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CONNECTOR BASICS

ILLUSTRATION 2

9 10

11

12

13

>PEI<

9 10

11

12

13

>PEI<

14

31

24

40

47

40

47

48

57

48

57

24

31
36

36

J2
P2

J13 P13

J13 P13
J2
P2

21

11

ECM
FUEL
CONTROL
RELAY + RETURN

FUEL
CONTROL
RELAY + RETURN

23

23

14

ENGINE
HARNESS

ECM

ENGINE
HARNESS

11

B
58

59 60

61 62

65 66

63

67 68

58

69 70

59 60

61 62

65 66

63

67 68

69 70

J16/P16

Latch

J15/P15

ENGINE
MOUNTED
EMERGENCY
STOP
BUTTON

ENGINE
MOUNTED
EMERGENCY
STOP
BUTTON

J19

J19

TECJET 50 PLUS

TECJET

J12/P12

M
L

P24

J11/P11

C
R

V
T

J10/P10

N
U

L
S

CIRCUIT BREAKER
6 AMP

J9/P9

CIRCUIT BREAKER
16 AMP

J5/P5

NOT
USED

TECJET
D

P50 CONNECTOR (13)

CUSTOMER SUPPLIED
HARNESS

P16

FUEL CONTROL
RELAY

FUEL CONTROL
RELAY

(GSOV)

(GSOV)

ILLUSTRATION 3

Illustrations 1 and 2:
ENGINE
HARNESS

J
H

ECM

FUEL
CONTROL
RELAY + RETURN

GECM

GECM

J2/P2

J1/P1

Latch

J2
P2

J16

P14

J14
H

J12

J23

22

P12

J12

J11

J9

SEAL
3

INCORRECT ROUTING

DETAIL B
INCORRECT INSTALLATION

(1) Each wire exits the connector in a straight manner.


(2) The wires are pulled together near the connector.
(3) The wires are pulling to the side of the connector.

Harness connectors for the various sensors


(A) 5 volt supply (B) Return (C) Signal (1) Signal (2) Return

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A
A. Verify that the suspect sensors connector is disconnected
from the engine harness.
B. At the harness connector for the suspect sensor, measure
the voltage between terminal B and terminal C, or between
terminal 1 and terminal 2.

G3516B Engine
Electrical System
CFD1-UP
CSC1-UP
CME1-UP
CTW1-UP
CEY1-UP
7EZ1-UP
ZBB1-UP
ZBC1-UP

DETAIL A

Inspect the Connector Terminals


A. Visually inspect each terminal in the
connector. Verify that the terminals are not
damaged. Verify that the terminals are
properly aligned in the connector and verify
that the terminals are properly located in the
connector.

SEAL

2005 Caterpillar, All Rights Reserved

C
TYPICALLY, THE CONNECTOR IS
REMOVED FROMTHE END OF
THE HARNESS.THE RESISTOR IS
CONNECTEDTO THE ENDS OF
THE WIRES.

If the GSOV is controlled by the customers


equipment, the circuit for the ECM must be a
complete path. The circuit must include a resistor.
Refer to Illustration 3.

470
5 WATT

Printed in U.S.A.

ENGINE COOLANT
PRESSURE SENSOR (OUTLET)
OXYGEN SENSOR
PRESSURE SENSORS FOR
FILTERED AND UNFILTERED OIL

J10
H
I

Latch

P11

F
M

NOT AVALIBLE ON ENGINES EQUIPT


WITH CHARGE DENSITY.

N
K

GSOV CONNECTOR

THERMOCOUPLE;
CYLINDER EXHAUST
PORT TEMPERATURE

OXYGEN BUFFER

J9

J9

J8

SEALING PLUG

The following information describes the systems


operation when the GSOV is controlled by the
customers equipment:

J10

J5

CORRECT INSTALLATION

Illustration 3:

168-2028
WIRING
HARNESS

b
a

F
V

G
W

J11

Connector:
Ignition Harness

CORRECT ROUTING

J13

22

P15

Harness Routing

B. Check all of the wiring harness fasteners in


order to verify that the harness is properly
secured. Also check all of the fasteners in
order to verify that the harness is not
compressed. Pull back the harness sleeves in
order to check for a flattened portion of wire. A
fastener that has been overtightened flattens
the harness. This damages the wires that are
inside the harness.

There are two configurations for the wiring when the


fuel shutoff valve is controlled by the ECM. The fuel
shutoff valve may be connected to the P9 connector
via wiring that is provided by the customer.
Alternatively, the fuel shutoff valve may be connected
to the P13 connector via the engine harness. Refer to
Illustrations 1 and 2.

J19

J13

J19

ENGINE
MOUNTED
EMERGENCY
STOP
BUTTON

P13

J15

J14

P1

J16

J15
P2

A
B

21

11

Pin and Socket Retention

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The following information describes the systems


operation when the GSOV is controlled by the ECM:
The ECM output for the fuel shutoff valve is called the
fuel control relay. This output is energize-to-run.The
ECM provides +Battery voltage to this output when
the logic determines that fuel is required for engine
operation. The ECM removes the voltage from this
output in order to stop the engine. The fuel shutoff
valve is de-energized. This stops the fuel flow.

J13 P13

PLUG
WEDGE

A. Carefully inspect each wire for signs of


abrasion, of nicks, and of cuts. Inspect the
wires for the following conditions:

TERMINAL BOX

PLUG

PIN OR SOCKET

SEAL

DETAIL A

If moisture or corrosion is evident in the


connector, the source of the moisture entry
must be found and the source of the moisture
entry must be repaired. If the repair is not
made, the problem will recur. Simply drying the
connector will not fix the problem. The
following list includes likely paths for the
entrance of moisture:

P13 CONNECTIONS

P9 CONNECTIONS

JACK

PLUG

Thoroughly inspect ECM J1/P1 and J2/P2


connectors for evidence of moisture entry.

B A

B A

PLUG

ECM CONNECTORS

B. Check all of the wiring harnesses in order to


verify that the harness does not make a sharp
bend (2, 3) out of a connector. This will deform
the connector seal and this will create a path
for the entrance of moisture.

