810742 disco borger tx - a9[1]. engine accessories - cat wiring schematics
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Volume 1 of 2: Non-CSA
RENR5900-02November 2008
G3408C and G3412C EnginesElectrical System6ZM1-UP8YR1-UP9RR1-UP3WR1-UP6FW1-UP8LW1-UPBAZ1-UP
©2008 CaterpillarAll Rights Reserved
Printed in U.S.A.
GOVERNORMPU CONNECTOR
GOVERNORMPU
ALTERNATORCIRCUIT BREAKER (OPTIONAL)ELECTRIC STARTCIRCUIT BREAKER (OPTIONAL)BATTERYCIRCUIT BREAKER
STARTER MOTOR MAG SWITCHSMMS (OPTIONAL)
STARTER MOTOR MAG SWITCHSMMS (OPTIONAL)
REAR VIEWOF ENGINE
TO LOW WATERLEVEL SWITCH
RIGHT SIDE VIEWOF ENGINE
FOR CLIP, SEE WATERLEVEL GAGE GP
ELECTRONIC IGNITION SYSTEM MODULE(EISM)
LEFT SIDE VIEW ALTERNATE LOCATIONSPEED TIMING SENSOR
LOCATION ON G3408
FRONT VIEWOF ENGINE
SPEED TIMING SENSOR(SP/TIM)
CAT
RIGHT HANDDETONATION SENSOR(RHDS)
RIGHT SIDE VIEWOF ENGINE
ELECTRONIC IGNITION SYSTEM MODULE(EISM)
LOW WATERTEMPERATURESWITCH
LOCATION ON G3412
LEFT SIDE VIEWOF ENGINE
LEFT HANDDETONATION SENSOR(LHDS)
RIGHT HANDDETONATION SENSOR(RHDS)
LEFT HANDDETONATION SENSOR(LHDS)
ALTERNATORCIRCUIT BREAKER (OPTIONAL)ELECTRIC STARTCIRCUIT BREAKER (OPTIONAL)BATTERYCIRCUIT BREAKER
ENGINE MOUNTEDINTERFACE BOX
ENGINE MOUNTEDINTERFACE BOX
MANIFOLD AIRPRESSURE SENSOR(MAPS)
MANIFOLD AIRPRESSURE SENSOR(MAPS)
ELECTRONIC IGNITION SYSTEM MODULE(EISM)
D080-DDTC-D-WH, D081-CR1-2-WHS7
S6D080-DDTC-E-BK, D081-CR1-43-BK
D080-DDTC-CU, D081-CR1-57-CUS1
S2
D600-EISC-Y-BK
D080-EISC-d-CU
D080-EISC-K-BK
S111-BK, S111-CU, S850-BK, S850-CU
P681-CR1-48-RD, P680-CR1-3-RD, P680-DDTC-A-RD, P680-CR1-46-RD
P390-DDTC-B-BK, P390-CR2-D-BK, P391-CR2-C-BK S5
S4
P390-EISC-B-BK
J023-CU, J043-CU, J063-CU, J083-CU,J103-CU, J123-CU
J013-CU, J033-CU, J053-CU, J073-CU, J093-CU, J113-CUP680-EISC-A-RD
P301-EGND-GN/YL
D080-EISC-G-WH
P302-EGND-GN/YL
S3
S10
S9
EBC SHIELD DRAINGROUND LUG
S382-BK, S382-CU, D600-DDTC-CU, S381-BK, S381-CU
SPLICE DETAIL
EISC
P500-EISC-Z-GNA330-CU
A330-BK
A330-RD
S270-BK
S270-RD
S270-CU
(OPTIONAL)2301A GOV CONTROL
GOVC-7GOVC-8
GOVC-GND
GOVC-9
GOVC-10
GOVC-6
GOVC-1
GOVC-4
GOVC-5
GOVC-3
GOVC-2
GOVC-14
GOVC-15
GOVC-11
GOVC-13
GOVC-12
GOVC-17
GOVC-16
CB4
TB-2
TB-101
NOT USED
OPTIONAL CUSTOMER SPEED CONTROL
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
P630-RD P631-RD
C860-RD
C861-BK
NOTE: THE CUSTOMER MUSTREMOVE THE JUMPER ONGOV-11 AND GOV-12 WHENINSTALLING REMOTESPEED TRIM
OPTIONAL CUSTOMER SPEED CONTROL
GSC-RM13
GSC-RM14
P380-BK
NOT USED
PRO-ACT GOV CONTROL
GOVC-3
S270-BK
S270-RD
S270-CU
GOVC-14 NOT USED
GOVC-16
GOVC-17
GOVC-15 NOT USED
OPTIONAL CUSTOMER SPEED CONTROL
NOT USED
GOVC-GND
(OPTIONAL)
GOVC-12
GOVC-13
GOVC-11
GOVC-9
GOVC-10
GOVC-7
GOVC-8
GOVC-6
GOVC-4
GOVC-5
NOT USED
NOT USED
CB4
GOVC-1
GOVC-2
TB-2
TB-101
NOT USED
NOT USED
NOT USED
NOT USED
GOVC-18
GOVC-19
GOVC-22
GOVC-23
GOVC-21
GOVC-20
GOVC-25
GOVC-24
NOT USED
NOT USED
NOT USED
NOT USED
OPTIONAL CUSTOMER SPEED CONTROL
OPTIONAL CUSTOMER SPEED CONTROL
A340-RD
A350-BK
A330-CU
A330-WH
A330-BK
A330-RD
A340-RD
A350-BK
P680-RD
P380-BK
JUMPER MUST BE INSTALLED BETWEEN BATTERY (-) (GOVC-25)AND GOVERNOR CHASSIS GROUND STUD (GOVC-GND)
P680-RD
P380-BK
P220-RD
C253-BK
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
CP29X-4391
CR2103-0213
144270
2639535525516745
11
50
P220-RD
C253-BK
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
CP29X-4391
CR2103-0213
144270
2639535525516745
11
50
REMARKSCOILREQUIREMENTS
PEAKCURRENT
CONTINUOUSCURRENT
VOLTAGEREQUIREMENTSDEVICE
15 AMPS10 AMPS20 AMPS10 AMPSTBD
10 AMPS
<200 MILLI-AMPS
TBD
3 AMPS3 AMPS10 AMPS10 AMPSTBD
10 AMPS
24-32 VDC18-32 VDC18-32 VDC18-32 VDC18-32 VDC18-32 VDC
18-32 VDC
GAS SHUTOFF VALVEEIS CONTROL MODULEPROACT ACTUATORFCR RELAYISR RELAYFUSE F2
FUSE F3
16.8 WATTS NORMAL POWER CONSUMPTIONPEAK CURRENT DRAW IS FOR MILLISECONDSPEAK CURRENT DRAW IS FOR 2 TO 3 SECONDS(NO CONTACTS)NO CONTACTS ARE RECOMMENDEDTBD: SIZE TO BE DETERMINED BY CUSTOMER BASED ONEQUIPMENT HE INSTALLSSIZED TO PROTECT 16 GAGE WIRE
1. SEQUENCE OF OPERATION FOR ENERGIZED-TO-RUN SYSTEMSA. START/RUN CYCLE:- CUSTOMER'S ENGINE CONTROL PANEL IS POWERED.- ENGINE START-STOP SWITCH IS PLACED IN THE CRANK POSITION AND STARTER MOTOR IS ENGAGED.- CUSTOMER'S CONTROL PANEL SENSES ENGINE SPEED, ENGINE OIL PRESSURE, AND ENGINE COOLANT TEMPERATURE.- NORMALLY CLOSED GAS SHUTOFF VALVE IS OPENED, AND CR13-3 (PIN L OF EISM) MUST BE CONNECTED TO GROUND BY CLOSURE OF CUSTOMER PROVIDED IGNITION SHUTOFF RELAY (ISR) NORMALLY OPEN CONTACTS.- AFTER ENGINE REACHES CRANK TERMINATION SPEED (TYPICALLY 250 RPM), STARTER MOTOR IS DISENGAGED.- GAS SHUTOFF VALVE MUST REMAIN OPEN.- CR13-3 (PIN L OF ELECTRONIC IGNITION SYSTEM MODULE (EISM)) MUST REMAIN CONNECTED TO GROUND- IT IS RECOMMENDED THAT THE CUSTOMER WIRE THE CUSTOMER PROVIDED ISR AND FSR RELAYS TO PROVIDE "ENERGIZED TO RUN" CONTROL LOGIC.
B. EIS DIAGNOSTIC RESET SWITCH: THE EIS DIAGNOSTIC RESET SWITCH INPUT ALLOWS THE OPERATOR TO CLEAR ALL DIAGNOSTIC CODES. DIAGNOSTIC CODES CANNOT BE SELECTIVELY CLEARED ON THE EIS SYSTEM, SO TOGGLING THE DIAGNOSTIC RESET SWITCH WILL CLEAR ALL OF THE DIAGNOSTIC CODES. GROUNDING THE DIAGNOSTIC RESET INPUT ON THE EIS IS THE ONLY WAY TO CLEAR THE DIAGNOSTIC CODES.
