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Injector Harness

Connector
P300

Turbo Outlet
Pressure
Sensor
(Intake
Manifold Air)
J200

FRONT VIEW

Fuel
Temperature
Sensor
P105

Fuel
Pressure
Sensor
J209

Harness And Wire Electrical Schematic Symbols

RENR7934-02
October 2008

Symbols

Intake Manifold
Air Temperature
Sensor
P103

Pressure
Symbol

Temperature
Symbol

Level
Symbol

Circuit Breaker
Symbol

Flow
Symbol

Symbols and Definitions


Fuse: A component in an electrical circuit that will open the circuit if too much current flows
through it.

Switch (Normally Open): A switch that will close at a specified point (temp, press, etc.). The
circle indicates that the component has screw terminals and a wire can be disconnected from it.

Secondary Engine
Speed/Timing
Sensor
(Camshaft)
P402

Switch (Normally Closed): A switch that will open at a specified point (temp, press, etc.).
No circle indicates that the wire cannot be disconnected from the component.
Ground (Wired): This indicates that the component is connected to a grounded wire. The
grounded wire is fastened to the machine.

Timing Calibration
(TC) Probe Connector
P400

Engine Coolant
Temperature
Sensor
P100

ECM
Ground
Strap

Condition

E009

High Altitude Derate

E096

High Fuel Pressure

E194

High Exhaust Temperature

E197

High Engine Oil Temperature

E198

Low Fuel Pressure

Engine Oil
Pressure
Sensor
J201

Low Coolant Temperature

E255

Diagnostic Reset

E264

Emergency Stop Activated

E360

Low Engine Oil Pressure

E361

High Engine Coolant Temperature

E362

Engine Overspeed

Relay (Magnetic Switch): A relay is an electrical component that is activated by electricity.


It has a coil that makes an electromagnet when current flows through it. The
electromagnet can open or close the switch part of the relay.
Solenoid: A solenoid is an electrical component that is activated by electricity. It has a
coil that makes an electromagnet when current flows through it. The electromagnet
can open or close a valve or move a piece of metal that can do work.

STD1-UP
PDH1-UP (engine)

Magnetic Latch Solenoid: A magnetic latch solenoid is an electrical component that is


activated by electricity and held latched by a permanent magnet. It has two coils (latch and unlatch)
that make electromagnet when current flows through them. It also has an internal switch that places
the latch coil circuit open at the time the coil latches.

Harness and Wire Symbols


Deutsch connector: Typical representation
of a Deutsch connector. The plug contains all
sockets and the receptacle contains all pins.

1
2

LEFT SIDE VIEW

Harness Identification Letter(s):


(A, B, C, ..., AA, AB, AC, ...)

Wire, Cable, or Harness Assembly Identification:


Includes Harness Identification Letters and Harness
Connector Serialization Codes

C-C4
130-6795

Harness Connector Serialization Code: The "C" stands


for "Connector" and the number indicates which
connector in the harness. (C1, C2, C3, .....)

Part Number for


Connector Plug

AG-C3
130-6795

Pin

L-C12
3E-5179

AG-C4
111-7898

Socket

5A
Pin or Socket
Number

High Fuel Temperature

E368

High Intake Manifold Air Temperature

SENR9706

Systems Operation / Testing and Adjusting

SENR9708

Engine Oil Pressure Sensor

Injector #1

110

Engine Coolant Temperature Sensor

0002

Injector #2

111

Engine Coolant Level Sensor

0003

Injector #3

168

Electrical System Voltage

0004

Injector #4

190

Engine Speed Sensor

0005

Injector #5

0006

Injector #6

0041

8 Volt DC Supply

0091

Throttle Position

0100

Engine Oil Pressure

0110

Engine Coolant Temperature

0168

System Voltage

0172

Intake Manifold Air Temp

0174

Fuel Temperature

0175

Engine Oil Temperature

0190

Engine Speed

0247

Data Link Communications

0253

Personality Module

0261

Engine Timing

0262

5 Volt Sensor DC Power Supply

0268

Check Programmable Parameters

0273
0274

248

CAT Data Link

268

EMCP Electronic Control (Generator Set)

269

Sensor Power Supply

333

Annunciator Switch

334

Spare Output

155-2267

169-8670

336

Engine Control Switch

441

Electronic Governor Relay

442

Generator Fault Relay

443

Crank Terminate Relay

Starter Motor Relay

445

Run Relay

446

Air Shutdown Relay

447

Fuel Control Relay

500

EMCP Electronic Control (Generator Set)

566

Invalid Engine Shutdown

590

Engine Control Module

3E-3388

32

47

40

57

48

70

58

155-2264

6
5

Failure Description

24

39

Failure Mode Identifiers (FMI)

31

160-7690

The CID is a diagnostic code that indicates which component is faulty.

14

444

EMCPII+ Diagnostic Codes


CID

23

Ether Start Relay

13

3E-3370

Exhaust Temperature

Printed in U.S.A.

