RENR8103-09

BATTERY
March 2011
NOTE D
+ -
CB1
24V ALT
60A
PS1
SM1
PS2
SM2
2 30
CB1 SMMS1
1 PS1
25A
SMMS2
PS2 12

INTERNAL CIRCUITRY 15
FLYBACK RM27 GPHI 12
17 18 BATT (-)
LOW COOLANT 13 R9
GPLO 11
SMR TEMP ALARM
F4 BATTERY 14
RM33 RM6 RM21 3 10
10A
K4 CHARGER 18
SMR ESPB2 9
RM18 1 2 4 5 LOW OIL 16
K4 R8 8
PRESS ALARM
ASR 17
F3 7
RM32 RM5 RM19 6
10A 21
K6 6
FCR
F2 19
RM31 RM4 RM15 7 SYSTEM NOT IN R7 5
10A
K7 AUTO ALARM
20 5 6 7 8 9 10 11
RM29 36 SPA 24
SPARE OUTPUT 14 13 12 11 10 9 8
CTR HIGH COOLANT 22
F1 A B R6 ELECTRONIC CONTROL
RM30 RM3 RM16 TEMP FAULT
10A AUX
K3 23 GROUP
CTR
27 7 6 5 4 3 2 1

G3500C and G3500E Generator

RM17
CUSTOMER
K3 SHUTDOWN 12 1 4 3 2
LOW OIL 25 R5
SPARE INPUT 1 23 SW1 44 2
PRESS FAULT
26

Electrical System
SPARE INPUT 2 24 SW2 4
30
3
SPARE INPUT 3 25 SW3 OVERCRANK 28
R4
FAULT 2
SPARE INPUT 4 29 SW4 29
1
ESPB2
38 3 4
33
GZA1-UP GZM1-UP
OVERSPEED 31
CUST-ESTOP FAULT
32
R3 RWA1-UP GZN1-UP
41 42
ESPB1 36 GSB1-UP B9P201-UP
J6-2 J9-10 J9-16 J6-12 HIGH COOLANT
TEMP ALARM
34
R2
GZB1-UP GHP1-UP
35
CUSTOMER CAT DL+
39
TJB1-UP DKR1-UP
J6-7
CAT DATA LINK + 19 PDA+ 34
TO GECM J1/P1-8 EMCP DIAGNOSTIC 37 R1
GZC1-UP SSR1-UP
GSC+ CUSTOMER CAT DL-
FAULT
38
CUSTOMER
TJC1-UP GAS1-UP
INTERFACE
J6-17
CAT DATA LINK - 20 PDA- 36
TO GECM J1/P1-9 40 CIM MODULE MAD1-UP LGS1-UP
NOTE K
SHD 1 TJD1-UP NGS1-UP
A EN
FR
B GZE1-UP HAT1-UP
RM34
F5
RM7
GFR
RM22 13
A
a
SH
B GHG1-UP CWW207-UP
10A
K2 TC GZG1-UP GNX1-UP
1 70
C
B
+
-
12 GZH1-UP CWY207-UP
2 71
15
12 GZJ1-UP SLY1-UP
B- 72 13
EGR
J6-29
R9
OUTPUTS
R9 11 GZK1-UP SXY1-UP
RM14 30 14
10
K1
TO GECM J1/P1-62 (ENGINE START)
18
9
GZL1-UP GZZ1-UP
RM13 21

NOTE E
R8 16
R8 8
HAL1-UP
11 OUTPUTS
17
7
13 19 21 RDM
6
F6
RR
2 20 19
Volume 1 of 2: Low and Medium Voltage
RM35 RM8 RM24 R7 R7 5
10A IDS
K5 OUTPUTS
20 5 6 7 8 9 10 11 © 2011 Caterpillar Printed in U.S.A.
3
7 24 All Rights Reserved
14 13 12 11 10 9 8
26 46
B+ CBR R6 22
3 R6 ELECTRONIC CONTROL
4 14 27 47 2 OUTPUTS
SAP 23 GROUP
1 10K
27 7 6 5 4 3 2 1
15 28 48
LOADSHARE

10 R5 25 12 1 4 3 2
MODULE

R5
OUTPUTS
26
11 LOAD SHARING LINES 4
30
12 3
RR R4 28
F7 R4
RM36 RM9 RM23 OUTPUTS 2
10A 24 22
16 29 1
K5
15
25 21 33 LOAD
R3 31
R3 3 OR 4 POLE
OUTPUTS OPTIONAL MOLDED CASE
32
RM27 FLYBACK B- LO L1 L2 L3 CIRCUIT BREAKER
36

RENR8103-09 VOL 1 of 2
35 ALM 18
R2 34
KLWR R2 BATT (-)
30 RDM OUTPUTS
35
RM28
34 39 LINE
T0 T1 T2 T3
R1 37 R1
NES-2 TS1-30 OUTPUTS
RM2 38 RELAY

(Dimensions: 39 inches x 28 inches)

DRS DRIVER
J6-14 40
1 2 10
TO GECM J1/P1-70 RDM MODULE
CTR FCR TS1-2 BATT -
ECS (KEYSWITCH) 1
K3 K7
10 3
RM1 10 6 CT1

37 7 4
9
11 5
CT2
8
GSC+ 7 TS1-30
8 6
2 ELEMENT KILOWATT TRANSDUCER
50

(LOW VOLTAGE/MEDIUM VOLTAGE)

12 1 +
2 1 ALM - PRIME PT1 INSTRUMENT
OFF 39
POWER POWER 51
RESET (OPTIONAL) 9 2 -
COOLDOWN 32 5 :7- DC
:1+ KW TRANSDUCER
STOP 20 LOLAS
PT2 OUTPUT
40 3 S1 :8
AUTO
:9
33 4
START CUSTOMER
START
14

