
NOTE:A 50/60 Hz SELECTION NOTE:B REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448

S1 STATISME P2 S2 S1

TI04 P1 N

NOTE:G

2
1 1 21 67 2 1 1 REF. B05 E EARTH (MOUNTING SCREW) 60 65 + MAG PICKUP IA IB IC I RETURN VA VB 22 66 AC 51 31 52 47 53 57 50 39 108 13 109 11 110 9 VC 101 7

G407

G408

G409

CAN1+

CAN1-

CAN2+

TABLE: 2 50 HZ VOLTAGE WYE TENSION P1 380) 380) 380) 220) 220)

470ohm POT

NOTE:I

59 +

49 RS485 NOTE G

17 REF

50 34 42 + SRN CAN1 J1939

62 64 63 + SRN CAN2 J1939 NOTE G

5 +

4 3 REF MODBUS (RS485) NOTE G +5V 16 12

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

(T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3 (T1,T2&T3

R731 U
110 400 230 400

V
230 400 110

W
230 110 N 4 3 2

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 SPLIT 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

SPACE HEATER CIRCUIT

BLOCK HEATER CIRCUIT

12 22 23

2 CB2 (20A) 24 + 24V PS1 CB3 (15A) CB1 (60A) 2

_ _ BATTERY (12/24Vdc)

EMCP4.1/4.2

NOTE G 69 SINK O/P 1 NOTE G 68 SINK O/P 2

95 96

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)

132

17

131 132
M4
1P 10A MCB

14

- (T1,T2&T3 220)

RELAY BOX
SR/1

55 A+ 1 :30 55

52 18

+ + RLY1 RLY2 FUEL CONTROL RLY3 ASR SWITCH RLY4 AUDIBLE ALARM RLY5 GFR SWITCH RLY6 GRR SWITCH ENG CRANK NOTE G RLY7 PROG O/P NOTE G RLY8 PROG O/P LOW COOLANT LEVEL I/P 1 54 18 FUEL LEAK I/P 2 53 77 21 13 15 EARTH FAULT I/P 3 45 73 20 LOW FUEL LEVEL I/P 4 44 72 PROG I/P 5 36 93 33 PROG I/P 6 28 94 34
EXCITATION CEILING ADJUST P5

ANALOG VOLTAGE REGULATOR DIAGRAM (3 PHASE SENSING)

OIL PRESSURE PASSIVE ANALOG 1+ 56 15 ENGINE TEMP PASSIVE ANALOG 2+ 38 16 OIL TEMP PASSIVE ANALOG 3+ 30 19 OIL PRESSURE PASSIVE ANALOG 146 62 ENGINE TEMP PASSIVE ANALOG 237 62 OIL TEMP PASSIVE ANALOG 329 62
50Hz 60Hz

SMMS1/1 25

:87

40

(OPTIONAL) BATTERY ISOLATOR SWITCH KEY REMOVABLE

SM1

PS1

B+ CHARGING ALTERNATOR

ALT DC F5 (10A) 1 F4 (10A) 55 55 REF. A05 41 34 CAN 150 CAN 1+ 2 A B C 1A 10 11 17 18 55 55 8 36 16 1A 51 14 61 55 48 41 58 2 35 37 43 55 33 36 41 55 32 6 40 55 26 38 27 55 2 25 15 1 24 14 97 98 99 59 60 61

EMERG STOP 70 17

REMOTE START 55 57

D
NOTE:A
ST3

AREP
SUPPLY - AUXILIARY WINDING 10/YELLOW 11/RED
J3 10A FUSE

SHUNT
SUPPLY 140V MAX 50/60HZ X2 10/YELLOW 1/2 PHASE T1- T4 OR T8 - T11 X1 Z2 X2

PMG
SUPPLY STATOR PMG 14

CONSTANT VOLTAGE CHARGER

140

1
PMG 15 16

90 91 92 56 57 58

9/GREEN
X2

X1

9/GREEN

TO STARTER MOTOR 2

140 GND 131

12/BLACK
Z1 X1 ST2 Z2

93 CHARGER FAIL 30 CHARGER COMMON

33 45

FUEL LEAK SWITCH

37 :86 AIR ASOR SHUTOFF RELAY 2 :85 4

6 :2 ALR ALARM RELAY :10 2 3 COMMON ALARM

31
40

32 28 30
CAN 1CAN 1+ H J G PANEL LIGHT SWITCH :3 :2 EMER. STOP 34

38 :2 GRR :10 2 GEN RUNNING

57

AIR SHUTOFF
1

62 13 14 23 19

STABILITY ADJUST P3

5
E+

OPTIONAL RFI KIT CONNECTIONS

_ +

R448
VOLTAGE ADJUST P2
ST6

E0 110

CONNECTION TO EXCITER BLACK W ALTERNATOR WINDING CONNECTIONS

BATTERY CHARGER CIRCUIT (120V L-N)