Atmospheric Pressure

0545

13

23

14

31

24

39

32

47

40

57

48

70

58

128-2312

Component

100

Engine Oil Pressure Sensor

110

Engine Coolant Temperature Sensor

111

Engine Coolant Level Sensor

168

Electrical System Voltage

175

Engine Oil Temperature Sensor

190

Engine Speed Sensor

248

CAT Data Link

268

EMCP Electronic Control (Generator Set)

269

Sensor Power Supply

Data valid but above normal operational range.

333

Annunciator Switch

Data valid but below normal operational range.

334

Spare Output

Data erratic, intermittent, or incorrect.

336

Engine Control Switch

Voltage above normal or shorted high.

441

Electronic Governor Relay

Voltage below normal or shorted low.

442

Current below normal or open circuit.

443

Current above normal or grounded circuit.

444

Starter Motor Relay

Mechanical system not responding properly.

445

Run Relay

Abnormal frequency, pulse width, or period.

446

Air Shutdown Relay

Abnormal update.

447

Fuel Control Relay

10

Abnormal rate of change.

448

Spare Relay

11

Failure mode not identifiable.

475

Relay Driver Module

12

Bad device or component.

13

Out of calibration.

14

Parameter failures.

15

155-2269

G
2

103-0213

9 10 11 12 13 14

15 16 17 18 19 20 21

22 23 24 25 26 27 28

Generator Fault Relay

29 30 31 32 33 34 35

36 37 38 39 40 41 42

Crank Terminate Relay

43 44 45 46 47 48 49

50 51 52 53 54 55 56

57 58 59 60 61 62 63

64 65 66 67 68 69 70

290-8858

10

11

12

9X-4391

500

EMCP Electronic Control (Generator Set)

14 13 12 11 10 9

566

Invalid Engine Shutdown

28 27 26 25 24 23 22

Parameter failures.

590

Engine Control Module

16

Parameter not available.

770

Customer Communication Module Data Link

17

Module not responding.

858

Generator Close Breaker

18

Sensor supply fault.

859

Generator Kilowatt Relay

19

Condition not met.

20

Parameter failures.

The FMI is a diagnostic code that indicates what type of failure has occurred.

Wire Gauge

Turbo Outlet Pressure

0535

Wire Color

160-7689

Loss of Secondary Engine Speed

Circuit Identification
Number

174-0502

0342

Ground
Connection

Component

100

0001

Fuel Pressure

Volume 1 of 3: ENGINE AND EMCPII CODES

200-L32 BK-14

EMCPII Diagnostic Codes


CID

Component

Harness identification code:


This example indicates wire
135 in harness "AG".

Fuse
(5 Amps)

Component
Part Number

2008 Caterpillar
All Rights Reserved

Electronic Control Module (Engine)


CID

9X-1123

Plug

Form Number

Troubleshooting

Part Number For


Connector Recepticle

Receptacle

Related Electrical Service Manuals


Title

Sure-Seal connector: Typical representation


of a Sure-Seal connector. The plug and receptacle
contain both pins and sockets.

1
2

Single Wire
Connector

E363

FMI No.

325-AG135 PK-14

E199

0094

ZKB1-UP
C6C1-UP
G4C1-UP
STM1-UP
STH1-UP (engine)

Sender: A component that is used with a temperature or pressure gauge. The sender
measures the temperature or pressure. Its resistance changes to give an indication to
the gauge of the temperature or pressure.

155-2252

12

1038

Governor Adjust Analog Output

1167

EPG (Electric Power Generation) Circuit Breaker

1168

Dead Bus Sensor

1169

ATB (A/C Transformer Box) Sensor

1170

BTB (Bus Transformer Box) Sensor

11

10

21 20 19 18 17 16 15

42 41 40 39 38 37 36

35 34 33 32 31 30 29

56 55 54 53 52 51 50

49 48 47 46 45 44 43

70 69 68 67 66 65 64

63 62 61 60 59 58 57

(Dimensions: 34 inches x 24 inches)

Event Codes For ADEM III ECM


Event Code

ECM
Connector
P2/J2

C18 Generator Set


with EMCPII, EMCPII+, and EMCP3
Electrical System

16 Page,

Atmospheric
Pressure
Sensor
J203

ECM
Connector
J1

Reed Switch: A switch whose contacts are controlled by a magnet. A magnet closes the
contacts of a normally open reed switch; it opens the contacts of a normally closed reed switch.

RENR7934-02 VOL 1 of 3

Primary Engine
Speed/Timing
Sensor
(Crankshaft)
P401

Electronic
Control
Module
(ECM)

Ground (Case): This indicates that the component does not have a wire connected to ground.
It is grounded by being fastened to the machine.