F8 :2 DATA 19
RM39 17 S3 :10
10A
PLS 21 LWLAS
PL1 S4 :11
2 3 2 1
2 1
17
PL2

10
52 CT1
IA 3
CUSTOM & REMOTE
53 7

BATT + :1+ CUSTOM :8 SPARE FAULT INPUT LED #1 CT2

VA 4
55 8 LIGHT 12
VB
GECM
5
:9 SPARE FAULT INPUT LED #2 IB
57
9
:10 SPARE FAULT INPUT LED #3 VC 6

J1/P1 63 CT3

30 Page,
11
:11 SPARE FAULT INPUT LED #4
BATT -
65
67 8
IC
1
50
+
3 ELEMENT KILOWATT TRANSDUCER
:3 SPARE FAULT INPUT LED #5
69 ESPB1 J6 CUST-ESTOP ESPB2 :4 SPARE FAULT INPUT LED #6
INSTRUMENT 6a
51 (LOW VOLTAGE/MEDIUM VOLTAGE)
J9-13 J9-19 11 43 6 5 37
POWER 12a
2 -
ESTOP OUT 31 10 :12 TEST
:5 DC
SPARE FAULT INPUT LED #7 KW TRANSDUCER OUTPUT
ESTOP RETURN 22 20 :13 SILENCE PT1
26 :6 SPARE FAULT INPUT LED #8
NORMAL STOP 23 30
:14 HORN :7-
DRIVEN EQPT 21 9 21 PT2

AUTO 64 39 29

SECONDARY TIMING 20 8 25 SECONDARY TIMING PT3

IDLE/RATED 28 40 38 IDLE/RATED

ON/OFF GRID 66 28 19 ON/OFF GRID

STOP 61 19 35 REMOTE
CUSTOM :8 SPARE FAULT INPUT LED #1
OPTIONAL SPEED- 37 27 23 16 LIGHT
:1+ :9 SPARE FAULT INPUT LED #2
DIGITAL RETURN 31 13 22
:10 SPARE FAULT INPUT LED #3
OPTIONAL SPEED+ 36 37 18
13 :11 SPARE FAULT INPUT LED #4
BREAKER TRIP 56 18
38 N831 :3 SPARE FAULT INPUT LED #5
GAS BTU SOURCE 6
GAS BTU RETURN 39 16 N833 :4 SPARE FAULT INPUT LED #6
:12 TEST
SHIELD 35 35 17 :5 SPARE FAULT INPUT LED #7 1 2 3
50 50
SPEED RETURN 35 15 16 :13 SILENCE :6 SPARE FAULT INPUT LED #8 CT1 4 5 51
15 51
AN SPEED 16 25 :14 HORN :7-
SPEED +5VDC 18 5 14

CT2 6 7 52
52

:8 SPARE FAULT INPUT LED #1 CT3 53

8 9 53
LOAD SHARE MODULE (OPTIONAL)
J6
RUN RELAY 28 22 28
:1+ :9 SPARE FAULT INPUT LED #2 LOAD SHARE MODULE
(OPTIONAL)
(LOW VOLTAGE/MEDIUM VOLTAGE)
:10 SPARE FAULT INPUT LED #3 20 ATB+
CRANK TERMINATE 29 32 24
(AC TRANSFORMER BOX)
20 :11 SPARE FAULT INPUT LED #4
ENGINE FAILURE 30 23 TX2

ACTIVE ALARM 31 33 27 :3 SPARE FAULT INPUT LED #5 24

39
GSOV(+) 11 21 NOTE F :4 SPARE FAULT INPUT LED #6
:12 TX1 22
40 TEST
GSOV(-) 21 31 :5 SPARE FAULT INPUT LED #7
GECM :13 SILENCE :6 SPARE FAULT INPUT LED #8 TRANSFORMER
J7 GSOV
J2/P2 70 +
:14 HORN :7-
SHELF

NOTE J
50 -
SMMS(+) 10 28 SMMS1

SMMS(-) 20 56
SMMS2
ALARM INPUT CHART
ALM INPUT
TERMINAL
8 10 11 LOW/MEDIUM VOLTAGE KILOWATT TRANSDUCER/ LOADSHARE OPTIONS
NFPA 99 SPARE SPARE SPARE

NFPA 110 SPARE SPARE BCF (+) BATTERY

LOW/MEDIUM VOLTAGE DC SCHEMATIC DC OPTIONS

(-) BATTERY / SENSOR RETURN
 NOTE A
LOAD
SS
L3 6 3 L23
F
3 OR 4 POLE LO L1 L2 L3
OPTIONAL MOLDED CASE L1 L11
F
CIRCUIT BREAKER 4 1

SL SL
1 2
LOAD
LINE
T0 T1 T2 T3
SLR1 SLR2

T1 3 OR 4 POLE
T1 J1-1 LO L1 L2 L3
F1 OPTIONAL MOLDED CASE
H1 X1 CIRCUIT BREAKER
T11

PRI
H21 H2 X2

LINE
T2 T2 J1-2
F2 T0 T1 T2 T3
H1 X1 PT
T12 H1 VIOLET
T1

PRI
WH/BK
T1 J1-1
H22 F1
H2 X2 H4 OR H1 X1
T11

PRI
T1
PT VIOLET
H1 T2
WH/BK H21 H2 X2
T3 T3 J1-3
F3 H4 OR
T13 H1 X1
PT

PRI
H1 VIOLET
T3 T2 J1-2
WH/BK F2
T0 H23 H2 X2 H1 X1
H4 OR T12

PRI
T2
50
T0 H22 H2 X2
CT1 51 HI J1-4
51
BK
T4
BR
GSC+ MODULE

PRI
T3 J1-3
ATB+ F3
H1 X1
T13
(AC TRANSFORMER BOX) T3

PRI
BK PU

H23 H2 X2
CT2
52 52 HI T5 J1-5
BK BR 50

PRI
CT1
51 HI J1-4
CT3
51
BK
T4
BR
GSC+ MODULE
53

PRI
BK PU
ATB+
(AC TRANSFORMER BOX)
53 HI T6 J1-6 BK PU
BK BR

PRI
CT2
52 52 HI T5 J1-5
50 J1-7 AC GND BK BR

PRI
BK PU
J1-8 AC GND CT3
53
BK PU
SERVICE SERVICE
5 TOOL 5
P12-2 P12-2 TOOL 53 HI T6 J1-6
P9-2 F F
P9-2 BK BR

PRI
P9-3 C C
6 P9-3
P12-1 6
P12-1
P9-1 G 50 J1-7 AC GND
P9-1 G
TRANSFORMER BK PU
SHELF
22 P12-3
P12-12 VdcB P12-12 P12-3 VdcB
J1-8 AC GND
TX1
24
P12-11 P12-11
P12-6 VdcA P12-6
DT VdcA
TX2
CONNECTOR P12-10
20
P12-10
P12-5 FSD T1 T2 T3 F2
P12-5
U V W F2GEN P6-4 FSD
T1 T2 T3 F2 EXC
U V W F2GEN P6-4 F1
P6-5
F1GEN
EXC
F1 P12-4 ALM T4 T5 T6
F1GEN P6-5 P12-4 ALM
T4 T5 T6
CUSTOMER CUSTOMER
CONNECTIONS DT
P12-9 CONNECTIONS
DS50 P12-9 CONNECTOR
VOLTAGE VOLTAGE DS50