JACK
C

Moisture or Corrosion

SEALING PLUG

Check the Wires for Damage to the


Insulation

J9

RIGHT SIDE

FRONT VIEW (OUTSIDE)

TECJET 50 PLUS

PLUG

RECEPTACLE
WEDGE

A. Ensure that the connector seals and the


white sealing plugs are in place. If any of the
seals or plugs are missing, replace the seal or
plug. If necessary, replace the connector.

168-2028
WIRING
HARNESS

Connector:
Ignition Harness

E-STOP

168-2028
WIRING
HARNESS

J9

MS

JACK

JACK

Check the Connectors for Moisture or


Corrosion:

H
N

C
G

Deutsch connectors have a plastic housing.


The pins and the sockets are crimped onto the
electrical wires. The connector has a locking
mechanism in order to hold the pins and the
sockets. These connectors are repairable
without cutting the wires.

DT
SOCKET
CONTACT

The MS connectors have a metal housing. The


pins and the sockets are soldered to the
electrical wires. The solder connections are
usually protected by a chemical potting which
prevents access to the solder point.

J14/P14
J13/P13

SEALING
PLUG

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21

PIN
CONTACT

NOT AVALIBLE ON ENGINES EQUIPT


WITH CHARGE DENSITY.

FRONT VIEW (INSIDE)


A

(1) Electronic Control Module (ECM)

ECM

(7) Harness to the ignition transformers

9 8 J1

19 25 J1

P1

P1

F
G

(4) ECM connector J1

K
J

(5) Service tool connector J23 for the Caterpillar Electronic Technician

13

20
19

ECM

(6) Connector for the 168-2028 Wiring Harness

(3) ECM connector J2

(8) 16 amp circuit breaker for the engine

LOAD SIGNAL +

b
d

CAT DATA LINK CAT DATA LINK +

(2) Ground strap for the ECM

ITSM

TERMINAL BOX

TERMINAL BOX

P10

LOAD SIGNAL -

21

R
S

(9) 6 amp circuit breaker for the switched +Battery


(10) Connectors J5/P5 for the harness to the Integrated temperature
sensing module

TERM
NO.

(11) This connector is not used.

17

(12) Junction box harness


(13) P50 connector for calibration of the speed/timing sensor
(14) Connectors J9/P9 for the wiring to the customers connections

16

(15) Connectors J10/P10 for the harness to the speed/timing sensor,


throttle actuator, and oxygen buffer (if equipped)
(16) Connectors J11/P11 for the harness to the detonation sensors
(17) Connectors J12/P12 for the harness to the analog sensors
(18) Connectors J13/P13 for the wiring to the gas shutoff valve
(19) Connectors J14/P14 for the wiring to the starting motor

M
S

a
f

b
g

K
P

p
v

r
x

y
z

J9

X E J9

P9

P9

5K

34

36

PDA+

POWER SENSOR

PDAINPUTS

19 20

Sockets

GSC+

L1
N

POTENTIAL TRANSFORMERS
AND CURRENT TRANSFORMERS

ECM TERMINAL BOX

CONNECTORS

AIR START
MOTORS

BO

EMCPII+

L2

ON

GENERATOR
OUTPUT
WIRING

SPEED/TIMING
SENSOR

CTI

12 Gauge

L3

UN

16 Gauge

MJ

12

EC

10

J
T

CAN DATA LINK SHIELD


CAN DATA LINK +
CAT DATA LINK +
STOP
DETONATION DERATE +
CAN DATA LINK CAT DATA LINK E-STOP IN
IDLE/RATED
DETONATION DERATE UNUSED
UNUSED
UNUSED
G.S.O.V. +
UNUSED
G.S.O.V. JUNCTION BOX E-STOP CONTACT 1
BATTERY +
UNUSED
JUNCTION BOX E-STOP CONTACT 2
BATTERY UNUSED

P9
CUSTOMER CONNECTOR

14
11

G
N

a
b
c
d
e
f
g
h
j
k
l
m
n
p
r
s
t
u
v
w
x
y

IND

(22) Emergency stop button

DESCRIPTION

EH

(21) Connectors J16/P16 for the harness to the fuel metering valve

TERM
NO.

DB

(20) This connector is not used.

SWITCHED BATTERY +
E-STOP OUT
DIGITAL RETURN
MANUAL PRE-LUBE
KILOWATT SIGNAL RETURN
UNUSED
UNUSED
DESIRED SPEED POT +5V
ANALOG IN
DESIRED SPEED POT RETURN
OPTIONAL DESIRED SPEED +
ON/OFF GRID
ENGINE FAILURE
DRIVEN EQUIPMENT
DIGITAL RETURN
OPTIONAL DESIRED SPEED CRANK TERMINATE
TIMING SETTING 2
NORMAL STOP
ACTIVE ALARM
RUN RELAY
UNUSED
KILOWATT SIGNAL
AUTO
START

ATE

15

LOC

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
R
S
T
U
V
W
X
Y
Z

DESCRIPTION

LOAD SIGNAL LOAD SIGNAL +

18

AIR START MOTORS


JUNCTION BOX

SERVICE TOOL CONNECTOR

GENERATOR OUTPUT POWER SENSING (OPTIONS)

DETONATION
SENSORS

LEFT SIDE VIEW

ECM TERMINAL BOX

16

14

ITSM

15

2
ECM
TERMINAL BOX

3
DETAIL B

DETAIL A

4
RIGHT SIDE VIEW
LEFT SIDE VIEW

6, 7

10

11

LEFT SIDE VIEW


12
1. P50 Connector
2. 6V-3093 Transducer Adapter
3. 6V-2197 Magnetic Transducer
4. 7X-1695 Cable

