C 18.pdf
September 19, 2017 | Author: Chmubasher Maqsoodalam | Category: N/A
Short Description
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Description
Injector Harness Connector P300
Turbo Outlet Pressure Sensor (Intake Manifold Air) J200
FRONT VIEW
RENR7934-01 March 2006
Fuel Temperature Sensor P105
Fuel Pressure Sensor J209
Harness And Wire Symbols Connector Reference Designator
Intake Manifold Air Temperature Sensor P103
P174 1306795
High Fuel Pressure
E194
High Exhaust Temperature
E197
High Engine Oil Temperature
E198
Low Fuel Pressure
E199
Low Coolant Temperature
E255
Diagnostic Reset
E264
Emergency Stop Activated
E360
Low Engine Oil Pressure
E361
High Engine Coolant Temperature
E362
Engine Overspeed
Electronic Control Module (ECM)
ECM Ground Strap
Primary Engine Speed/Timing Sensor (Crankshaft) P401
Ground Connection
High Fuel Temperature
E368
High Intake Manifold Air Temperature
200 BK-14
Atmospheric Pressure Sensor J203
ECM Connector P2/J2
ECM Connector J1
C18 Generator Set with EMCPII, EMCPII+ and EMCP3 Electrical System STD1-UP PDH1-UP (Engine)
C6C1-UP G4C1-UP STM1-UP STH1-UP (Engine)
Engine Oil Pressure Sensor J201
LEFT SIDE VIEW
E363
Fuse Pin or Socket Number
Timing Calibration (TC) Probe Connector P400
Condition
E096
Wire Color
Component Part Number
Event Codes For ADEM III ECM High Altitude Derate
2
Wire Gauge
105-9344
Engine Coolant Temperature Sensor P100
E009
Plug
Part Number For Connector Assembly
325 PK-14 Receptacle
1
Socket
Single Wire Connector Circuit Number Identification
C
Secondary Engine Speed/Timing Sensor (Camshaft) P402
J274 3E5179
P274 1117898 325 PK-14
Pin
Event Code
J174 1306795
Related Electrical Service Manuals Title
Form Number
Troubleshooting
SENR9706
Systems Operation / Testing and Adjusting
SENR9708
Volume 1- Engine and EMCPII Codes Printed in U.S.A.
© 2006 Caterpillar All Rights Reserved
EMCPII Diagnostic Codes
Component
Component
100
Engine Oil Pressure Sensor
0001
Injector #1
110
Engine Coolant Temperature Sensor
0002
Injector #2
111
Engine Coolant Level Sensor
0003
Injector #3
168
Electrical System Voltage
0004
Injector #4
190
Engine Speed Sensor
0005
Injector #5
248
CAT Data Link
0006
Injector #6
0041
8 Volt DC Supply
0091
Throttle Position
0094
Fuel Pressure
0100
Engine Oil Pressure
0110
Engine Coolant Temperature
0168
System Voltage
0172
Intake Manifold Air Temp
0174
Fuel Temperature
0175
Engine Oil Temperature
0190
Engine Speed
0247
Data Link Communications
0253
Personality Module
0261
Engine Timing
0262
5 Volt Sensor DC Power Supply
0268
Check Programmable Parameters
0273
Turbo Outlet Pressure
0274
Atmospheric Pressure
0342
Loss of Secondary Engine Speed
0535
Exhaust Temperature
0545
Ether Start Relay
¹ The CID is a diagnostic code that indicates which component is faulty.
Failure Mode Identifiers (FMI)¹ FMI No.
Failure Description
268
EMCP Electronic Control (Generator Set)
269
Sensor Power Supply Annunciator Switch
334
Spare Output
336
Engine Control Switch
441
Electronic Governor Relay
160-7689 3E-3370
A
B C
443
Crank Terminate Relay
444
Starter Motor Relay
445
Run Relay Air Shutdown Relay
C
A
Generator Fault Relay
Fuel Control Relay
1
2
B
442
447
B
169-8670
333
446
A B
A
C
C
3E-3388
500
EMCP Electronic Control (Generator Set)
566
Invalid Engine Shutdown
590
Engine Control Module
5
4
6
3
7
CID
Engine Oil Pressure Sensor
110
Engine Coolant Temperature Sensor
111
Engine Coolant Level Sensor
168
Electrical System Voltage
175
Engine Oil Temperature Sensor
190
Engine Speed Sensor
248
CAT Data Link
268
EMCP Electronic Control (Generator Set)
269
Sensor Power Supply
Data valid but above normal operational range.
333
Annunciator Switch
1
Data valid but below normal operational range.
334
Spare Output
2
Data erratic, intermittent, or incorrect.
336
Engine Control Switch
3
Voltage above normal or shorted high.
441
Electronic Governor Relay
4
Voltage below normal or shorted low.
442
Generator Fault Relay
5
Current below normal or open circuit.
443
Crank Terminate Relay
6
Current above normal or grounded circuit.
444
Starter Motor Relay
7
Mechanical system not responding properly.
445
Run Relay
8
Abnormal frequency, pulse width, or period.
446
Air Shutdown Relay
9
Abnormal update.
447
Fuel Control Relay
10
Abnormal rate of change.
448
Spare Relay
11
Failure mode not identifiable.
475
Relay Driver Module
12
Bad device or component.
13
Out of calibration.
14
Parameter failures.
15
500
EMCP Electronic Control (Generator Set)
566
Invalid Engine Shutdown
Parameter failures.
590
Engine Control Module
16
Parameter not available.
770
Customer Communication Module Data Link
17
Module not responding.
858
Generator Close Breaker
18
Sensor supply fault.
859
Generator Kilowatt Relay
19
Condition not met.
20
Parameter failures.
1038
Governor Adjust Analog Output
1167
EPG (Electric Power Generation) Circuit Breaker
1168
Dead Bus Sensor
1169
ATB (A/C Transformer Box) Sensor
1170
BTB (Bus Transformer Box) Sensor
1
23
14
31
24
39
32
47
40
57
48
70
58
160-7690
8
2
1
8
2
7
3
6
4
5
1
Component
100
13
155-2264
EMCPII+ Diagnostic Codes
0
¹The FMI is a diagnostic code that indicates what type of failure has occurred.
155-2269
174-0502
3E-8969 (early engines)
7
8
9
6
5
4
13
1
23
14
31
24
39
32
47
40
57
48
70
58
10 11 12
128-2312 3
2
1
D
E
C
8
7
9
10
11
J
G
262-6073
B
A
F
H
12
103-0213 5
6
4
3
2
1 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
155-2252
12
11
10
9
8
7
9X-4391
1
2
3
4
5
6
14 13 12 11 10 9
8
28 27 26 25 24 23 22
7
6
5
4
3
2
1
21 20 19 18 17 16 15
42 41 40 39 38 37 36
35 34 33 32 31 30 29
56 55 54 53 52 51 50
49 48 47 46 45 44 43
70 69 68 67 66 65 64
63 62 61 60 59 58 57
16 Page
CID CID
155-2267
RENR7934-01 VOL 1
Electronic Control Module (Engine)
JAKE BRAKE MED/HI
JAKE BRAKE MED/HI
INJECTOR HARNESS CONNECTOR 1552252
P2 1607690
ANALOG SNSR POWER (+5V) ANALOG SNSR COMMON
JAKE BRAKE COMMON JAKE BRAKE MED/HI JAKE BRAKE LOW/HI ATMOSPHERIC PRESS. SNSR FUEL PRESS. SNSR PASSIVE SNSR RETURN
INJECTOR COMMON 1 & 2 INJECTOR COMMON 3 & 4 INJECTOR COMMON 5 & 6 PRIMARY SP/TMG SIG + PRIMARY SP/TMG SIG -
INJECTOR 5 INJECTOR 6 SECONDARY SP/TMG SIG + SECONDARY SP/TMG SIG -
A747/GY 413/BR R993/BR
G811/YL G810/PU 994/GY
GY-16 PU-16 BR-16 GN-16 BU-16 GY-16 BK-16 YL-16 GN-16 OR-16 BR-16 WH-16
NO.5 CYLINDER INJECTOR
NO.6 CYLINDER INJECTOR A706 GY-16 D791 YL-16
NO.4 CYLINDER INJECTOR
NO.3 CYLINDER INJECTOR
NO.2 CYLINDER INJECTOR
D790 OR-16
NO.1 CYLINDER INJECTOR
FUEL TEMPERATURE P105
ENGINE COOLANT TEMPERATURE P100
D791 YL-16
ENGINE OIL PRESSURE J201
D790 OR-16 D789 WH-16
P400 1552269 G811/YL G810/PU
1 2
3E3364 TIMING CALIBRATION (TC) PROBE
P920/BR F732/PK 998/BR 999/WH 995/LTBU R993/BR 997/OR 993/BR A746/PK A747/GY 994/GY F421/YL 413/BR C967/LTBU
P920/BR F732/PK
1 2
1 2
P100 1552269 995/LTBU R993/BR
1 2
J200 3E3370 997/OR A 993/BR B A746/PK C
995/LTBU F421/YL C967/LTBU A701/GY A702/PU A703/BR A704/GN A746/PK
ENGINE COOLANT TEMPERATURE SENSOR 130-9811
SIGNAL COMMON
OR-18 YL-18 GN-18
ATMOSPHERIC PRESSURE SENSOR 194-6722
J201 3E3370 A B C
OR-18 YL-18 GN-18
+5V RETURN SIGNAL
ENGINE OIL PRESSURE SENSOR 194-6725
SIGNAL COMMON
FUEL TEMPERATURE SENSOR 130-9811
OR-18 YL-18 GN-18
+5V RETURN SIGNAL
FUEL PRESSURE SENSOR 194-6725
P103 1552269 1 2
SIGNAL COMMON
INTAKE MANIFOLD AIR TEMPERATURE SENSOR 130-9811
P105 1552269 1 2 J209 3E3370 A B C
C967/LTBU R993/BR
999/WH 998/BR
JUNCTION BOX
1
1
TURBO OUTLET PRESSURE (INTAKE MANIFOLD AIR) J200
D789
D789
TIMING CALIBRATION(TC) PROBE CONNECTOR P400
SPLICE 997
SPLICE R993
SPLICE D789
SPLICE D788
13 23 31 39 47 57 70
PRIMARY ENGINE SPEED / TIMING (CRANKSHAFT) P401
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 122-1486
1 14 24 32 40 48 58
ELECTRONIC CONTROL MODULE P2
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 238-1773
ENGINE OIL TEMPERATURE
JUNCTION BOX
(+) WH-12 60A CB2 6T-3645
START RELAY (SMMS) 9X-8124
30
SPLICE D791
(+) WH-14
20A CB1 200-8577
87a
D790
D790
D791
A702
(+) WH-16
15A CB3 9M-9085
ECM RELAY 206-9427
A705
SECONDARY ENGINE SPEED / TIMING (CAMSHAFT) P402
A701
SPLICE D790
A703
INJECTOR #1
INJECTOR #2
TURBO OUTLET PRESSURE SENSOR (INTAKE MANIFOLD AIR) 194-6724
+5V RETURN SIGNAL
+5V RETURN SIGNAL
F421/YL R993/BR
A705/BU A706/GY
A706
OR-18 YL-18 GN-18
997/OR 993/BR 413/BR
INTAKE MANIFOLD AIR TEMPERATURE P103
SPLICE 993
L983/WH L984/OR L985/YL F732/PK P920/BR
D786
D788
INJECTOR #3
INJECTOR #4
A704
D791
J203 3E3370 A 997/OR B 993/BR C A747/GY
997/OR 993/BR 994/GY
INJECTOR #5
INJECTOR #6
(CAMSHAFT POSITION) SECONDARY ENGINE SPEED/TIMING SENSOR 188-7513
SIGNAL(-) SIGNAL(+)
BK-18 WH-18
D787
ATMOSPHERIC PRESSURE J203
SPLICE D786
(CRANKSHAFT POSITION) PRIMARY ENGINE SPEED/TIMING SENSOR 189-9266
SIGNAL(-) SIGNAL(+)
P402 1552269 998/BR 999/WH
D788
D786
D788 P401 1552269
FUEL PRESSURE J209
D789 WH-16
1
INTAKE MANIF. AIR TEMP. SNSR INJECTOR 1 INJECTOR 2 INJECTOR 3 INJECTOR 4 TURBO OUTLET PRESS. SNSR
J702/BK J700/BR J701/GN
A701 A702 A703 A704 A705 A706 D788 D791 D787 D790 D786 D789
3
ENGINE COOLANT TEMP. SNSR FUEL TEMP. SNSR
997/OR 993/BR
1 2 3 4 5 6 7 8 9 10 11 12
5
TIMING CALIBRATION PROBE + TIMING CALIBRATION PROBE ENG OIL PRESS. SNSR
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
A701/GY A702/PU A703/BR A704/GN A705/BU A706/GY J702/BK L985/YL J701/GN L984/OR J700/BR L983/WH
2
ELECTRONIC CONTROL MODULE (ECM)
A705 BU-16
JAKE BRAKE LO/HI
J300 2626073 3E8969 EARLY
P300
4
ECM MOUNTING BOLT
A702 PU-16 A703 BR-16 A704 GN-16
6
ECM GROUND STRAP
P300 INJECTOR HARNESS CONNECTOR
INJECTOR HARNESS CONNECTOR J300
A701 GY-16
EARTH
25
+
+
40
4
2
2
(25) WH-14
COOLANT LEVEL
10
87 86
85
B+
3
(2) WH-16
(25) WH-14 (+) WH-12 (+) WH-14 (+) WH-16
(YGN) WH-16
G
(2) WH-16
STARTING MOTOR
S
MTR
BAT.
