393-4639 WIRING GP-EIS S/N ZBA1-UP PART OF 393-4640 CONTROL GP-ENGINE ELECTRONIC G3516 GENERATOR SET

ELECTRICAL AND STARTING SYSTEM

WIRING GP

0. 393-4639 WIRING GP-

STARTING MOTOR GP

1. 166-8367 WIRING GP-

WIRING GP

2. 145-5138 WIRING GP-
3. 104-3174 WIRING GP-
4. 120-9715 WIRING GP-
5. 129-5684 WIRING GP-
6. 131-3875 WIRING GP-
7. 141-1483 WIRING GP-
8. 154-3848 WIRING GP-
9. 154-3851 WIRING GP-
0. INFORMATION

GENERATOR SET G3516 GENERATOR SET ZBA
G3516 Generator Set ZBA00001-UP SEBP3860 G3516 ZBA (2004)

ELECTRICAL AND STARTING SYSTEM

WIRING GP

154-3856 WIRING GP-EIS

175-7731 WIRING GP-EIS

393-4639 WIRING GP-EIS

166-8367 WIRING GP-ELECTRIC STARTING

145-5138 WIRING GP-ELECTRONIC CONTROL

104-3174 WIRING GP-ENGINE

#SEBP38601190

393-4639: WIRING GP-EIS

WIRING GP-EIS

393-4639 WIRING GP-EIS
S/N ZBA1-UP
PART OF 393-4640 CONTROL GP-ENGINE ELECTRONIC

i05857678 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	7K-1181	[35]	STRAP-CABLE
2.	101-8925 Y	[1]	MOUNTING GP-INSTRUMENT PANEL
3.	393-4623 Y	[1]	WIRING GP-INSTR & IGNITION
4.	0S-0509	[13]	BOLT (3/8-16X0.75-IN)
5.	0S-1620	[1]	BOLT (1/2-13X0.75-IN)
6.	1B-2578	[2]	NUT (3/8-16-THD)
7.	352-3969	[1]	CLIP (LADDER)
8.	4P-7428	[2]	CLIP (LADDER)
9.	4P-8134	[24]	CLIP (LADDER)
10.	5M-2894	[16]	WASHER-HARD (10.2X18.5X2.5-MM THK)
11.	5P-8245	[1]	WASHER-HARD (13.5X25.5X3-MM THK)
12.	0S-1594	[1]	BOLT (3/8-16X1-IN)
	Y		SEPARATE ILLUSTRATION

#SEBP38601191

166-8367: WIRING GP-ELECTRIC STARTING

WIRING GP-ELECTRIC STARTING

166-8367 WIRING GP-ELECTRIC STARTING -STARTING MOTOR
S/N ZBA1-UP
AN ATTACHMENT

i01371730 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Part No	Qty	Parts name
166-8371 Y	[1]	HARNESS AS-WIRING (ENGINE STARTING)
170-5399 Y	[1]	STRIP GP-TERMINAL (DC)
169-5384 Y	[1]	SWITCH GP-REMOTE (STARTING)

4F-7957	[2]	BOLT (1/4-20X0.875-IN)
4P-8134	[2]	CLIP (LADDER)
156-6175	[3]	CLIP (LADDER)
2D-0388	[1]	GROMMET (25.4-MM ID)
9X-6772	[5]	STRAP-CABLE
5P-0537	[2]	WASHER-HARD (7.2X14.5X2-MM THK)
Y		SEPARATE ILLUSTRATION

#SEBP38601192

145-5138: WIRING GP-ELECTRONIC CONTROL

WIRING GP-ELECTRONIC CONTROL

145-5138 WIRING GP-ELECTRONIC CONTROL
S/N 5TA1035-UP; 5YA1175-UP; 3BM785-UP; 5WN1842-UP; 5ZA755-UP; 6AA2900-UP; 6NA4075-UP; 6PA2600-UP; 6SA2380-UP; ZBA1-UP; 8ZD865-UP; 2DM1838-UP
DIGITAL VOLTAGE REGULATOR POWER
AN ATTACHMENT

i00661117 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Part No	Qty	Parts name
128-0830 B	[1]	HARNESS AS-POWER (DIGITAL VOLTAGE REGULATOR)
1S-9593	[5]	STRAP-CABLE
5P-2321	[2]	TERMINAL-FORK (14-GA TO 16-GA, NO. 6 SCREW)
B		USE AS REQUIRED