REAR

1. Engine coolant pump pressure switch (inlet pressure)


2. Detonation sensor
3. Actuator pressure switch
4. Inlet air temperature sensor
5. Engine coolant temperature sensor
6. Pressure sensor for unfiltered oil
7. Pressure sensor for filtered oil
8. Engine coolant pressure sensor (outlet)
9. Oxygen sensor (Not avalible on engines equipt with Charge Density.)
10. Manifold air pressure sensor
11. Engine oil temperature sensor
12. Oxygen buffer (Not avalible on engines equipt with Charge Density.)
13. Speed/timing sensor
14. Thermocouple for the temperature of the cylinder exhaust port
15. Thermocouple for the temperature of the exhaust inlet to the turbocharger
16. Thermocouple for the temperature of the exhaust outlet from the turbocharger turbine

COOLANT PRESSURE SWITCH


(PUMP INLET PRESSURE)

13

LEFT SIDE VIEW

TEST CONNECTION

ENGINE SENSORS

RIGHT SIDE VIEW

DETONATION
SENSORS

SERVICE TOOL CONNECTOR

(Dimensions: 48 inches x 35 inches)

HD

Intermittent electrical problems are often


caused by poor connections. Always check for
an active diagnostic code before you open any
connection. Immediately after you reconnect
the connector, check for codes again.
Sometimes, simply disconnecting a connector
and then reconnecting the connector can solve
a problem. If this occurs, the following
conditions are likely causes:

TERMINAL BOX

TERMINAL BOX

GECM J1/P1

Inspecting Electrical Connectors:

36 Page,

ILLUSTRATION 1

P1

P2

RENR2460-05

ECM

GECM J2/P2

RENR2460-05
October 2005

P16

P24

SWITCHED +BATTERY

10

15

20

25

30

35

40

45

50

55

60

65

70

WIRE COLOR DESCRIPTIONS

J24

+BATTERY

PWM FUEL COMMAND

-BATTERY

TECJET
50 PLUS

S850-RD
S850-BK
S850-WH

P300L-BK
P600B-RD

CAN TERMINATE

(SEE NOTE 2)

M300A-WH

M300B-WH

TIMING CAL
P50

CAN DATA LINK +

CAN DATA LINK -

P16

P24

PWM FUEL COMMAND

PWM SHIELD

RAPTOR

CONNECTOR COLOR DESCRIPTIONS

CAN TERMINATE

GECM CONNECTOR 1
GECM CONNECTOR 2

120

J24

CAN TERMINATE

C
D

CAN DATA LINK +


CAN DATA LINK -

FUEL VALVE CONNECTOR


GSOV CONNECTOR
ANALOG SENSOR CONNECTOR
DETONATION SENSOR CONNECTOR
SPEED/TIMING - HYDRAX/O2 CONNECTOR
ITSM THERMOCOUPLE CONNECTOR.
PRELUBE CONNECTOR.
AIR START CONNECTOR.
CUSTOMER CONNECTOR
GAUGE PANEL CONNECTOR
IGNITION WIRE CONNECTOR
SERVICE TOOL CONNECTOR

SWITCHED +BATTERY

SWITCHED +BATTERY

PWM FUEL COMMAND

-BATTERY

CONNECTOR

CAT DATA LINK PLUS (+).


CAN DATA LINK MINUS (-).
CAN DATA LINK PLUS (+).
E-STOP

-BATTERY

NOTE 2: P16 REQUIERS


MODIFICATION FOR USE
WITH THE TECJET 50 PLUS.
SEE SPECIAL INSTRUCTION
REHS2404-01

NOTE 1: SOME ENGINES


THAT ARE EQUIPPED WITH
THE TECJET 50 PLUS ARE
NOT EQUIPPED WITH A
JUMPER WIRE.

CAN TERMINATE

C
D

CONNECTORS

(+) BATTERY.
(+) BATTERY SWITCHED.
STARTING CIRCUIT.
BATTERY MINUS (-) / SENSOR RETURN
CAT DATA LINK MINUS (-).

SWITCHED +BATTERY

120

M400-WH
P503B-BK

P503B-BK
P613A-BK
P615A-RD
P300H-BK
P614A-RD
P300J-BK
M020-WH
P300K-BK

P200N-RD
M400-WH

P200M-RD

D200G-YL
S850-BK
P200K-RD
P200L-RD

M060-WH
M050-WH
M000-WH
C256C-BK
M010-WH
M030-WH
M500-WH
M500-BK
SP02-RD
SP02-BK
M020-WH

SP02-BK

SP02-RD

M300B-WH
M300A-WH
D200G-GY
S850-RD

P501C-BK
P401A-RD
P402A-RD
C205D-WH
S110-WH
S910-WH
S190-WH
S010-WH
S000-WH
S101-WH
S100-WH
S030-WH

M300A-WH

M300B-WH

P300K-BK

P300J-BK

S850-WH
D200G-GN
M170A-BK
M500-WH
M500-BK

C205D-WH
P500C-BK
P300H-BK

P501A-BK

P300L-BK

M170A-BK

D200G-YL

D200G-GY

D200G-GN

M050-WH
M000-WH
C256C-BK
M010-WH
S101-WH
S990-WH
S100-WH
S030-WH
M030-WH
D100A-PK

P401A-RD
P501A-BK
P402A-RD
P501C-BK
P200K-RD

C130-WH

S130-WH

P24

(SEE NOTE 1)

S510-WH
S130-WH
C130-WH
C295A-WH

A201-BK
C295-WH
S510-WH
C295-BK
S510-BK
S510-RD
P502A-BK
P502B-BK
P402C-RD
P402B-RD
S380-WH
S382-WH
S384-WH
S386-WH
S381-WH
S383-WH
S385-WH
S387-WH

A432-RD
A432-BK
A201-WH

A310-BK

A310-RD

M040-WH

P697A-WH
C295A-WH

A330B-BK
P696A-WH
P698A-WH

A330B-WH
A320-BK
A320A-RD

A310-BK
A330B-BK
A320-BK
S510-BK
J031-RD
JO32-BK
J041-RD
J042-BK
M040-WH
P696A-WH
P698A-WH
P697A-WH
J091-RD
J092-BK
J101-RD
J102-BK
S380-WH
S382-WH
S384-WH
S386-WH
J151-RD
J152-BK
J161-RD
J162-BK
S381-WH
S383-WH
S385-WH
S387-WH
J111-RD
J112-BK
J121-RD
J122-BK
J081-RD
C295-BK
P502A-BK
P502B-BK
P402B-RD
P402C-RD
J131-RD
J132-BK
J141-RD
J142-BK
J082-BK
A201-WH
A201-BK