BLACK RFI UNIT V

NOTE:D

27
39

ETHER START
11 45 46 17 30 44

1 F27 (16A) 23
FOR USE WITH CVDR 78 VOLTS ADJUST POTENTIOMETER SEE NOTE F
ST9

NOTE:G 3 NOTE:C 2 W V ALTERNATOR WINDING CONNECTIONS

220 380 J1

29

COMMON ALARM
ALR/3 :12 :14 :11

ST1

NOTE:F

NOTE:E T1 S1 S2

BLACK BLUE

133
U

20

C
5 8 D+ 9 D40 41 23 30 2 2 2 70 10 66 S-SPD 53 68 D-SPD 35 36 37 REF. B04 S-SPD D-SPD 45 REF. A03 3 4 D+ DSERVICE CONNECTOR 15 REF. C04

10 :30 :30 EPIR/1 :87 23A 19

14

55

:2 80 :1 :3 82

C
J2

3ph

POT 470ohm

132 133
M4
1P 6A MCB

17

F D E PANEL LIGHT 9 :2 CR :10 55

REMOTE START CONTACT

45

ASOR/1 :87

64 46

65 47

66 48
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)
ST4

P1 QUADRATURE DROOP ADJUST

NOTE:B

REMOTE CONTACTS FOR GENERAL ALARM 12

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 SPLIT LINK - - -

41 2 34 30 REF. C05 46 17 48 17 30 25 30 30 65 GEN CONN. 70 WAY 49 34

59 23A
78 72 59 9 64 54 55 56 70 80 82

136 :4 FOR 5A CHARGER FIT (6A) BREAKER FOR 10A CHARGER FIT (10A) BREAKER CR/1 :1 140

U P2 S2 S1 TI04 P1

13 18

GENERATOR RUNNING
GRR/3 :12 :14 :11
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)

NOTE:H

48 52

PWM SPEED CONTROL

38 39 40

7
10

17

50 46

20

S-SPD D-SPD
11 10

S D +B -B

44

SPEED ADJ. POT. (2K, 10T)

78 59 23A 3 4

80

82

87 49

88 50

89 51

MCB 1P

CONSTANT VOLTAGE CHARGER 36 +

140 E

:1 2 43 :2 :3 1
R

7
EMER. STOP ON ENCLOSURE 8 WAY PLUG

REMOTE CONTACTS FOR GENERATOR RUNNING

ANALOG VOLTAGE REGULATOR DIAGRAM (SINGLE PHASE SENSING)

SECTION COLOR LEGEND

+ 1

M3

(*) - 5 2 -

132

61

42

78

80

82

30
63

8
SPEED CONTROL
4 10 :86 SMMS1 SR :85 2

2
FOR USE WITH CVDR

COMMON ALARM RELAY

6(-) F2 CONNECTION F1

BATTERY CHARGER CIRCUIT (240V L-N)

F2 9 F1 5(+)

14
65 21 8 22 ES27 28

8 ES-

9 24

E
8
REF. E03 REF. E04 DOOR CHASSIS BODY

E 50 E E E E 2

GENERATOR ALARM RELAY

FUEL LEVEL SWITCH REF B05 45 45 18
2

ST4 AVR
EMCP CONNECTION
G
VOLTS ADJUST POTENTIOMETER (MOUNTED IN CONTROL PANEL) 82
T1 T2 T3

TO EXCITER
30 30

F30 (10A) 10 11

10 11 12

ENGINE ELECTRONIC CONTROL MODULE(ECM)