#SEBP38601193

104-3174: WIRING GP-ENGINE

WIRING GP-ENGINE

104-3174 WIRING GP-ENGINE
S/N ZBA1-UP
PART OF 104-4221 CONTROL GP-ENGINE ELECTRONIC

i00472664 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	104-5597 Y	[1]	WIRING GP-INSTR & IGNITION
2.	9X-6772	[56]	STRAP-CABLE
3.	4P-7581	[27]	CLIP (LADDER)
3A.	4P-7581 B	[7]	CLIP (LADDER)
4.	4P-8134	[16]	CLIP (LADDER)
5.	5M-2894	[22]	WASHER-HARD (10.2X18.5X2.5-MM THK)
6.	101-8925 Y	[1]	MOUNTING GP-INSTRUMENT PANEL
7.	4P-7428	[1]	CLIP (LADDER)
8.	5P-8245	[5]	WASHER-HARD (13.5X25.5X3-MM THK)
9.	0S-1621	[1]	BOLT (1/2-13X1-IN)
10.	0S-0509	[1]	BOLT (3/8-16X0.75-IN)
11.	4P-7429	[3]	CLIP (LADDER)
13.	6H-1717	[2]	BOLT (1/2-13X1.125-IN)
15.	1F-7958	[2]	NUT-FULL (1/2-13-THD)
	B		USE AS REQUIRED
	Y		SEPARATE ILLUSTRATION

#SEBP38601194

120-9715: WIRING GP-ENGINE

WIRING GP-ENGINE

120-9715 WIRING GP-ENGINE -FUEL RATIO CONTROL
S/N ZBA1-UP
AN ATTACHMENT

i00525762 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	037-7692	[1]	NUT (2-11 1/2NPS)
2.	108-1702	[18]	TERMINAL (SINGLE)
3.	116-5137	[1]	SPACER (TERMINAL)
4.	116-5142	[5]	TERMINAL (DOUBLE)
5.	116-5193	[1]	COVER-END
6.	120-9714	[1]	KIT-MARKER
7.	123-4873	[1]	BUSHING
8.	123-4875	[1]	BUSHING
9.	123-5222	[1]	PLATE

#SEBP38601195

129-5684: WIRING GP-ENGINE

WIRING GP-ENGINE

129-5684 WIRING GP-ENGINE -EIS
S/N ZBA1-UP
AN ATTACHMENT

i00496502 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
2.	3E-0356	[1]	BLOCK-TERMINAL
3.	5N-9072	[1]	CLIP
4.	5N-9117	[1]	ADAPTER
5.	9X-9616	[1]	COVER-END
6.	9X-9675	[2]	BRACKET-END
7.	036-8642	[1]	RESISTOR
8.	104-3651	[1]	LOCKNUT (1-11-1/2 NPT THD)
9.	114-1143	[1]	CIRCUIT BREAKER AS (16-AMPERE)
10.	115-1322	[2]	TERMINAL (DOUBLE)
11.	115-2538	[1]	COVER-END
12.	115-2542	[1]	PLUG
13.	116-5140	[15]	TERMINAL
14.	129-5683	[1]	KIT-MARKER