REGULATOR REGULATOR
(CDVR) (CDVR)
P9-9 V/Pf P9-9 V/Pf
RENR8103-09 VOL 1 of 2

P9-8 FRES T7 T8 T9
P9-8 FRES
T7 T8 T9 P6-1 P6-1

P9-7 EDIS P9-7 EDIS

P6-2 P6-2
(Dimensions: 39 inches x 28 inches)

P6-3 T10 T11 T12 P6-3

P6-6 GND P6-6 GND
P12-7

P12-8
P9-5
P9-6
P9-4

T10 T11 T12

P12-7

P12-8
P9-5
P9-6
P9-4
T0
11 26 N 11 26
10A 10A
T0 NOTE B
I1
N COM2 I1
NOTE B I3
LWR RSE LWR COM2 RSE
I3
I2
12 28 12 28
I2
2 2
13 30
3 1 GEN 3 1
10A B- B+ 13 30
PHASE ROTATION 1-2-3 10A B- B+
GEN VAS VAS
PHASE ROTATION 1-2-3

LOW VOLTAGE AC SCHEMATIC MEDIUM VOLTAGE AC SCHEMATIC

30 Page,

SYMBOLS ABBREVIATIONS
A AMMETER EG ELECTRONIC GOVERNOR (SPEED SENSING) L LOAD LEADS RSE VOLTAGE REGULATOR VOLTAGE RAISE
GENERATOR RTD TERMINAL POINT
T3
H1 X1

POTENTIAL TRANSFORMER AUTOMATIC RESET ON AC ALTERNATING CURRENT EGA ELECTRONIC GOVERNOR ACTUATOR LOLAS LOW OIL LEVEL ALARM SWITCH
NOTE A: CONNECT WIRES FROM TS1 TERMINALS L1 & L3 THROUGH A CUSTOMER SUPPLIED
PRI

H2 X2

GENERATOR AC TERMINAL POINT ADS ENGINE COMBUSTION AIR DAMPER POSITION SWITCH EGR ELECTRONIC GOVERNOR RELAY LSM LOAD SHARING MODULE SAP SPEED ADJUST POTENTIOMETER 600 VAC, 100,000 AMP INTERRUPTING CAPACITY FUSE TO THE PHASE 1 & 3
NON-AUTO RESET
SCREW TERMINAL POINT
POTENTIAL TRANSFORMER OFF ALM ALARM EIS ELECTRONIC IGNITION SYSTEM LWLAS LOW WATER LEVEL ALARM SWITCH SEC SECOND LOAD SIDE OF THE GENERATOR OUTPUT BREAKER. THIS WILL ENABLE CONTROL
GSC CONNECTOR CONTACT AUTOMATIC START-STOP MODE ALS ALARM SILENCE PUSH BUTTON ENFR ENGINE FAULT RELAY LWTL LOW WATER TEMPERATURE LIGHT SHTC CIRCUIT BREAKER SHUNT TRIP COIL PANEL SYNCHRONIZING LIGHT OPERATION FOR MANUAL SYNCHRONIZING.
GENERATOR MAIN TERMINAL POINT HI T3
ALT ALTERNATOR EOPS ENGINE OIL PRESSURE SENSOR LWR VOLTAGE REGULATOR VOLTAGE LOWER SIG SIGNAL
BK BR

CURRENT TRANSFORMER SYSTEM NOT IN AUTOMATIC START-STOP MODE LIQUID LEVEL SWITCH NOTE B: PROPERLY EARTH GROUND THE GENERATOR CHASSIS & CONNECT THE
PRI