{ENGINE MOUNTED}
11 2 12 2

ES-

:86 :1 MAN EPIR :2 AUTO :85 ETHER START SWITCH 2

RELAY BOX

8 NOTE F 5 7 NOTE E 30 30 30 16 6 5A NOTE G 28 28 26 16 F30 (10A) 14 14

START AID
:3 :2 10k 0.5W :1

82 NOTE H 6A 4 80

28

12 9

CONNECTION TO AREP

11

133

21

132

18

-VE SUPPLY

ETHER START

80

DROOP CT

REF B05

2 10 2 A B COOLANT LOSS C

59 SASV 2
2

AIR SHUT-OFF SOLENOID ASOS

AIR SHUTOFF
(+) BATTERY (+) BATTERY SWITCHED STARTING CIRCUIT (-) BATTERY / SENSOR RETURN SENSOR / ACTUATOR SUPPLY

POLARITY MARKS

S1

CONNECTION 16 TO PMG
15

26

26

F26 (10A)

55
M2 2P 16A MCB

:1 :2

:3 :4

26

26

GENERATOR CONNECTION

F26 (10A)

15

CONNECT FOR AREP EXCITATION GENERATORS

:11 CR/3 :8
NOTE:B CONNECT 1A DROOP CT BETWEEN TERMINALS 5 AND 6 CONNECT 5A DROOP CT BETWEEN TERMINALS 5A AND 6 NOTE:C FOR SE GENERATOR JUMPER TERMINAL 20 TO 28 TERMINAL 22 TO 30 TERMINAL 24 TO 36 REMOVE JUMPERS FOR PM OR AREP GENERATOR NOTE:D CONNECT VAR/PF CONTROL TO TERMINALS 2 AND 3 JUMPER TERMINALS 2 AND 3 WHEN NOT USING VAR/PF CONTROL NOTE:E FACTORY DEFAULT IS 2V/Hz UNDER FREQUENCY SLOPE. FOR 1V/Hz UNDER FREQUENCY SLOPE, ADD JUMPER TO TERMINALS 6A AND 8. NOTE:F FACTORY DEFAULT IS THREE PHASE SENSING. FOR SINGLE PHASE SENSING REMOVE JUMPER BETWEEN TERMINALS 6A AND 9. NOTE:G JUMPER 4 AND 7 WHEN USING INTERNAL VOLTAGE ADJUST, REMOVE WHEN USING REMOTE VOLTAGE ADJUST RHEOSTAT. NOTE:H CONNECT REMOTE ADJUST RHEOSTAT (10, 0.5w)

S2 NOTE B

UENR3165 VOL 2 of 2

3 2 30

REF. C05

RELAY BOX

CONNECT FOR PMG EXCITATION GENERATORS

TH1 ENGINE MOUNTED THERMOSTAT TH2 :A1 HC :A2

134

138

SIGNAL TO ECM CAT DATA LINK J1939(CAN) DATA LINK RS-232/RS-485 DATA LINK

ESTOP CONNECTION
L1 L2 L3

(Dimensions: 39 inches x 24 inches)

NOTE D 22 22

22

T1

22

ECM CONNECTION
24 24

24

T2

20 20 20

T3

CONNECTION TO GENERATOR TERMINALS (LINE PTS)

30 24 28 20 26

T4

T5

T6

CONNECTION TO GENERATOR TERMINALS (CENTER PTS)

:3

:5

:4 JW1

:6

GND

VR6-B
240V OR BELOW: (PARALLEL CONNECTION) ABOVE 240V: (SERIES CONNECTION)

HIGH LIMIT THERMOSTAT

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

OR

FUEL PUMPED FROM FREE STANDING BULK TANK - FUEL SYSTEM NO. 3

TERMINAL BOX
HIG HIG HH SW4

BETWEEN TERMINALS 6A AND 7.