J021-RD
J022-BK
JO61-RD
JO62-BK
J041-RD
J042-BK
J101-RD
J102-BK
J161-RD
J162-BK
J121-RD
J122-BK
J081-RD
J141-RD
J142-BK
J082-BK

A310-RD
A330B-WH
A320A-RD
S510-RD
JO51-RD
JO52-BK
JO61-RD
JO62-BK
J072-BK

J011-RD
J012-BK
J021-RD
J022-BK
J071-RD
A432-RD
A432-BK

J011-RD
J012-BK
J071-RD
JO51-RD
JO52-BK
J072-BK
J031-RD
JO32-BK
J091-RD
J092-BK
J151-RD
J152-BK
J111-RD
J112-BK
J131-RD
J132-BK

(Dimensions: 48 inches x 35 inches)

J1
P1

J2
P2

Color Codes for Wiring


Code

Color

BK

Black

BR

Brown

S100-RD

1
3

EMERGENCY STOP BUTTON


(E-STOP)

P200A-RD

35
P200P-RD

1
2
1
2

P500A-BK
C256A-BK
M900A-WH
M900C-WH

P200R-RD
P200S-RD

P100C-RD

D200J-GY

DOOR PANEL

P300W-BK

14

36

P300C-BK

7
A320A-RD
A330B-BK

P300M-BK

P300D-BK

P300N-BK

C295A-WH
P696A-WH

P300D-BK

P697A-WH
A330B-WH

P698A-WH

P500A-BK

P500A-BK

M900A-WH

P200F-RD

A330D-WH
C256A-BK
M900C-WH

D100F-PK

B
A
B
C
D
SERVICE TOOL
E
CONNECTOR
F
G
H
J
K

P698B-WH

D200H-YL

P698A-WH

D200H-GY

P500A-BK

P500C-BK

P300N-BK

P500B-BK

P500E-BK
P500D-BK
P500F-BK

D100G-PK

D100F-PK

D100A-PK

D200J-YL

D100G-PK

D100B-PK

15
M170C-RD

D200J-GY
M170C-BK

D200H-GY
D200H-GN
P300N-BK

M170C-WH

P500B-BK
M170C-WH

M170B-WH

31

M170B-BK

M170C-BK

M170C-RD
A320B-RD

23

P613B-BK

P200J-RD
P300M-BK
P500B-BK
P600A-RD
P696B-WH
P698B-WH
P697B-WH
D200J-YL
D200J-GN
C256A-BK
M900B-WH
M900C-WH
C256B-BK
A330D-WH
D200J-GY
M170C-BK
M170C-WH
M170C-RD
A330E-WH

P615B-RD

P600A-RD
A330D-WH
C256A-BK
M900C-WH

21

P696B-WH

P200J-RD
P600A-RD
M170C-BK
D200J-GY

A320B-RD

P614B-RD
P615B-RD
P613B-BK
M030C-WH

P300R-BK

P501A-BK

P300S-BK

M170A-BK

P300T-BK
P300V-BK

P300L-BK

M400-WH

P300H-BK

P600G-RD

A310-RD
A310-BK

A330A-WH
A330A-BK

P401A-RD
P402A-RD
P501C-BK
S110-WH
S910-WH
S190-WH
S010-WH
S000-WH
S101-WH
S100-WH
S030-WH
C205D-WH
C295B-WH

P100A-RD
P100B-RD
P200A-YL
P613C-BK
P615C-RD

P500E-BK

P615A-RD

P500D-BK

P615C-RD

P200A-RD

D200H-YL

D200A-YL

M170B-RD

D200E-YL

S990-WH

P501A-BK

C205C-WH

P501D-BK
P500F-BK
S130-WH
C130-WH

P401A-RD
C295B-WH
P501D-BK
S190-WH
S100-WH
S101-WH
S910-WH
S000-WH
S030-WH
S010-WH
P402A-RD
S110-WH
P501C-BK
S130-WH
P500F-BK
C130-WH
C205D-WH

A320D-RD
C205B-WH

P501E-BK

A330C-WH

P501B-BK

J12

P501B-BK
D100B-PU

27

A320D-RD

A320A-RD

A320C-RD

C205B-WH

20
A330E-WH

25
A330B-BK

26

M170B-BK

P502A-BK
S380-WH
S382-WH
S384-WH
P502B-BK
P402C-RD
S386-WH
S381-WH
S383-WH
P402B-RD
S385-WH
S387-WH

P300A-BK
P300B-BK
A330C-BK

C205A-WH

P600D-RD

C205C-WH

D200A-YL

A330A-WH

D200A-GN

A330C-WH

D100B-PK

A330A-WH

D100B-PU
S990C-BK

A330C-BK

M900B-WH

J11

C295C-WH
C295A-WH

C256B-BK

C295B-WH

34

D100G-PK

D100G-PU

J19

P600H-RD

S990-WH

P300P-BK

S990C-BK

D100E-PU

S990-WH

D100E-PK

S850-RD
S850-BK
S850-WH
S990C-BK
C295C-WH
D220E-GN
P501E-BK

D200G-GN
D200J-GN

D200E-GN

D200H-GN

D200A-GN

13

A432-BK
A432-RD
A201-WH
A201-BK
C295C-WH
S510-WH
S510-RD
S510-BK
C295-BK

A432-RD
A432-BK
A201-WH
A201-BK
S990C-BK
P501E-BK
C295-BK
C295C-WH
S510-RD
S510-BK
S510-WH

S850-RD
S850-BK
S850-WH

A310-BK

MOTOR
MAGNETIC
SWITCHES

A
B

30 AMP

P300B-BK

A330C-BK

P300A-BK

D200A-GY

M170B-BK

J5

16
12

P200R-RD

16

P100B-RD

12

P200S-RD

16

P200A-RD

12

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
d
A
B
C
D
E
F
G
H
I
J
K
L
M
N