#SEBP38601196

131-3875: WIRING GP-ENGINE

WIRING GP-ENGINE

131-3875 WIRING GP-ENGINE
S/N ZBA1-UP
PART OF 133-3695 CONVERSION AR-ENGINE
AN ATTACHMENT

i00509306 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	9X-6772	[40]	STRAP-CABLE
2.	4P-7581	[8]	CLIP (LADDER)
3.	4P-8134	[25]	CLIP (LADDER)
4.	130-7061	[1]	HARNESS AS-WIRING
	5P-6009 D		TUBE-HEAT SHRINK (9.52-MM DIA)(0.5-M)
	6I-0755	[2]	PLUG AS-CONNECTOR (3-PIN)
	8T-5346 E		TUBE-HEAT SHRINK (19.1-MM DIA)(10-CM)
	186-3735	[3]	PIN-CONNECTOR (16-GA TO 18-GA)
	186-3736	[2]	SOCKET-CONNECTOR (16-GA TO 18-GA)
	8T-8731	[1]	PLUG-CONNECTOR (3-PIN)
	8T-8732	[1]	RECEPTACLE-CONNECTOR (3-PIN)
	9X-3467	[1]	CAP-PLUG
	126-9424 E		TUBE-HEAT SHRINK (3.2-MM DIA)(44-CM)
5.	130-7064	[1]	HARNESS AS-SENSOR (MANIFOLD AIR PRESSURE)
	5P-6009 D		TUBE-HEAT SHRINK (9.52-MM DIA)(0.5-M)
	8T-6342 E		TUBE-HEAT SHRINK (3.2-MM DIA)(3-CM)
	186-3735	[3]	PIN-CONNECTOR (16-GA TO 18-GA)
	8T-8732	[1]	RECEPTACLE-CONNECTOR (3-PIN)
	126-9424 E		TUBE-HEAT SHRINK (3.2-MM DIA)(44-CM)
	131-4885	[1]	PLUG AS-CONNECTOR
6.	4P-7428	[1]	CLIP (LADDER)
	D		ORDER BY THE METER
	E		ORDER BY THE CENTIMETER

#SEBP38601197

141-1483: WIRING GP-ENGINE

WIRING GP-ENGINE

141-1483 WIRING GP-ENGINE -EIS
S/N ZBA642-UP
PART OF 141-1484 CONTROL GP-ENGINE ELECTRONIC

i00501193 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	9X-6258	[4]	SCREW-MACHINE (6-32X0.5-IN)
2.	9X-6772	[32]	STRAP-CABLE
3.	141-1848	[1]	PLUG AS-CONNECTOR
	7X-6222	[1]	PLUG AS-CONNECTOR (24-PIN)
	3E-8558 M	[1]	BOLT (M5X0.8X39.37-MM)
	3E-4367	[1]	RING-RETAINING
	9X-3265	[2]	SEAL-CONNECTOR (24-PIN)
	5P-5623 D		WIRE-ELECTRICAL (16-GA, BLACK)(0.1-M)
	5P-5677 D		WIRE (18-GA, BLACK)(0.1-M)
	8T-8730	[24]	SOCKET-CONNECTOR (16-GA TO 18-GA)
	8T-8737	[16]	PLUG-SEAL
4.	149-1390 Y	[1]	HARNESS AS-SENSOR (EMCP II)
5.	0S-0509	[15]	BOLT (3/8-16X0.75-IN)
6.	1F-7958	[2]	NUT-FULL (1/2-13-THD)
7.	4P-7429	[2]	CLIP (LADDER)
8.	4P-7581	[2]	CLIP (LADDER)
9.	4P-8134	[22]	CLIP (LADDER)
10.	5M-2894	[15]	WASHER-HARD (10.2X18.5X2.5-MM THK)
11.	5P-8245	[4]	WASHER-HARD (13.5X25.5X3-MM THK)
12.	6H-1717	[2]	BOLT (1/2-13X1.125-IN)
13.	4P-7428	[1]	CLIP (LADDER)
	D		ORDER BY THE METER
	M		METRIC PART
	Y		SEPARATE ILLUSTRATION

#SEBP38601198

154-3848: WIRING GP-ENGINE

WIRING GP-ENGINE

154-3848 WIRING GP-ENGINE -EIS
S/N ZBA1-UP
PART OF 154-3847 CONTROL GP-EMCP ELECTRONIC
AN ATTACHMENT

i00917470 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	3S-2093	[1]	STRAP-CABLE
2.	9X-6772	[8]	STRAP-CABLE
3.	116-0118	[1]	CLIP
4.	154-3849	[1]	HARNESS AS-ENGINE
	5P-6009 D		TUBE-HEAT SHRINK (9.52-MM DIA)(0.1-M)
	5S-7433	[1]	PLUG AS-CONNECTOR (2-PIN)
	7X-6222	[1]	PLUG AS-CONNECTOR (24-PIN)
	186-3735	[31]	PIN-CONNECTOR (16-GA TO 18-GA)
	186-3736	[30]	SOCKET-CONNECTOR (16-GA TO 18-GA)
	8T-8731	[1]	PLUG-CONNECTOR (3-PIN)
	8T-8737	[11]	PLUG-SEAL
	9X-1339	[1]	RECEPTACLE AS-CONNECTOR (40-PIN)
	126-9424 E		TUBE-HEAT SHRINK (3.2-MM DIA)(116-CM)
	134-6258 E		CABLE-ELECTRICAL (16-GA)(677-CM)
	155-2260	[3]	KIT-CONNECTING PLUG (3-PIN)
			(EACH INCLUDES PLUG AS & WEDGE)
5.	0S-0509	[1]	BOLT (3/8-16X0.75-IN)
6.	4P-7581	[2]	CLIP (LADDER)
7.	5M-2894	[1]	WASHER-HARD (10.2X18.5X2.5-MM THK)
	D		ORDER BY THE METER
	E		ORDER BY THE CENTIMETER

