GE Power & Water

Distributed Power

Waukesha* gas engines TOPIC:

IDENT NO:
Electronic Controls
17-4001
DATE: December 2014

ESM *
SUBJECT: Updated Power Distribution Junction Box
SUPERSEDES: NEW

MODELS AFFECTED: All Waukesha gas engines with ESM

The purpose of this bulletin is to announce the release EXISTING INSTALLATION WITH REMOTE
of a updated Power Distribution Junction Box (PDB) FAULT INDICATOR DISPLAY OPTION
(P/N 309204C). The updated PDB is completely
interchangeable with previous versions of the PDB To benefit from the remote fault indicator display
used on ESM engines. option, components must be updated. See Table 1 for
The updated PDB incorporates the following features: the required components that apply to your engine.
Table 1: Customer Panel Harnesses
• Improved Sealing – CSA type 4
PDB TO BULKHEAD TO
• Self-Centering Rubber Plugs on the Customer ENGINE
BULKHEAD CUSTOMER PANEL
Connection Openings – prevent the potential for
C740268P – 25 ft
misalignment that was possible with the previous VHP C740268R – 50 ft
metal plugs. 275GL+ 740945A
APG 1000 C740268S – 100 ft
• LED Circuit Indicators (red) – indicate that specific C740268T – 200 ft
circuit is energized.
• Internal Fault LED (yellow) – to let the user know the INSTALLATION REQUIREMENTS
Power Distribution Junction Box has detected an
electrical short or an over-current and locked out
power to one of the engine circuits. ! WARNING
• Remote PDB Fault Indicator – the ability to send a Do not install, set up, maintain or
remote signal to the customer’s panel when the operate any electrical components
internal fault LED is illuminated. unless you are a technically
qualified individual who is familiar
• Reset Switch – an integrated power reset switch with the electrical elements
allows the circuits to be reset without the need to involved.
cycle the power to the box.
All installations require CSA type 4 (or equivalent) wire
• Enhanced Noise Suppression and More Robust
connectors.
Circuit Board Components – provides more
consistent performance under adverse conditions. 1. Choose an appropriately sized sealing gland for
the +24 VDC power cable.
EXISTING INSTALLATION WITHOUT
2. Feed the power cable through the power cord grip.
REMOTE FAULT INDICATOR DISPLAY
OPTION 3. Verify that all wires feeding into the box use an
appropriate CSA type 4 (or equivalent) connector
The updated PDB can be installed using the existing that is in good condition and can provide a
wiring harnesses. watertight seal upon installation in the new box.

All non-GE trademarks, service marks, logos, slogans, and trade names
are the properties of their respective owners.
* Trademark of General Electric Company

12/19/2014
Copyright © 2014, General Electric Co. Page 1 of 4
Service Bulletin No. 17-4001

4. Install an appropriately sized ring terminal on the

power cable. NOTICE
5. Attach the power ring terminal to the positive Be sure to properly reinstall the PDB cover
3/8 in. stud located in the Power Distribution anytime that it has been removed for wiring or
Junction Box (see Figure 1). troubleshooting using the internal LEDs. DO NOT
leave the cover off when work is not actively being
done. This includes indoors or overnight. When
reinstalling the cover, all six latches must properly
engage the cover and the latch screws must be tight.
1
When the cover is properly installed, plugs are
properly in place and NEMA 4 connectors, fittings
and grommets are used for wiring, the PDB is
watertight under reasonable conditions.
Use caution when pressure-washing the engine. Do
not spray the high-pressure water stream directly at
the cover gasket, at any plug or wiring connector on
the PDB or at any engine-mounted electronics, as
water entry may occur and component damage may
2 result.
3
LED FUNCTIONS

! WARNING
Use caution when accessing the
LED indicator panel, including
when removing or replacing the
Power Distribution Junction Box
cover. Avoid contact with electrical
terminals inside the box.
Never open the PDB while the
engine is running.

Figure 2 illustrates LED numbering, PDB harness wire

Figure 1 number and function.

1 - Positive (+) Battery 3 - Terminal Block NOTE: Refer to the wiring diagrams for the applicable
Connection engine model for accurate labeling information.
2 - Negative (-) Battery
Connection
Reference the wiring diagram specific to the engine
being serviced. These diagrams are in the
6. Attach prelube motor solenoid contacts to correctly documentation section of the electronic service
labeled terminals (if customer-supplied). program (ESP) used to communicate with the ESM
7. Attach fuel valve solenoid contact to correctly system. To view these documents on your computer,
labeled terminals. navigate to the following directory:
C:\Program Files(x86)\ESM\Documentation

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Copyright © 2014, General Electric Co. Page 2 of 4
 Service Bulletin No. 17-4001

RESETTING PDB

! WARNING
Do not install, set up, maintain or
operate any electrical components
unless you are a technically
qualified individual who is familiar
with the electrical elements
involved.

NOTE: The cover must be removed to view the yellow

internal fault LED if the remote fault indicator display
option is not used.
The outputs from the PDB are protected against short
circuits and current overloads. If one of these incidents
occurs, the red power LED will go out and the yellow
internal fault LED will illuminate. If the yellow internal
fault LED is illuminated or the remote indicator is
shown on the customer panel, the PDB will need to be
reset.

Figure 2

Figure 3: Power Distribution Junction Box (Typical)

1 - Reset Switch 2 - Internal Fault LED

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Copyright © 2014, General Electric Co. Page 3 of 4
Service Bulletin No. 17-4001

NOTICE
De-energize any source of inputs (customer PLC,
etc.) to the ECU prior to cycling the power or
pressing the reset switch on the PDB. Failure to do
so may produce a voltage or current into the ECU
that is out of range, causing the circuit to disable. To
de-energize the inputs to the ECU, disconnect the
customer interface cable at the ECU.

Reset the PDB output power as follows:

1. Stop the engine.
2. Press and hold the reset switch about 3 seconds
until all LEDs turn off.
3. Release the switch.
NOTE: After completing the PDB reset procedure, if
the problem is not corrected, contact your local
Waukesha Distributor for technical support.

12/19/2014
Copyright © 2014, General Electric Co. Page 4 of 4