S100-RD

AIR START

S100-WH
S100-CU

P401A-RD

S101-RD
P501A-BK

S101-BK

S190-WH

S101-WH
S101-CU
S910-RD

S100-WH
S101-WH

S910-BK

S910-WH

S910-WH
S910-CU

S000-WH

S000-RD

S030-RD

S000-BK

S010-WH

S000-WH
S000-CU

P402A-RD

S303-RD
S110-WH

S303-BK
S010-RD

S130-WH

S010-BK
P500F-BK

S010-WH
S010-CU

C130-WH

S110-RD
S110-BK
S110-WH
S110-CU
S130-RD
S130-BK
S130-WH
S130-CU

A
B

P15

P13

A
B

A330-WH
A330-BK

A
B

2 AMP SIGNAL OUT

C130-WH

RETURN

NOTE: SEE (GSOV CONNECTOR) SECTION LOCATED


ON THE OPPOSITE SIDE OF THE SCHEMATIC FOR
MORE INFORMATION

A
B

A320-BK

P10

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
d

A432-RD
A432-BK
A201-BK

2
1

S990C-CU

KILOWATT SIGNAL
KILOWATT SIGNAL RETURN
WATT INPUT

A
B

BYPASS VALVE +
BYPASS VALVE -

THROTTLE ACT. +
THROTTLE ACT. THROTTLE ACT.

A
B

BYPASS VALVE +
BYPASS VALVE -

A
B
C

C295-WH
C295-BK

S510-RD
S510-BK

A
B
C
D
E
F
G
H
I
J
K
L
M
N

SWITCH RETURN
SWITCH IN

HYDRAX PRESSURE SWITCH

S510-WH

A
B
C
S510-CU

A
B
C

S850-WH

+12 VDC

DIGITAL OUT
RETURN
PWM SIGNAL IN

P502A-BK

S381-WH
S382-WH
S384-WH

UNUSED

S386-WH
S381-WH
S383-WH
P402B-RD
S385-WH
S387-WH

*O2 BUFFER

RETURN
SIGNAL IN

1
2

SENSOR IN

A
B
C

+5V

A
B
C

+5V

A
B
C

+5V

SENSOR IN

RETURN

OIL TEMPERATURE.

SENSOR IN

COOLANT
TEMPERATURE.

RETURN

INLET AIR
TEMPERATURE.

RETURN
SENSOR IN

INLET MANIFOLD AIR


PRESSURE.

RETURN
SENSOR IN

COOLANT OUT
PRESSURE.

RETURN
SENSOR IN

COOLANT INLET
PRESSURE SWITCH.

RETURN
SENSOR IN
+5V

* EXHAUST STACK

RETURN

BACK PRESSURE

SENSOR IN

S380-RD
S380-BK
S380-WH
S380-CU

A +8V
B RETURN
C SENSOR IN

DS 'A'

S382-RD
S382-BK
S382-WH
S382-CU

A +8V
B RETURN
C SENSOR IN

DS 'B'

S384-RD
S384-BK
S384-WH
S384-CU

A +8V
B RETURN
C SENSOR IN

DS 'C'

S386-RD
S386-BK
S386-WH
S386-CU

A +8V
B RETURN
C SENSOR IN

DS 'D'

S381-RD
S381-BK
S381-WH
S381-CU

A +8V
B RETURN
C SENSOR IN

DS 'E'

S383-RD
S383-BK
S383-WH
S383-CU

A +8V
B RETURN
C SENSOR IN

DS 'F'

S385-RD
S385-BK
S385-WH
S385-CU

A +8V
B RETURN
C SENSOR IN

DS 'G'

S387-RD
S387-BK
S387-WH
S387-CU

A +8V
B RETURN
C SENSOR IN

DS 'H'

DETONATION SENSOR #

G3516 CYL #

G H I

1&3

5&7

9 & 11

13 & 15

2&4

6&8

10 & 12

14 & 16

= NOT AVALIBLE ON ENGINES EQUIPT WITH CHARGE DENSITY

DETONATION SENSOR HARNESS

SPEED / TIMING - HYDRAX / O2 HARNESS

A B C D E F

K L

M N O P R S T

U V W X Y Z

m n

w x

P9

A B C D E F G H I J K L MN O P R S T U VWX Y Z a b c d e f g h j k m n p r s t u v w x y z