GENERATOR DC TERMINAL POINT BK PU

AR ARMING RELAY ESPB EMERGENCY STOP PUSH BUTTON SL SYNCHRONIZING LIGHT ELECTRICAL LOAD PER APPLICABLE CODES.
GENERATOR NES TERMINAL POINT ASR AIR SHUT OFF RELAY ESPB1 GECM JUNCTION BOX MOUNTED ESPB MAG MAGNETO SLM SYNCHRONIZING LIGHT MODULE
CURRENT TRANSFORMER CRANK LAMP
ESPB2 ECMP II+ PANEL MOUNTED ESPB NOTE C: CUSTOMER SUPPLIED AND INSTALLED POTENTIAL TRANSFORMERS FOR GENERATOR SET CONTROLLER.
CONTROL PANEL (EMCP II+) TERMINAL POINT ASSV AIR START SOLENOID VALVE MAN MANUAL SLR SYNCHRONIZING LIGHT RESISTOR
PANEL WIRING MANUALLY OPERATED CONTROL ADJUSTABLE LOW-HI ATB AC TRANSFORMER BOX ESL EMERGENCY STOP LIGHT MPU MAGNETIC SPEED PICKUP SM STARTING MOTOR
LAMP NOTE D: CONNECT CRANKING/CONTROL BATTERIES TO STARTER MOTOR, OR JUNCTION BOX
AUX AUXILIARY TERMINAL STRIP EXC GENERATOR EXCITER SMMS STARTING MOTOR MAGNETIC SWITCH
CUSTOMER WIRING ON AIR START GENSETS.
OPERATED BY TURNING AC VOLTS PANEL ILLUMINATION LIGHT AUXREL AUXILIARY RELAY (CRANK TERMINATION) NC NORMALLY CLOSED SMR STARTING MOTOR RELAY
ALTERNATIVE WIRING V
AWG AMERICAN WIRE GAUGE F FUSE SP SPEED ADJUST POTENTIOMETER NOTE E: REMOVE JUMPERS IF LOADSHARING MODULE IS USED.
FCR FUEL CONTROL RELAY OCL OVERCRANK LIGHT SPA GSC SPARE OUTPUT
SPEED SWITCH CONTACT LOW OIL PRESSURE
SHIELDED WIRE SYSTEM BATTERY VOLTAGE FRES FAULT RESET NOTE F: CUSTOMER MUST PROVIDE A JUMPER OR N.C. CONTACTS TO COMPLETE THE GAS
BATT BATTERY OCT OVERCRANK TIMER SS SYNCHRONIZING SWITCH
FSD FAULT SHUT DOWN DRIVER SHUTOFF VALVE CIRCUIT.
SPEED SWITCH CONTACT OVERSPEED BCF BATTERY CHARGER FAILURE SWITCH OP OIL PRESSURE SW SWITCH
TIME CLOSED CONTACT
SERVICE HOURS OPG OIL PRESSURE GAUGE NOTE G: CUSTOMER SUPPLIED AND INSTALLED CURRENT TRANSFORMERS AND INSTRUMENT GRADE POTENTIAL
n T GENERATOR LINE LEADS
C COMMON GECM GAS ENGINE CONTROL MODULE OPL OVERSPEED LIGHT TRANSFORMERS FOR KILOWATT TRANSDUCER. LOW VOLTAGE, MEDIUM VOLTAGE AND
EMERGENCY STOP
TIMED OPENED CONTACT T TRANSFORMER
BREAKDOWN DIODE BIDIRECTIONAL CB CIRCUIT BREAKER GFR GENSET FAULT RELAY OSL OIL PRESSURE LIGHT HIGH VOLTAGE PACKAGES SHOULD USE PROPERLY SIZED 2 ELEMENT OR 3 ELEMENT TRANSDUCERS.
TD TIME DELAY RELAY
CBR CIRCUIT BREAKER AUXILIARY CONTACT GND GROUND
FAIL TO START (OVER CRANK) ENGINE-STOP
TIMED CLOSED TIMED OPENED CONTACT GOV GOVERNOR
TS TERMINAL STRIP NOTE H: KILOWATT TRANSDUCER INSTRUMENT POWER 85V-135VAC.
BREAKDOWN DIODE BIDIRECTIONAL CCM CYCLE CRANK MODULE PL PANEL ILLUMINATION LIGHT
TSC TRANSFER SWITCH POSITION INDICATING CONTACT
CCT CROSS CURRENT TRANSFORMER GPLO GROUND POST LOW PM GENERATOR PERMANENT MAGNET TERMINAL
ENGINE RPM NOTE J: UPTO 3 ALARM MODULES WITH A COMBINED WIRE LENGTH OF 300
RELAY CONTACT (NORMALLY OPEN) CDM ENGINE COOLDOWN TIMER MODULE GPHI GROUND POST HIGH PLS PANEL LIGHT SWITCH
DIODE LOW COOLANT TEMPERATURE METERS MAY BE DRIVEN FROM THE DATA LINK.
RELAY CONTACT (NORMALLY OPEN) GS GOVERNOR SWITCH V AC VOLTMETER
LAMP/DISPLAY TEST CDVR CATERPILLAR DIGITAL VOLTAGE REGULATOR POT POTENTIOMETER
RELAY CONTACT (NORMALLY CLOSED) VAR VOLTAGE ADJUST RHEOSTAT
DIODE COM2 VOLTAGE REGULATOR LWR/RSE COMMON GSC GENERATOR SET CONTROL PP PRELUBE PUMP NOTE K: VARIOUS CUSTOMER SWITCHES CAN BE ACCOMMODATED FOR INTERFACE WITH
RELAY CONTACT (NORMALLY CLOSED) GSM GOVERNOR SYNCHRONIZING MOTOR VAS VOLTAGE ADJUST SWITCH OPTIONAL ALARM MODULES PROVIDED IN THE GENERATOR CONTROL PANEL.
GENERATOR SYNCHRONIZING INDICATOR CT CURRENT TRANSFORMER PPMS PRELUBE PUMP MAGNETIC SWITCH
FUSE HIGH COOLANT TEMPERATURE VDCA
RESISTOR CTR CRANK TERMINATION RELAY GSOV GAS SHUT-OFF VALVE +/- 10V DC VOLTAGE INPUT A (+)
PPPS PRELUBE PUMP OIL PRESSURE SWITCH NOTE L: KWT OUTPUT DC VOLTAGE CONNECTS TO ENGINE INTERCONNECT HARNESS CIRCUIT A786
GENERATOR FRAME (CHASSIS) GROUND FUSE VDCB +/- 10V DC VOLTAGE INPUT B (-)
V-A AMMETER VOLTMETER PHASE SELECTOR SWITCH
D DIODE
PR PRE-REGULATOR
HORN H1 PT PRIMARY WINDING TERMINAL 1 PRI TRANSFORMER PRIMARY WINDING
V/PF VOLTAGE REGULATOR VAR/PF REGULATION NOTE M: FOR LOW VOLTAGE GENERATOR DOGHOUSE TERMINAL STRIPS SEE
EARTH GROUND
DC DIRECT CURRENT
EMERGENCY SWITCH BATTERY CHARGER MALFUNCTION H2 PT PRIMARY WINDING TERMINAL 2 PS PINION SOLENOID WT WATER TEMPERATURE
PRESSURE SWITCH DCV DC VOLTMETER
HORN SILENCE/ACKNOWLEDGE SWITCH HI CT PRIMARY WINDING PT POTENTIAL TRANSFORMER WTG WATER TEMPERATURE GAUGE
DRS DIAGNOSTIC RESET SWITCH HZ FREQUENCY METER
RELAY COIL WTL WATER TEMPERATURE LIGHT
PRESSURE SWITCH DIAGNOSTIC RESET SWITCH DS50 DRIVER SUPPLY (50)
P RAISE R RELAY THIS SCHEMATIC IS FOR THE G3500C AND G3500E GENERATOR
IA KWT PHASE A / LINE 1 CURRENT RAN REMOTE ANNUNCIATOR X1 PT SECONDARY WINDING TERMINAL 1
RELAY COIL ELECTRICAL SYSTEM.
TEMPERATURE SWITCH LOWER ECLS ENGINE COOLANT LOSS SENSOR IB KWT PHASE B / LINE 2 CURRENT RDM RELAY DRIVER MODULE X2 PT SECONDARY WINDING TERMINAL 2
ECS ENGINE CONTROL SWITCH
VOLUME 1 OF 2: LOW AND MEDUIM VOLTAGE
CIRCUIT BREAKER IC KWT PHASE C / LINE 3 CURRENT RM RELAY MODULE
ECTS ENGINE COOLANT TEMPERATURE SENSOR IDS ISOCHRONOUS DROOP SWITCH
Z ZENER DIODE MEDIA NUMBER: RENR8103-09
RPL REVERSE POWER LIGHT
EDIS EXCITATION DISABLE PART NUMBER: 311-8558, CHANGE: 01, VERSION: -
RPR REVERSE POWER RELAY
EFL ENGINE FAILURE LIGHT KWLR KILOWATT LEVEL RELAY
RR RUN RELAY Components are shown installed on a fully operable generator.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.