C. EIS WARNING LIGHT: THE EIS WARNING LAMP DRIVER PROVIDES THE OPERATOR A VISUAL INDICATION OF AN EIS DETECTED WARNING BY ACTIVATING OR FLASHING A YELLOW LAMP OR LED WHEN A WARNING FAULT IS DETECTED.
D. EIS SHUTOFF LIGHT: THE EIS SHUTDOWN LAMP DRIVER PROVIDES THE OPERATOR A VISUAL INDICATION OF AN EIS REQUESTED SHUTDOWN BY ACTIVATING A RED LAMP WHEN A SHUTDOWN FAULT IS DETECTED.
2. SHUTDOWN CONTROL LOGIC 2. SHUTDOWN CONTROL LOGIC (Cont'd)A. OPERATOR INITIATED SHUTDOWN:- OPERATOR PLACES START-STOP SWITCH INTO STOP POSITION. CUSTOMER MUST WIRE HIS CONTROL LOGIC TO CAUSE THE FOLLOWING TO OCCUR:- THE GAS SHUTOFF VALVE CLOSES.- ISR RELAY CONTACTS REMAIN CLOSED UNTIL ENGINE SHUTS OFF.
B. FAULT SHUTDOWN:- LOW OIL PRESSURE- HIGH COOLANT TEMPERATURE- LOW COOLANT LEVEL- ENGINE DETONATION
1. IF LOW OIL PRESSURE, HIGH COOLANT TEMPERATURE OR OPTIONAL LOW COOLANT LEVEL ARE DETECTED, CUSTOMER'S SHUTOFF SYSTEM MUST DE-ENERGIZE THE GAS SHUT OFF VALVE COIL CAUSING THE NORMALLY CLOSED GAS SHUTOFF VALVE TO CLOSE. CUSTOMER'S SHUTOFF SYSTEM MUST MONITOR ENGINE DECELERATION. IF THE ENGINE HAS NOT DECELERATED BY 100 RPM WITHIN 5 SECONDS, NORMALLY OPEN CONTACT FOR ISR (IGNITION SHUTOFF RELAY) MUST BE OPENED TO BREAK GROUND CONTACT WITH PIN L TO INSURE ENGINE SHUTDOWN BY DISABLING THE IGNITION SYSTEM. IF ENGINE IS DECELERATING, ISR REMAINS CLOSED UNTIL ENGINE RPM DROPS TO ZERO. THEN COIL FOR CUSTOMER INSTALLED IGNITION SHUTOFF RELAY (ISR) MUST BE DE-ENERGIZED; CAUSING NORMALLY OPEN CONTACT FOR ISR TO OPEN. AN OPEN CIRCUIT TO PIN L OF THE EISM SHUTS OFF THE EISM AND DISABLES THE IGNITION SYSTEM.
2. IF THE EISM DETECTS DETONATION OR OTHER CRITICAL IGNITION SYSTEM FAULTS, IT PROVIDES A 200 MILLI-AMP SIGNAL FROM EISM PIN F (CR1-15 - P420) TO THE PROTECTION SYSTEM THRU SLAVE RELAY (SR) REQUESTING AN ENGINE SHUTDOWN.
THE CUSTOMER'S ENERGIZED-TO-RUN PROTECTION SYSTEM MUST INCLUDE AN ISR RELAY WITH A NORMALLY OPEN CONTACT THAT CONNECTS BATTERY ( - ) TO EISM PIN L (CP1-30 (P421) WHEN THE SYSTEM IS ENERGIZED AND OPERATING NORMALLY. WHEN AN IGNITION SYSTEM FAULT IS DETECTED, THE CUSTOMER'S PROTECTION SYSTEM MUST CAUSE THEIR CLOSED NORMALLY OPEN ISR CONTACT TO OPEN AND REMOVE BATTERY (-) FROM EISM PIN L (CP1-30 (P421).
CUSTOMER MUST FURNISH AND INSTALL APPROPRIATE BATTERY CONNECTIONS, FUSE AND MEANS OF DISCONNECT TO SUPPLY SWITCHED BATTERY (+) TO CR13-1 (P680-RD) AND CR13-4 (P681-RD) USING ONE 14 AWG AND ONE 16 AWG WIRE. CUSTOMER MUST USE HERMETICALLY SEALED CERAMIC FUSE COMPLYING WITH CSA REQUIREMENTS FOR Class I, Division 2, Group C & D.
SLAVE RELAY (SR) PROVIDES CUSTOMER WITH A NORMALLY OPEN (N.O.) AND A NORMALLY CLOSED (N.C.) SET OF CONTACTS. CUSTOMER MUST DETERMINE WHICH CONTACTS ARE APPROPRIATE FOR HIS PROTECTION SYSTEM AND MAKE THE APPROPRIATE CONNECTIONS TO CR-13 TO INSURE THAT WHENEVER SLAVE RELAY (SR) COIL IS ENERGIZED THE GROUND CIRCUIT THRU HIS IGNITION SHUTOFF RELAY (ISR) WILL INTERRUPT BATTERY (-) CIRCUIT TO EISM PIN L (CP13-J421).
3. BATTERY (-) (P390-BK) IS PROVIDED FOR CUSTOMER USE AND IS OBTAINED THRU CP13-2
C. EMERGENCY SHUTDOWN:- EMERGENCY STOP PUSH-BUTTON- ENGINE OVERSPEED
1. IF ENGINE OVERSPEED IS DETECTED OR THE EMERGENCY STOP PUSH-BUTTON IS PRESSED, CUSTOMER SHUTOFF SYSTEM MUST SIMULTANEOUSLY CLOSE GAS SHUTOFF VALVE AND REMOVE GROUND CONNECTION TO PIN L OF EISM. IE. COILS FOR CUSTOMER PROVIDED IGNITION SHUTOFF RELAY (ISR) AND FUEL CONTROL RELAY (FCR) ARE SIMULTANEOUSLY DE-ENERGIZED CAUSING NORMALLY OPEN CONTACTS IN ISR AND FCR TO OPEN. THIS IN TURN REMOVES THE BATTERY (-) AND SHUTS OFF POWER TO THE ELECTRONIC IGNITION SYSTEM MODULE (EISM) AND ALLOWS THE NORMALLY CLOSED GAS SHUTOFF VALVE TO STOP GAS FLOW WHEN GAS SHUT OFF VALVE SOLENOID IS DE-ENERGIZED.
D. FOR TEST PURPOSES, CONNECT CR13 CONTACT 3 (J421-BK) TO TEST CELL ISR (B-) TO PROVIDE ENGINE PROTECTION SIMILAR TO THAT SHOWN ON SHEET 2 OF THIS SCHEMATIC. WHEN ISR IS NOT PRESENT, PROVIDE AND INSTALL JUMPER WIRE BETWEEN CR13-2 (B-) AND CR13-3 TO PROVIDE THE GROUND CIRCUIT TO EISM PIN L NECESSARY FOR THE ENGINE TO RUN.
WARNING: WHEN CR13-3 (J421) IS JUMPERED TO CR13-2 (BATTERY (-)), ENGINE WILL NOT SHUTDOWN FOR ANY IGNITION SYSTEM FAULTS.
ALL CUSTOMER WIRING SHALL BE SIZED IN ACCORDANCE WITH THE NATIONAL ELECTRIC CODE AND FOR THE POWER AND LENGTH REQUIREMENTS. MINIMUM RECOMMENDED WIRE FOR EIS LAMPS AND DIAGNOSTIC RESET SWITCH IS 16 AWG FOR LENGTHS UP TO 150 FEET. REFER TO SHEET ONE FOR BATTERY CABLE SIZING.
NOTE: CUSTOMER MUST PROVIDE FCR AND ISR RELAYS. SEE NOTES AA, BB, AND CC.
THE CATERPILLAR SUPPLIED SHUTOFF RELAY (SR) IS CONTAINED IN THE ENGINE INTERFACE BOX. THE RELAY COIL HAS A MAXIMUM CURRENT RATING OF 75 mA @ 24 VDC. A MIN CURRENT OF 0.5 AMP AT 24V DC IS REQUIRED TO INSURE RELAY CONTACTS REMAIN CLEAN.