R448 ANALOG VOLTAGE REGULATOR
RD-00 STARTING MOTOR
ALTERNATOR
P1 1607689
DIGITAL RETURN
ENGINE STOP
J1939 DATA (-)
START/RUN/STOP
+BATTERY (SWITCHED) J1939 DATA (+) +BATTERY (SWITCHED) +BATTERY (SWITCHED)
-BATTERY -BATTERY -BATTERY THROTTLE POSITION SENSOR
+BATTERY (KEYSWITCH) ELECTRONIC CONTROL MODULE (ECM)
2
(2) WH-16 (2) WH-16
(4) WH-16 (B+) (B+) (B+) (B+)
(D+) WH-12 (D-) WH-16
WH-16 WH-16 WH-16 WH-16 (10) WH-16 (10) WH-16
(D+) WH-12 (D-) WH-16 (20) WH-16 (45) WH-16
(20) WH-16
(ATA-) (ATA+) SHIELD (45) WH-16
(D+) WH-12 (D-) WH-16
(D+) WH-12 (D-) WH-16
(ATA-) (ATA+) SHIELD
(ATA-) (ATA+) SHIELD
(1) WH-16
(1) (1) (D+) (D-)
WH-16 WH-16 WH-12 WH-16
(10) WH-16
(2) WH-16
(20) WH-16 (45) WH-16 (41) WH-16
(20) WH-16 (45) WH-16 (41) WH-16
(SSPD) WH-12 SHIELD
(SSPD) WH-12 SHIELD
(41) WH-16
1
(20) WH-16 (2) WH-16 (2) WH-16 (41) WH-16 (45) WH-16
(SSPD) WH-12
(10) WH-16
(10) WH-16 SHIELD
(2) WH-16 (2) WH-16 (2) WH-16
BATTERY 12V
4
(34) (46) (12) (11) (17) (30)
(2) WH-16
WH-16 WH-16 WH-16 WH-16 WH-16 WH-16
(62L) (18) (67L) (620) (19) (670)
WH-16 WH-16 WH-16 WH-16 WH-16 WH-16
(ATA-)
(41) WH-16
11
12
17
30
2
46
4
34
3E-3388 1552264 WH-16 WH-16 WH-16 WH-16 WH-16 WH-16 WH-16 WH-16
1 2 3 4 5 6 7 8
(17) WH-16 (30) WH-16 (12) WH-16 (11) WH-16 (46) WH-16 (2) WH-16 (34) WH-16 (4) WH-16
(21) (22)
(4) WH-16 (2) WH-16 (34) WH-16 (46) WH-16 (12) WH-16 (11) WH-16 (17) WH-16 (30) WH-16
SHIELD (SSPD) WH-12 SHIELD (ATA+) (ATA-) SHIELD
(B+) WH-16 (ATA+) (B+) WH-16 (B+) WH-16
EMERGENCY STOP SWITCH 206-9509
1552269 ENGINE SPEED SENSOR 6V-2455
SIGNAL(+) SIGNAL(-)
BK-18 WH-18
(21) (22)
1 2
SHIELD 1552267
COOLANT LEVEL SENSOR 165-6634
+V RETURN SIGNAL
RD BK GN
A B C
ENGINE OIL TEMPERATURE 134-2252
+V RETURN SIGNAL
OR BK WH
A B C
(2) WH-16 (SSPD) WH-12
(10) WH-16
(67L) WH-16 (62L) WH-16 (18) WH-16
(11) (12) (17) (34) (46)
WH-16 WH-16 WH-16 WH-16 WH-16
1552267
(2) WH-16 (2) WH-16
CORE BALANCE CURRENT TRANSFORMER (IF EQUIPPED) R448 ANALOG VOLTAGE REGULATOR
80
9X4391 (1) WH-16 (2) WH-16
(2) WH-16
(10) WH-16
BK-00
82
CORE BALANCE CURRENT TRANSFORMER
25
ST4
(670) WH-16 (620) WH-16 (19) WH-16 (EF1) WH-16 (EF2) WH-16 (80) WH-16 (82) WH-16
(80) WH-16 (82) WH-16
(EF1) WH-16 (EF2) WH-16 (30) WH-16
+
+
+
1
Y/G
2
2
2
2
EF1 EF2
(1) WH-16
(2) WH-16
(2) WH-12 (2) WH-16
CAT DATA LINK (+) CAT DATA LINK (-)
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
BATTERY 12V
BK-00
1 2 3 4
16 Page, Color 2
RENR7934-01 VOL 1
(40) WH-12
(4) WH-16 (2) WH-16
(10) WH-16 (2) WH-16
(B+) WH-16
+
EMERGENCY STOP SWITCH
103-0213
ENGINE SPEED
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
SPLICE(2) #3
2
ALTERNATOR
40 SPLICE(10) SPLICE(2) #2
SPLICE(B+) SPLICE(2) #4
SPLICE(1) SPLICE(2) #1
(+) BATTERY REFERENCE GENERATOR SET CONTROL SCHEMATIC VOL2 AND VOL3 1
THRU
(+) BATTERY SWITCHED
70
STARTING CIRCUIT (-) BATTERY / SENSOR RETURN SENSOR / ACTUATOR SUPPLY SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM
CONTROL PANEL
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 244-1172 (FOR EMCPII AND EMCPII+)
CAT DATA LINK J1939 DATA LINK RS-232/RS-485 DATA LINK
ELECTRONIC CONTROL MODULE (ECM) P1
THIS SCHEMATIC IS FOR THE C18 GENERATOR SET S/N: G4C STM C6C STD HARNESS 238-1773 122-1486 244-1172
CHG 00 (J2 / ENGINE HARNESS) 07 (INJECTOR HARNESS) 02 (J1 / GENERATOR SET CONTROL HARNESS FOR EMCPII AND EMCPII+)
NEUTRAL EARTH LINK
T1
HIGH COOLANT TEMP
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
4
8 9 10 11 12 13 14
33
108
CORE BALANCE C.T.
T11
110
6
U
U
34
:A :B :C :D :E
110
NOTE:
IF 4 POLE BREAKER FITTED CHANGE N T0
T13
G
LOW BATTERY VOLTAGE
157
:4/:L1
V
V
W
W
18
35
159
:6/:L3 R
19
36
F32 (2A)
157
154
F33 (2A)
159
156
L2
T3
L3
N
N
E
E
43
37
EF1
10
EF2
k
A1
38
l
22
21
12
24
`EFU'
30
A2 BENDER EARTH FAULT RELAY
11
30
14
73
31
TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
73
12
SP2
17
(FRONT)
(REAR)
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
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 &
(REAR)
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
110 110 110 110 110 110 110 110
SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD SHOULD
BE BE BE BE BE BE BE BE
CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED CONNECTED
DC NEG. 2
TO TO TO TO TO TO TO TO
C18 Generator Set with EMCPII, EMCPII+ and EMCP 3 Electrical System
RESISTOR PIN D RESISTOR PIN C RESISTOR PIN B RESISTOR PIN B RESISTOR PIN B RESISTOR PIN A RESISTOR PIN A SINGLE RESISTOR
C6C1-UP G4C1-UP STM1-UP STH1-UP (Engine)
DC POS. 38
39
2 :5
22
4
3456
6
1
3456
:30
8
1
EPIR/1
51
:87
23
:1 MAN :2 AUTO
2
:86 EPIR :85
ETHER START SWITCH
2
:30
59
ASOR/1 :87
59 :86 AIR SHUT-OFF ASOR :85 RELAY
1
3
2
SASV
HORN
+ 10
4
30
6
DC
:7 -
LINK
:11
4
SPARE FAULT INPUT (LED 8) 72
:8
SILENCE SWITCH ALARM DATALINK
SPARE FAULT INPUT (LED 7)
:4
:1 +
HORN
LINK
:10
6
LOW FUEL LEVEL
10
90
17
:2
20
:12
:14
+ 10
:1 +
30
:7 -
SILENCE SWITCH
LAMP TEST
:13
-
SPARE FAULT INPUT (LED 1)
:9
SPARE FAULT INPUT (LED 2)
:10 DC
:13
HORN ON
SPARE FAULT INPUT (LED 3)
2 2
FV
2
3
5
2
2
-VE SUPPLY
-VE SUPPLY
:2 ETHER START SWITCH
FIRST ALARM MODULE
:1 +
SPARE FAULT INPUT (LED 1)
:9
SPARE FAULT INPUT (LED 2)
:10
SPARE FAULT INPUT (LED 3)
3 :2
13
:1
37
ACT+
SPARE SHUTDOWN INPUT (LED 6)
:4
SPARE SHUTDOWN INPUT (LED 6)
SPARE SHUTDOWN INPUT (LED 7)
:5
SPARE SHUTDOWN INPUT (LED 7)
:5
6
:7 -
68
:13
ALARM MUTE
SPARE SHUTDOWN INPUT (LED 8)
30
ALARM DATALINK
ALARM DATALINK
17
DC
:13
90
:6 :12
:2
20
NOTE: IF CONTROL PANEL IS SGCP THEN SWITCH IS MOUNTED REMOTELY.
