COOLANT LEVEL SENSOR

RENR4967
September 2001

RPM MAGNETIC PICK-UP

SUF557 Skid Mounted Power Pack

Electrical System
LTF1-UP

STARTER MOTOR AND SOLENOID

INSIDE CONTROL PANEL:

ENGINE KILL RELAY
ENGINE START SOLENOID
REMOTE CONTROL RELAY

LEFT SIDE VIEW

© 2001 Caterpillar Printed in U.S.A.

All Rights Reserved

10
1
STARTER PANEL
7 8 9
4 4 4 14 32 33
2 2 2

TOP VIEW PDB-1A RMR

Potter and
Brumfield
11
1 N
34 O MEAS
PDB-2 T PART NO. NAME
1
E ITEM QTY UNI T
EK R

Potter and
Brumfield
PARTS LIST

MERLIN GERIN
CB1

1-ON
80A-type B
277Vac
C60N
multi9
R1 R1
15
1
16
1
17
1
1 1 PC 149-6119 SWITCH-OPERATOR

MERLIN GERIN
12 CB2 1 1
2 1

1-ON
16A-type B
PC 140-2914 INDICATOR

277Vac
C60 N
multi9
2 2
1
1
2 2
3 PC 140-2915 LENS-LIGHT

MERLIN GERIN
CB3 3 3

1-ON
25A-type B
ALTERNATOR

277Vac
C60 N
35

multi9
4 4
5
6
5
6
1
4 1 PC 140-2916 LAMP
13
1
7
8
7
8
37 5 1 PC 6T-7337 METER-SERVICE
1
9
10
9
10 6 1 PC 140-2929 SWITCH-TOGGLE
7 10 PC 1H-4393 LOCKWASHER
11 11
12 12 23
14
10 PC
13 13
D3 D3 8 4B-4863 WASHER
10
D5 D5
D7 D7
36
1
9 PC 177-7288 SCREW
10 1 PC 140-2909 BLOCK
18
3 11 1 PC 139-8410 CIRCUIT BREAKER
22
3
19
12 1 PC 125-9963 CIRCUIT BREAKER
1 13 1 PC 151-0114 CIRCUIT BREAKER
14 2 PC 140-2919 RELAY
7 8 9 7 8 9
15 1 PC 3E-0356 BLOCK-TERMINAL
2 2 2 4 4 4
16 1 PC 9G-8770 RESISTOR
ESS 17 1 PC 115-2542 PLUG-COMPONENT
18 3 PC 9X-9675 BRACKET-END
19 1 PC 125-9969 RAILL
20 1 PC 140-2912 SOLENOID
21 21 1 PC 5N-4988 DIODE AS
20
1 1
22 3 PC 140-2948 DIODE
23 14 PC 115-1322 TERMINAL-DOUBLE
24 1 PC 198-8303 ENCLOSURE AS
25 1 PC 6V-3507 SEAL-RECTANGULAR
2 3 4
26 3 PC 5L-5180 WASHER-SEALING
24
1 1 1 27 3 PC 156-0330 SEAL
1 28 1 PC 077-8200 SWITCH-TOGGLE
29 6 PC 143-8541 FITTING-GLAND
30 1 PC 143-8542 FITTING-GLAND
31 1 PC 140-2927 SWITCH-TOGGLE
32 2 PC 115-7948 SOCKET-RELAY
33 2 PC 1G-6420 PRING-HOLD DOWN
34 1 PC 9X-9616 COVER-END
35 1 PC 115-2538 COVER-END
5
1
25
1
36 1 PC 3E-0369 BRIDGE-INSERTION
37 1 PC 3E-5503 BAR-FIXED BRIDGE
MAIN POWER
SERVICE METER

VO-1

DISCONNECT
HOURS

DIAGNOSTIC LAMP 000000

OFF
ENG HOURS
ON MISC. REF
- 1 PC 208-2361 INSTRUCTIONS
ENGINE ENGINE
REMOTE RPM INC START

RUN

1
LOCAL RPM DEC KILL
1
26 27 28
1 1 1

6 26 27 31 26 27
1 1 1 1 1 1

30
1

RIGHT SIDE VIEW FRONT VIEW

29
6
 LOCAL CONTROL PANEL
CB-ALT 80A ALT C12 POWER PACK
1 + -

6
4 AWG WH MPU-2 TB-6 WH 2
MAGNETIC
2 C6 PICK-UP #1
BLK MPU-1 TB-2 BLK 1
2
TB-2
SHLD MPU-SHLD

4 AWG 4 AWG
MDS OFF CB1 80A 7

2 PDB-1A 3 ON 4 AWG PDB-2 WH(+) EMSS(+)

C8 TB-7 WH (+) +
ENGINE MAGNETIC
2
SM BLK(-) EMSS(-) TB-2 BLK (-) -
STARTER SOLENOID

2 1
4 AWG
P61/J61

GND TB-1 BLK 1

TB1
1
BLK CCP61-1 TB-1 WH/BLK 31
1
WH/BLK CCP61-31 TB-1 RD/BLK 32
CUSTOMER SUPPLIED 1
12 VOLTS RD/BLK CCP61-32 TB-13 WH 26
13
WH CCP61-26
3
TB-8 RD 24
C7
8 ENGINE