 RENR8103-09
BATTERY
March 2011
NOTE D
+ -
CB1
24V ALT
60A
PS1
SM1
PS2
SM2
2 30
CB1 SMMS1
1 PS1
25A
SMMS2
PS2 12

INTERNAL CIRCUITRY 15
12
FLYBACK RM27 GPHI 17 18 BATT (-)
LOW COOLANT 13 R9 11
SMR GPLO TEMP ALARM
F4 BATTERY 14
RM33 RM6 RM21 3 10
10A
K4 CHARGER 18
SMR ESPB2 9
RM18 1 2 4 LOW OIL 16
R8 8
K4 PRESS ALARM
ASR 17
F3 7
RM32 RM5 RM19 6
10A 21
K6 6
FCR
F2 SYSTEM NOT IN 19
RM31 RM4 RM15 7 R7 5
10A AUTO ALARM
K7 20 5 6 7 8 9 10 11
RM29 36 SPA 24
SPARE OUTPUT 14 13 12 11 10 9 8
CTR HIGH COOLANT 22
F1 A B R6 ELECTRONIC CONTROL
RM30 RM3 RM16 TEMP FAULT
10A AUX 23 GROUP
K3
CTR 7 6 5 4 3 2 1
RM17 27

G3500C and G3500E Generator

CUSTOMER
K3 SHUTDOWN 25 12 1 4 3 2
LOW OIL R5
SPARE INPUT 1 23 SW1 2
PRESS FAULT
26

Electrical System
24 SW2 4
SPARE INPUT 2 30
3
SPARE INPUT 3 25 SW3 OVERCRANK 28
R4
FAULT 2
29 SW4 29
SPARE INPUT 4 1
SPARE INPUT 4 ESPB2 33
38 3 4
GZA1-UP GZM1-UP
OVERSPEED 31
R3
CUST-ESTOP FAULT
32
RWA1-UP GZN1-UP
41 42
ESPB1
36 GSB1-UP B9P201-UP
J6-2 J9-10 J9-16 J6-12 HIGH COOLANT
TEMP ALARM
34
R2 GZB1-UP GHP1-UP
35
CUSTOMER CAT DL+ 39
TJB1-UP DKR1-UP
J6-7
CAT DATA LINK + 19 PDA+
TO GECM J1/P1-8 EMCP DIAGNOSTIC 37 R1
GZC1-UP SSR1-UP
GSC+ CUSTOMER CAT DL-
FAULT
38
CUSTOMER
INTERFACE TJC1-UP GAS1-UP
20 PDA- J6-17 MODULE
CAT DATA LINK - TO GECM J1/P1-9 40 CIM MAD1-UP LGS1-UP
NOTE K
SH 1 TJD1-UP NGS1-UP
A EN
FR
B GZE1-UP HAT1-UP
RM34
F5
RM7
GFR
RM22 13 A a
SH B GHG1-UP CWW207-UP
10A
K2 TC GZG1-UP GNX1-UP
1 70
C
B
+
-
12 GZH1-UP CWY207-UP
2 71
15
12 GZJ1-UP SLY1-UP
B- 72 R9 13 R9
EGR
J6-29 OUTPUTS
14
11
GZK1-UP SXY1-UP
RM14 30 10
TO GECM J1/P1-62 (ENGINE START)
K1 18
9
GZL1-UP GZZ1-UP
RM13 21

NOTE E
R8 16
R8 8 HAL1-UP
OUTPUTS
11 17
7
13 19 21 RDM
6

RM35
F6
RM8
RR
RM24
2 20 R7 19 R7
Volume 2 of 2: High Voltage
10A 5
K5 IDS OUTPUTS
20 5 6 7 8 9 10 11
3 WOODWARD © 2011 Caterpillar Printed in U.S.A.
115 LSM 24
7 14 13 12 11 10 9 8 All Rights Reserved
26 105
B+ CBR R6 22
3 R6 ELECTRONIC CONTROL
4 14 27 106 2 OUTPUTS
SAP 23 GROUP
114 1 10K 7 6 5 4 3 2 1
15 28 107 27

R5 25 12 1 4 3 2
10 108 R5
OUTPUTS
26
11 109 4
LOAD SHARING LINES
30
12 110 3
RR R4 28
F7 R4
RM36 RM9 RM23 OUTPUTS 2 LOAD
10A 24 111 22 29
16 1
K5
112 15 33 3 OR 4 POLE
25 21
OPTIONAL MOLDED CASE
R3 31 LO L1 L2 L3 CIRCUIT BREAKER
SH R3
OUTPUTS
32
RM27 FLYBACK B-
36

RENR8103-09 VOL 2 of 2
35 ALM 18 NOTE G
R2 34
KLWR R2 BATT (-)
OUTPUTS LINE
30 RDM 35
T0 T1 T2 T3
RM28 39 PT T1 F1 T11
34 NES-2 TS1-30 301
1.5A

R1 37 H1 X1
R1
OUTPUTS H21
38 RELAY H2 X2

(Dimensions: 39 inches x 28 inches)

TS1-2 BATT -
RM2 DRIVER
40 MODULE
DRS J6-14 RDM
1 2 10 1
TO GECM J1/P1-70
CTR FCR ECS PT T2 F2 T12
(KEYSWITCH) 302
1.5A
K3 K7
H1 X1
RM1 10 6 H22
37 H2 X2
9