:1
28
MOT1
MPU-
44
3
1
4
2
MPU+
6
10 11 12
MAGNETIC PICK UP No.2
58
60
3 13
43
7
9
2
4
2
35
:2 :1
:3
14
42
8 1
59
MOT2
3
5
SASV 57
36
SPEED ADJUST POTENTIOMETER (2K W, 10 TURN)
LINK WOODWARD ELECTRONIC LINK FUEL GOVERNOR (ISOCHRONOUS)
SATS
SPARE SHUTDOWN INPUT (LED 8) 38
:3
59
ACT-
59 27
SPARE SHUTDOWN INPUT (LED 5)
:4
17
10
:8
SPARE FAULT INPUT (LED 4)
SPARE SHUTDOWN INPUT (LED 5)
:2
4
:14
:3
SPARE FAULT INPUT (LED 4)
:3
90
69
:14
:4
40
9
SPEED LOWER/RAISE SWITCH
:11
:11
:6
:12
LAMP TEST (IF REQUIRED)
38
:8
37 (OPTIONAL) FLAP VALVE
23A
SASV - START AID SOLENOID VALVE
:6 :3
(16A)
F27
ASOR+
STD1-UP PDH1-UP (Engine)
7
10 ES-
ACTUATOR
:14
3406C
27 68
3406C
-
73
11
+
(FRONT)
(REAR)
CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL
8
-
CONNECTION DESCRIPTION WIRE No. 10 (GSC RM39) & HORN +VE WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK JUMPER TO 10 JUMPER TO 11 NOT CONNECTED NOT CONNECTED WIRE No. 30 (GSC RM27) & SILENCE SWITCH LOW FUEL LEVEL SWITCHED -VE INPUT NOT CONNECTED LED 7 (SPARE) LED 8 (SPARE) LAMP TEST -VE INPUT (IF REQUIRED) SILENCE SWITCH HORN -VE
TERM. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
T2
8
-
(FRONT)
L1
6
ALARM SILENCE
+
T1
42
LAMP TEST
ALARM SILENCE
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A01)
CORE BALANCE CURRENT TRANSFORMER
R
R
TO BREAKER BOX
T2 T3 N E
SLR/2
LOW COOLANT TEMP
T
T
108
RENR7934-01 March 2006
SLR/1
:A :B :C :D :E
23
LAMP TEST (IF REQUIRED)
24
2
MOT1
MOT2
Volume 2- EMCPII and EMCPII+
GENERATOR SYNCHRONIZING MOTOR
M
SASV - START AID SOLENOID VALVE SATS - START AID TEMPERATURE SWITCH
-VE SUPPLY
Printed in U.S.A.
© 2006 Caterpillar All Rights Reserved
ALTERNATOR TERMINAL BOX
PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 1
3
D +
6
5
74
P +
E 7
S 2
Q
1
R
3
D +
6
5
74
75 30
S 2
7
30
30
R
6 mm 2
6 mm 2
HC :A2
:14
:2
:4
:6
202
142 9 NOTE A
131
PUMP STOP
139 19
3
6
5
CONSTANT VOLTAGE CHARGER
7 +
75 30
30
75
TO STARTER MOTOR
8
14
13
10
143
131
-
NOTE A
75
205
206
:X1 PUMP TRIP/ STOP :X2
13
:X2
16
74
13
2
6 mm
132
CONNECT TO ALARM MODULE SPARE
25
74
74
F16 (2A)
12
F17 (6A) 136
131
F18 (4A)
F19 NOTE:A
135
2
6 mm
131
T2
:A1
BATTERY CHARGER & HEATERS
T3
135
131 :1
A2 131
2
5
4
O/L 1
13
6
3
2
14
5
4
97
6
2
141
N
:3
:5
:4
:6
23 2 .5 mm
10
208 PUMP STOP
23
K
ALREADY FITTED AS STANDARD
205
:9
SW3
:X1 PUMP TRIP/ STOP :X2
NORMALLY OPEN
SW2
83
SW1
2
+
PR :10
-
NORMALLY CLOSED
204
208 211 131
A1
1
A2 131
NORMALLY CLOSED
NORMALLY CLOSED
3
5
13
84
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
:6 PR/2 :7 36
85
2
4
6
14
O/L 1
3
5
97
95
2
4
6
98
96
:2 MV :1 MOT. -VE SUPPLY
N
23 2 .5 mm
131
2 .5 mm
:3 PR/1 :1 20
81
81
83
2
2
:2
+
PR :10
-
:A2
:2
131
131
140
WHITE
RED
- 3
164
*
164
S 2
Q
1
3
R
3
D +
6
71
36
2
140
+
(*) 2
131
-
131
131
ENGINE JACKET WATER HEATER
2
F15
2
1
ALTERNATOR HEATER
6 mm
+ 1 24V DC SUPPLY
P +
NOTE:
2 .5 mm
RTD PT100
163
5
NOTE:A IF 120V IF 230V IF 120V IF 230V
9
9
JACKET WATER JACKET WATER BLOCK HEATER BLOCK HEATER
24V
COPPER BUSBAR
F16 (2A)
THERMOCOUPLE RELAY
F17 (6A) 136
131
T2
15
CONNECT TO ALARM MODULE SPARE
137
76
14
2
132
2
131
:A1
4
71
10
+ 1
CONNECT TO ALARM MODULE SPARE 1
71
F15
1
- 3
*
131
111A
2
2
-
POWER SUPPLY REF. B03 BREAKER DRAWING
117
REF. D10
NOTE: ADD FUSE F41, REMOVE LINK AND CONNECT WIRE 111A TO 3RD PHASE IF VOLTAGE IS 240V L-L
135
:1 :3 UVT/1
107
402A
:6
:7
POWER WIRING FROM GENERATOR
OPEN SIGNAL REF. C03 BREAKER DRAWING
402
BAR/2
GCR/1
5
77
:3
:1
111
L1
T2
L2
T3
L3
N
N
E
E
2
SW1
LOW
LOW LOW
CABLE
SW3
B
159
CLOSE SIGNAL REF. C03 BREAKER DRAWING
159
BCR/1
24V DC SHUNT TRIP
SW1
NORMALLY CLOSED
CONNECT TO ALARM MODULE SPARE 45 1
REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
B B B
233
:14
231
:12
232
F40
178B
:1
72
LEVEL SWITCH (TOP VIEW)
84 HIG HIG HH
17
11
72
CONNECT TO ALARM MODULE SPARE
64
SW1
65
30
LOW LEVEL FUEL SWITCH
LOW FUEL LEVEL SWITCH
2CR/1
72
:11
SW4
:2 UVT :10
SW1
NORMALLY CLOSED
111
CONNECT TO ALARM MODULE SPARE 10
L1
TERMINAL BOX
:6 :7 36
LEVEL SWITCH (SIDE VIEW)
85 :2 MV :1 MOT.
TERMINAL BOX
VALVE
LOW-LOW FUEL LEVEL SWITCH
:2
+
PR :10
-
-VE SUPPLY
2
T2
L2
T3
L3
N
N
REF. CO5 BREAKER DRAWING 6
157
6
158
POWER WIRING FROM GENERATOR
10
COPPER BUSBAR
26
F32 (2A)
F31 (2A) 157
220
N
R
30
F18 (4A)
412
411
158
F16
6 mm
136
F19 NOTE:A
131
6 mm
141
2
2
137
5
D-
14
31
131
12
22
56 51
52
SCROLL SWITCH `SS'
6
:2
:1
:3 :6 :2
54
5
:5
99
BREAKER OPEN
2
BREAKER CLOSED
REF. B05
:C11 ST
6
24V DC SHUNT TRIP
:C12
29
2 REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
55
HARNESS CODE 18
6 mm
:3
2
:4
57 53
99 REF. B05
31 MODE/ CLEAR SWITCH `MCS'
:3
2
2
2
16
17
23 SRV
B B B
231
:11
:12
233
:13
:14
232 BREAKER AUXILIARY
ABB ACB
134
141
:A1
3
E
E
33 CLR
CATERPILLAR MONITORING SYSTEM 2
DC NEGATIVE
2 .5 mm
2
6 mm
HEATERS
32
EMSII
D+
46
2
B12
412 BLACK
B11
411
F37 (2A)
WHITE
J1-1 J1-2 J1-3 J1-4 217 218 98
B22
GREEN
BREAKER CLOSE
131
B2
B1 B21 F36 (2A)
CUSTOMER 100V TO 250V AC SUPPLY
31
1
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
CR/1 :1
LINK
RED
REF. B02
BUS TRANSFORMER BOX (BTB+)
BROWN
BREAKER OPEN
CAT DATA LINK
45
10
134
:4
219
132
4
HC5
FUSED DC POSITIVE
410
HC4
158
HC3
N
B
HC1
157
B
HC2
:2 BCR :10
B
HC0
B
REF. B02 REF. E04
410
2
30
N
Q/1
35
46
54
C
31
Q/2
Related Electrical Service Manuals 9
11
:13 BKRR :14
:5
54
:6
:3 BAR/1 :1
46
426
47
:11
414
437
48
217 14
218 15
:13 BUSR :14
:5 8
ENGINE JACKET WATER HEATER
ALTERNATOR HEATER
415
131
131
9
2
416
:6
~
:1
NOTE: IF NO ALARM MODULE FITTED THEN RELAY WILL ACTIVATE ON SHUTDOWN ONLY.
SECONDARY 120V AC L-L
6 mm
:14 :13 :15
SYNCHRONIZE SWITCH
139 19
142 20
2
:4 :5 :8 :10
16
221
131
2 .5 mm
219
30
131
ORANGE
30
NOTE PT PRIMARY WIRE COLORS - WHITE = 240V AC - GREEN = 380V AC - BROWN = 480V AC - RED = 600V AC - BLACK = COMMON
BLACK/WHITE
98
:4
9
38
NOTE:A IF 120V IF 230V IF 120V IF 230V
JACKET WATER JACKET WATER BLOCK HEATER BLOCK HEATER
HEATER IS HEATER IS IS FITTED IS FITTED
FITTED FUSE F19 FITTED FUSE F19 FUSE F19 SHOULD FUSE F19 SHOULD
SHOULD BE 30A SHOULD BE 16A BE 16A BE 10A
:2 GRR :10
GRR/3 :8
6 :11 87 32
2 3
BKRR/1
5
:9
88 33
89
:2 ALR :10
34
REMOTE CONTACTS FOR GENERATOR RUNNING
2 3
ALR/3 :8
26
:11 BKRR/3
:9
64
65 30
:4 BKKR/4 :12
66 31
REMOTE CONTACTS FOR GENERAL ALARM
24 37
2
25
31 SP4
6
26A
:3
:9 :11
29
3
19
146
29 38
30 8
145 41
:9 BUSR/1 :1
:2 ALR :10
144 40
3
2
2
AUXILIARY CONTACTS
REF. B02
54A :10 BAR :2
:2 GCR :10
10
REF. A02
18
B
HC :A2
Title 54
REF. G08
ENTRY
H HIG
PR/2
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02)
T1
LOW
SP2
30
2
111
SW2
S W3
35 17
72 NORMALLY CLOSED
20
HIGH LEVEL FUEL SWITCH
65
NORMALLY CLOSED
SW2
:3 PR/1 :1
83 64
ABB MCCB
11
72
LOW LOW
84
21
30
NORMALLY OPEN
131
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
17
72
CABLE
SW4
10
30
72
BREAKER AUXILIARY
UV COIL SUPPLY REF. C03 BREAKER DRAWING
178
178
:3
DC CIRCUIT
30
72
SW3
107
1 F23 (2A)
7
H HIG
TERMINAL BOX
:C2
140 111
131
77
FUEL LEAK SWITCH
ENTRY
TERMINAL BOX
:C1
6
SW2
LEVEL SWITCH (SIDE VIEW) ST
26
28
CR/2 117
NEUTRAL REF. C03 BREAKER DRAWING
2
:5
:6
107
LINK
:4
:1
178 F41 (6A)
(6A) 131
117
IF REQUIRED
:2 131
117
117
REF. F02
140
+
(*)
71
9
36
407
~
71
SP1
111B
:1
:A2 CONSTANT VOLTAGE CHARGER
F42 (6A)
46
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
131
NOTE: IF VOLTAGE IS 240V L-L CONNECT 111A TO 3RD PHASE, FOR 480V USE TRANSFORMER
406 E
CUSTOMER 100V TO 250V AC SUPPLY
HC
16
T1
45
6 mm
BATTERY CHARGER 76
NORMALLY CLOSED
HIG HIG HH
4 POLE BREAKER OPTIONAL (SEE NOTE REF.A02)
T3
135
CR/1 :1 8
6 mm
6 mm
:4
76
30
T1
E
33
77
SW4
2
76
SHOULD BE 30A SHOULD BE 16A BE 16A BE 10A
+
30
SW2
FUEL SYSTEM No. 2
131
LEVEL SWITCH (TOP VIEW)
N
7
30
FITTED FUSE F19 FITTED FUSE F19 FUSE F19 SHOULD FUSE F19 SHOULD
G
76 30
HEATER IS HEATER IS IS FITTED IS FITTED
IF 4 POLE BREAKER FITTED CHANGE N T0
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
2 E -
NORMALLY CLOSED
139 19
142 20
CONSTANT VOLTAGE CHARGER
2
SW3
GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 2
WT1
NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.