SM STARTING MOTORSMMS STARTING MOTOR MAGNETIC SWITCHSMR STARTING MOTOR RELAY
SP/TIM SPEED/TIMING SENSOR
T WIRING TERMINALTM TACHOMETERTP TEMPERATURE PROBE
V VOLTSVDC VOLTS DIRECT CURRENT
WH WHITE
WLS WATER LEVEL SWITCHWTS2 WATER TEMPERATURE SHUTDOWN 2
XDCR TRANSDUCER
GOV MPU GOVERNOR MAGNETIC PICKUPGS GOVERNOR SPEED SWITCH
GSOV GAS SHUTOFF VALVEGSM GOVERNOR SPEED MOTOR
HIATS HIGH INLET AIR TEMPERATURE SWITCHHOTAS HIGH OIL TEMPERATURE ALARM SWITCHHWTS HIGH WATER TEMPERATURE SHUTDOWN
IC INITIATE CONTACTISR IGNITION SHUTOFF RELAY
JIC JOINT INDUSTRY COUNCILJWPS JACKET WATER PRESSURE SWITCH
LHDS LEFT HAND DETONATION SENSORLJWDP LOW JACKET WATER DIFFERENTIAL PRESSURELTS LAMP TEST SWITCHLWTS LOW WATER TEMPERATURE SWITCH
MAG MAGNETICMAPS MANIFOLD AIR PRESSURE SENSORMATS MANIFOLD AIR TEMPERATURE SENSORMPU MAGNETIC SPEED PICKUP
N/C NORMALLY CLOSEDN/O NORMALLY OPEN
OP OIL PRESSUREOR ORANGE
PDB POWER DISTRIBUTION BOX
PS PINION SOLENOIDPU PURPLE
RCP REMOTE CONTROL PANELRD REDRHDS RIGHT HAND DETONATION SENSORRR RUN RELAY
SG SWITCH GAGESIG SIGNAL
ABBREVIATIONSAFRC AIR FUEL RATIO CONTROL ALT ALTERNATOR
AMM AMMETERASSV AIR START SOLENOID VALVEAWG AMERICAN WIRE GAUGE
BATT BATTERYBK BLACK
C COMMONCAL CALIBRATIONCB CIRCUIT BREAKERCC CONTACT CLOSURE
CIM CUSTOMER INTERFACE MODULECP CONTROL PANELCR CONTROL RELAYCSA CANADIAN STANDARDS ASSOCIATIONCTR CRANK TERMINATION RELAYCU COPPER OR TINNED COPPER(SILVER COLOR)
D DIODEDC DIRECT CURRENTDDT DIGITAL DIAGNOSTIC TOOLDDTC DIGITAL DIAGNOSTIC TOOL CONNECTOR
EBC ENGINE BULKHEAD CONNECTORECM ENGINE CONTROL MODULE
ECS ENGINE CONTROL SWITCHEGA ELECTRONIC GOVERNOR ACTUATOREIS ELECTRONIC IGNITION SYSTEMEISC ELECTRONIC IGNITION SYSTEM CONNECTOREISM ELECTRONIC IGNITION SYSTEM MODULE
EMIB ENGINE MOUNTED INTERFACE BOX
EOPS ENGINE OIL PRESSURE SENSORESPB EMERGENCY STOP PUSH BUTTON
F FUSEFCR FUEL CONTROL RELAY
GN/YL GREEN WITH YELLOW STRIPEGND GROUND
EMCP ENGINE MONITORING, CONTROL,& PROTECTION
GSC GENERATOR SET CONTROL
PIL POWER INDICATOR LIGHT
SIL SHUTDOWN INDICATOR LIGHT
WIL WARNING INDICATOR LIGHT
ENFR ENGINE FAILURE RELAY
ECTS ENGINE COOLANT TEMPERATURE SENSORECLS ENGINE COOLANT LEVEL SENSOR
CDIS CAT DIGITAL IGNITION SYSTEM
SPL SPLICE (WHEN USED IN CIRCUIT ID)
SR SHUTOFF RELAY
S SPLICE (WHEN S IS FOLLOWED BY 1 OR 2 DIGITS)
GSC
EIS
STARTER (AIR ORELECTRIC)
ENGINE IGNITION
ENGINE SHUTOFFS
GOV ACTUATOR(EG3P OR PRO-ACT)
REFERENCE FOR G3400 MODULAR HARNESSES
CONTACTORMONITORED PARAMETER
10
23456789AZ
TO DISTINGUISH BETWEEN DEVICES
ZA98765432
01 1
0
23456789AZ
HIGHLOW
WITH IDENTICAL CODES
COMMONDEVICE NO.4DEVICE NO.3DEVICE NO.2DEVICE NO.1
NORMALLY CLOSEDNORMALLY OPEN
MISC
FUELAIR/OXYGEN
WATERCRANKCASE
RESET
MEDIUM/DEVICE
TEMPERATUREPRESSURESWITCHDETONATION/VIBRATIONRESETLEVELDELTA-PIONIZATIONSPEED/STARTINGMISC
OIL
GOVERNOR/SPEEDSTATUS CONTROL MODULEEMERGENCY STOP PUSH BUTTON
MISC
C
MISC
MISC
COMBUSTIONSPEEDANGLE
OIL
MISCSPEEDIONIZATIONDELTA-PLEVEL/PERCENTRESTRICTIONDETONATION/VIBRATIONMAGNETIC PICKUPPRESSURETEMPERATURE
MEDIUM DEVICE OPERATES IN
TIMINGCRANKCASEWATER
AIR/OXYGENFUEL
MISC
MISCDEVICE NO.9DEVICE NO.8
DEVICE NO.1DEVICE NO.2DEVICE NO.3DEVICE NO.4DEVICE NO.5
WITH IDENTICAL CODES
DEVICE NO.6DEVICE NO.7
ZA98765432
011
0
23456789AZ
TO DISTINGUISH BETWEEN DEVICES
ZA98765432
01
MONITORED PARAMETER
ENGINE CONTROL #3ENGINE CONTROL #2ENGINE CONTROL #1/GOVSTATUS CONTROLTIMING CONTROL1
0
23456789AZ
TO DISTINGUISH BETWEEN DEVICES
ZA98765432
01 1
0
23456789AZ
MISC
DEVICE NO.7DEVICE NO.6
WITH IDENTICAL CODES
DEVICE NO.5DEVICE NO.4DEVICE NO.3DEVICE NO.2DEVICE NO.1ELECTRONIC IGNITION CONTROL
SENSORS
UNUSEDUNUSED
DEVICE NO.8DEVICE NO.9
DEVICE NO.9DEVICE NO.8
MISCTERMINAL STRIPUNUSED
UNUSEDSPEED
2ND MODULE1ST MODULEMODULEM
ELECTRONIC IGNITION CONTROL
MISC
GOVERNOR/SPEEDFUEL
DEVICE NO.1DEVICE NO.2DEVICE NO.3DEVICE NO.4DEVICE NO.5
WITH IDENTICAL CODES
DEVICE NO.6DEVICE NO.7
AIR
DDTC/DISPLAY MODULEENGINE CONTROL #3ENGINE CONTROL #2ENGINE CONTROL #1/GOVSTATUS CONTROLTIMING CONTROLELECTRONIC IGNITION CONTROL
MISC
UNUSED
ACTUATOR
CONTROLLED PARAMETER
ZA98765432
011
0
23456789AZ
TO DISTINGUISH BETWEEN DEVICES
SOURCE OF CONTROL
ZA98765432
01 TIMING CONTROL
STATUS CONTROL
CONTROL PANELTERMINAL BOXDDTC/DISPLAY MODULEENGINE CONTROL #3ENGINE CONTROL #2ENGINE CONTROL #1/GOVSTATUS CONTROLTIMING CONTROL
DATA LINKD
10
23456789AZ
SOURCE
ENGINE CONTROL #1/GOV
TO DISTINGUISH BETWEEN DEVICES
ZA98765432
01 1
0
23456789AZ
ENGINE CONTROL #2ENGINE CONTROL #3DDTC/DISPLAY MODULE
ACTUATORA
MISCRS 232CATERPILLAR DATA LINK
MISC
ELECTRONIC IGNITION CONTROLTIMING CONTROLSTATUS CONTROLENGINE CONTROL #1/GOVENGINE CONTROL #2ENGINE CONTROL #3DDTC/DISPLAY MODULETERMINAL BOX
DEVICE NO.7DEVICE NO.6
WITH IDENTICAL CODES
DEVICE NO.5DEVICE NO.4DEVICE NO.3DEVICE NO.2DEVICE NO.1
DESTINATION
MISCRS 232CATERPILLAR DATA LINKTERMINAL/SPLICE
INDICATOR LAMPDEVICE 3-10MISCELLANEOUS
CONTROL PANELTERMINAL BOXDDTC/DISPLAY MODULEMANUAL
DEVICE NO.1DEVICE NO.2STOPOFF/RESETAUTO
WITH IDENTICAL CODES
ACTUATORSTARTING MOTOR
POWER DISTRIBUTION BOXCONTROL PANELTERMINAL BOXDDTC/DISPLAY MODULEENGINE CONTROL #3ENGINE CONTROL #2ENGINE CONTROL #1/GOVSTATUS CONTROLTIMING CONTROLELECTRONIC IGNITION CONTROL
MISCAMMETERBATTERY CHARGERSWITCHED POWERCONDITIONED POWER (-)CONDITIONED POWER (+)BATTERY NEGATIVE (-)BATTERY FUSED (+)BATTERY UNFUSED (+)ALTERNATOR
MISC
ZA98765432
011
0
23456789AB
DEVICE NO.9DEVICE NO.8DEVICE NO.7DEVICE NO.6DEVICE NO.5DEVICE NO.4DEVICE NO.3DEVICE NO.2DEVICE NO.1
WITH IDENTICAL CODESTO DISTINGUISH BETWEEN DEVICES
TO DISTINGUISH BETWEEN DEVICES