8
GSC+ 7
TS1-30 PT
303 T3 F3
1.5A
T13
ALM - PRIME
H1 X1
POWER
OFF 39 2 1 (OPTIONAL) H23
RESET :7-
:1+ H2 X2 300
COOLDOWN 32 5 20 LOLAS
STOP S1 :8
40 3 :9
AUTO
1 301A
33 4
START CUSTOMER
START 2
14 302A
:2 DATA 19
F8 S3 :10
RM39 17 3 303A
10A 21 LWLAS
PLS S4 :11
PL1 304 50

2 3 2 1 CT1
305 4 5 51
2 1
17 NOTE G
PL2
GECM J1/P1
52 CUSTOM & REMOTE CT2
306 6 7 52
53 :1+ CUSTOM :8 SPARE FAULT INPUT LED #1
8 LIGHT
BATT +
55 :9 SPARE FAULT INPUT LED #2
57 :10 SPARE FAULT INPUT LED #3
63

30 Page,
:11 SPARE FAULT INPUT LED #4
CT3 8 9 53
65 307
BATT - :3 SPARE FAULT INPUT LED #5
67 ATB+
:4 SPARE FAULT INPUT LED #6 (AC TRANSFORMER BOX)
69 ESPB1 J6 CUST-ESTOP ESPB2 :12 TEST LOAD SHARE MODULE
J9-13 J9-19 43 44 6 5 45 :5 SPARE FAULT INPUT LED #7
ESTOP OUT 31 10 (OPTIONAL)
:13 SILENCE
ESTOP RETURN 22 20 :6 SPARE FAULT INPUT LED #8

NORMAL STOP 23 30 116 :14 HORN :7-

DRIVEN EQPT 21 9 117

AUTO 64 39 118 10 3

119 SECONDARY TIMING IA

SECONDARY TIMING 20 8 VA
7 4
IDLE/RATED 28 40 120 IDLE/RATED
VB 5
ON/OFF GRID 66 28 121 ON/OFF GRID 12
REMOTE
CUSTOM :8 SPARE FAULT INPUT LED #1 IB
STOP 61 19 122 VC 6
9
16 LIGHT
OPTIONAL SPEED- 37 27 123
:1+ :9 SPARE FAULT INPUT LED #2 1 + NOTE L 3 ELEMENT KW TRANSDUCER
11 DC OUTPUT
DIGITAL RETURN 31 13 124
125
:10 SPARE FAULT INPUT LED #3
IC 2 - (HIGH VOLTAGE)
OPTIONAL SPEED+ 36 37 :11 SPARE FAULT INPUT LED #4 8 NOTE H
6a
BREAKER TRIP 56 18 126 SPARE FAULT INPUT LED #5 INSTRUMENT
:3
12a POWER
GAS BTU SOURCE 38 6 N831
:4 SPARE FAULT INPUT LED #6
N833 :12 TEST
GAS BTU RETURN 39 16 KW TRANSDUCER
:5 SPARE FAULT INPUT LED #7
SHIELD 35 35 SHD :13 SILENCE :6 SPARE FAULT INPUT LED #8
103
SPEED RETURN 35 15
:14 HORN :7-
102
AN SPEED 16 25
101 304 T0 ATB TERM 50
SPEED +5VDC 18 5 10 3
CT1
305
7 4

NOTE G
:8 SPARE FAULT INPUT LED #1 5

:1+ :9 SPARE FAULT INPUT LED #2

GECM J2/P2 J6 FROM ATB TERM 53 11 6

RUN RELAY 28 22 127 :10 SPARE FAULT INPUT LED #3

1 +
NOTE L 2 ELEMENT KW TRANSDUCER
128 DC OUTPUT
CRANK TERMINATE
ENGINE FAILURE
29
30
32
23 129
:11 SPARE FAULT INPUT LED #4 CT3
307
8
2 - (HIGH VOLTAGE)
:3 SPARE FAULT INPUT LED #5 NOTE H
12
ACTIVE ALARM 31 33 130 INSTRUMENT
:4 SPARE FAULT INPUT LED #6 POWER
131 :12 9
GSOV(+) 11 21 NOTE F TEST PT
132 :5 SPARE FAULT INPUT LED #7
GSOV(-) 21 31 KW TRANSDUCER
:13 SILENCE H1 X1
:6 SPARE FAULT INPUT LED #8 301
:14 HORN :7-
J7 GSOV H2 X2
70 + NOTE J
PT 302
50 -
SMMS(+) 10 28 H1 X1
SMMS1

SMMS(-) 20 56 303
SMMS2 ALARM INPUT CHART H2 X2

ALM INPUT
8 10 11
TERMINAL

NFPA 99 SPARE SPARE SPARE (+) BATTERY

NFPA 110 SPARE SPARE BCF (-) BATTERY / SENSOR RETURN

HIGH VOLTAGE DC SCHEMATIC DC OPTIONS HIGH VOLTAGE KILOWATT TRANSDUCER/ LOADSHARE OPTIONS
 3 OR 4 POLE
OPTIONAL MOLDED CASE
CIRCUIT BREAKER LO L1 L2 L3

LINE NOTE C

PT T1 T11
301 T1 J1-1
F1
H1 X1 301A H1 X1
T0 T1 T2 T3

PRI
H2 X2 H21 H2 X2

PT T12
302 T2 T2 J1-2
F2
H1 X1
H1 X1 302A

PRI
H2 X2 H22 H2 X2

PT 303 T3 T13
T3 J1-3
F3
H1 X1
H1 X1

PRI
H2 X2 300 T0 H23 H2 X2

CT1
305 51 HI T4 J1-4
GSC+ MODULE
BK BR

PRI
NOTE C

303A BK PU

CT2
306 52 HI T5 J1-5
BK BR

PRI
CT3
307
BK PU

304
53 HI T6 J1-6
BK BR

PRI
50 J1-7 AC GND
BK PU
J1-8 AC GND
ATB+
(AC TRANSFORMER BOX)

SERVICE
308 TOOL
P12-2
P9-2 F

P9-3 C
309
P12-1
NOTE C
P9-1 G

P12-12 P12-3 VdcB

DT
CONNECTOR

P12-11
P12-6 VdcA

P12-10
P12-5 FSD

T1 T2 T3 F2 313
U V W F2GEN P6-4
EXC
F1 312 P12-4 ALM
F1GEN P6-5
T4 T5 T6
CUSTOMER
CONNECTIONS
P12-9 DS50
VOLTAGE
REGULATOR
(CDVR) P9-9 V/Pf