+5V

* INTAKE AIR HUMIDITY

RETURN

P502B-BK

F
*

A
B
C

SENSOR IN

P402C-RD

SPEED/TIMING SENSOR

S850-CU

+5V

FILTERED OIL
PRESSURE

RETURN

= NOT AVALIBLE ON ENGINES EQUIPT WITH CHARGE DENSITY

P11

C295-BK

S850-RD
S850-BK

A
B
C

SENSOR IN

ANALOG SENSOR HARNESS

TURBO SURGE BYPASS VALVE

A
B

A201-WH
S990C-BK
P501E-BK

+5V

UNFILTERED OIL
PRESSURE

RETURN

PRELUBE HARNESS

GSOV HARNESS

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Z
Y
a
b
d

RETURN

PRELUBE PUMP
SOLENOID

S190-WH
S190-CU
2 AMP SIGNAL OUT

A
B
C

A
B
C

S190-RD

P15
A320-RD

+5V

A
B
C

C130-BK

S190-BK

P13

A
B
C

P501C-BK

J9

A B C D E F GH J K L MN

24 VDC
POWER
SUPPLY

MOTOR

P300A-BK
P300B-BK

P600D-RD

P501B-BK

D200A-YL

D200A-GN

A330C-BK
M900B-WH
P100A-RD
P100B-RD
M900A-WH

D100B-PU

S990-WH

D100B-PK

M170B-RD

SP02-BK
A320D-RD
M060-WH
A330C-WH

P200A-RD

M170B-WH

C256C-BK
M030A-WH

A320D-RD

A330C-WH

SP02-RD
D200A-GN
D100B-PU

D100A-PU

C205C-WH

P500E-BK

P500D-BK

D200A-GY
D200A-YL
D100B-PK
P613C-BK

P615C-RD

P614C-RD

S990-WH
P614C-RD
P615C-RD

P613C-BK

P200A-YL

M010-WH
P697C-WH
M040-WH

P100A-RD

P100B-RD

P698C-WH

P697C-WH

P696C-WH

M040-WH

C256B-BK

M500-WH
M020-WH
P698C-WH
M000-WH
P500E-BK
M500-BK
P696C-WH
M050-WH

M900B-WH

M170B-RD
M170B-WH
M170B-BK

P600-RD
C256B-BK
P500D-BK

C205C-WH
P501B-BK

M060-WH
M050-WH
M000-WH
C256C-BK
M010-WH
M030-WH
M500-WH
M500-BK
SP02-RD
SP02-BK
M020-WH

D100E-PU

D100E-PK

P600H-RD
P300P-BK

J021-RD
J022-BK
JO61-RD
JO62-BK
J041-RD
J042-BK
J101-RD
J102-BK
J161-RD
J162-BK
J121-RD
J122-BK
J081-RD
J141-RD
J142-BK
J082-BK

J011-RD
J012-BK
J071-RD
JO51-RD
JO52-BK
J072-BK
J031-RD
JO32-BK
J091-RD
J092-BK
J151-RD
J152-BK
J111-RD
J112-BK
J131-RD
J132-BK

M900A-WH

J10

A B C D E F G H J R N P L M S K r s n p k m h j e f c d X Z VW

A310-RD

A
B

P501E-BK

C295C-WH

A
B

JUNCTION BOX

D200A-GY

D100E-PU

A320B-RD

2 AMP SIGNAL OUT

J13

P698C-WH

P614C-RD

D100F-PU

P14

J14

P697C-WH

P614C-RD

D100A-PU

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
d

P696C-WH

P614A-RD

D100G-PU

WH

J15

P501D-BK

P501D-BK

P600J-RD
P100A-RD

S100-BK

A
B

P500F-BK

P698B-WH

16

RD

P12

RETURN

C295B-WH

M170B-WH

CAN DATA LINK -

M400-WH

D200G-YL

12

18
18

FUEL VALVES

J16
A320C-RD
A320-BK

P600G-RD

D200J-YL

C205B-WH

D200E-GY

P697B-WH

P300M-BK
D100G-PU
D100G-PK
D200J-GN
D200J-YL
P500B-BK
M170C-WH
M170C-RD
A330E-WH
P614B-RD
P615B-RD
P613B-BK
P696B-WH
P698B-WH
P697B-WH
A320B-RD
C205B-WH

C205B-WH

D200G-GN

P300V-BK

P613C-BK

P614B-RD

P615B-RD

D200E-YL

P300T-BK

P613A-BK

22

C
D

P300R-BK

M170A-BK

P613B-RD

A330E-WH
P614B-RD

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
k
m
n
p
r
s

30

P300N-BK
P300W-BK

12

P200T-RD

M170A-WH

16

P300E-BK

CAN DATA LINK +

YL

A
B
C
D
E
F
G
H
I
J
K
L
M
N

P200R-RD

M170B-RD

P600H-RD

16

D200E-GY

P600G-RD
D200E-YL
D200E-GN
D200E-GY
M400-WH
P503B-BK
P300T-BK
P300R-BK
P200V-RD
P200R-RD
P200S-RD
P200T-RD
P300S-BK
P300V-BK

D200E-YL

M170A-RD

29

18

P300S-BK

D200E-GN

D100E-PK

16

P200F-RD

12

D200E-GN

P300S-BK

P200J-RD

16

P600G-RD

12

A330A-BK

24

18

P600A-RD

18

P300D-BK

A320C-RD

P698C-WH

18

D200J-GY

16

P503B-BK

A330A-WH

17

D100G-PU

P300M-BK

J23

D200H-GN

D200H-GY

P300R-BK

M400-WH

P200V-RD

P697A-WH

16
16

Yellow

P300R-BK

D100F-PU

Gray
Orange

P300T-BK
P300V-BK

12

P200S-RD

P697B-WH

GY
OR

18
18

P300B-BK

P300K-BK

P697C-WH

Blue
Green

D200A-GY
D200E-GY

16

P300J-BK

P696A-WH

BU
GN

Gauge

P300P-BK

D200G-GY

P696C-WH

P696B-WH

Wire
Color

Wire
Number

Gauge

White

P200T-RD

P300V-BK

GECM J2

12

P200V-RD

P300P-BK

D200J-GN

P200F-RD
D100F-PK
D100F-PU
D200H-YL

P200F-RD
P300N-BK
D200H-GY
D100F-PK
D100F-PU
D200H-GN
D200H-YL

37

19

P300A-BK

D200G-YL

P300T-BK

GECM J1

16

D200G-GY

P300S-BK

Fuel Valve(s)

P300M-BK

P200S-RD

P300B-BK

Prelube

Red

D100A-PK

P300A-BK

L
M

12

D100A-PU

P300K-BK

Air Start

P200P-RD

P600H-RD

P300J-BK

GSOV

P200B-RD

P600G-RD

P300H-BK

J
K

16

P200R-RD

P300L-BK

Analog Sensors

16

S990-WH

D200A-GY

Detonation Sensors

P200T-RD

P500C-BK

D200E-GY

D200H-GY

Speed / Timing - Hydrax / O2

P200V-RD

CB2 6A

Customer

Pink

P600B-RD

P600D-RD

P600J-RD

P600E-RD

ITSM Thermocouple

Purple

P615A-RD

P600B-RD
P600A-RD

Gauge Panel

PK

M170A-RD

P100B-RD

PU

M170A-WH

P100A-RD

Service Tool

P200N-RD

P613A-BK

P200T-RD

CAN TERMINATE

P200M-RD

P614A-RD

P200V-RD

P200L-RD

P200N-RD

CB1 16A
A330B-WH
A330D-WH

P200K-RD

P200M-RD

P200F-RD

1
2

P200K-RD
P200L-RD

P200B-RD

P200J-RD

NOTE 3: FOR SOME ENGINES


THAT ARE EQUIPPED WITH
A TECJET, THE 120 OHM
TERMINATION
RESISTOR
MAY
BE
CONNECTED
BETWEEN P24-N AND P24-V.