COIL NEGATIVECOIL POSITIVE
MISC9876543210
21
MISC
ELECTRONIC IGNITION SYSTEMMAGNETO INTERFACE BOX
SHUTDOWN INDICATORALARM INDICATORSHUTDOWN SIGNALALARM SIGNALCASE GROUND
Circuit Identification Tables
98765432
ELECTRONIC IGNITION CONTROL
SOURCE 2SOURCE 1
ZA98765432
01
POWERP
ZA9876543
MAGNETO2
2ND DIGIT CYLINDER NUMBER (0-9)XCYLINDER 10-161CYLINDER 1-90
IGNITION SYSTEMJTYPE OF DEVICE
3RD DIGIT OF TERMINAL (0-9)2ND DIGIT OF TERMINAL (0-9) XX1ST DIGIT OF TERMINAL (0-9)X
TERMINAL CONNECTIONT
MISCELLANEOUS TERMINALMTGOVERNOR TERMINALGOVEMERGENCY STOP PUSH BUTTON TERMINALESPB
ECSMECS
CIRCUIT BREAKER TERMINALSCB
ELECTRONIC STATUS CONTROL MODULE TERMINAL
MISC. TERMINALS
ENGINE CONTROL SWITCH TERMINAL
GROUNDMAGNETIC SWITCH (MURPHY)OVERSPEED SWITCH
MAGNETIC SWITCH (MURPHY)OVERSPEED SWITCH
EAMMETER/VOLTMETERCIRCUIT BREAKER
ALTERNATORDC
01
NOTE D: OPTIONAL GAS SHUTOFF VALVE FOR CUSTOMER SUPPLIED SHUTOFFS
NOTE X: SEE REFERENCED DRAWING FOR 20', 30', AND 50' INTERCONNECT HARNESSES W/ AND W/O BRAIDNOTE W: SEE REFERENCED DRAWING FOR EMCP II EMIB HARNESS WITH E-STOP SWITCH ONLYNOTE V: SEE REFERENCED DRAWING FOR EMCP II EMIB HARNESS WITH EIS LAMPS, DIAGNOSTIC RESET AND E-STOP SWITCHESNOTE U: SEE REFERENCED DRAWING FOR ELECTRIC HOUR METER HARNESS
NOTE B: CUSTOMER MUST FURNISH AND INSTALL A 240 OHM RESISTOR ACROSS TERMINALS CR1-43 AND CR1-2 IN CUSTOMER'S REMOTE CONTROL PANEL IF DDTC IS REMOTELY LOCATED OFF OF THE ENGINE.
NOTE R: SEE REFERENCED DRAWING FOR G3408 AND G3412 A/F RATIO 70-PIN INTERCONNECT HARNESSNOTE S: SEE REFERENCED DRAWING FOR G3408 AND G3412 A/F RATIO MPU HARNESSNOTE T: SEE REFERENCED DRAWING FOR A/F RATIO MPU W/HOUR METER HARNESS
NOTE P: SEE REFERENCED DRAWING FOR G3408 AND G3412 A/F RATIO 70-PIN ENGINE MTD HARNESSNOTE N: SEE REFERENCED DRAWING FOR G3408 OR G3412 EIS CSA IGNITION HARNESSNOTE M: SEE REFERENCED DRAWING FOR AIR OR ELECTRIC STARTING WIRING GPNOTE L: SEE REFERENCED DRAWING FOR PRO-ACT ACTUATOR HARNESS
NOTE C: CUSTOMER MAY OBTAIN LAMP REMOVAL TOOL FROM CATERPILLAR DEALER
NOTE K: SEE REFERENCED DRAWING FOR EG3P ACTUATOR HARNESSNOTE J: SEE REFERENCED DRAWING FOR AIR OR ELECTRIC STARTING HARNESSNOTE H: SEE REFERENCED DRAWING FOR EMCP II SHUTOFF HARNESSNOTE G: SEE REFERENCED DRAWING FOR G3408 OR G3412 NON-CSA EXTERNAL IGNITION HARNESSNOTE F: SEE REFERENCED DRAWING FOR PRO-ACT OR 2301A SPEED CONTROL HARNESS IN EMCP II REMOTE PANEL
NOTE A: FOR EXPLANATION OF CIRCUIT IDENTIFICATION CODE, SEE TABLE
NOTE E: SEE REFERENCED DRAWING FOR EMCP II REMOTE PANEL-BASIC HARNESS
NOTE AA: CUSTOMER MUST PROVIDE FLYBACK DIODES ACROSS GSOV AND SMMS COILS TO PREVENT DAMAGE TO ELECTRONIC COMPONENTS WHEN COILS ARE DE-ENERGIZEDNOTE BB: CUSTOMER MUST PROVIDE A MEANS OF DISCONNECTING SWITCHED AND UNSWITCHED POWER FROM WIRING AND CONTROL SYSTEM WHEN SERVICING IT.
NOTE Y: REFERENCED RELAY IS FOR USE ON CSA APPLICATIONS. CUSTOMER'S CONNECTED EQUIPMENT MUST DRAW A MINIMUM OF 500 mA AT 24 V DC TO ENSURE THAT CONTACTS REMAIN CLEAN. MAXIMUM CURRENT: 20 A.NOTE Z: REFERENCED RELAY IS FOR USE ON NON-CSA APPLICATIONS
NOTE CC: CUSTOMER IS RESPONSIBLE FOR PROVIDING SWITCHED, FUSED 24 V DC POWER TO CUSTOMER CONNECTOR PER CP13 PER CUSTOMER CONNECTION TABLENOTE DD: FOR EIS IGNITIONNOTE EE: FOR ALL EIS (ELECTRONIC IGNITION SYSTEM) ENGINES: CIRCUIT S011-BK-CR1-49 OF THE PROTECTION SYSTEM HARNESS (195-8022) OR MATING INTERCONNECT HARNESSES IS NOT USED AND IS TO BE COVERED WITH HEAT SHRINK AND TIE STRAPPED TO THE MAIN HARNESS TRUNK WHENEVER THE ENGINE HAS AIR FUEL RATIO CONTROL (AFRC). ON O2 BASED AFRC ENGINE 197-3224 NEEDS TO BE INSTALLED IN CR1-49 AND CR1-49 APPROPRIATELY.
Notes PartNumber Description
A 108-1661 Circuit Identification Tables
B 121-9195 240 Ohm Resistor
C 1U-6189 Lamp Removal Tool
D 130-5177 Gas Shutoff Valve
E 194-0898 EMCPII Remote Panel Basic Harness
F 194-0899 EMCPII Remote Panel Pro-Act Speed Control Harness
F 194-0900 EMCPII Remote Panel 2301A Speed Control Harness
G 195-8020 G3408 EMCPII Non-CSA External Ignition Harness
G 195-8021 G3412 EMCPII Non-CSA External Ignition Harness
H 195-8022 EMCPII Shutoff Harness
J 195-8023 EMCPII Air Start Harness
J 195-8024 EMCPII Electric Start Harness
K 195-8025 EMCPII EG3P/2301A Actuator Harness
L 195-8026 EMCPII Pro-Act Actuator Harness
M 195-8029 Industrial Wiring Group With Air Start
M 195-8030 Industrial Wiring Group With Electric Start
N 195-8031 G3408 EIS CSA Ignition Harness
N 195-8032 G3412 EIS CSA Ignition Harness
P 197-3223 EMCPII Air Fuel Ratio 70 pin Engine Mounted Harness
R 197-3224 EMCPII Air Fuel Ratio 70 pin Interconnect Harness
S 198-2791 Air Fuel Ratio MPU Harness
T 198-2792 Air Fuel Ratio MPU Harness with Hour Meter
U 202-4927 Hour Meter Harness
V 194-0903 EMCPII EMIB Harness with EIS Lamps, DiagnosticReset, and Emergency Stop Switch
W 194-0904 EMCPII EMIB Harness with Emergency StopSwitch Only
X 194-0891 30 foot Interconnect Harness without Braid
X 194-0892 30 foot Interconnect Harness with Braid
X 194-0893 50 foot Interconnect Harness without Braid
X 194-0894 50 foot Interconnect Harness with Braid
X 194-0895 20 foot Interconnect Harness without Braid
X 194-0896 20 foot Interconnect Harness with Braid
Y 231-3930 Relay for CSA Applications
Z Relay for non-CSA Applications
SEE OTHER SIDEUPPER LEFT
SEE OTHER SIDEUPPER LEFT
NOTE FF: APPLIES TO 6ZM02849-UP NON-CSA ENGINES ONLY. REPLACE O2 BUFFER WITH NOX BUFFER IN SUPPORT OF NSPS EMISSIONS. NOX BUFFER LOCATED ON TOP RIGHT OF ENGINE. REFER TO HARNESS TABLE FOR HARNESS PART NUMBER CHANGES.