P9-8 FRES
P6-1
RENR8103-09 VOL 2 of 2

T7 T8 T9

P9-7 EDIS
P6-2

P6-3
P6-6 321

P12-7

P12-8
P9-5
P9-6
P9-4
T10 T11 T12
(Dimensions: 39 inches x 28 inches)

PM1 328
10A
T0
I1
N
NOTE B I3
LWR COM2 RSE
I2
PM2 327
2
3 1
PM3 326 2
10A 1A
GEN VAS
PHASE ROTATION 1-2-3

HIGH VOLTAGE AC SCHEMATIC

30 Page,

SYMBOLS ABBREVIATIONS
A AMMETER EG ELECTRONIC GOVERNOR (SPEED SENSING) L LOAD LEADS RSE VOLTAGE REGULATOR VOLTAGE RAISE
GENERATOR RTD TERMINAL POINT
T3
H1 X1

POTENTIAL TRANSFORMER AUTOMATIC RESET ON AC ALTERNATING CURRENT EGA ELECTRONIC GOVERNOR ACTUATOR LOLAS LOW OIL LEVEL ALARM SWITCH
NOTE A: CONNECT WIRES FROM TS1 TERMINALS L1 & L3 THROUGH A CUSTOMER SUPPLIED
PRI

H2 X2

GENERATOR AC TERMINAL POINT ADS ENGINE COMBUSTION AIR DAMPER POSITION SWITCH EGR ELECTRONIC GOVERNOR RELAY LSM LOAD SHARING MODULE SAP SPEED ADJUST POTENTIOMETER 600 VAC, 100,000 AMP INTERRUPTING CAPACITY FUSE TO THE PHASE 1 & 3
NON-AUTO RESET
SCREW TERMINAL POINT
POTENTIAL TRANSFORMER OFF ALM ALARM EIS ELECTRONIC IGNITION SYSTEM LWLAS LOW WATER LEVEL ALARM SWITCH SEC SECOND LOAD SIDE OF THE GENERATOR OUTPUT BREAKER. THIS WILL ENABLE CONTROL
GSC CONNECTOR CONTACT AUTOMATIC START-STOP MODE ALS ALARM SILENCE PUSH BUTTON ENFR ENGINE FAULT RELAY LWTL LOW WATER TEMPERATURE LIGHT SHTC CIRCUIT BREAKER SHUNT TRIP COIL PANEL SYNCHRONIZING LIGHT OPERATION FOR MANUAL SYNCHRONIZING.
GENERATOR MAIN TERMINAL POINT HI T3
ALT ALTERNATOR EOPS ENGINE OIL PRESSURE SENSOR LWR VOLTAGE REGULATOR VOLTAGE LOWER SIG SIGNAL
BK BR

CURRENT TRANSFORMER SYSTEM NOT IN AUTOMATIC START-STOP MODE LIQUID LEVEL SWITCH NOTE B: PROPERLY EARTH GROUND THE GENERATOR CHASSIS & CONNECT THE
PRI