CAN TERMINATE

120
(SEE NOTE 3)

Wire
Number

Ignition Wiring

Wire
Number

Sample Wire Code:

Harness
Letter

DESCRIPTION

Wire Gauge

TECJET

36 Page,

ENGINE JUNCTION BOX:


INTERNAL HARNESSING FOR CONTROLS, SAFETIES AND DATA LINKS

C205C-WH

MANUAL PRELUBE

D200A-GY

CAN DL SHIELD

D200A-YL

CAN DL+

D200A-GN

CAN DL -

D100B-PK

CAT DL+

D100B-PU

CAT DL-

NOTE: SEE (GENERATOR OUTPUT POWER


SENSING OPTIONS) SECTION LOCATED ON
THE OPPOSITE SIDE OF THE SCHEMATIC
FOR MORE INFORMATION

C256B-BK

E-STOP

N. C.

C256C-BK

GSOV -

A330C-WH

CUSTOMER CONNECTIONS

THERMOCOUPLES
CYLINDER 1

IGNITION HARNESS TERMINATION AND FIRING ORDER

STANDARD ROTATION
REVERSE ROTATION
EBC PIN ORDER
GECM PIN ORDER
CYL
CYL
CYL
CYL
NO. 15 NO. 13 NO. 11 NO. 9

1
1
A
B
1
2

2
6
V
W
3
4

5
5
E
F
14
15

G3516B
6 3 4
4 3 10
c C X
d D Z
16 24 26
17 25 27

9
9
J
R
32
33

10
16
h
j
34
35

15
15
S
K
40
41

16
12
r
s
42
43

11
11
N
P
48
49

12
14
k
m
50
51

13
13
L
M
58
59

14 7 8
8 7 2
n G e
p H f
60 5 52
61 18 62

CYL
CYL
CYL
CYL
NO. 7 NO. 5 NO. 3 NO. 1

J011-RD
J012-BK
J031-RD
J032-BK
J051-RD
J052-BK
J071-RD
J072-BK
J091-RD
J092-BK
J111-RD
J112-BK
J131-RD
J132-BK
J151-RD
J152-BK
J161-RD
J162-BK
J141-RD
J142-BK
J121-RD
J122-BK
J101-RD
J102-BK
J081-RD
J082-BK
J061-RD
J062-BK
J041-RD
J042-BK
J021-RD
J022-BK

A
B
C
D
E
F
G
H
J
R
N
P
L
M
S
K
r
s
n
p
k
m
h
j
e
f
c
d
X
Z
V
W

J021-RD
J022-BK

J041-RD
J042-BK

J061-RD
J062-BK

J081-RD
J082-BK

J101-RD
J102-BK

J121-RD
J122-BK

A
B
C
D
E
F
G
H
J
R
N
P
L
M
S
K
r
s
n
p
k
m
h
j
e
f
c
d
X
Z
V
W
J141-RD
J142-BK

GAUGE PANEL

GAUGE PANEL INTERCONNECT HARNESS

TERMINATING HARNESS

(OPTIONAL)

*USED ONLY WITH GAUGE PANEL OR BASIC INTERFACE PANEL

*USED IN PLACE OF GAUGE PANEL INTERCONNECT

ENGINE BULKHEAD
CONNECTOR

J012-BK
J011-RD

J032-BK
J031-RD

J052-BK
J051-RD

J072-BK
J071-RD

J092-BK
J091-RD

J112-BK
J111-RD

J132-BK
J131-RD

J152-BK
J151-RD

G3520B MASTER ECM


IGNITION WIRING

J161-RD
J162-BK

RENR2460-05

S990-WH

70

D100A-PU

65

M170A-WH
S000-WH
M170A-RD

60

P600B-RD

55

P500C-BK

50

P615A-RD

45

M170A-RD

40

M170A-WH

35

D100A-PK
D100A-PU
S110-WH
S910-WH
S190-WH
M060-WH
S010-WH

30

P613A-BK

25

P614A-RD

20

P200N-RD

15

P200L-RD

10

SWITCHED +BATTERY

GECM CONNECTOR J1

P200M-RD

P16

W
1K

GECM CONNECTOR J2
1

J24

UNSWITCHED B+
BATT DIGITAL RETURN
SWITCHED BATT +
ENGINE ON
ENGINE FAILURE
ENGINE FAULT
CAN +
120
CAN E-STOP IN
UNUSED
UNUSED
E - STOP OUT
GSOV E-STOP +
CAN SHIELD
SPEED POT SPEED POT SIG
SPEED POT +
GSOV E-STOP DIGITAL RETURN
PRELUBE PB
UNUSED
PRELUBE LIGHT +
PRELUBE LIGHT SPARE #2
SPARE #3
AUTO
START
STOP
SPARE #5
DVR1-OUT
DVR1-RET
DVR2-OUT
DVR2-RET
SPARE LAMP +
SPARE LAMP SPARE SWITCH 1
SPARE #1

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
k
m
n
p
r
s

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
k
m
n
p
r
s

P19
P200-RD
P300-BK
P500-BK
P600-RD
P696-WH/GN
P698B-WH/RD
P697-WH/OR
D200-YL
D200-GN
C256-WH
M900B-WH
M900C-WH
C256-BK
A330-WH/GN
D200-CU
M170A-BK
M170-WH
M170-RD
A330-OR
C220-BK
C205-RD
UNUSED
SC04-OR
C105-WH
SC02-WH/RD
SC03-WH/OR
P614-BK
P615-BK
P613-BK
SP05-RD
P48A-RD
P58A-BK
P48B-WH
P58B-LTGN
P490-RD
P590-BK
C220-RD
SC01-WH/GN