D 311-3014 Gas Shutoff Valve
P 308-5687
R 308-5688
Air Fuel Ratio Sensor 70 pin Harness(6ZM02849-UP, non-CSA ONLY)
Air Fuel Ratio Control 70 pin Interconnect Harness(6ZM02849-UP, non-CSA ONLY)
RE
NR
5900-0
2 V
OL
130 P
ag
e,
(Dim
en
sio
ns
: 3
9 i
nc
he
s x
28
in
ch
es
)
REMOTE MOUNTED EMCPII PANEL
P680-RD
P681-RD
S271-RD
S271-CU
S271-BK
P220-RD
C253-BK
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
D081-CU
D081-BK
D081-WH
J430-BK
J421-BK
C280-BK
J420-BK
P391-BK
P390-BK
P290-RD
P291-RD
J440-BK
C220-BK
CP29X-4391
70-PINCONN
C537-RD
C537-CU
C537-BK
C537-WH
S030-BK
S030-WH
S030-CU
S030-RD
S100-CU
S100-BK
S100-WH
S100-RD
P398-BK
S100-WHS100-BK
S100-RD8T-8731
8T-8731
8T-8731
3E-1802
7L-9737
8T-8731
155-2269
8L-8422
6I-0755
9X-0482
8T-8732
8T-8731
155-2267
S100-CU
S030-WHS030-BK
S030-RD
S030-CU
C537-WHC537-BK
C537-RD
C537-CU
A220-RDA220-BK
A220-BK
PROPANE SWITCH
SHUTDOWN LAMP DRIVER
DIAGNOSTIC RESET
SHUTDOWN SWITCH
SHUTDOWN RELAY DRIVER
WARNING LAMP DRIVER
S850-BK
S850-WH
SIG
S850-RD
S382-WH
S382-BK
S382-BK
S382-RD
S381-WH
S381-BK
S381-BK
S381-RD
S111-WH
S111-BK
S111-RD
SIG
S2
SIG
+13V
+13V
CYL 12 G3412 IGNITION CIRCUITS
CYL 5 G3412 IGNITION CIRCUITS
CYL 6 G3412 IGNITION CIRCUITS
CYL 7 G3412 IGNITION CIRCUITS
CYL 9 G3412 IGNITION CIRCUITS
CYL 12 G3412 IGNITION CIRCUITS
CYL 6 G3412 IGNITION CIRCUITS
CYL 9 G3412 IGNITION CIRCUITS
CYL 6 G3408/CYL 7 G3412 IGNITION CIRCUITS
CYL 2 G3408/CYL 10 G3412 IGNITION CIRCUITS
CYL 7 G3408/CYL 1 G3412 IGNITION CIRCUITSCYL 4 G3408/CYL 3 G3412 IGNITION CIRCUITS
CYL 5 G3408/CYL 2 G3412 IGNITION CIRCUITS
CYL 2 G3408/CYL 10 G3412 IGNITION CIRCUITS
CYL 3 G3408/CYL 8 G3412 IGNITION CIRCUITS
CYL 1 G3408/CYL 11 G3412 IGNITION CIRCUITS
CYL 8 G3408/CYL 4 G3412 IGNITION CIRCUITS
CYL 4 G3408/CYL 3 G3412 IGNITION CIRCUITS
CYL 3 G3408/CYL 8 G3412 IGNITION CIRCUITS
CYL 6 G3408/CYL 7 G3412 IGNITION CIRCUITS
CYL 5 G3408/CYL 2 G3412 IGNITION CIRCUITS
CYL 7 G3408/CYL 1 G3412 IGNITION CIRCUITS
CYL 8 G3408/CYL 4 G3412 IGNITION CIRCUITS
SIG
GND
+13V
GND
D080-CU
D080-BK
D080-WH
S3
S1
+13V
GND
TIMING CALIBRATE
DATA LINK +
DATA LINK -
D080-CU
D080-BK
D080-WH
D600-CU
D600-CU
D600-RD
GND
S6
S7
S5
S4
-BATT
+BATT
EISMP391-BK
J430-BK
J421-BK
J440-BK
C220-BK
C280-BK
P390-BK
J420-BK
P680-RD
P390-BK
S510-RD
S510-BK
S510-WH
S510-CUS112-RD
S112-BK
S112-WH
S112-CU
CP9
S111-CU
P681-RD
P680-RD
J421-BK
A620-CU
A620-BK
A620-WH
A620-RD
A621-RD
A621-WH
A621-BK
A621-CU
P220-RD
CR123E-3370
CP12155-2267
J421-BK
P500-GN
P220-RD
P291-RD
P290-RD
BATT (-)
BATT (+)
P39A-BK
P39B-BK
P39C-BK
P39D-BK
P39E-BK
P39A-BK
P39B-BK
P39C-BK
P39D-BK
P39E-BKP39-BK
P39-BK
P291-RDP290-RD
P291-RD
P290-RD
CB1
114-1143
OUT IN
OUT IN
P39G-BK
P190-RD P190-RD
P330-BK
C253-BK
P390-BK
C253-BK
P390-BK
CR2
P680-RD
S011-BK
S011-BK
S011-BK
S11
P391-BK
P390-BK
S510-BK S21
S112-BK
S273-CU
S273-BK
S273-RD
P391-BK
P390-BK
OPTIONAL CONFIGURATION W/O AFRCOPTIONAL HOUR METER
S270-RD
S270-BK
S270-CU
A330-BK55
51
67
A330-RD
A330-CU
A350-BK
A340-RD
A330-CU
A330-RD
A330-WH
A330-BK
S270-CU
S270-RD
S270-BK
FOR USE WITH CAT SHUTOFFSENGINE MOUNTED INTERFACE BOX
A340-RD
A350-BK
BATT (+)NOTE Z
PINIONSOLENOID COILCOIL
SMMS1P680-RD
P180-RDP330-BK
P220-RD
ENGINE WIRING
NOTE:U
S290-RD
S290-BK
HOUR METER
+-
SOLENOID VALVEAIR START
BATT (+)
NOTE Z
S13
CB1
P220-RD
P330-BK
P39G-BK
P190-RD
P330-BK
CP15155-22693E-3364
A620-CU
A620-BKA620-WH
A620-RD
A621-RD
A621-WH
A621-BK
A621-CU
A620-BK
S22
S23
A621-BK S24
S29
P681-RD
P680-RD
MANIFOLDAIR PRESSURESENSOR3E-1854
(ALTRONIC AFR ONLY)
(ALTRONIC AFR ONLY)
S20
S19
S18
S17
CP7 CR7
+13V
SIG
S111-CU
S111-RD
S111-BK
S111-WH
S3
CR5
S110-CU
S110-WH
S110-BK
S110-RD
C220-BK
D081-CU
D081-BK
D081-WH
J430-BK
J440-BK
J421-BK
C280-BK
J420-BK
P291-RD
P290-RD
P391-BK
P390-BK
A350-BK
A340-RD
A330-CU
A330-RD
A330-WH
A330-BK
S270-CU
S270-BK
S270-RD
A340-RD
A350-BK
C220-BK
D081-CU
D081-BK
D081-WH
J430-BK
J440-BK
J421-BK
C280-BK
J420-BK
P291-RD
P290-RD
P391-BK
P390-BK
P220-RD
A350-BK
A340-RD
A330-CU
A330-RD
A330-WH
A330-BK
S270-CU
S270-BK
S270-RD
A340-RD
A350-BK
C253-BK
P39G-BK
P39G-BK
P391-BK
P390-BK
P39-BK
P390-BK
P398-BK
S850-CU
S382-CU
S382-CU
S381-CU
S381-CU
S111-CU
S111-RD
S111-BK
S111-WH
S112-RDS112-BK
S112-WH
S112-CU
EISM