NORMALLY OPEN
2
M
E
3
SW4
HC
N1
163
LEVEL SWITCH (SIDE VIEW)
TERMINAL BOX
21
HIGH LEVEL FUEL SWITCH
ALREADY FITTED AS STANDARD
35
24
2
FUEL PUMP
M
LOW LEVEL FUEL SWITCH
VALVE
211 209 210
2
2
6 mm 2 46 131
PC
35
:2
131
204 :X1
:X2
96
18
:95 O/L :96
81
PUMP RUN
H
TERMINAL BOX
15
PR/3 :11
81
HIG
ENTRY
12
203
21
LEVEL SWITCH (SIDE VIEW)
LOW
LOW LOW
L
22
SW3
SW 2
SW1
PUMP RUN
205
SW4
95
98
2 .5 mm
20
84
AC SUPPLY CUSTOMER 100V TO 250V
11 J
CABLE
SW 4
24
131
24
2
FUEL PUMP
134
:3 PR/1 :1
HIGH LEVEL FUEL SWITCH
211 209 210
46
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
6 mm
137
2 .5 mm
T1
6 mm
2
ALTERNATOR TERMINAL BOX
3
PC
131
203
H IG HIG HH
16
TERMINAL BOX
21
LOW LEVEL FUEL SWITCH
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
134
141
2
CR/1 :1
1
4
206
6 mm 2 46 131
208 211 131
A1
CUSTOMER 100V TO 250V AC SUPPLY
:4
G
45
SP1
204
2 .5 mm
COPPER BUSBAR
74
131
204 :X1 PUMP RUN
202
TERMINAL BOX
18
:95 O/L :96
12
207
202
:9
NOTE:A IF 230V JACKET WATER HEATER IS FITTED MCB M2 SHOULD BE 16A IF 230V BLOCK HEATER IS FITTED MCB M2 SHOULD BE 10A
148
ENTRY
H HIG
15
PR/3 :11
20
CABLE
:97 O/L :98
12
ENGINE JACKET WATER HEATER
CONNECT TO ALARM MODULE SPARE
32
75
2
131 140
+
LOW
LO W LO W
L
203
21
SW2
SW1
PUMP RUN
205 K
ALTERNATOR (GENERATOR) HEATER
84
AC SUPPLY CUSTOMER 100V TO 250V
23
202
E -
75
74
208
SW 3
:13 AUX :14
LEVEL SWITCH (TOP VIEW)
ALREADY FITTED AS STANDARD
M
SW4
24
11 J
HIG HIG HH
16
203
10
2
D +
74 30
75
Q
1
75
:5
4
F21 (6A) 84
13
207
22
3
P +
:3
192
2 E -
:1
F22 (2A)
SP3
Form Number
EMCPII Troubleshooting/ Systems Operation / Testing and Adjusting
RENR2483
EMCPII+ Troubleshooting/ Systems Operation / Testing and Adjusting
RENR2484
SW4
NORMALLY OPEN
SW3
NORMALLY CLOSED
SW2
NORMALLY CLOSED
SW1
NORMALLY CLOSED
30 Page
1
R
138
:13
:97 O/L :98
AC CIRCUIT
DC CIRCUIT
84
6 mm 2 45 132
2
2
Q
134
:A1
ALREADY FITTED AS STANDARD
M :13 AUX :14
LEVEL SWITCH (TOP VIEW)
84
13
(2A)
COPPER BUSBAR
6 mm
S -
3
2
147
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6mm 2 TERMINALS.
6 mm 2
F21 (6A)
6 mm
P +
191
141
138
F22 (2A)
6 mm 2 45 132
1 F23
1
DC CIRCUIT
84
(2A)
2
3
182
-
137
134
AC CIRCUIT
2
181
172
CR/1 :1
147
6 mm 2
171
CR/2 :6
NOTE A
14
AC CIRCUIT
1 F23
1
COPPER BUSBAR
2
24V
141
2 .5 mm 2
NOTE: WIRE DIRECTLY ONTO RELAY TERMINALS.
:4
BATTERY CHARGER 140 & HEATERS (120V Charger, 240V Heaters)
+
2
136
:5
AC CIRCUIT
2 .5 mm
3
3
135
2 .5 mm 2
WHITE
RED
WHITE
RED
RED
RTD PT100
RTD PT100
WHITE
RTD PT100
F16 (2A)
120
AC SUPPLY (AC TERMINAL RAIL)
M2 NOTE:A MCB
2 .5 mm 2
BT3
BT2
BT1
F17 (10A)
M1 2P 6A MCB
240 18
2
131
E
16
2 .5 mm
133
2
132
6 mm 2
2
6 mm 2
FUEL PUMPED FROM FREE STANDING BULK TANK FUEL SYSTEM No. 3
2 .5 mm
COPPER BUSBAR
N1
2
T3
mm 2.5
G
CUSTOMER 100V TO 250V
mm 2.5
T2
RENR7934-01 VOL 2
T1
9
8
7 REF. D-5 4
10
REF. 2 D-8
2
40
39
REF. ENGINE SCHEMATIC VOL1
F
65
ATA-
64
ATA+
D
G E
T1
P1
P2
T2
S1 P1
S2 P2
CT1
T3
S1 P1
S2 P2
CT2
S1
S2
CT3
N
H
2
1
9
L1
10
L2
L3
11
N
E
ATA+
29
22
3
METERING C.T.s
ATA-
30
23
4
12
E 13
J
1
71
17
72
31
73
25
74
32
75
SERVICE CONNECTOR 41
51
SCR
:2
:x
EMCPII
:x
82
SPEED ADJ. POT. (1K ohm, 10T) :1
98
:2
REF. D-2
50
50
T1
T2
T3
101
14
EMCPII+
8
9
10
13
12
14
28
34
80
80
35
44
82
SPEED CONTROL
36
43
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.
53
50
LINK
LINK
LINK
T1
T2
T3
H23 F11 (2A)
H21 F12 (2A)
H22 F13 (2A)
101
101
2
33
76
110
110
27
28
81
4
84
57
MOT1
58
MOT2
63
KWR/3
5
109
109
T11
108
J1-1
EMCPII
26
:11
4
108
42
:9
:8
T12
J1-2
91
16
18
EMCPII
T13
3
EMCPII
48
47 C
42
2
3
33
52
AC TRANSFORMER BOX (ATB)
J1-3
92
H
51
J1-4
93
G
92
82
15
J1-5
94
F
93
:2
REF. C-9
50
J1-6
95
E
94
J1-7
96
D
95
:1
50
J1-8
16
97
C
96
(1K ohm , 1 TURN)
98
B
97
:3
82
A (EMCPII)
80
80
:3
53
1
VOLTS ADJUST POTENTIOMETER :x
:3
52
71
72
73
74
C
49
7 EMCPII
C
50
REMOTE CONTACTS FOR KW LEVEL
1
EMCPII
76
81
84
51 EMCPII
52
S
56
EMCPII
D +B -B
29
OFF/RESET S-SPD
30
10
D-SPD
57
REF. C-5 30
31
REF. C-3
:8 AUTO START :9 COOLDOWN/STOP :10
:6
D+
2
CONTROL MODE SWITCH REF. C-2
32
P2/2
35
EMCPII+
EMCPII+
37
1
5
3
SEE NOTE A
EMCPII+
EMCPII+
EMCPII+
27
25
26
18
13
20 EMCPII+
17
61
15
99
5
63
35
13
217
5
6
32
31
CCM+
218 P
52
Q
EMCPII+
18
1
1
61
50
CCM-
51
REF. F-8
RDM
7
17
99
8
90
EMCPII+
REF. F-8
19
D-
B+ POST
RM
RM
RM
RM
RM
RM
RM
RM
RM
31
35
30
33
2
1
32
34
36
RM
45
46
416
63
F3 (10A)
F1 (10A)
F6 (10A)
CTR
RM
RM
RM
RM
4
8
3
6
FCR
RR
RM 12
SMR
CTR
F4 (10A)
F7 (10A)
F5 (10A)
RM 5
34
23
FCR F2 (10A)
35
KW
36
ALARM
18
SPARE
D+
20 D+
47
426
RR
15
EMCPII+
GFR F10 (10A)
SET OP6 SETPOINT SP17 TO 6 SET OP6 SETPOINT SP18 TO 7
ASR
21
37
EMCPII+
21
23
D-
24
RDM
CCM-
19
30
22
+
EMCPII+
EMCPII+
EMCPII+
-
20
+
RDM
CCM DATALINK
EMCPII+
20
-
D-
LOW OIL PRESSURE EMERGENCY STOP HIGH WATER TEMPERATURE ENGINE OVERSPEED LOW COOLANT LEVEL OVERCRANK FAULT SHUTDOWN FAULT ALARM
97
16
94
4
93
12
RM
RM
RM
RM
RM
RM
GPLO RM
27
15
24
17
16
13
14
28
2
13
2
39
38
37
15
20
41
11
30
38
39
23
24
17
RM
RM
RM
18
21
39
REF. C-3
38
11
42
38
20
41
30
17
34
REF. F-4 REF. F-2
5
50
27
28
11
5
27
29
REF. F-6
25
26
91
22
6
33
2
6
6
5 34
ASOR+
SD-PWR
SD-RTN
23A
ASOR+
39
44
SD-RTN
37
13
23
22
24
SP1 5 62
15
16
67
6
25
SP2
40
SP4
SP3
41
39
29
42
55
42
40
33
56
32
57
3
40
54
55
34
56
44
37
36
49
60
SP1
61
16
62
SP2 17
63
SP3
:2 :3 :4 :5
SP4 19
18
REF. E-7 D-7
EMCPII+
9
30 6
62
66
67
16
15
67
62
18
67
62
67
19
OFF/RESET AUTO START COOLDOWN/STOP
SP4
26A
70A
RDM
CCM+
CCM-
16
22
4
PANEL LIGHTS
9
37
RELAY CONTACT N/O
:3 25
EMCPII
26
EMCPII
18
EMCPII
25
EMCPII
26
EMCPII
27
EMCPII
:3 PANEL LAMP SWITCH :2
EARTH
E
9
:1
:2 :3 :4 :5
11
ENGINE CONTROL SWITCH
O
117
202
203
205
207
131
117
217
R
220
10
35
S
402
T
108
U