#SEBP38601199

154-3851: WIRING GP-ENGINE

WIRING GP-ENGINE

154-3851 WIRING GP-ENGINE -ELECTRIC START
S/N ZBA1-UP
AN ATTACHMENT

i00916337 SEBP3860

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	154-3852	[1]	HARNESS AS-WIRING (ELECTRIC START)
	2L-8066	[2]	TERMINAL-RING (10-GA TO 12-GA, NO. 10 SCREW)
	2L-8071	[2]	TERMINAL-RING (10-GA TO 12-GA, 1/2-IN SCREW)
	140-3063	[1]	PLUG AS-CONNECTOR (4-PIN)
2.	9X-6772 B	[2]	STRAP-CABLE
	B		USE AS REQUIRED

Information:

ELECTRICAL AND STARTING SYSTEM

WIRING GP

Engine News

New Control Panel Films Show That SR4B Generators Are Not To Be Wired In The Delta Configuration{7557,7566}
1999/04/01

Correction to The Pocket Guide, SEBD0402 Is Available as a Reference for Routing and Installing Wire Harness Assemblies {1408}
2000/07/01

270-5051 Repair Kit (Electrical Connectors) Available for Repairs to Wiring Harnesses with Ampseal 16 and A4E 2 Connectors {0709, 1408}
2006/03/20

Bulk Wiring Harnesses Are Available for Use with Caterpillar Products {1408}
2010/05/13

Special Instruction

Cross-Reference for Electrical Connectors {7553}
Cross-Reference for Electrical Connectors {7553}

Circuit Breaker Harness Assembly {1420}
Circuit Breaker Harness Assembly {1420}

Service Of Machined Terminals And Service of Stamped and Formed Terminals{7553}
Service Of Machined Terminals And Service of Stamped and Formed Terminals{7553}

Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications{1091, 1408, 7490, 7498}
Installation and Operation of the Exhaust Monitor Used in All Diesel Particulate Filter (DPF) Retrofit Emissions Applications{1091, 1408, 7490, 7498}

Grounding Design Guide for Electric Power Generation Products {4450, 4459}
Grounding Design Guide for Electric Power Generation Products {4450, 4459}

Guidelines for Routing and Installing Wire Harness Assemblies {1408, 7553}
Guidelines for Routing and Installing Wire Harness Assemblies {1408, 7553}

Repair Procedure for Damaged Harness Wiring {1408}
Repair Procedure for Damaged Harness Wiring {1408}

Procedure for Installing Continuous Telematics Power Retrofit (CTPR) for Electric Power{7606}
Procedure for Installing Continuous Telematics Power Retrofit (CTPR) for Electric Power{7606}

Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451}
Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2B {1408, 4490, 7418, 7426, 7451}

Schematic

Schematics & Wiring Diagrams
ELECTRONIC MODULAR CONTROL PANEL II (EMCP II)

Schematics & Wiring Diagrams
CATERPILLAR SWITCHGEAR

Tool Operating Manual

Using the 362-3555 Connector Repair Kit to Service Harnesses with Ampseal 16 Connectors{0685, 1408}
Using the 362-3555 Connector Repair Kit to Service Harnesses with Ampseal 16 Connectors{0685, 1408}

Using the U5MK1110 Ampseal Connector Kit for Wiring Harness Repairs on Perkins Engines{7553}
Using the U5MK1110 Ampseal Connector Kit for Wiring Harness Repairs on Perkins Engines{7553}