ENGINE JACKET WATER HEATER 2

CABLE ENTRY
H

CONNECTION TO ALTERNATOR WINDINGS U T1 V T2 W T3

CONNECTION TO EXCITER

CONNECTION TO PMG

ABBREVIATIONS
ACB ASOR ASOS ALR AVR CR CT CTR CDVR ECM EMCP EPIR E/STOP GFR GRR LCD MCCB MV O/L PC POT PR PTS PWM RTD SASV SMMS SRN AIR CIRCUIT BREAKER AIR SHUT-OFF RELAY AIR SHUT-OFF SOLENOID ALARM RELAY AUTOMATIC VOLTAGE REGULATOR CONTROL RELAY CURRENT TRANSFORMER CRANK TERMINATION RELAY CAT DIGITAL VOLTAGE REGULATOR ENGINE CONTROL MODULE ELECTRONIC MODULAR CONTROL PANEL ETHER POWER INJECTOR RELAY EMERGENCY STOP GENSET FAULT RELAY GENERATOR RUNNING RELAY LIQUID CRYSTAL DISPLAY MOLDED CASE CIRCUIT BREAKER MOTORIZED VALVE OVERLOAD PUMP CONTACTOR POTENTIOMETER PUMP RELAY POWER TERMINAL STRIP PULSE WIDTH MODULATED RESISTIVE TEMPERATURE DETECTOR STARTER AID SOLENOID VALVE STARTER MOTOR MAGNETIC SWITCH SCREEN

VR6-B VOLTAGE REGULATOR DIAGRAM

5

JW2

AC CIRCUIT
NOTE:B IF 120V FUEL TRANSFER PUMP IS FITTED FUSE F21 SHOULD BE 10A IF 230V FUEL TRANSFER PUMP IS FITTED FUSE F21 SHOULD BE 6A 84 PUMP RUN F22 (2A) 81 PUMP STOP PUMP 205 :9 TRIP/ STOP :X2 F21 NOTE:B 6 mm 2 132 16 AC SUPPLY 207 131 :3 PR/1 :1 81 208 14 CUSTOMER 100V TO 250V

SW1

SW2

SW3

5+

6F28 (10A)

14 F29 (10A)

15 F30 (10A)

16

1 F23 (2A)

84

- OW LOW L LOW

HIG

CONNECTION TO AREP

SYMBOLS

JACKET WATER HEATER CIRCUIT

11

LEVEL SWITCH (TOP VIEW)

T1

T2

T3

F1 +

F2 4

12-3

12-4

12-5

12-6

12-9

14A

15A

16A

12

11

10

CHASSIS CUSTOMER TERMINAL LOCATED ON DC TERMINAL RAIL CHASSIS DC TERMINAL LOCATED ON DC TERMINAL RAIL CHASSIS AC TERMINAL LOCATED ON AC TERMINAL RAIL DOOR TERMINAL :2 :3 :1

:10 POWER TERMINAL CONNECTION GSC 40 WAY HARNESS CONNECTOR :1 ATB TERMINAL R/1 :3 :3 PANEL LAMP SWITCH :2 RELAY CONTACT N/O SCREEN CABLE
NOTE F: POTENTIOMETER NOT REQUIRED WITH CDVR. VOLTS ADJUST RAISE/LOWER SWITCH IS FITTED WITH CDVR (REF. CDVR DIAGRAM ON OUTSIDE PAGE). NOTE G: NOT AVAILABLE WITH EMCP 4.1 NOTE H: WIRE SIZES ARE MAXIMUM TERMINAL CAPABILITIES. 208AC IS ACCEPTABLE VOLTAGE FOR AC FEED, BUT THE JW HEATER WILL DERATE. DO NOT TURN ON AC POWER UNTIL FIELD TECHNICIAN HAS CHECKED WIRING. SEE SEPARATE DRAWINGS FOR INTERCONNECT POINTS ONTO OPTIONAL SHIP LOOSE ITEMS. SEE SEPARATE SHEET FOR THE LOCATION OF THE TERMINAL STRIP ON GENSET. NOTE J: CUSTOMER SUPPLY FROM 2 POLE BREAKER IN EMERGENCY PANEL POWERS OPTIONAL JW HEATER, UNIT MOUNTED BATTERY CHARGER AND GENERATOR SPACE HEATER.

R :2

RELAY COIL

IDENT Y X

HARNESS 258-4700 269-8103

CHG 07 06

DESCRIPTION EMCP HARNESS J1 / GENERATOR SET CONTROL HARNESS

207

84 :6 PR/2 :7
55

54

TERMINAL BOX
SW4 NORMALLY OPEN

LOW LEVEL FUEL SWITCH

52

+ 18-32 VDC -

10

8 12 11 10
5

11

3 6

DIGITAL A.V.R. (WITH PMG) 2 7 1 2 3 7 8 9 6 5 4 2 1

:X1

203

85 :2 MV :1 MOT. -VE SUPPLY VALVE

HIGH LEVEL FUEL SWITCH 83

53

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

LEVEL SWITCH (SIDE VIEW)