110
V
157
W
159
218
220
402
108
110
157
159
8
9
10
CIRCUIT BREAKER 11
7
6
12
EMCPII
13
EMCPII
:2 :3
:1
POTENTIOMETER
14
15
D
11
CHASSIS CUSTOMER TERMINAL
11
CHASSIS DC TERMINAL
8
CHASSIS AC TERMINAL
28
DOOR TERMINAL
3
5
16
17
37 7
30
CHASSIS TO DOOR DC SOCKET
ENGINE SOCKET
30
C
57
J
CHASSIS TO DOOR AC SOCKET
38
9
3
8
ES-
EF1
59
EF2
POWER TERMINAL
4 12
REMOTE START CONTACT
:2
11
12
SD-PWR
ASOR+
23A
2
8
51
SD-RTN
52
53
ASOR+
8
51
REF. ENGINE SCHEMATIC VOL1
NOT CONNECTED
REF. ENGINE SCHEMATIC VOL1
23A
EMCPII+
52
GSC 40 WAY HARNESS CONNECTOR
30
2
GSC RELAY MODULE TERMINAL
3
3
SD-RTN
SD-PWR
1
REF. D-2
CR 1 2
8
2
:10
2
54
R/1
EMCPII
62 30
2
1
31
19
:1
57
P1/2 REF. E-5
30
1
SCR
24
58
7
1
SCREEN CABLE
23
7
CONTROL MODE SWITCH
E
BODY
21
58
:1
59
22
21
9
TRANZORB
20
19
18
E
DOOR
37
EMCPII+
EMCPII
59
:2
45
E
CHASSIS
43
8
7
9
LCL
REF. E-7
53
41
29
SD-PWR
37
3
36
3
EMCPII
28
EMCPII+
LOP
N
131
EMCPII
RM
6
10
23A
E
15
:3
10
EMCPII+
22 EMCPII
46
25
:9
EMCPII
45
26A
8
CR/3
EMCPII
PANEL LIGHT SWITCH
REF. F-8
45
:11
EMCPII+
4
HET
V+ 31
2
1
10
EMCPII+
V-
-
21
26A
14
EMER. STOP
2
30 Page, Color 2
RENR7934-01 VOL 2
REF. F-8
38
+
207
Q
AUX. ALARMS/SHUTDOWNS SWITCHED -VE POST B-
M
92
19
GPHI RM
L
205
95
10
EGR
203
EMCPII
5
EMCPII
K
P
RM
EMCPII+
F
30 MOT2
96
6
EMCPII+
19
REF. B-3
98(EMCPII)
17
J
202
D+
DATA LINK
GENERATOR SET CONTROL (GSC)
LOW OIL PRESSURE EMERGENCY STOP HIGH WATER TEMPERATURE ENGINE OVERSPEED OVERCRANK LOW COOLANT LEVEL (SPARE 1) HIGH OIL TEMPERATURE (SPARE 2) SPARE 3 FAULT SHUTDOWN FAULT ALARM
19
437
26
EMCPII+
SPARE
GENERATOR SET CONTROL (GSC+)
RM 9
RM 7
17
SPARE
SMR
D
EMCPII+
RELAY COIL
:2
21
21
EMCPII+
CCM+
EMCPII+
14
EMCPII+
12
14
90
43
46
22
C
:10
13
D-
:2 EMCPII+ KWR :10
5
36 1
EMCPII+
5
48
67
PANEL LAMP 12
29 MOT1
55
REF. ENGINE SCHEMATIC VOL1
11
R 75
EMCPII+
R
E
EMERGENCY STOP PUSHBUTTON
10
24
(1K ohm, 10 TURN)
:1
FUSE
4 POLE BREAKER OPTIONAL
B
D-
REF. 32 E-2
5
A
D+
REF. 31 E-3
6
12 6
53
47
11
41
46
10
REF.ENGINE SCHEMATIC VOL1
NOT CONNECTED EMCPII
30
20
15
65
30 25
17 48
34 49
45 17
46 50
8
10 7
ES27
REF. ENGINE SCHEMATIC VOL1
21
59
28
31
59
22 32
33
62T
67T
42
43
REF. ENGINE SCHEMATIC VOL1
16
15 14
13
67P
62P
44
45
18 20
67L
62L
21
19
NOT CONNECTED
19 23
67O
62O
EF1
EF2
D-
D+
22
61
62
4
3
24
ATB TERMINAL 5
REF. ENGINE SCHEMATIC VOL1
EMCPII+
EMCPII
NOT CONNECTED EMCPII
B
B
ANALOG VOLTAGE REGULATOR DIAGRAM (3 PHASE SENSING) NOTE:A
AREP
ST3
10/YELLOW
60Hz
9/GREEN
10A FUSE
R448
ST6
A
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
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
6
E-
NOTE:D
POT 470ohm
3ph
380) 380) 380) 220) 220)
+
NOTE:C
W
2
380
T1 S1 S2
J1
V
1 4
S2
+
S1 STATISME P2
470ohm POT TENSION P1
_
P1
STABILITY ADJUST P3 W
V
VOLTAGE ADJUST P2
ALTERNATOR WINDING CONNECTIONS
NOTE:I
W N
110
230
110
400
400
230
230
110
400
4 2 1
8
415/240V 400/230V 380/220V 220/127V 600V
NOTE:H NOTE:A 50/60 Hz SELECTION
(T2 (T2 (T2 (T2 (T2
380) 380) 380) 220) 220)
6
9/GREEN
14
X2
PMG
15
X1
16
Z2
Z2
ST2
5
E+
R448
ST6
6
E-
ST9
NOTE:E
NOTE:F 3ph
_
BLACK
POT 470ohm
T1 S1 S2
NOTE:G 3
220
NOTE:C
380
ST4
2
W V
RFI UNIT ALTERNATOR WINDING CONNECTIONS
V
BLACK
ALTERNATOR WINDING CONNECTIONS
(+) BATTERY (+) BATTERY SWITCHED
U
STARTING CIRCUIT N
(-) BATTERY / SENSOR RETURN
SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM
NOTE:A 50/60 Hz SELECTION
S2 S1
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.
P2
TI04
A
SENSOR / ACTUATOR SUPPLY
N
U
NOTE:H
P1 N
5
BLACK
U
P1 QUADRATURE DROOP ADJUST
AIR SHUT-OFF RELAY AC TRANSFORMER BOX CONTROL RELAY CRANK TERMINATION RELAY ELECTRONIC GOVERNOR RELAY FUEL CONTROL RELAY GENSET FAULT RELAY GROUND POST HIGH GROUND POST LOW GENERATOR SET CONTROL HIGH ENGINE TEMPERATURE HIGH OIL TEMPERATURE KILOWATT LOW COOLANT LEVEL LOW OIL PRESSURE POTENTIOMETER SCREEN STARTER MOTOR RELAY
W
BLUE
J1
J2
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)
OPTIONAL RFI KIT CONNECTIONS
CONNECTION TO EXCITER
+
0
NOTE:D
ST1
-
X1
NOTE:B
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.
7
9/GREEN X2
1/2 PHASE T1- T4 OR T8 - T11
X1
50 HZ VOLTAGE WYE N
10/YELLOW
12/BLACK
TABLE: 1
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
3
10A FUSE
110
U
X2
SUPPLY STATOR PMG
Z1
NOTE:B REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448
+
V
BLACK
BLUE
P2
TI04
N
S1
R731 U
RFI UNIT
N
U
S2
BLACK
BLACK
_
NOTE:G
OPTIONAL RFI KIT CONNECTIONS
ALTERNATOR WINDING CONNECTIONS
U
P1 QUADRATURE DROOP ADJUST
ST4
60Hz
UNDER SPEED ADJUST P4
3
SUPPLY 140V MAX 50/60HZ
11/RED
EXCITATION CEILING ADJUST P5
NOTE:B
J2
380) 380) 380) 220) 220) 220)
10/YELLOW
50Hz
CONNECTION TO EXCITER
PMG
SHUNT
SUPPLY - AUXILIARY WINDING
J3 _
220
ST9
NOTE:E
- (T1,T2&T3 220)
9
AREP
16
5
0
NOTE:F
50 HZ VOLTAGE WYE
Z2
PMG
15
ST3
E+
ST1
415/240V 400/230V 380/220V 220/127V 600V
X1
14
Z2
ST2
TABLE: 2
380) 380) 380) 220) 220)
X2
NOTE:A
110
(T2 (T2 (T2 (T2 (T2
9/GREEN
1/2 PHASE T1- T4 OR T8 - T11
X1
VOLTAGE ADJUST P2
-
10/YELLOW
12/BLACK
STABILITY ADJUST P3
50 HZ VOLTAGE WYE
SUPPLY STATOR PMG
Z1
UNDER SPEED ADJUST P4
415/240V 400/230V 380/220V 220/127V 600V
X1
X2
EXCITATION CEILING ADJUST P5
TABLE: 1
X2
11/RED
J3
50Hz
SUPPLY 140V MAX 50/60HZ
ASR ATB CR CTR EGR FCR GFR GPHI GPLO GSC HET HOT KW LCL LOP POT SCR SMR
ANALOG VOLTAGE REGULATOR DIAGRAM (SINGLE PHASE SENSING)
PMG
SHUNT
SUPPLY - AUXILIARY WINDING
ABBREVIATIONS
4
CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM
OR FOR 3 PHASE SENSING. AND R448
CAT DATA LINK J1939 DATA LINK DATA LINK
. 7000 FRAME SIZE REQUIRES SPILT LINK - - -
3
2
1
This schematic is for the C18 Generator Set S/N: G4C STM C6C STD Part Number 247-5088 DK00 (EMCP II+) Part Number 247-5087 DK01 (EMCP II)
