340-5459 WIRING GP-ALTERNATOR S/N E6R1-UP 60-AMPERE FOR USE WITH ENGINES WITH AIR START AND 60-AMPERE ALTERNATOR AN ATTACHMENT G3516

ELECTRICAL AND STARTING SYSTEM

WIRING GP

0. 340-5459 WIRING GP-
1. 340-5462 WIRING GP-
2. 113-3380 WIRING GP-
3. 154-3856 WIRING GP-
4. 175-7731 WIRING GP-

STARTING MOTOR GP

5. 166-8367 WIRING GP-
6. 420-2419 WIRING GP-

WIRING GP

7. 145-5138 WIRING GP-
8. 141-1483 WIRING GP-
9. 154-3848 WIRING GP-
0. INFORMATION

GENERATOR SET G3516 GENERATOR SET E6R
G3516 Generator Set E6R00001-UP SEBP6611 G3516 E6R (2015)

ELECTRICAL AND STARTING SYSTEM

WIRING GP

320-8994 WIRING GP-ALTERNATOR

320-9651 WIRING GP-ALTERNATOR

340-5459 WIRING GP-ALTERNATOR

340-5462 WIRING GP-ALTERNATOR

113-3380 WIRING GP-EIS

154-3856 WIRING GP-EIS

#SEBP66110940

340-5459: WIRING GP-ALTERNATOR

WIRING GP-ALTERNATOR

340-5459 WIRING GP-ALTERNATOR
S/N E6R1-UP
60-AMPERE
FOR USE WITH ENGINES WITH AIR START AND 60-AMPERE ALTERNATOR
AN ATTACHMENT

i03996529 SEBP6611

3405459 WIRING GP-ALTERNATOR Parts scheme

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	7H-3937	[1]	LOCKWASHER
2.	8L-8413	[2]	STRAP-CABLE (WHITE)
3.	9X-6772	[18]	STRAP-CABLE
4.	126-9187	[1]	MOUNT-FLEXIBLE
5.	340-9219 Y	[1]	HARNESS AS-WIRING
6.	3B-4505	[1]	LOCKWASHER
7.	3E-9860	[1]	LOCKNUT (5/16-18-THD)
8.	5S-0003	[1]	NUT (5/16-18-THD)
9.	6T-3645	[1]	CIRCUIT BREAKER GP (60-AMPERE)
	6V-8378	[2]	NUT (10-32-THD)
	8F-1434	[2]	LOCKWASHER
	8T-0328	[2]	WASHER-HARD (5.5X10X1-MM THK)
10.	9M-1974	[1]	WASHER-HARD (8.8X16X2-MM THK)
11.	9X-8486	[2]	SCREW-MACHINE (8-32X0.75-IN)
	Y		SEPARATE ILLUSTRATION

#SEBP66110941

340-5462: WIRING GP-ALTERNATOR

WIRING GP-ALTERNATOR

340-5462 WIRING GP-ALTERNATOR
S/N E6R1-UP
35-AMPERE
FOR USE WITH ENGINES WITH AIR START
AN ATTACHMENT

i03996501 SEBP6611

3405462 WIRING GP-ALTERNATOR Parts scheme

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	7H-3937	[1]	LOCKWASHER
2.	8L-8413	[2]	STRAP-CABLE (WHITE)
3.	9X-6772	[18]	STRAP-CABLE
4.	126-9187	[1]	MOUNT-FLEXIBLE
5.	340-3694 Y	[1]	HARNESS GP-WIRING
6.	3B-4505	[1]	LOCKWASHER
7.	3E-9860	[1]	LOCKNUT (5/16-18-THD)
8.	5S-0003	[1]	NUT (5/16-18-THD)
9.	6T-3645	[1]	CIRCUIT BREAKER GP (60-AMPERE)
	6V-8378	[2]	NUT (10-32-THD)
	8F-1434	[2]	LOCKWASHER
	8T-0328	[2]	WASHER-HARD (5.5X10X1-MM THK)
10.	9M-1974	[1]	WASHER-HARD (8.8X16X2-MM THK)
11.	9X-8486	[2]	SCREW-MACHINE (8-32X0.75-IN)
	Y		SEPARATE ILLUSTRATION