GENERATOR DC TERMINAL POINT BK PU

AR ARMING RELAY ESPB EMERGENCY STOP PUSH BUTTON SL SYNCHRONIZING LIGHT ELECTRICAL LOAD PER APPLICABLE CODES.
GENERATOR NES TERMINAL POINT ASR AIR SHUT OFF RELAY ESPB1 GECM JUNCTION BOX MOUNTED ESPB MAG MAGNETO SLM SYNCHRONIZING LIGHT MODULE
CURRENT TRANSFORMER CRANK LAMP
ESPB2 ECMP II+ PANEL MOUNTED ESPB NOTE C: CUSTOMER SUPPLIED AND INSTALLED POTENTIAL TRANSFORMERS FOR GENERATOR SET CONTROLLER.
CONTROL PANEL (EMCP II+) TERMINAL POINT ASSV AIR START SOLENOID VALVE MAN MANUAL SLR SYNCHRONIZING LIGHT RESISTOR
PANEL WIRING MANUALLY OPERATED CONTROL ADJUSTABLE LOW-HI ATB AC TRANSFORMER BOX ESL EMERGENCY STOP LIGHT MPU MAGNETIC SPEED PICKUP SM STARTING MOTOR
LAMP NOTE D: CONNECT CRANKING/CONTROL BATTERIES TO STARTER MOTOR, OR JUNCTION BOX
AUX AUXILIARY TERMINAL STRIP EXC GENERATOR EXCITER SMMS STARTING MOTOR MAGNETIC SWITCH
CUSTOMER WIRING ON AIR START GENSETS.
OPERATED BY TURNING AC VOLTS PANEL ILLUMINATION LIGHT AUXREL AUXILIARY RELAY (CRANK TERMINATION) NC NORMALLY CLOSED SMR STARTING MOTOR RELAY
ALTERNATIVE WIRING V
AWG AMERICAN WIRE GAUGE F FUSE SP SPEED ADJUST POTENTIOMETER NOTE E: REMOVE JUMPERS IF LOADSHARING MODULE IS USED.
FCR FUEL CONTROL RELAY OCL OVERCRANK LIGHT SPA GSC SPARE OUTPUT
SPEED SWITCH CONTACT LOW OIL PRESSURE
SHIELDED WIRE SYSTEM BATTERY VOLTAGE FRES FAULT RESET NOTE F: CUSTOMER MUST PROVIDE A JUMPER OR N.C. CONTACTS TO COMPLETE THE GAS
BATT BATTERY OCT OVERCRANK TIMER SS SYNCHRONIZING SWITCH
FSD FAULT SHUT DOWN DRIVER SHUTOFF VALVE CIRCUIT.
SPEED SWITCH CONTACT OVERSPEED BCF BATTERY CHARGER FAILURE SWITCH OP OIL PRESSURE SW SWITCH
TIME CLOSED CONTACT
SERVICE HOURS OPG OIL PRESSURE GAUGE NOTE G: CUSTOMER SUPPLIED AND INSTALLED CURRENT TRANSFORMERS AND INSTRUMENT GRADE POTENTIAL
n T GENERATOR LINE LEADS
C COMMON GECM GAS ENGINE CONTROL MODULE OPL OVERSPEED LIGHT TRANSFORMERS FOR KILOWATT TRANSDUCER. LOW VOLTAGE, MEDIUM VOLTAGE AND
EMERGENCY STOP
TIMED OPENED CONTACT T TRANSFORMER
BREAKDOWN DIODE BIDIRECTIONAL CB CIRCUIT BREAKER GFR GENSET FAULT RELAY OSL OIL PRESSURE LIGHT HIGH VOLTAGE PACKAGES SHOULD USE PROPERLY SIZED 2 ELEMENT OR 3 ELEMENT TRANSDUCERS.
TD TIME DELAY RELAY
CBR CIRCUIT BREAKER AUXILIARY CONTACT GND GROUND
FAIL TO START (OVER CRANK) ENGINE-STOP
TIMED CLOSED TIMED OPENED CONTACT GOV GOVERNOR
TS TERMINAL STRIP NOTE H: KILOWATT TRANSDUCER INSTRUMENT POWER 85V-135VAC.
BREAKDOWN DIODE BIDIRECTIONAL CCM CYCLE CRANK MODULE PL PANEL ILLUMINATION LIGHT
TSC TRANSFER SWITCH POSITION INDICATING CONTACT
CCT CROSS CURRENT TRANSFORMER GPLO GROUND POST LOW PM GENERATOR PERMANENT MAGNET TERMINAL
ENGINE RPM NOTE J: UPTO 3 ALARM MODULES WITH A COMBINED WIRE LENGTH OF 300
RELAY CONTACT (NORMALLY OPEN) CDM ENGINE COOLDOWN TIMER MODULE GPHI GROUND POST HIGH PLS PANEL LIGHT SWITCH
DIODE LOW COOLANT TEMPERATURE METERS MAY BE DRIVEN FROM THE DATA LINK.
RELAY CONTACT (NORMALLY OPEN) GS GOVERNOR SWITCH V AC VOLTMETER
LAMP/DISPLAY TEST CDVR CATERPILLAR DIGITAL VOLTAGE REGULATOR POT POTENTIOMETER
RELAY CONTACT (NORMALLY CLOSED) VAR VOLTAGE ADJUST RHEOSTAT
DIODE COM2 VOLTAGE REGULATOR LWR/RSE COMMON GSC GENERATOR SET CONTROL PP PRELUBE PUMP NOTE K: VARIOUS CUSTOMER SWITCHES CAN BE ACCOMMODATED FOR INTERFACE WITH
RELAY CONTACT (NORMALLY CLOSED) GSM GOVERNOR SYNCHRONIZING MOTOR VAS VOLTAGE ADJUST SWITCH OPTIONAL ALARM MODULES PROVIDED IN THE GENERATOR CONTROL PANEL.
GENERATOR SYNCHRONIZING INDICATOR CT CURRENT TRANSFORMER PPMS PRELUBE PUMP MAGNETIC SWITCH
FUSE HIGH COOLANT TEMPERATURE VDCA
RESISTOR CTR CRANK TERMINATION RELAY GSOV GAS SHUT-OFF VALVE +/- 10V DC VOLTAGE INPUT A (+)
PPPS PRELUBE PUMP OIL PRESSURE SWITCH NOTE L: KWT OUTPUT DC VOLTAGE CONNECTS TO ENGINE INTERCONNECT HARNESS CIRCUIT A786
GENERATOR FRAME (CHASSIS) GROUND FUSE VDCB +/- 10V DC VOLTAGE INPUT B (-)
V-A AMMETER VOLTMETER PHASE SELECTOR SWITCH
D DIODE
PR PRE-REGULATOR
HORN H1 PT PRIMARY WINDING TERMINAL 1 PRI TRANSFORMER PRIMARY WINDING
V/PF VOLTAGE REGULATOR VAR/PF REGULATION NOTE M: FOR LOW VOLTAGE GENERATOR DOGHOUSE TERMINAL STRIPS SEE
EARTH GROUND
DC DIRECT CURRENT
EMERGENCY SWITCH BATTERY CHARGER MALFUNCTION H2 PT PRIMARY WINDING TERMINAL 2 PS PINION SOLENOID WT WATER TEMPERATURE
PRESSURE SWITCH DCV DC VOLTMETER
HORN SILENCE/ACKNOWLEDGE SWITCH HI CT PRIMARY WINDING PT POTENTIAL TRANSFORMER WTG WATER TEMPERATURE GAUGE
DRS DIAGNOSTIC RESET SWITCH HZ FREQUENCY METER
RELAY COIL WTL WATER TEMPERATURE LIGHT
PRESSURE SWITCH DIAGNOSTIC RESET SWITCH DS50 DRIVER SUPPLY (50)
P RAISE R RELAY THIS SCHEMATIC IS FOR THE G3500C AND G3500E GENERATOR
RELAY COIL IA KWT PHASE A / LINE 1 CURRENT RAN REMOTE ANNUNCIATOR X1 PT SECONDARY WINDING TERMINAL 1 ELECTRICAL SYSTEM.
TEMPERATURE SWITCH LOWER ECLS ENGINE COOLANT LOSS SENSOR IB KWT PHASE B / LINE 2 CURRENT RDM RELAY DRIVER MODULE X2 PT SECONDARY WINDING TERMINAL 2
ECS ENGINE CONTROL SWITCH VOLUME 2 OF 2: HIGH VOLTAGE
CIRCUIT BREAKER IC KWT PHASE C / LINE 3 CURRENT RM RELAY MODULE
ECTS ENGINE COOLANT TEMPERATURE SENSOR Z ZENER DIODE MEDIA NUMBER: RENR8103-09
IDS ISOCHRONOUS DROOP SWITCH RPL REVERSE POWER LIGHT
EDIS EXCITATION DISABLE PART NUMBER: 311-8558, CHANGE: 01, VERSION: -
RPR REVERSE POWER RELAY
EFL ENGINE FAILURE LIGHT KWLR KILOWATT LEVEL RELAY
RR RUN RELAY Components are shown installed on a fully operable generator.

Refer to the appropriate Service Manual for Troubleshooting, Specifications.