SPN 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 1147 1148 1149 1150 1151 1152 1153 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
RENR7934-01 March 2006 RTD MODULE
RTD TERMINAL STRIP
40-PIN CONNECTOR RTD #1 - H RTD #1 - M RTD #1 - L RTD #1 - GND RTD #1 - SHIELD RTD #2 - H
1
4
11
13
RTD #2 - GND
14
21
RTD #3 - M
22
24
RTD #3 - SHIELD
25 31
RTD #4 - M
32
RTD #4 - L
33
RTD #4 - GND
34
RTD #4 - SHIELD
35
RTD #5 - H
6
RTD #5 - M
7
RTD #5 - L
8
RTD #5 - GND
9
RTD #5 - SHIELD
10
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
THERMOCOUPLE #1
11
341
THERMOCOUPLE #2
21
342
172
WHITE
113
THERMOCOUPLE #2
31
343
114
THERMOCOUPLE #3
2
344
RED
181
115
THERMOCOUPLE #3
12
345
THERMOCOUPLE #4
22
346
THERMOCOUPLE #4
32
347
116
THERMOCOUPLE #5
3
348
117
THERMOCOUPLE #5
13
349
THERMOCOUPLE #6
23
350
THERMOCOUPLE #6
33
351
THERMOCOUPLE #7
4
352
119
THERMOCOUPLE #7
14
353
120
THERMOCOUPLE #8
24
354
121
THERMOCOUPLE #8
34
355
THERMOCOUPLE #9
7
356
RTD PT100 182
WHITE
RED
191
118
RTD PT100
23
RTD #3 - GND
RTD #6 - M
340
RTD PT100
15
RTD #3 - H
RTD #6 - H
1
192
WHITE
RED
163
RTD PT100 164
WHITE
132
CHANNEL5 DEFAULT SPN='EXHAUST GAS PORT 5 TEMP'
133 134
CHANNEL6 DEFAULT SPN='EXHAUST GAS PORT 6 TEMP'
135 136
CHANNEL7 DEFAULT SPN='EXHAUST GAS PORT 7 TEMP'
137 138
CHANNEL8 DEFAULT SPN='EXHAUST GAS PORT 8 TEMP'
139 140
CHANNEL9 DEFAULT SPN='EXHAUST GAS PORT 9 TEMP'
12
305
INPUT #7
22
306
INPUT #8
32
307
INPUT #9
3
308
INPUT #10
13
309
INPUT #11
23
310
INPUT #12
33
311
INPUT COMMON #1
4
312
INPUT COMMON #2
14
313
INPUT COMMON #3
24
314
INPUT COMMON #4
34
315
OUTPUT #1 (N/O)
7
316
OUTPUT #1 (N/C)
5
317
OUTPUT #1 (COM)
6
318
INPUT 5 DEFAULT SPN='AIR SHUTOFF DAMPER CLOSED'
77
INPUT 6 DEFAULT SPN='GEN BREAKER CLOSED'
78
INPUT 7 DEFAULT SPN='UTILITY BREAKER CLOSED'
79
INPUT 8 DEFAULT SPN='ATS IN NORMAL POSITION'
80
INPUT 9 DEFAULT SPN='ATS IN EMERGENCY POSITION'
81 INPUT 10 DEFAULT SPN='SPARE' 82
INPUT 11 DEFAULT SPN='SPARE'
83
INPUT 12 DEFAULT SPN='SPARE'
84 85 86 87 88
17
319
15
320
THERMOCOUPLE #11
16
OUTPUT #2 (COM)
16
321
THERMOCOUPLE #12
27
OUTPUT #3 (N/O)
27
322
THERMOCOUPLE #12
25
OUTPUT #3 (N/C)
25
323
THERMOCOUPLE #13
26
OUTPUT #3 (COM)
26
324
THERMOCOUPLE #13
37
OUTPUT #4 (N/O)
37
325
THERMOCOUPLE #14
35
OUTPUT #4 (N/C)
35
326
THERMOCOUPLE #14
36
OUTPUT #4 (COM)
36
327
THERMOCOUPLE #15
10
OUTPUT #5 (N/O)
10
328
THERMOCOUPLE #15
8
OUTPUT #5 (N/C)
8
329
THERMOCOUPLE #16
9
OUTPUT #5 (COM)
9
330
THERMOCOUPLE #16
20
OUTPUT #6 (N/O)
20
331
THERMOCOUPLE #17
18
OUTPUT #6 (N/C)
18
332
THERMOCOUPLE #17
19
OUTPUT #6 (COM)
19
333
THERMOCOUPLE #18
30
OUTPUT #7 (N/O)
30
334
THERMOCOUPLE #18
28
OUTPUT #7 (N/C)
28
335
THERMOCOUPLE #19
29
OUTPUT #7 (COM)
29
336
THERMOCOUPLE #19
40
OUTPUT #8 (N/O)
40
337
THERMOCOUPLE #20
38
OUTPUT #8 (N/C)
38
338
THERMOCOUPLE #20
39
OUTPUT #8 (COM)
39
339
BATT(+)
1
55
BATT(-)
4
2
CAN_H
2
CAN2 +
CAN_L
3
CAN2 -
SHIELD
5
SHIELD
40
141 142
CHANNEL10 DEFAULT SPN='EXHAUST GAS PORT 10 TEMP'
143
8-PIN CONNECTOR
8-PIN CONNECTOR BATTERY POSITIVE(12-24V DC)
SHIELD
INPUT #6
INPUT 4 DEFAULT SPN='COOLANT LEVEL LOW SHUTDOWN'
76
OUTPUT #2 (N/C)
39
3
304
OUTPUT #2 (N/O)
38
SHIELD
2
359
37
5
BATTERY NEGATIVE (12-24VDC)
62
J1939 DATA LINK - HIGH
63
INPUT #5
INPUT 3 DEFAULT SPN='COOLANT LEVEL LOW WARNING'
75
15
36
CAN2 -
303
17
30
4
31
THERMOCOUPLE #11
29
CAN_L
INPUT #4
INPUT 2 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW SHUTDOWN
74
THERMOCOUPLE #10
28
CAN2 +
302
123
27
2
CHANNEL4 DEFAULT SPN='EXHAUST GAS PORT 4 TEMP'
131
21
INPUT 1 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW WARNING'
73
358
8-PIN CONNECTOR
CAN_H
130
INPUT #3
72
6
26
2
CHANNEL3 DEFAULT SPN='EXHAUST GAS PORT 3 TEMP'
129
301
THERMOCOUPLE #10
20
55
128
300
11
122
19
6
CHANNEL2 DEFAULT SPN='EXHAUST GAS PORT 2 TEMP'
127
1
INPUT #2
357
18
5
126
INPUT #1
5
17
BATT(-)
CHANNEL1 DEFAULT SPN='EXHAUST GAS PORT 1 TEMP'
125
1
BATT(+)
J1939 DATA LINK - LOW
64
55
BATT(-)
4
2
CAN_H
2
CAN1 +
CAN_L
3
CAN1 -
SHIELD
5
SHIELD
2
40-PIN CONNECTOR
THERMOCOUPLE #9
16
BATT(+)
124
5
2
DISCREET I/O MODULE
THERMOCOUPLE TERMINAL STRIP
THERMOCOUPLE #1
112
5
12
RTD #4 - H
40-PIN CONNECTOR
3
RTD #2 - L
RTD #3 - L
RED
171
THERMOCOUPLE MODULE
2
RTD #2 - M
RTD #2 - SHIELD
18
BATTERY POSITIVE(12-24V DC)
5
BATTERY NEGATIVE (12-24VDC) 29
J1939 DATA LINK - HIGH
27
J1939 DATA LINK - LOW
31
89
6
OUTPUT 1 DEFAULT SPN='COOLANT TEMP HIGH WARNING'
90
C18 Generator Set with EMCPII, EMCPII+ and EMCP 3 Electrical System
91 92
OUTPUT 2 DEFAULT SPN='OIL PRESSURE LOW WARNING'
93 94 95
OUTPUT 3 DEFAULT SPN='COOLANT TEMP LOW WARNING'
96 97 98
OUTPUT 4 DEFAULT SPN='GENERATOR CONTROL NOT IN AUTO'
99
C6C1-UP G4C1-UP STM1-UP STH1-UP (Engine)
100 101 OUTPUT 5 DEFAULT SPN='OIL PRESSURE LOW SHUTDOWN' 102 103 104 OUTPUT 6 DEFAULT SPN='COOLANT TEMP HIGH SHUTDOWN'
3
STD1-UP PDH1-UP (Engine)
7
9
8
Control Panel Callouts Description Electronic Modular Control Panel (EMCP) Panel Lights (optional) Panel Lights Switch (PLS) (optional) Annunciator Module Spare Slot (for additional annunciator module) Emergency Stop Push Button (ESPB) Start Aid Switch (SAS) (optional) Speed Potentiometer (SP) (optional) Voltage Adjust Toggle Switch
105 106 107 OUTPUT 7 DEFAULT SPN='ENGINE OVERCRANK' 108
Callout 1 2 3 4 5 6 7 8 9
109 110 OUTPUT 8 DEFAULT SPN='ENGINE OVERSPEED' 111
18 BATTERY POSITIVE(12-24V DC) 5
62
J1939 DATA LINK - HIGH
63
J1939 DATA LINK - LOW
64
Related Electrical Service Manuals Title
Form Number
EMCP 3 Systems Operation/ Troubleshooting/ Testing and Adjusting
RENR7902
Volume 3- EMCP 3 Printed in U.S.A.