Using the U5MK1110 Ampseal Connector Kit for Wiring Harness Repairs on Perkins Engines{0374, 0599, 0701, 0709}
Using the U5MK1110 Ampseal Connector Kit for Wiring Harness Repairs on Perkins Engines{0374, 0599, 0701, 0709}

Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439}
Using the 453-3204 Pressure and Temperature Test Group{0374, 0599, 0706, 0708, 0709, 0731, 0732, 0738, 1408, 1439}

Systems Operation

Wiring Harness
PL1000E Communication ECM

Wiring Harness
GENSET, SR4, SR4 HV, SR4B and SR4B HV Electric Power Generation, 3126, 3176B, 3176C, 3196, 3408E, 3412C, 3412E, 3508, 3508B, 3512, 3512B, 3516, 3516B and G3616 Engines, 3406E GEN SET Generator Set, 3406E IND, 3408C IND and 3456 IND Industrial Engines and 3126B MARINE, 3176C MARINE, 3196 MARINE and 3406E MARINE Marine Engines PL1000T

Testing and Adjusting

Electrical Connector - Inspect
PL1000E Communication ECM

Wiring Harness (Open Circuit) - Test
PL1000E Communication ECM

Wiring Harness (Short Circuit) - Test
PL1000E Communication ECM

Electrical Connector - Inspect
GENSET, SR4, SR4 HV, SR4B and SR4B HV Electric Power Generation, 3126, 3176B, 3176C, 3196, 3408E, 3412C, 3412E, 3508, 3508B, 3512, 3512B, 3516, 3516B and G3616 Engines, 3406E GEN SET Generator Set, 3406E IND, 3408C IND and 3456 IND Industrial Engines and 3126B MARINE, 3176C MARINE, 3196 MARINE and 3406E MARINE Marine Engines PL1000T

Wiring Harness (Open Circuit) - Test
GENSET, SR4, SR4 HV, SR4B and SR4B HV Electric Power Generation, 3126, 3176B, 3176C, 3196, 3408E, 3412C, 3412E, 3508, 3508B, 3512, 3512B, 3516, 3516B and G3616 Engines, 3406E GEN SET Generator Set, 3406E IND, 3408C IND and 3456 IND Industrial Engines and 3126B MARINE, 3176C MARINE, 3196 MARINE and 3406E MARINE Marine Engines PL1000T

Wiring Harness (Short Circuit) - Test
GENSET, SR4, SR4 HV, SR4B and SR4B HV Electric Power Generation, 3126, 3176B, 3176C, 3196, 3408E, 3412C, 3412E, 3508, 3508B, 3512, 3512B, 3516, 3516B and G3616 Engines, 3406E GEN SET Generator Set, 3406E IND, 3408C IND and 3456 IND Industrial Engines and 3126B MARINE, 3176C MARINE, 3196 MARINE and 3406E MARINE Marine Engines PL1000T

Troubleshooting

Connector Locations
GENSET, SR4, SR4 HV, SR4B and SR4B HV Electric Power Generation, 3126, 3176B, 3176C, 3196, 3408E, 3412C, 3412E, 3508, 3508B, 3512, 3512B, 3516, 3516B and G3616 Engines, 3406E GEN SET Generator Set, 3406E IND, 3408C IND and 3456 IND Industrial Engines and 3126B MARINE, 3176C MARINE, 3196 MARINE and 3406E MARINE Marine Engines PL1000T

Connector Locations
PL1000E Communication ECM

Service Magazine

Correction to The Pocket Guide, SEBD0402, Is Available as a Reference for Routing and Installing Wire Harness Assemblies {1408}
2000/06/26

Dielectric Grease Should Not Be Used in Electrical Connectors {1408, 7553}
2000/10/09

Service of the Machined Terminals and the Stamped and Formed Terminals {7553}
2006/11/13

Updated Instruction For The Bypass Harness {0785, 1408}
2008/03/17

Bulk Wiring Harnesses Are Available for Use with Caterpillar Products {1408}
2012/03/05

Striped Wire Is Replaced With Improved Ink Jet Identification for Legacy (Parts Service) Wire harnesses {1408}
2012/06/08

Use Conductive Fasteners for Electrical Grounding on All Cat Products {7553, 7556}
2012/05/08

Information On Battery Cables and Wire Assemblies for Assembling at Dealer Site {4459}
2012/09/21