#SEBP66110942

113-3380: WIRING GP-EIS

WIRING GP-EIS

113-3380 WIRING GP-EIS
S/N E6R1-UP
PART OF 394-2299 MODULE AS-EXHAUST TEMPERATURE
AN ATTACHMENT

i02630956 SEBP6611

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	3S-2093 C	[32]	STRAP-CABLE
2.	5N-2126	[16]	CONNECTOR (THERMOCOUPLE)
3.	9X-6772 BC	[10]	STRAP-CABLE
4.	116-0118 C	[16]	CLIP
5.	180-5420 Y	[1]	SENSOR GP-TEMPERATURE (TURBOCHARGER OUTLET, RH)
5A.	180-5420 Y	[1]	SENSOR GP-TEMPERATURE (TURBOCHARGER OUTLET, LH)
6.	241-9591 Y	[16]	SENSOR GP-TEMPERATURE (CYLINDER EXHAUST)
7.	243-5282 Y	[1]	HARNESS AS-SENSOR (EXHAUST)
8.	0S-0509 C	[14]	BOLT (3/8-16X0.75-IN)
9.	3B-4501 C	[4]	LOCKWASHER
10.	4P-7429	[2]	CLIP (LADDER)
11.	4P-8134 BC	[34]	CLIP (LADDER)
12.	5M-2894 C	[17]	WASHER-HARD (10.2X18.5X2.5-MM THK)
13.	6B-5072	[2]	ADAPTER
14.	9X-6259	[4]	SCREW-MACHINE (6-32X0.375-IN)
15.	0S-1594	[1]	BOLT (3/8-16X1-IN)
	B		USE AS REQUIRED
	C		CHANGE FROM PREVIOUS TYPE
	Y		SEPARATE ILLUSTRATION

#SEBP66110943

154-3856: WIRING GP-EIS

WIRING GP-EIS

154-3856 WIRING GP-EIS
S/N E6R1-UP
PART OF 384-9198 ACTUATOR GP-GOVERNOR
AN ATTACHMENT

i00917318 SEBP6611

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	4B-4281	[1]	WASHER (16.8X33X2.5-MM THK)
2.	9X-5392	[1]	SENSOR GP-SPEED (ENGINE)
	8T-8729	[2]	PIN-CONNECTOR (16-GA TO 18-GA)
	8T-8732	[1]	RECEPTACLE-CONNECTOR (3-PIN)
	8T-8737	[1]	PLUG-SEAL
	9X-1386 E	[1]	SLEEVE (14CM)
3.	154-3857	[1]	HARNESS AS-WIRING (GOVERNOR ACTUATOR)
4.	0L-1351	[1]	BOLT (3/8-16X0.875-IN)
5.	9X-6772	[3]	STRAP-CABLE
6.	5M-2894	[1]	WASHER-HARD (10.2X18.5X2.5-MM THK)
7.	4P-7581	[3]	CLIP (LADDER)
	E		ORDER BY THE CENTIMETER

#SEBP66110944

175-7731: WIRING GP-EIS

WIRING GP-EIS

175-7731 WIRING GP-EIS -LANDFILL
S/N E6R1-UP
AN ATTACHMENT

i03194609 SEBP6611

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Parts for your G3516 GENERATOR SET:

CATERPILLAR SIS

Pos.	Part No	Qty	Parts name
1.	9X-6772	[33]	STRAP-CABLE
2.	4P-8134	[4]	CLIP (LADDER)
3.	141-5883 Y	[1]	HARNESS AS-ENGINE
	Y		SEPARATE ILLUSTRATION

#SEBP66110945

166-8367: WIRING GP-ELECTRIC STARTING

WIRING GP-ELECTRIC STARTING

166-8367 WIRING GP-ELECTRIC STARTING -STARTING MOTOR
S/N E6R1-UP
AN ATTACHMENT

i01371730 SEBP6611

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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

#SEBP66110946

420-2419: WIRING GP-ELECTRIC STARTING

WIRING GP-ELECTRIC STARTING

420-2419 WIRING GP-ELECTRIC STARTING -STARTING MOTOR
S/N E6R1-UP
AN ATTACHMENT

i05317703 SEBP6611

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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)
169-5384 Y	[1]	SWITCH GP-REMOTE (STARTING)
4P-8134	[2]	CLIP (LADDER)(LADDER)
156-6175	[3]	CLIP (LADDER)(LADDER)
2D-0388	[1]	GROMMET (25.4-MM ID)
7K-1181	[5]	STRAP-CABLE
Y		SEPARATE ILLUSTRATION

#SEBP66110947

145-5138: WIRING GP-ELECTRONIC CONTROL

WIRING GP-ELECTRONIC CONTROL

145-5138 WIRING GP-ELECTRONIC CONTROL
S/N 5TA1160-UP; 5YA1250-UP; 5ZA865-UP; 2DM1-UP; 3BM1-UP; 5WN1-UP
DIGITAL VOLTAGE REGULATOR POWER
AN ATTACHMENT

i00661117 SEBP6611

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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

#SEBP66110948

141-1483: WIRING GP-ENGINE

WIRING GP-ENGINE

141-1483 WIRING GP-ENGINE -EIS
S/N E6R1-UP
PART OF 385-2478 CONTROL GP-ENGINE ELECTRONIC
AN ATTACHMENT

i00501193 SEBP6611

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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

#SEBP66110949

154-3848: WIRING GP-ENGINE

WIRING GP-ENGINE

154-3848 WIRING GP-ENGINE -EIS
S/N E6R1-UP
PART OF 417-9860 WIRING GP-ENGINE
AN ATTACHMENT

i00917470 SEBP6611

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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

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