© 2006 Caterpillar All Rights Reserved
CONNECTOR PINOUTS FOR HARNESS 269-8103
CONNECTOR PINOUTS FOR HARNESS 258-4700
155-2264
160-7689 128-2312
1
23
14
31
24
39
32
47
40
28 27 26 25 24 23 22
21 20 19 18 17 16 15
57
48
42 41 40 39 38 37 36
35 34 33 32 31 30 29
70
58
56 55 54 53 52 51 50
49 48 47 46 45 44 43
70 69 68 67 66 65 64
63 62 61 60 59 58 57
ECM (J1) PLUG
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
FMI 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 31
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+ Dn/a 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 n/a n/a n/a n/a 21 22 SCR n/a SSPD n/a SCR n/a ATA+ ATASCR 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 n/a
9X-4391 14 13 12 11 10 9
8
7
6
5
4
3
2
1
WIRE 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 n/a n/a 45 n/a n/a n/a n/a n/a n/a n/a n/a n/a n/a ATAn/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 ATA+ B+ B+ n/a n/a n/a n/a n/a n/a n/a n/a 2 n/a 2 n/a 2 SSPD n/a n/a n/a 10
8
2
7
15 16 17 18 19 20 21
22 23 24 25 26 27 28
32
29 30 31 32 33 34 35
36 37 38 39 40 41 42
1
2
3
4
5
6
7
8
9 10 11 12 13 14
43 44 45 46 47 48 49
50 51 52 53 54 55 56
4
5
57
48
57 58 59 60 61 62 63
64 65 66 67 68 69 70
70
58
EMCP 3 PLUG
WIRE 17 30 12 11 46 2 34 4
SPLICE(2) #4
ETHER START 59
R
2
L
SPLICE(2) #2
SPLICE(45) #7
SPLICE(B+) #5
CONTROL PANEL ELECTRONIC CONTROL MODULE (ECM) P1
SPLICE(10) #6
260
72 30
FUEL LEVEL
2.5mm
25
30 2
E/STOP 2
SPLICE(2) #3
2 4
230 230 245 245 360 360 250 210 180
EARTH 25
40 + 2.5mm
+
21
CAT DIGITAL VOLTAGE REGULATOR
R 30
L
2
10
215 215
10
+
24
39
40
SPLICE(1,2) #1
4mm
14
47
30
4mm
23 31
6
PIN 1 2 3 4 5 6 7 8
2.5mm
1
3
E /STOP PLUG 8 WAY
GENERATOR PLUG 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
1
13
19
2
ENGINE OIL TEMPERATURE
22
2.5mm
L
ENGINE SPEED
4mm
+ + +
290 215 215 215 215
1
STARTER MOTOR 4mm
2
2
2
270 270 270 270 270 270 270
78 ANALOG VOLTAGE 80 REGULATOR 82
B+ TERMINAL BOX
R
EF1
EF2 CORE BALANCE CURRENT TRANSFORMER A-10
4mm
40
B-2 C-18
30
B C
A
COOLANT LOSS
ALTERNATOR 4mm
2
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 269-8103
2
2 ETH 30
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 n/a SRN 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 n/a n/a 51 6 36 CAN 137 93 n/a n/a 50 55 55 SRN 55 72 73 n/a 52 41 n/a CAN 1+ 14 55 77 18 57 n/a 53 2 n/a n/a 55 CAN 2+ SRN CAN 22 22 21 96 95 17
D+ D-
WIRE 1 1 D+ DSRN n/a 10 n/a n/a n/a 2 2 n/a n/a 41 41 45 n/a n/a 18 n/a n/a n/a n/a 30 n/a n/a ESn/a n/a 21 22 SRN n/a SSPD DSPD n/a 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 n/a 80 82 n/a n/a 59 n/a EF1 EF2 n/a 72 30 n/a n/a n/a 79 SRN
C B
A
2 55 CAN 1CAN 1+
J
G
CAN 1-
H
SERVICE CONNECTOR
GENERATOR RECEPTICLE 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
D
E F
CAN 1+
WIRE 55 2 D+ DCAN 1+ CAN 1CAN 1+ CAN 1-
PIN A B D E F G H J
GENERATOR RECEPTACLE
SERVICE CONNECTOR RECEPTACLE PANEL LIGHT
10 55
2
55 1
1A 41
9
CONTROL RELAY CR
55
3 6 10 10 23A 30 30 37 38 55 55 59 73 77 95 96 ESEF1 EF2 CAN1CAN1+ SCREEN 93 94 M+ MSCREEN CAN2+ CAN2SCREEN 10
ETHER START ES-
2
36
ALARM BUZZER 2 1A
PANEL LIGHT SWITCH
9
EMCP 3 PLUG
EARTH
E/STOP
45
E/STOP
30
17
1 2
34
14
46
55 57 30
108 109 110
50 51 52 53 101 108
90 91 97 98 99 D-SPD S-SPD SCREEN
80
VOLTAGE 82 ADJUST 79
EARTH
SPLICE(55) SPLICE(101)
SPLICE(50) SPLICE(10)
SPLICE(2) SPLICE(41)
SPLICE(45) SPLICE(ES-)
SPLICE(30) SPLICE(1) SPLICE(CAN1-)
CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 258-4700
SPLICE(108) SPLICE(17) SPLICE(CAN1+)
20 Page
103-0213 13
RENR7934-01 VOL 3
160-7689
1237
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
4 1
CAT
Suspect Parameter Number (SPN) 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 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
CR/1 :1 137
TO STARTER MOTOR
:13
HC :A2
-
6 mm 2
2 .5 mm 2
137
BATTERY CHARGER & HEATERS (Both use the same voltage)
138
:6
131
135
134
141
:1
:3
:5
HC :A2
:2
:4
:6
131
140
F16 (2A)
NOTE A
ENGINE JACKET WATER HEATER
NOTE A
F18 (4A)
142 9
131
:4
24V DC + SUPPLY (DC TERMINAL RAIL)
148
*
12
1
5
1 F15
36
+
(*) 2
2
131
:A1
131
-
:4 131
CUSTOMER 100V TO 250V AC SUPPLY (AC TERMINAL RAIL)
F17 (6A)
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
15 131
131
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
:4
16
HEATERS
1 F15
24V DC + 1 SUPPLY (DC TERMINAL 2 - 5 RAIL)
36
(*) 2
14
CUSTOMER 100V TO 250V AC SUPPLY (AC TERMINAL RAIL)
131
L1
T2
L2
T3
L3
N
N
E
E
67
231
:11
:12
233
:13
:14
15 POWER WIRING FROM GENERATOR
30
14
EARTH FAULT RELAY k l
A2
EF1
30
14 20
73
T2
S1 P1
S2 P2
CT1
T3
S1 P1
S2 P2
CT2
S2
S1
61
62
26
25
6
GENERATOR PLUG 9X4391
EF2
21
2
EMCP3 PLUG 1607689
1
HARNESS Y SPLICE 1
24
1
CB1 (60A)
1.5 mm 2
6 mm 2
22
21
22
67 MAG
+
50
33
RELAY BOX
-
SM1
AC
66
52
31
47
IA
IB
53
52
57
ENG CRANK
ALT
-VE SUPPLY
DC
TERMINAL RAIL LINK
EMCP3 PLUG 1607689 HARNESS Y SPLICE 55
F4 (10A)
34 50
RLY2
RLY3
FUEL CONTROL
ASR SWITCH
RLY4 AUDIBLE ALARM
RLY5
RLY6
HARNESS Y SPLICE 101
101 108
HARNESS Y SPLICE 108
108
109
110
101
13
11
9
5
7
6
120 OHMS
CAN1+
CONNECTION
:3
132
16
:X1
203
NOTE A
1
41 40
CAN 1-
55
GFR SWITCH
GRR SWITCH
48
58
35
43
33
41
32
40
26
27
14
55
41
2
37
55
36
55
6
55
38
55
31
2 HARNESS Y SPLICE CAN1-
39 29
B
CAN 1-
HARNESS Y SPLICE CAN1+
CAN 1+
15
1A 17
27
CAN 1+
55
A
PANEL LIGHT SWITCH
J
:3
VB
:X2
(2A)
13
208
131
1
3
5
2
34
64
CAN2-
63
62
SRN CAN2CAN2+
BATT +
2
2
BATT -
3
3
NC
4
4
CAN2 SRN
5
5
CAN2 -
6
6
CAN2 +
# 1
63
64
35
36
CAN2+
34
42 SRN CAN1 J1939
CAN2-
9
40 23 ECM PLUG P1 1607689 70
48 52
66
HARNESS X SPLICE B+ 68
53
D+
D+
4
D-
D-
15
41
EMERG STOP
2
90
25
91 57
15
1
92
24
97
58
59
60
I/P 1 70
14
98
REMOTE START
99
I/P 2 55
17
FUEL LEAK
LOW COOLANT LEVEL I/P 3 54
57
EARTH FAULT
I/P 4 53
77
18
61
21
I/P 5 45
LOW FUEL LEVEL I/P 6 44
73
72
20
10
S-SPD
38 36
62 +
63 SRN CAN2 J1939 64
D +B
10
65
28
ES-
43
5 +
3
1
42
17
46
30 8
SPEED CONTROL
13
9
PROG I/P 8
OIL PRESSURE
I/P 7 36
I/P 8 28
PASSIVE ANALOG 1+ 56
ENGINE TEMP PASSIVE ANALOG 2+ 38
69
95
SINK O/P 2
68
96
OIL TEMP PASSIVE ANALOG 3+ 30
OIL PRESSURE PASSIVE ANALOG 146
ENGINE TEMP
OIL TEMP
PASSIVE ANALOG 237
53
VALVE 14
2
4
6
207
ENGINE ELECTRONIC CONTROL MODULE(ECM)
2
4
6
98
131
211
2
34
CR/3
This pin does not exist on EMCP3.1
HARNESS Y SPLICE 45
10
16
11
TERMINAL RAIL LINK
7
3
17
46
8
17
18
48
50
34
46
10
17
209
210
203
COMMON ALARM 78
80
ALR/3
82 :8
20
65
23A
59
18
9
59
72 64
5
E/STOP RECEPTACLE 3E3388
E/STOP RECEPTACLE 3E3388
8
HARNESS X SPLICE 10
:9
54
55
56
70
64
65
RUN
:X2
7
77
8
30
M 77
RELAY CONTACT N/O
EARTH
21
(DC TERMINAL RAIL) 13
30
CIRCUIT BREAKER
22 JUMPER PLUGS
CUSTOMER CONNECTIONS:
WIRE IDENT:-
23
EMCP3 PLUG 1607689
SPARE SPARE SPARE SPARE
BATTERY BATTERY BATTERY BATTERY
-
AWG AWG AWG AWG
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
12 12 12 12
AIR SHUTOFF RELAY
AWG 12
SPARE BATTERY + SPARE BATTERY +
AWG 12 AWG 12
FUEL LEAK DETECT
AWG 12
J1939 PRIMARY COMMUNICATION
AWG 12
J1939 PRIMARY COMMUNICATION
AWG 12
SHIELD
AWG 12
MODBUS RS485 COMMUNICATION MODBUS RS485 COMMUNICATION SHIELD
AWG 12 AWG 12 AWG 12
ECM POWER LINK
AWG 12
ECM POWER LINK 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 AWG AWG AWG AWG AWG AWG AWG AWG
12 12 12 12 12 12 12 12 12
66
47
48
GENERATOR RUNNING :8 78
80
GRR/3
:9
82
87
2
FOR USE WITH CDVR
E/STOP PLUG 1552264
10
J1939 SECONDARY COMMUNICATION J1939 SECONDARY COMMUNICATION SHIELD BREAKER AUX N/C BREAKER AUX COM BREAKER AUX N/O
AWG AWG AWG AWG AWG AWG
12 12 12 12 12 12
49
88 50
1 2 3 4 5 6 7 8 9 10 11 12 13
89 51
REMOTE CONTACTS FOR GENERATOR RUNNING
ST4 R448
45
:85
RELAY BOX
45
45
HARNESS X SPLICE 45 18
10 3
AIR SHUTOFF AIR
ETHER START 1
2
2
2
A
C
B
COOLANT LOSS TERMINAL RAIL LINK
:1 R/1
PANEL LAMP SWITCH
:11
1
6
E/STOP PLUG 1552264 4
SMMS1
6
2
-1 -1 -2 -2 -2 -2 -3 -6 -8 -10 -10 -23A -30 -30 -37 -38 -55 -55 -59 -73 -77 -95 -96 -ES-EF1 -EF2 -CAN1-CAN1-CAN1+ -CAN1+ -SRN -93 -94 -M+ -M-SRN -S-SPD -D-SPD -SRN -10 -10 -55 -57 -30 -64 -65 -66 -87 -88 -89 -81 -83 -84 -85 -90 -91 -92 -97 -98 -99 -CAN2+ -CAN2-SRN -231 -232 -233
ABBREVIATIONS
120 OHM RESISTOR BETWEEN 27 & 29
CHASSIS DC TERMINAL RAIL
59 SASV 2
SHUT-OFF SOLENOID
AUTOMATIC VOLTAGE REGULATOR (AVR) 72 LOW FUEL LEVEL
ASOS
(+) BATTERY SWITCHED STARTING CIRCUIT 120 OHM RESISTOR BETWEEN 62 & 63
NOTE: SEE AVR DIAGRAM ON VOLUME 2
AWG 8 CUSTOMER 120/240VAC L1 SUPPLY FROM 2 POLE 110/120VAC BREAKER IN EMERGENCY 220/240VAC PANEL POWERS: AWG 8 N JW HEATER, UNIT MOUNTED L2 AWG 8 CHARGER AND OPTIONAL GENERATOR SPACE HEATER
-50 -51 -52 -53 -101 -108 -209 -210 -142 -140 -131 -131 -143
14
-131
15
-131
16
-132
17
-132
18
-133
19
-139
20
2
2 HARNESS X SPLICE 2-1
30
HARNESS X, SPLICE 30 2
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
(+) BATTERY
(-) BATTERY / SENSOR RETURN SENSOR / ACTUATOR SUPPLY SIGNAL PLUS TO ECM SIGNAL MINUS TO ECM CONTROL PLUS FROM ECM CONTROL MINUS FROM ECM CAT DATA LINK J1939 DATA LINK DATA LINK
OPTIONAL WIRING
CHASSIS AC TERMINAL RAIL
-148 -5O EARTH
2
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
:11
:86
5
-VE SUPPLY
:2
23A
59
E/STOP PLUG 1552264
SR
4
-
SCREEN CABLE
:3
REMOTE CONTACTS FOR GENERAL ALARM
2
2
PR :10
PUMP
82
30
2
2
:1
E/STOP RECEPTACLE 3E3388
:86 :1 MAN EPIR :2 AUTO :85 ETHER START SWITCH
GENERATOR RECEPTACLE 1030213
:3
46
12
GENERATOR PLUG 9X4391
80
23A
59
30 25
78
12
19
14
:2
:87 23A
TERMINAL HARNESS Y RAIL LINK SPLICE 30 13 30 30
7
ASOR/1 :87
45
VOLTS ADJUST POTENTIOMETER (2K W, 10 TURN)
FOR USE WITH CDVR
:30
:30 EPIR/1
:9 42
23
E/STOP RECEPTACLE 3E3388
ETHER START
+
:X1
8
ES-
:2
:3
95
PASSIVE ANALOG 329
This pin does not exist on EMCP3.1
94
93
SINK O/P 1
(16A)
EMERGENCY STOP ON ENCLOSURE
PWM SPEED CONTROL
ES-
TRANZORB (SURGE SUPPRESSOR)
The below does not function on EMCP3.1
1
10
57
30
REMOTE START CONTACT
E/STOP PLUG 1552264
SPEED ADJ. POT. (2K , 10T)
85
4 SRN
RS485
1
F27
:11
10
49
7
:3
-B
24
11
GEN RUNNING
HARNESS Y SPLICE 10
34
:2
10
{ENGINE MOUNTED}
3 COMMON ALARM
HARNESS Y SPLICE 17
2
44
R
22
27
8
2
RELAY COIL :2
FUEL LEAK DETECTOR
The above does not function on EMCP3.2 or EMCP3.1
PROG I/P 7
33
ETHER START
:1
40 21
3
S
D-SPD
39
61 63
38 :2 GRR :10
TERMINAL RAIL LINK
41
HARNESS Y SPLICE 2
GENERATOR PLUG 9X4391 35
ECM POWER LINK
HARNESS Y SPLICE 41
PANEL LIGHT
41
37
HARNESS X SPLICE 2-2
6 :2 ALR ALARM RELAY :10 2
45
41
GENERATOR RECEPTACLE 1030213
D-SPD
16
44
9
45
S-SPD
ALARM
:2 CR :10
E
:7
M-
The below does not function on EMCP3.1
9
D
R
:2 MV :1 MOT.