P39-BK
CP16
CP4
S010-RD
S010-BK
S010-WH
+24V Power Supply
Return +24V Power Supply
+24V Switched O2 Buffer
Signal O2 Buffer
Signal Inlet Manifold Pressure
Return for O2 Buffer
Return Inlet Manifold Pressure
Ground for Speed Sensor Shield
Negative Input from Speed Sensor
Positive Input from Speed Sensor
Coil 1 of Fuel Valve
Coil 3 of Fuel Valve
Coil 2 of Fuel Valve
Coil 4 of Fuel Valve
Return for Coil 1 & 3
Return for Coil 2 & 4
+5V Supply Inlet Manifold Temp Sensor
Return for inlet Manifold Temp Sensor
Signal from Inlet Manifold Temp Sensor
S010-RDS010-BK
S010-WH
S010-CU
S010-RD
S010-BK
S010-WH
S010-CU
P680-RD
P390-BK
S510-RD
S510-BK
S510-WH
S510-CU
S112-RD
S112-BK
S112-WH
S112-CU
CP28C-36547T-3272
8C-3654
CR15
CUSTOMERWIRING
CUSTOMERWIRING
FLYBACK DIODEGROUND
P280-RDCB2
BATT (-)
G3408 IGNITIONCIRCUITS
J023-CU,J043-CU,J063-CU,J083-CU
EBC1
EBC2
1 2 21 1 2 21
J021-RD
J022-BK
J041-RD
J042-BK
J061-RD
J062-BK
J081-RD
J082-BK
FIRING ORDER: 1-8-4-3-6-5-7-2EISC DRIVER PIN ORDER: AA-AB-AC-AD-AE-AF-AG-rEISC RETURN PIN ORDER: n-t-w-z-p-x-v-y
CYL NO. 2 CYL NO. 4 CYL NO. 6 CYL NO. 8
P302-EGND-GN/YL
EBC SHIELD DRAIN GROUND LUG
P301-EGND-GN/YL
JO13-CU,J033-CU,J053-CU,J073-CU
EBC2EBC1
EBC4 EBC3
FIRING ORDER: 1-4-9-8-5-2-11-10-3-6-7-12EISC DRIVER PIN ORDER: AA-AB-AC-AD-AE-AF-AG-r-f-a-W-REISC RETURN PIN ORDER: n-t-w-z-p-x-v-y-q-u-e-k
G3412 IGNITIONCIRCUITS
J012-BK
J011-RD
J032-BK
J031-RD
J052-BK
J051-RD
J072-BKJ071-RD
J082-BK
J081-RD
J062-BK
J061-RD
J042-BK
J041-RD
J022-BK
J021-RD
P680-RD
P390-BK
D600-RD
D080-WH
D080-BKDDTC
6N-9776
112-3537
ABC
EFG
D
S13
ABC
EF
D
12
S510-RD
S510-BK
S510-WH
S510-CU
S112-RD
S112-BK
S112-WH
S112-CU
S273-CU
S273-BK
S273-RD
S273-CU
S273-BK
S273-RD
S010-RD
S010-BK
S010-WH
S010-CU
A620-CU
A620-BK
A620-WH
A620-RD
A621-RD
A621-WH
A621-BK
A621-CU
S010-RDS010-BK
S010-WH
S010-CUS510-RD
S510-BK
S510-WH
S510-CU
A620-CU
A620-BK
A620-WH
A620-RD
A621-RD
A621-WH
A621-BK
A621-CU
CP10155-2269
155-2269
21
CP10
21
CP2
ABC
EF
D
127-5484
1
127-5483
BATT (-)127-5483
1
127-5484
ABC
SPEED/TIMING
102-9029
ABC
LEFTHAND
DETONATION163-4411
RIGHTHAND
DETONATION163-4411
ABC
CR7
ABC
MAPS
12
S271-RD
S271-BK
S030-WH
S100-WH
S030-WH
S100-RD
C537-WH
P290-RD
C537-WH
J440-BK
J430-BK
J420-BK
GSC31-BK
P622-BK P622-BK
P625-BK P625-BK
C252-BK
P624-BK
P624-BK
P623-BK
P623-BK
(MPU GND) GSC-2
(MPU SIG IN) GSC-1
SPARE INPUT
EGR
K1
RR
K5
RR
K5
FCR
OFF RESET
COOLDOWN STOP
GFR
K2
START
F8 10A
F710A
F610A
FLYBACKRM27
RM28
RM34
B+
RM36
K3CTR
K7
RM7
RM9
F510ARM35 RM8
RM39
RM1
RM2
B-
RM22
RM23
RM24
RM14
RM13
SPARE INPUT 3 (SW 3)
SMR
K4SMR
K4
FCR
K7
CTR
K3
CTR
K3
ASR
K6
SPARE INPUT 2 (SW 2)
SPARE INPUT 1 (SW 1)
GENERATOR SET CONTROL
F210A
F110A
F310A
F410ARM30
RM32
RM31
RM33
RM3
RM4
RM5
INTERNAL CIRCUITRY
RM6
RM17
RM16
RM15
RM20
RM18
RM21
OIL PRESSURE SENSOR IN
CAT DATA LINK DATA -
SENSOR V-
ALARM DATA OUT
CAT DATA LINK DATA +
COOLANT TEMP SENSOR IN
COOLANT LOSS SENSOR IN
SENSOR V+
EMERGENCY STOP IN
RM29
METAL JUMPER PRE-INSTALLED ON GSC
P290-RD
WIRE JUMPER PRE-INSTALLED
P398-BK
AUTO
610
9
8
7
3
4
5
2 1
1 2 21 1 2
J021-RD
J022-BK
J041-RD
J042-BK
J061-RD
J062-BK
CYL NO. 2 CYL NO. 4 CYL NO. 6
1 2 21 1 2
J081-RD
J082-BK
J101-RD
J102-BK
J121-RD
J122-BK
CYL NO. 8 CYL NO. 10 CYL NO. 12
P301-EGND-GN/YLP302-EGND-GN/YL
ECS CHART
X-INDICATES "CLOSED"
STOP
MANUAL
AUTO
OFF/RESET
CONTACTS
ENGINE CONTROLRESET
X
XX
X
X
X
X
X
X
X
X
X
XX
XX
12345678910
+24V MODULE SUPPLY
+24V MODULE SUPPLY RETURN
NOX VS
CAN/J1939+
NOX GND
P680-RD
P390-BK
S510-BK
D200-GN
D200-YL
D200-CU
S510-WH
S510-BK
S510-WH
120OHM
P390-BK
P680-RD
CR2 CP28C-36547T-3272
ABC
EF
DTO S13BATT.(-)
TO S4BATT.(+)
CAN/J1939-
CAN/SHIELD
S510-BK
S510-WH
THIS DIAGRAM IS FOR THE G3408C AND G3412C non-CSA ENGINES.DIAGRAM- 194-0911 CHG 03 DIAGRAM- 308-5686 CHG 02 (NSPS FOR 6ZM02849-UP ONLY)
REFER TO THE APPROPRIATE SERVICE MANUAL FOR TROUBLESHOOTING SPECIFICA-TIONS AND SYSTEM OPERATIONS
CUSTOMER WIRING AND OPTIONAL FEATURE WIRING SHOWN ARE RECOMMENDED.
ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN ENGINE FEA-TURES.
CONTACT CATERPILLAR ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL.
COMPONENTS ARE SHOWN WITH THE KEY OFF.
NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL.