4 AWG 4 AWG RD CCP61-24 TB-9 GRN 30 CUSTOMER

LINE 16 12VDC 9
GRN CCP61-30 TB-10 OA 39
CONNECTOR

+ - 10
OA CCP61-39 TB-2 BLU 29
2
BLU CCP61-29
A A WH CCP61-8 CLS-A WH 8
+8V
C10
COOLANT C RD CCP61-36 CLS-C RD 36
VM LEVEL SENSOR
SIGNAL C

4 + - TB-2 (165-6634) RETURN B B BLK CCP61-15 CLS-B BLK 15

VOLTMETER

D3
C A CB-ALT
ALTERNATOR
LRS C5 1 2 C4 + C3
CB2 16A
-
PDB-1A
TB-3 3 RMR WH VM(+)
80A

LOCAL REMOTE 13 14 TB-2 REMOTE CONTROL C11 PDB-1A WH (+) + VOLTMETER

5
2 - (104-5687)
TB-2 BLK (-)
12 SOLENOID BLK VM(-)
2 1 + -
7, 8, 9, 10, 21, 22, 23, 24
SM

TB-4 RMR
5 9 D4
REMOTE START C A
12 AWG
+ -

RMR ESS
START 1 9 + - CB1
BATTERY

6 1 ENGINE START 1 2 C2 C2 CUSTOMER SUPPLIED

12 VOLTS
80A
14
ESRKS 2
RUN
PDB-2 C1 C1
RMR EKR
2 10 13 14 ENGINE KILL
3 12
KILL 19
TB-5 RMR
7 6 10
REMOTE KILL C A
D5

MPU 1 RPM MAGNETIC

PICK-UP
8 RB1
2.2K
2

HM

9 + - HOUR METER
1
1
CB-ALT ALTERNATOR

C5 1 2 C4 + - C3
D7 80A
C A
14 AWG 14 AWG
CB3 25A ESS EMSS +
SM
- C1

10 1 3 7 + - 2 ENGINE MAGNETIC
9
STARTER 1

+ -

BATTERY
GAUGE PANEL
(VOLTMETER) 2 4 5 8
CUSTOMER SUPPLIED 1 1 2 1
TB-3 TB-2 12 VOLTS
11 12VDC GROUND
CUSTOMER REMOTE CUSTOMER REMOTE C2
C6 MAGNETIC
3 5 6
PICK-UP #1
33 7 1
C1 C11

LOCAL CONTROL PANEL

C6 7 5
LINE 3 1 3
C12 POWER PACK
C2 ENGINE COOLANT
C7 C7 C10
CUSTOMER LEVEL
ENGINE CONNECTOR SENSOR

J61/P61 CUSTOMER CONNECTOR

C8

12
P61-1 BATT (+) C9

UNSWITCHED POWER C8 +
EMSS
_ ENGINE MAGNETIC
STARTER SOLENOID
BATT (+)
P61-31
UNSWITCHED POWER
BATT (+)
EKR P61-32
UNSWITCHED POWER CUSTOMER
C9
13 TB-3 4 12 TB-13 REMOTE NOTE A
BATT (+) CONSOLE

P61-26
UNSWITCHED POWER
DL
2 1 TB-8
RD P61-24 DIAGNOSTIC LAMP

RMR
TB-11 7 11
14 REMOTE
INCREASE
SPEED INCREASE RMR
1 TB-9
3 11 PTO RAMP UP ENGINE THROTTLE
P61-30
2 SWITCH INCREASE
ERPMS RMR
4 12 TB-10 PTO RAMP DOWN ENGINE THROTTLE
3 P61-39 DECREASE
SWITCH
15 SPEED DECREASE
RMR
REMOTE TB-12 8 12
DECREASE
PTO ENABLE
2 P61-29
SWITCH

16

CAT RECOMMENDATION FOR CUSTOMER N

MEAS
REMOTE CUSTOMER WIRING
O
T PART NO. NAME
ITEM QTY UNIT
MAIN LOCAL
E

PARTS LIST
CONTROL PANEL 1 1 PC 171-2210 BREAKER AS-CKT
2 1 PC 4P-5820 SENSOR GP-SPEED
12 VDC 3 33 PC 8T-8737 PLUG-SEAL
TB-4 4 1 PC 155-2270 PLUG KIT-CONN
START 5 12 PC 8T-8730 SOCKET-CONNECTOR NOTE A: ITEM IS SHOWN BUT NOT REQUIRED
1 6 1 PC 9X-0141 PLUG AS-CONN
(CUSTOMER PROVIDED WIRING)

NOTE B: ALL FACTORY WIRES ARE TO ENTER THROUGH

7 1 PC 155-2260 PLUG KIT-CONN CENTER PANDUIT AND TERMINATE FROM THE
8 1 PC 5P-8248 WASHER CENTER PANDUIT IF POSSIBLE.
RESRKS 2 — 1515 CM 158-7854 WIRE (BULK)
WIRES ARE SHOWN ON LEFT SIDE OF BLOCKS
TB-3 RUN — 3118 CM 154-6456 WIRE (BULK)
ONLY FOR DRAWING PURPOSES.