83
37
M+
EMCP 3.3 or 3.2 or 3.1
43
3
:10
:6 PR/2
55
HIGH LEVEL FUEL SWITCH
5
J16 1
:3 PR/1 :1 52
97
96
PANEL LAMP
84
LOW LEVEL FUEL SWITCH
120 OHMS
AIR SHUTOFF
55
J 8
84 54
131 207
EMERGENCY STOP PUSHBUTTON
F23
The above does not function on EMCP3.1
38
8
36
4
EMER. STOP
:2
6
55
37 :86 AIR ASOR SHUTOFF RELAY 2 :85
18
TERMINAL RAIL LINK
H
1
POTENTIOMETER
FUSE
DC CIRCUIT
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
TRIP/ STOP
AC SUPPLY 100V TO 250V
14
:1
GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK FUEL SYSTEM No. 2
CUSTOMER
207
205
1
E/STOP CHASSIS TO DOOR SOCKET POWER TERMINAL
FUEL LEAK SWITCH
CAN1-
50 +
VC
The items below do not RLY7 function on RLY8 EMCP3.1 PROG PROG O/P O/P
61
5
2
H
101
CAN2+
62
39
51
55
F
2
110
C
2
5
SRN
J
I RETURN
56
2 SERVICE CONNECTOR RECEPTACLE 1282312
CAN 1+
ECM PLUG P1 1607689
SRN(CAN1)
RELAY BOX
30 2
109
E
P16
GENERATOR SOCKET
SW1 NORMALLY CLOSED
PUMP
ANNUNCIATOR
30
2
5
E/STUD 2
CAN 1-
E/STUD 1
108
B+ F5 (10A)
3
+
:87
6 mm 2
-
208
55
18
43
2
B
E
E
55
A
SERVICE CONNECTOR
50
IC
101
_
RLY1
CHARGING ALTERNATOR
PR :10
PUMP STOP
ANNUNCIATOR
CHASSIS TO DOOR DC SOCKET
SW2 NORMALLY CLOSED
131
BREAKER AUXILIARY
CAN 2 SERVICE CONNECTOR
LCD DISPLAY
65
40
PS1
:11
+
O/L
BATTERY (12/24Vdc) 55
25
232
OIL TEMPERATURE SENSOR SOCKET
EARTH (MOUNTING SCREW)
SR/1
SMMS1/1
:12
D
BOTH OF THESE WIRES CONNECT TO THE STANDARD STUD IF THE OPTIONAL STUD IS NOT SUPPLIED
CHASSIS CHASSIS STANDARD OPTIONAL STUD STUD 51
T3 F3 4A)
HARNESS Y SPLICE 50
E
:30 PS1
24V
231
:2
F21 NOTE:B
207
A2
VA
EMCP3 PLUG 1607689 2
A+ +
20 Page, Color 2
1 EARTH
T2 F2 (4A)
PICKUP E
2 CB3 (15A)
66
F22 (2A)
:14
2
SW3 NORMALLY CLOSED
PC
TERMINAL RAIL LINK
2.5 mm 2
CB2 (20A)
RENR7934-01 VOL 3
4
DOOR
32
21
-
OPTIONAL BATTERY ISOLATOR SWITCH KEY REMOVABLE
3
T1 F1 (4A)
50
53
22
31
GENERATOR PLUG 9X4391
1
+VE SUPPLY
52
2
GENERATOR RECEPTACLE 1030213
6 mm 2
65
233
N
1
EF1
GENERATOR RECEPTACLE 1030213
2.5 mm 2
67
START AID SOLENOID VALVE SOCKET
58
6 mm 2
L3
E
1
HARNESS X SPLICE 1
:C2
2
:2
L2
CT3
MAGNETIC PICK UP No.1
GENERATOR PLUG 9X4391
24V DC SHUNT TRIP
ST
LEVEL SWITCH (SIDE VIEW)
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
:C1
CHASSIS AC TERMINAL LOCATED ON AC TERMINAL RAIL
TERMINAL BOX
AC CIRCUIT
A1
EF1
GENERATOR RECEPTACLE 1030213
E
8
HIGH
SW4 NORMALLY OPEN
:11
E
2
EF1
E
L1
P2
EF2
14
EF2
N
CHASSIS DC TERMINAL LOCATED ON DC TERMINAL RAIL
5
204
P1
51
11
N
METERING C.T.s
SRN(CAN1)
A1
L3
11
TERMINAL BOX
PR/3
CAN 1+
10
T3
ENTRY
53
This circuitry applies to fuel system No. 3 only. It does not exist in fuel system No. 1.
4 POLE BREAKER OR POWER TERMINAL STRIP (PTS) OPTIONAL
T2 T3 N E
12
24
L2
CHASSIS CUSTOMER TERMINAL LOCATED ON DC TERMINAL RAIL
83
:9
BREAKER
T1
EF2 21
T2
81
SW3
OW - L LOW LOW
LEVEL SWITCH (TOP VIEW)
HIGH LEVEL FUEL SWITCH
VALVE
-VE SUPPLY
L1
2
:3 PR/1 :1 81
52
T1
T1
E
22
:7 55
MCCB
N
10
PR/2
4 POLE BREAKER OPTIONAL
CAN 1-
AC GENERATOR
54
LOW LEVEL FUEL SWITCH
:2 MV :1 MOT.
REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
CORE BALANCE CURRENT TRANSFORMER IF REQUIRED
84
85
8
CORE BALANCE C.T.
Q/2
BREAKER AUXILIARY
3
NEUTRAL EARTH LINK
Q/1
ACB
NOTE A
84 PUMP RUN
HEATER
14
84
SW2
11
CABLE
SW4 SW1
(2A)
FOR 5A CHARGER FIT (6A) FUSE FOR 10A CHARGER FIT (10A) FUSE
*
1 F23
1
:6
131
HIG HIGHH-
DC CIRCUIT
232
66
SYMBOLS
FUEL PUMPED FROM FREE STANDING BULK TANK - FUEL SYSTEM NO. 3
:C12
65
FUEL LEVEL SWITCH DRAWING
OR
24V DC SHUNT TRIP
ST
+
-
PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK - FUEL SYSTEM No. 1
:C11
6
8
REMOTE TERMS FOR BREAKER OPEN & CLOSED POSITIONS
T1
2
3
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS.
140
CONSTANT VOLTAGE CHARGER
131
POWER WIRING FROM GENERATOR
131
CR/1 :1
ALTERNATOR ENGINE (GENERATOR) JACKET HEATER WATER
NOTE A
6 mm 2 135 136
BATTERY CHARGER
139 NOTE A 19
132
14
:6 142 9
6 mm 2
COPPER BUSBAR
:5
HEATER
14
131
16
134
:3
HC :A2
NOTE A
134
141
ALTERNATOR ENGINE (GENERATOR) JACKET HEATER WATER
140
6 mm 2
141
CR/1 :1
137
139 19
F19 NOTE:A
132
136
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6 mm 2 TERMINALS. 134
:A1
131
14
131
20 143
2
141
CONSTANT VOLTAGE CHARGER
ALTERNATOR (GENERATOR) HEATER
10 131
131
6 mm 2
COPPER BUSBAR
139 19
13
140
2
:5
:4
142 9 NOTE A
131
+
:2
135
CR/1 :1
NOTE: CUSTOMER CABLE TO ENTER DIRECTLY ONTO 6mm 2 TERMINALS.
6 mm
134 :3
:1
:14
131
CONSTANT VOLTAGE CHARGER
147
141
:A1
138
6 mm 2
6 mm 2
CR/2 :6
134
F19 NOTE:A
2 .5 mm 2
:4
147
6 mm 2
:5
BATTERY CHARGER 140 & HEATERS (120V Charger, 240V Heaters)
+
141
131
:4
6 mm 2
136
F18 (4A)
136
M2 NOTE:A MCB
2 .5 mm 2
135
NOTE A
6 mm 2
M1 2P 6A MCB
F16 (2A)
2 .5 mm 2
F17 (10A)
120
14
F17 (6A)
CUSTOMER 100V TO 250V AC SUPPLY (AC TERMINAL RAIL)
6 mm 2
131
F16 (2A)
16
4 POLE BREAKER OPTIONAL
6 mm 2
18
132
2 .5 mm 2
240
133
6 mm 2
COPPER BUSBAR
AC SUPPLY (AC TERMINAL RAIL)
2 2 .5 mm
6 mm 2
16
6 mm 2
132
CUSTOMER 100V TO 250V
6 mm 2
6 mm 2
COPPER BUSBAR
NOTE:A IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A
NOTE:A IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A
2 .5 mm 2
NOTE:A IF 230V JACKET WATER HEATER IS FITTED MCB M2 SHOULD BE 16A IF 230V BLOCK HEATER IS FITTED MCB M2 SHOULD BE 10A
2
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.
SECTION BORDER
THIS SCHEMATIC IS FOR THE C18 GENERATOR SET (S/N C6C, G4C, STM, STD) Diagram Part Number Diagram Part Number Diagram Part Number
269-3119 DK02 (EMCP3.1) 260-5248 DK02 (EMCP3.2) 260-5249 DK02 (EMCP3.3)
IDENT Y
HARNESS 258-4700
CHG 02
X
269-8103
01
EMCP3 HARNESS J1 / GENERATOR SET CONTROL HARNESS
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