A220-RD
P680-RD
P681-RD
S271-RD
S271-CU
S271-BK
P680-RD
P681-RD
S271-RD
S271-CU
S271-BK S271-RD
S271-CU S271-BK18-WH18-BK
D081-CU
D081-BK
D081-WH
J430-BK
J421-BK
C280-BK
J420-BK
P391-BK
P390-BK
P290-RD
P291-RD
P220-RD
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
C220-BK
D081-CU
D081-BK
D081-WH
J430-BK
J421-BK
C280-BK
J420-BK
J440-BK
C220-BK
CR1CP19X-4391 103-0213
70-PINCONN
P398-BK
C537-RD
C537-CU
C537-BK
C537-WH
S030-BK
S030-WH
S030-CU
S030-RD
S100-CU
S100-BK
S100-WH
S100-RD
P398-BK
P680-RD
P390-BKP680-RD
P390-BK
C537-RD
C537-CU
C537-BK
C537-WH
S030-BK
S030-WH
S030-CU
S030-RD
S100-CU
S100-BK
S100-WH
S100-RD
421470
2639535525516745
11
503116
441530565452272
59
4357124068348464728432186053319
6342062171295849
61
7213563
362264134169
8
23
376510243866
9
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
GOVMPU
CBA
GOVSYNCHRONIZINGACTUATOR/ELECTRONICGOV ACTUATOR
12
GOVERNOR MAGNETIC PICKUPABC
GSOVAB
HIATS(CDIS ONLY)NOTE EE
12
GENERATOR SET CONTROLMAGNETIC PICK UP9X-5392
CBA
PRO-ACTACTUATOR125-0547
9X-5392
AFDGBCE
ABC
ENGINE COOLANTTEMPERATURE SENSOR127-2016
ENGINE COOLANTLEVEL SENSOR
ENGINE OILPRESSURE SENSOR
ABC
VSGNDSIG
ABC
A B C
MANIFOLD AIRTEMPERATURESENSOR
ABC
O2BUFFER
ABC
STEPPER
AFE
MOTORBCD
421470
555167
503116174459
P220-RD
P219-RD
P290-RD
P398-BKP390-BK
P391-BK
P390-BK
P391-BK
P398-BK
9X-4391CR1
S273-RDS14
S15
S16
S273-BKS273-CU
AIR
HOUR METER (OPTIONAL)
FUELRATIOMPU
BCA
1(+)
2(-)
S272-RD
S272-BKS272-CU
ABC
ABC
VZU
112-3237ESIC
AIRFUELRATIOMPU
8T-8731
3E-1802
PROPANE SWITCH
SHUTDOWN LAMP DRIVER
DIAGNOSTIC RESET
SHUTDOWN SWITCH
SHUTDOWN RELAY DRIVER
WARNING LAMP DRIVER
S850-BK
S850-WH
SIG
S850-RD
S382-WH
S382-BK
S382-BK
S382-RD
S381-WH
S381-BK
S381-BK
S381-RD
S2
SIG
+13V
+13V
CYL 12 G3412 IGNITION CIRCUITS
CYL 5 G3412 IGNITION CIRCUITS
CYL 6 G3412 IGNITION CIRCUITS
CYL 7 G3412 IGNITION CIRCUITS
CYL 9 G3412 IGNITION CIRCUITS
CYL 12 G3412 IGNITION CIRCUITS
CYL 6 G3412 IGNITION CIRCUITS
CYL 9 G3412 IGNITION CIRCUITS
CYL 6 G3408/CYL 7 G3412 IGNITION CIRCUITS
CYL 2 G3408/CYL 10 G3412 IGNITION CIRCUITS
CYL 7 G3408/CYL 1 G3412 IGNITION CIRCUITS
CYL 4 G3408/CYL 3 G3412 IGNITION CIRCUITS
CYL 5 G3408/CYL 2 G3412 IGNITION CIRCUITS
CYL 2 G3408/CYL 10 G3412 IGNITION CIRCUITS
CYL 3 G3408/CYL 8 G3412 IGNITION CIRCUITS
CYL 1 G3408/CYL 11 G3412 IGNITION CIRCUITS
CYL 8 G3408/CYL 4 G3412 IGNITION CIRCUITS
CYL 4 G3408/CYL 3 G3412 IGNITION CIRCUITS
CYL 3 G3408/CYL 8 G3412 IGNITION CIRCUITS
CYL 6 G3408/CYL 7 G3412 IGNITION CIRCUITS
CYL 5 G3408/CYL 2 G3412 IGNITION CIRCUITS
CYL 7 G3408/CYL 1 G3412 IGNITION CIRCUITS
CYL 8 G3408/CYL 4 G3412 IGNITION CIRCUITS
SIG
GND
+13V
D080-CU
D080-BK
D080-WH
S1
GND
TIMING CALIBRATE
DATA LINK +
DATA LINK -
D080-CU
D080-BK
D080-WH
D600-CU
D600-CU
D600-RD
GND
S6
S7
S5
S4
-BATT
+BATT
EISMP391-BK
J430-BK
J421-BK
J440-BK
C220-BK
C280-BK
P390-BK
J420-BK
P681-RD
P680-RD
P220-RD
P291-RD
P290-RD
BATT (-)
BATT (+)
P39A-BK
P39B-BK
P39C-BK
P39D-BK
P39E-BK
P39-BK
P291-RDP290-RD
CB1OUT IN
P39G-BK
P190-RD P190-RD
P330-BK
CR2
P680-RD
P391-BK
P390-BK
P391-BK
P390-BK
A350-BK
A340-RD
A330-CU
A330-RD
A330-WH
A330-BK
S270-CU
S270-RD
S270-BK
A340-RD
A350-BK
COILSMMS1
P680-RD
P180-RDP330-BK
P220-RD
CONFIGURATION FOR ELECTRIC STARTALSO SEE OPTIONAL CONFIGURATION
FOR AIR STARTCP15155-22693E-3364
P681-RD
P680-RD
S3
P39G-BK
P391-BK
P390-BK
P39-BK
P390-BK
P398-BK
S850-CU
S382-CU
S382-CU
S381-CU
S381-CU
P680-RD
P390-BK
CP28C-3654
CR15
FLYBACK DIODEGROUND
P280-RDCB2
BATT (-)
P680-RD
P390-BK
D600-RD
D080-WH
D080-BKDDTC
112-3537
ABC
EFG
D
S13
ABC
EF
12
D
CP10155-2269
21
ABC
SP/TIM
ABC
LHDS
ABC
RHDS
P680-RD
P681-RD
S270-RD
S270-BK
S270-CU
A340-RD
A340-RD
A350-BK
A350-BK
A330-BK
A330-WH
A330-RD
A330-CU
D081-CU
D081-BK
D081-WH
J430-BK
J421-BK
C280-BK
J420-BK
J440-BKC220-BK
CR1CP19X-4391 103-0213
70-PINCONN
P398-BK
P680-RD
P681-RD
421470
2639535525516717
11
503116
441530565452272
59
43573484647
GOVMPU
ABC
PRO-ACTACTUATOR
AFDGBCE
C280-BK
C220-BK
D080-CU
P500-GN
D600-BK
D600-RD
S382-RD
S850-WH
S381-RD
EISC112-3537
J042-BK/J092-BK
J032-BK/J082-BK
J052-BK/J022-RD
J022-BK/J012-BK
J082-BK/J042-BK
J072-BK/J112-BK
J021-RD/J101-RD
J062-BK/J052-BK
J121-RD
ABC
EFGHJKLM
D
NOP
STUVWXYZ
R
abcdefghjkmnpqrstu
wxyz
v
P680-RD
P390-BK
P390-BK
J430-BK
S381-WH
J420-BK
D080-WH/CLR
S382-WH
S850-RD
D080-BK
J421-BK
J051-RD/J021-RD
J071-RD/J111-RD
G3408 AND G3412IGNITION CIRCUITS
J061-RD/J051-RD
J031-RD/J081-RD
J081-RD/J041-RD
J041-RD/J091-RD
J011-RD/J011-RD AAABACADAEAFAG
J061-RD
J072-BK
J031-RD
J122-BK
J062-RD
J032-BK
J071-RD
J042-BK/J092-BK
J032-BK/J082-BK
J052-BK/J022-RD
J022-BK/J012-BK
J082-BK/J042-BK
J072-BK/J112-BK
J021-RD/J101-RD
J062-BK/J052-BK
J051-RD/J021-RD
J071-RD/J111-RD
J061-RD/J051-RD
J031-RD/J081-RD
J081-RD/J041-RD
J041-RD/J091-RD
J011-RD/J011-RD
J061-RD
J072-BK
J031-RD
J122-BK
J062-RD
J032-BK
J071-RD
P39A-BK
P39B-BK
P39C-BK
P39D-BK
P39E-BK
P39-BK
P291-RD
P290-RD
OUT IN
SOLENOID VALVEAIR START
BATT (+)
NOTE Z
S13
CB1
P220-RD
P330-BK
P39G-BK
P190-RD
P330-BK
OPTIONAL CONFIGURATIONFOR AIR START
P39G-BK
CUSTOMERWIRING
CUSTOMERWIRING
155-2269CP10
21
CP2
ABC
EF
D
127-5484
1
127-5483
BATT (-)127-5483
1
127-5484
503116174459
P220-RD
P219-RD
P290-RD
P398-BKP390-BK
P391-BK
P390-BK
P391-BK
P398-BK
9X-4391CR1
CUSTOMER CONNECTIONS TABLECIRCUITIDENT
CR13-7
TERMINATION TERMINATIONCOLORIDENT
GA
CR13-2
CR13-8
CR13-1
CR13-3
CR13-4
CR13-6
CR13-5
CIRCUITIDENT
CR13-7
TERMINATION
CP14-1
TERMINATIONCOLORIDENT
BK16
GA
14 ESPB-L14P390-CR13-2
C253-CR13-8 ESPB-L1316
16 WARNING LIGHT (+)P680-CR13-1
J421-CR13-3 ESPB-R1116
BK
BK
14 CP1-48
RD
P681-CR13-4
CAA6-CR13-6CR13-6
BK
CP14-316
RD
BK
16 CP14-4BKCR13-5 CAA5-CR13-5