NOTE C: CUT SPARE WIRES SHORT AND SHRINK WRAP

— 3060 CM 158-7855 WIRE (BULK) ON FIELD END. TIE WRAP SPARE WIRES TO THE
TB-5 — 4174 CM 158-7857 WIRE (BULK) LONGEST WIRE TERMINATED ON THE MAIN
JUNCTION BOX SIDE OF THE CABLE. LEAVE
3 8-12" SLACK IN CABLE FOR FUTURE
RETERMINATION.
KILL NOTE D: USE AS NEEDED FOR CABLES C6, C7, C8, C10,
AND C11.
DL MISC. REF
TB-8 NOTE E: USE AS NEEDED FOR CABLES C1-C5.

2 1 9 1 PC 208-2359 PANEL GP-INTR

#4 AWG IS TO BE LABELED WITH
CLEAR SHRINK WRAP OVER THE TOP OF
RD CONDUCTOR LABELS.

TB-11
SPEED INCREASE
1
TB-2 2
SERPMS
TB-12
3
MAIN LOCAL SPEED DECREASE
CONTROL PANEL
GROUND

SCHEMATIC LEGEND ABBREVIATION DESCRIPTION

MAIN LOCAL CONTROL PANEL TERMINAL BLOCK ANODE

A
REMOTE PANEL TERMINAL BLOCK
ALT ALTERNATOR
INTERNAL PANEL WIRING AWG AMERICAN WIRE GAUGE
BATT BATTERY
FACTORY WIRING
C CATHODE
CABLE TYPE DESCRIPTION ABBREVIATION DESCRIPTION
CUSTOMER PROVIDED WIRING CB# CIRCUIT BREAKER NUMBER
ALT ALTERNATOR
C1 1/C #4 STARTING MOTOR (-) TO PDB-2 CABLE
+ - BATTERY D# DIODE # BATT BATTERY
DL C2 1/C #4 STARTING MOTOR (+) TO CB1-2 CABLE BLK BLACK
DIAGNOSTIC LAMP
CIRCUIT BREAKER
EKR EMERGENCY KILL RELAY C3 1/C #4 STARTING MOTOR (-) TO ALTERNATOR GROUND CABLE BLU BLUE
C# CABLE #
DIODE EMSS ENGINE MAGNETIC STARTER SOLENOID C4 1/C #4 ALTERNATOR POWER TO ALTERNATOR PROTECTION CABLE
CB# CIRCUIT BREAKER #
RELAY ERPMS ENGINE REVOLUTIONS PER MINUTE SWITCH C5 1/C #4 STARTING MOTOR (+) TO ALTERNATOR PROTECTION CABLE CC CUSTOMER CONNECTOR
ESRKS ENGINE START, RUN, KILL SWITCH CLS COOLANT LEVEL SENSOR
SOLENOID C6 3/C #16 SHLD MAGNETIC PICK-UP CABLE
ESS ENGINE START SOLENOID ECM ENGINE CONTROL MODULE
C7 10/C #16 CUSTOMER CONNECTOR CABLE SEMSS STARTER ENGINE MAGNETIC START SOLENOID
NORMALLY OPEN RELAY CONTACT GND GROUND
C8 2/C #14 ENGINE MAGNETIC START SOLENOID CABLE GRN GREEN
HM HOUR METER
NORMALLT CLOSED RELAY CONTACT MPU MAGNETIC PICK UP
LRS LOCAL REMOTE SWITCH C9 6/C #16 RECOMMENDED REMOTE CONSOLE CABLE OA ORANGE
LAMP C10 3/C #16 SHLD COOLANT LEVEL SENSOR CABLE PDB POWER DISTRIBUTION BLOCK
MDS MAIN DISCONNECT SWITCH
RD RED
MPU MAGNETIC PICK-UP UNIT C11 3/C #16 SHLD GAUGE PANEL - VOLTMETER CABLE SHLD SHIELD
SWITCH
PDB POWER DISTRIBUTION BLOCK SM STARTING MOTOR
1
PTO POWER TAKE-OFF TB# TERMINAL BLOCK #
2 VM VOLTMETER
START RUN KILL SWITCH RB# RESISTOR BLOCK NUMBER
3
WH WHITE
RD RED
1

2 RESRKS REMOTE ENGINE START, RUN, & KILL SWITCH

SPEED INCREASE/DECREASE SWITCH
3
RPM REVOLUTIONS PER MINUTE
RPMDEC REVOLUTIONS PER MINUTE DECREASE

FLYWHEEL RPMINC REVOLUTIONS PER MINUTE INCREASE

SM STARTING MOTOR
TB# TERMINAL BLOCK#
VM VOLTMETER
NOTE: ALL WIRING 18AWG UNLESS OTHERWISE SPECIFIED
ALL RELAY CONTACTS SHOWN IN THE DE-ENERGIZED MODE

ALL PRESSURE SWITCHES SHOWN WITHOUT PRESSURE PRESENT