F28 (10A)

F29 (10A)

F30 (10A)

SW3

NORMALLY CLOSED
14A 15A 16A 9-6 9-5 9-4

28

SW2

NORMALLY CLOSED

S2

S1

PR/3 :11 204 207 13 1 208 3 131 5 + A1 131

SW1 NORMALLY CLOSED

9-1 9-2 9-3 9-7 9-8 9-9 78 78 78 80 82 T2

S2 S2 S1 SENSING CT (5 AMP SECONDARY) (1 VA BURDEN)

S1 FROM GENERATOR PHASE B POLARITY MARK

START AID SOLENOID VALVE SOCKET

POTENTIOMETER

20 Page,

This circuitry applies to fuel system No. 3 only. It does not exist in fuel system No. 1.

:2 PR :10
5

58

PC
A2 14 2 4 6 207 O/L 97

FUEL LEVEL SWITCH

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

78

80

82

CHASSIS TO DOOR DC SOCKET

30

FUSE

EARTH
DASHED FONT INDICATES AN ATTACHMENT COMPONENT OR HARNESS. ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL. UNLESS OTHERWISE SPECIFIED: ALL WIRES CONNECTED TO J2 TO BE 16 OR 18 AWG. ALL OTHER WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR EQUIVALENT. NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL.

RAISE

ENGINE SOCKET 5 CHASSIS TO DOOR AC SOCKET

LOWER INPUT ADJUST FITTED IN CONTROL PANEL

EMERGENCY STOP PUSHBUTTON CIRCUIT BREAKER PANEL LAMP

96

95 131 PUMP RUN

2 211 :X1

4 209

6 210

98 203

DC CIRCUIT
1

CAT DIGITAL VOLTAGE REGULATOR (CDVR)

7
:X2 M

F23 (2A) 84 84
54

LOW LEVEL FUEL SWITCH

52

:3 PR/1 :1

:6 PR/2 :7
55

Harness identification code This example indicates wire 135 in harness "AG". J174 P174 1306795 1306795 325-AG135 PK-14 Pin Socket Wire Color

Connector Reference Designator P274 1117898 Plug Wire Gauge Part Number For J274 Connector Assembly 3E5179 325-A135 PK-14 1 Receptacle 2 Fuse Pin or Socket Number 200-L32 BK-14 Component Part Number 105-9344

Component Description and Part Number ABC MODULE 105-9344

P Indicates a Plug J Indicates a Receptacle P-B 1117898

CDL+ CDL-

Connector Identification Receptacle Part Number

FUEL TRANSFER PUMP CIRCUIT

HIGH LEVEL FUEL SWITCH 83

53

P-B J-B Signal 1117898 3E5179 Description 1 Plug Part Number Plug 2 3 Receptacle 8

85 :2 MV :1 MOT. VALVE + -VE SUPPLY

Circuit Identification Number

OPTIONAL WIRING

Plug Ground Connection Socket Receptacle Integral with Component

:2 PR :10
5

Single Wire Connector

Ground Circuit Connection Number Identification

GND

4 Pin or Socket Number

SECTION BORDER

Pin

THIS SCHEMATIC IS FOR THE C18 GENERATOR SET WITH EMCP 4.1/4.2 ELECTRICAL SYSTEM Volume 2 of 2: EMCP 4.1/4.2 MEDIA NUMBER: UENR3165 Diagram Part Number: 372-8295, Change: 01, Version: - (EMCP4.1/4.2) Diagram Part Number: 244-5866, Change: 02, Version: DK (VOLTAGE REGULATOR(3 PHASE) Diagram Part Number: 254-1260, Change: 01, Version: DK (DIGITAL VOLTAGE REGULATOR) Diagram Part Number: 239-5745, Change: 02, Version: DK (VOLTAGE REGULATOR(SINGLE PHASE) Diagram Part Number: 239-8007, Change: 01, Version: - (GENERATOR LEADS) Diagram Part Number: 261-5834, Change: 17, Version: DK (OPTIONAL EQUIPMENT) Diagram Part Number: 354-8363, Change: 03, Version: - (VR6-B)
Components are shown installed on a fully operable generator set with the key and engine off. Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

FUEL TRANSFER CIRCUIT

Harness And Wire Symbols-Engine

Harness And Wire Symbols- Controller and Generator