CAA4-CR13-7
FUNCTIONAL DESCRIPTION
SHUTOFF RELAY - COMMON CONTACT
SHUTOFF RELAY - NORMALLY OPEN (NO) CONTACT
SHUTOFF RELAY - NORMALLY CLOSED (NC) CONTACT
CUSTOMER PROVIDED SWITCHED AND FUSED (15A max) BATTERY (+)
NORMALLY CLOSED (NC) ESPB FOR CUSTOMER USE
CUSTOMER PROVIDED SWITCHED AND FUSED (10A max) BATTERY (+)
NORMALLY OPEN (NO) ESPB FOR CUSTOMER USE
BATTERY (-) FOR CUSTOMER USE
CR13-9 16 CP1-59P391-CR13-9 BK BATTERY (-) FOR CUSTOMER USE
FOR USE WITH CUSTOMER SHUTOFFS/NON-CSA)ENGINE MOUNTED INTERFACE BOX 194-0903
P680-RD
P390-BK
J421-BK
AMBERWARNINGLIGHT
REDSHUTDOWN
LIGHT
GREENPOWERLIGHT
1 2
21DIAGNOSTIC RESET
P680-RD
P390-BK
J421-BK
P681-RD
P680-RD
P680-RD
P680-RD
P680-RD
P680-RD
CAA5-BK
CAA6-BK
CAA4-BK
P680-RD
P680-RD
J440-BK
J430-BK
P390-BK
J420-BK
J421-BK
C280-BK
CR13
CP13
C253-BK
C253-BK
P390-BK
P680-RD
J430-BK
J440-BK
J421-BK
P681-RD
CAA5-BK
CAA6-BK
CAA4-BK
C253-BK
J420-BK
CAA4-BKCAA6-BK
CAA5-BK
FOR CUSTOMER WIRINGSEE CONNECTIONS TABLE
P681-RD
S28
P680-RD
P680-RDP390-BK
P390-BK
C280-BK
J421-BK
P390-BK
P390-BK
(+) (-)1 2(+) (-)
1 2(+) (-)
P391-BK
P391-BK
P391-BK
S32
7L-9737
8T-8731S270-RD
S270-BK
S270-CU
A330-BK55
51
67
A330-RD
A330-CU
70-PIN CONN.(GOV OPTION)
GOVMPU
CBA
GOVSYNCHRONIZINGACTUATOR/ELECTRONICGOV ACTUATOR
12
421470
555167
1 2 3 4 5 6 7 8 9 101112
CP14
43152
30
85
86
SR8787a
3E-6286
12345678910111213141516171819202122232425262728293031323334353637383940
R12
R14
R22
EMERGENCYSTOP PUSHBUTTON
R11
R13
R212301A-GOV-5
2301A-GOV-2
DDTC9D-5421
ISR5 9
1DIAGNOSTIC RESET
2
A220-RD
P680-RD
P681-RD
P680-RD
P681-RD
S271-RD
S271-CU
S271-BK
D081-CU
D081-BK
D081-WH
J430-BK
J421-BK
J421-BK
C280-BK
J420-BK
P391-BK
P390-BK
P290-RD
P291-RD
P220-RD
P290-RD
P360-BK
P676-RD
P680-RD
P680-RD
P680-RDECS6-RD
P380-BK
ENGINE CONTROLSWITCH
P680-RD
P680-RD
P680-RD
ESC6-RD
C253-BK
J440-BK
P220-RD
P380-BK
P380-BK
P380-BK
P380-BK
C280-BK
P380-BK
P380-BK
P380-BK
271-CU
271-CU
P380-BK
SHIELD-S27 GN/YL
SHIELD-S27 GN/YL
C250-RD
C250-RD
C253-BK
C252-BK
P380-BK
P380-BK
A220-RD
CR2103-0213
CB3
D081-BK
D081-WH
P292-RD
P391-BK
P390-BK
P398-BK
P290-RD
A
CB
DEFG
IH
J
C537-RD
C537-CU
C537-BK
C537-WH
S030-BK
S030-WH
S030-CU
S030-RD
S100-CU
S100-BK
S100-WH
S100-RD
144270
2639535525516745
11
50
3116
441530565452272
59
4357
124068
348
2812958
432186053319
6342062
17
61
ISR13 14 P380-BKCAB8-BK
T2
S26S100-BK
S030-BK
C537-BK
T1T1
01
C251-BK
111-13254-contact
Block
111-13242-contactBlock
C251-BK
S25S100-RD
S030-RD S030-RD
S030-BK
S100-WH
S100-BK
C537-RDC537-BK
C537-RD
S27
S100-CU
S100-CU
S030-CU
S030-CU
C537-CU C537-CU
ryACwAE
tABp
112-3537EISC
AFxABta
zAD
yr
kR
u
112-3537EISC
AGvAFxAD
nAAz
112-3537EISC
R12
R14
R22
EMERGENCYSTOP PUSHBUTTON
R11
R13
R21
S10
S9
G HFECBA D
2 1 12 2 1 12
J021-BK
J011-RD
J032-BK
J031-RD
J052-BK
J051-RD
J072-BK
J071-RD
CYL NO. 7CYL NO. 5CYL NO. 3CYL NO. 1
B ACDFGH E
FECBA D FECBA D
J023-CU,J043-CU,J063-CU,J083-CU,J103-CU,J123-CU
EBC SHIELD DRAIN GROUND LUG
JO13-CU,J033-CU,J053-CU,J073-CU,J093-CU,J113-CU
S10
S9
1 2 21 1 2
J021-RD
J022-BK
J041-RD
J042-BK
J061-RD
J062-BK
CYL NO. 1 CYL NO. 2 CYL NO. 5
1 2 21 1 2
J081-RD
J082-BK
J101-RD
J102-BK
J121-RD
J122-BK
CYL NO. 7 CYL NO. 9 CYL NO. 11
AGvACwW
pAE
qf
nAA
e
FECBA D FECBA D
J122-BK
J121-RD
J102-BK
J101-RD
J082-BK
J081-RD
J062-RD
J061-RD
J042-BK
J041-RD
J022-BK
J012-BK
J011-RD
J032-BK
J031-RD
J052-BK
J051-RD
J072-BK
J071-RD
J092-BK
J091-RD
J112-BK
J021-RD
J111-RD
142-3389CP8
KLM
ABDEF
11HJ
UVT
3E-6286
AFE
BCD
AIR FUELRATIO CONTROL
213-1986
R11 R12
L13 L14
J421-BKJ421-BK
P390-BKC253-BK
EMERGENCYSTOP PUSHBUTTON111-1323
N/O Block111-1324N/C Block
21
21
DEUTSCH CONNECTOR SOCKET
SHIELDED WIRE
ENGINE MOUNTED COMPONENT
RELAY CONTACT (NORMALLY OPEN)
RELAY CONTACT (NORMALLY CLOSED)
CHASSIS GROUND
EARTH GROUND
OPERATED BY TURNING
DIODE
FUSE
EMERGENCY STOPPUSH BUTTON
RELAY COIL
CIRCUIT BREAKER
SYMBOLS
SYSTEM NOT IN AUTOMATICSTART-STOP MODE
AUTOMATIC START-STOP MODE
CRANK
LOW OIL PRESSURE
OVERSPEED
EMERGENCY STOP
FAIL TO START(OVER CRANK)
HIGH COOLANTTEMPERATURE
ON
OFF
LAMP/DISPLAY TEST
ENGINE-STOP
ENGINE RPM
PLUG IN CONNECTOR
CONTACT
DEUTSCH CONNECTOR PIN
REMOTE MOUNTED PANEL TERMINAL
142-3389CP8
ABDER
AIR FUELRATIO CONTROL
308-5087
SN
9X-4391CP1
4647721354563
124
567
3
8
VSGNDJ1939+J1939-SHIELD
SPARE
D200-YLS33
S34
S35D200-GN
D200-CU
D200-YL
D200-GN
D200-CU
NOX BUFFER308-5689
ABC
CP4
CP16
CAN/J1939RESISTOR
D200-YL
D200-GN
D200-CU
70-PIN CONN.(GOV OPTION)
CONFIGURATION FORELECTRIC START
ALSO SEE OPTIONALCONFIGURATIONFOR AIR START
OPTIONAL CONFIGURATIONFOR AIR START
J440-BK
C280-BK
C220-BK
D080-CU
P500-GN
D600-BK
S111-WH
S111-RD
D600-RD
S382-RD
S850-WH
S381-RD
EISC103-0213
J042-BK/J092-BK
J032-BK/J082-BK
J052-BK/J022-RD
J022-BK/J012-BK
J082-BK/J042-BK
J072-BK/J112-BK
J021-RD/J101-RD
J062-BK/J052-BK
J121-RD
ABC
EFGHJKLM
D
NOP
STUVWXYZ
R
abcdefghjkmnpqrstu
wxyz
v
P680-RD
P390-BK
P390-BK
J430-BK
S381-WH
J420-BK
D080-WH/CLR
S382-WH
S850-RD
D080-BK
J421-BK
J051-RD/J021-RD
J071-RD/J111-RD
G3408 AND G3412IGNITION CIRCUITS
J061-RD/J051-RD
J031-RD/J081-RD
J081-RD/J041-RD
J041-RD/J091-RD
J011-RD/J011-RD AAABACADAEAFAG
J061-RD
J072-BK
J031-RD
J122-BK
J062-RD
J032-BK
J071-RD
J042-BK/J092-BK
J032-BK/J082-BK
J052-BK/J022-RD
J022-BK/J012-BK
J082-BK/J042-BK
J072-BK/J112-BK
J021-RD/J101-RD
J062-BK/J052-BK
J051-RD/J021-RD
J071-RD/J111-RD
J061-RD/J051-RD
J031-RD/J081-RD
J081-RD/J041-RD
J041-RD/J091-RD
J011-RD/J011-RD
J061-RD
J072-BK
J031-RD
J122-BK
J062-RD
J032-BK
J071-RD
NSPS WIRING VARIATIONFOR 6ZM02849-UP. SEE NOTE FF
43
21
21
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SENR6420
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