A
B
C
D
E
F
G
H
J
K
L
M
N
P
R
S
T
U
V
W
X
Y
Z
a
b
c
d
e
f
g
h
j
k
m
n
p
r
s

CYL
CYL
CYL
CYL
CYL
CYL CYL
CYL
NO. 16 NO. 14 NO. 12 NO. 10 NO. 8 NO. 6 NO. 4 NO. 2

IGNITION WIRING

CYLINDER 3

A
B

J
E

CYLINDER 5

A
B

AC
v

CYLINDER 7

A
B

q
e

CYLINDER 9

A
B

H
B

CYLINDER 11

A
B

u
j

CYLINDER 13

A
B

AF
z

CYLINDER 15

A
B

Y
O
A
B

LEFT TURBO INLET

P22

GAUGE PANEL WIRING

P19

120

H
J
K
L
M
N
P

r
f

A
B

g
X

LEFT TURBO OUTLET

A
B

C
F

RIGHT TURBO INLET

A
B

N
S

RIGHT TURBO OUTLET

A
B

m
b

CYLINDER 16

A
B

G
A

CYLINDER 14

A
B

t
h

CYLINDER 12

A
B

AG
AA

CYLINDER 10

A
B

Z
P

CYLINDER 8

A
B

AE
y

CYLINDER 6

A
B

CYLINDER 4

A
B

V
M
k
a

CYLINDER 2

A
B

R
W

ITSM

J18
BATT + A
BATT - B

CAT DATA + J

CAT DATA - N

P18
P600H-RD
P300W-BK

D100-PK

D100-PU

C
ITSM THERMOCOUPLE CONNECTOR

P5
A
B
C
D
E
F
G
H
J
K
L
M
N

TERM
NO.

DESCRIPTION

a
b
c
d
e
f
g
h
j
k
l
m
n
p
r
s
t
u
v
w
x
y

CAN DATA LINK SHIELD


CAN DATA LINK +
CAT DATA LINK +
STOP
DETONATION DERATE +
CAN DATA LINK CAT DATA LINK E-STOP IN
IDLE/RATED
DETONATION DERATE UNUSED
UNUSED
UNUSED
G.S.O.V. +
UNUSED
G.S.O.V. JUNCTION BOX E-STOP CONTACT 1
BATTERY +
UNUSED
JUNCTION BOX E-STOP CONTACT 2
BATTERY UNUSED

A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
R
S
T
U
V
W
X
Y
Z

PARALLELED WITH
OPTIONAL HARNES

A330C-BK

GSOV +

S990-WH

KILOWATT SIGNAL

P501B-BK

KILOWATT SIGNAL RETURN

SP02-RD

DETONATION DERATE -

SP02-BK

DETONATION DERATE +

SP02-RD

DROOP/ISOC

SP02-BK

PRELUBE PUMP DRIVER +

P100-RD

BATT -

P300A-BK

BATT +

P100B-RD

BATT -

P300B-BK

BATT +

M900B-WH

CONNECTOR (C) E-STOP

24V SUPPLY

24V SUPPLY

JUNCTION BOX E-STOP CONTACT 2

M900A-WH

4-20mA in OPTIONAL
+
DESIRED
_
SPEED
4-20mA in

M500-WH
M500-BK

+5

M170-RD

PRIMARY
DESIRED
SPEED

M170-WH
M170-BK

GND

TIMING
SETTING 2

M050-WH

P600D-RD

SWITCHED BATTERY +
E-STOP OUT
DIGITAL RETURN
MANUAL PRE-LUBE
KILOWATT SIGNAL RETURN
UNUSED
UNUSED
DESIRED SPEED POT +5V
ANALOG IN
DESIRED SPEED POT RETURN
OPTIONAL DESIRED SPEED +
ON/OFF GRID
ENGINE FAILURE
DRIVEN EQUIPMENT
DIGITAL RETURN
OPTIONAL DESIRED SPEED CRANK TERMINATE
TIMING SETTING 2
NORMAL STOP
ACTIVE ALARM
RUN RELAY
UNUSED
KILOWATT SIGNAL
AUTO
START

P615C-RD START
P613C-BK STOP
P614C-RD AUTO

(PARRALLELED) GAINS
DRIVEN
EQUIPMENT

M000-WH
NORMAL STOP

M010-WH
IDLE / RATED

M030-WH
ON/OFF GRID

M020-WH

CONTACT CLOSURE
REQUIRED TO RUN

7
8
9
10
2
3
4
5

START
STOP

AUTO

REMOTE
INITIATE

RESET
START
STOP

AUTO
RESET

MODE SWITCH

BATT +

CONTACT CLOSURE
REQUIRED TO RUN

CONTACT CLOSURE
SELECTS RATED SPEED
CONTACT CLOSURE
SELECTS SECONDARY
(PARRALLELED) GAINS

P500D-BK OR P500E-BK
CUSTOMER
EQUIPMENT

M040-WH
CUSTOMER
EQUIPMENT

CRANK TERMINATE OUTPUT

CUSTOMER
EQUIPMENT

ENGINE FAILURE OUTPUT

P696C-WH

P698C-WH
CUSTOMER
EQUIPMENT

P697C-WH

RUN RELAY OUTPUT

ENERGIZED FROM BEGINING OF CRANKING UNTIL THE


BEGINING OF SHUTDOWN
ENERGIZED FROM COMPLETION OF CRANKING UNTIL
COMPLETION OF SHUTDOWN

BATT.+

ACTIVE ALARM OUTPUT

CUSTOMER CONNECTOR
THIS SCHEMATIC IS FOR THE G3516B 50Hz or 60Hz. (237-5810 CHG 03)
WHERE DENOTED, DASHED WIRES INDICATE CUSTOMER SUPPLIED CIRCUITS.
(Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.)