RETARDER SOLENOID
MED/HI

P2
1607690

ANALOG SNSR POWER (+5V)


ANALOG SNSR COMMON

RETARDER SOLENOID COMMON


RETARDER SOLENOID MED/HI
RETARDER SOLENOID LOW/HI
ATMOSPHERIC PRESS. SNSR
FUEL PRESS. SNSR
PASSIVE SNSR RETURN

INJECTOR COMMON 1 & 2


INJECTOR COMMON 3 & 4
INJECTOR COMMON 5 & 6
PRIMARY SP/TMG SIG +
PRIMARY SP/TMG SIG -

INJECTOR 5
INJECTOR 6
SECONDARY SP/TMG SIG +
SECONDARY SP/TMG SIG -

A747/GY
413/BR
R993/BR

G811/YL
G810/PU
994/GY

NO.6
CYLINDER
INJECTOR
A706 GY-16
D791 YL-16

NO.4
CYLINDER
INJECTOR

NO.3
CYLINDER
INJECTOR

NO.1
CYLINDER
INJECTOR

NO.2
CYLINDER
INJECTOR

D790 OR-16

FUEL
TEMPERATURE
P105

ENGINE COOLANT
TEMPERATURE
P100

D791 YL-16

ENGINE OIL
PRESSURE
J201

D790 OR-16
D789 WH-16

P400
1552269
1
2

G811/YL
G810/PU

3E3364
TIMING CALIBRATION
(TC) PROBE

P920/BR
F732/PK
998/BR
999/WH
995/LTBU
R993/BR
997/OR
993/BR
A746/PK
A747/GY
994/GY
F421/YL
413/BR
C967/LTBU

P920/BR
F732/PK

1
2

1
2

P100
1552269
995/LTBU
R993/BR

1
2

TURBO OUTLET
PRESSURE SENSOR
(INTAKE MANIFOLD AIR)
194-6724

J203
3E3370
A
B
C

OR-18
YL-18
GN-18

+5V
RETURN
SIGNAL

ATMOSPHERIC PRESSURE
SENSOR
194-6722

ENGINE OIL PRESSURE


SENSOR
194-6725

SIGNAL
COMMON

FUEL TEMPERATURE
SENSOR
130-9811

OR-18
YL-18
GN-18

+5V
RETURN
SIGNAL

FUEL PRESSURE SENSOR


194-6725

P103
1552269
1
2

SIGNAL
COMMON

INTAKE MANIFOLD AIR


TEMPERATURE SENSOR
130-9811

P105
1552269
1
2
J209
3E3370
A
B
C

C967/LTBU
R993/BR

999/WH
998/BR

A705

INJECTOR
#1

INJECTOR
#2

SECONDARY ENGINE
SPEED / TIMING
(CAMSHAFT)
P402

A701

SPLICE
D790

A703
D790

D790

D791

SPLICE
D791

+5V
RETURN
SIGNAL

OR-18
YL-18
GN-18

F421/YL
R993/BR

997/OR
993/BR
413/BR

INTAKE MANIFOLD
AIR TEMPERATURE
P103

A702

D789

D789

TIMING CALIBRATION(TC)
PROBE CONNECTOR
P400

TURBO OUTLET PRESSURE


(INTAKE MANIFOLD AIR)
J200

SPLICE
993

L983/WH
L984/OR
L985/YL

A705/BU
A706/GY

A706

+5V
RETURN
SIGNAL

J201
3E3370
A
997/OR
B
993/BR
C
994/GY

F732/PK
P920/BR

D786

D788

INJECTOR
#3

INJECTOR
#4

A704

D791

OR-18
YL-18
GN-18

997/OR
993/BR
A747/GY

C967/LTBU
A701/GY
A702/PU
A703/BR
A704/GN
A746/PK

ENGINE COOLANT
TEMPERATURE SENSOR
130-9811

SIGNAL
COMMON

J200
3E3370
997/OR
A
B
993/BR
A746/PK
C

995/LTBU
F421/YL

INJECTOR
#5

INJECTOR
#6

(CAMSHAFT POSITION)
SECONDARY ENGINE SPEED/TIMING SENSOR
188-7513

SIGNAL(-)
SIGNAL(+)

BK-18
WH-18

D787

ATMOSPHERIC
PRESSURE
J203

SPLICE
D786

(CRANKSHAFT POSITION)
PRIMARY ENGINE SPEED/TIMING SENSOR
189-9266

SIGNAL(-)
SIGNAL(+)

P402
1552269
998/BR
999/WH

D788

D786

D788
P401
1552269

FUEL
PRESSURE
J209

D789 WH-16

INTAKE MANIF. AIR TEMP. SNSR


INJECTOR 1
INJECTOR 2
INJECTOR 3
INJECTOR 4
TURBO OUTLET PRESS. SNSR

J702/BK
J700/BR
J701/GN

GY-16
PU-16
BR-16
GN-16
BU-16
GY-16
BK-16
YL-16
GN-16
OR-16
BR-16
WH-16

ENGINE COOLANT TEMP. SNSR


FUEL TEMP. SNSR

997/OR
993/BR

A701
A702
A703
A704
A705
A706
D788
D791
D787
D790
D786
D789

TIMING CALIBRATION PROBE +


TIMING CALIBRATION PROBE ENG OIL PRESS. SNSR

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

NO.5
CYLINDER
INJECTOR

290-8858
1
2
3
4
5
6
7
8
9
10
11
12

1552252
A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY
J702/BK
L985/YL
J701/GN
L984/OR
J700/BR
L983/WH

A705 BU-16

RETARDER SOLENOID
LO/HI

J300

P300

A702 PU-16
A703 BR-16
A704 GN-16

ECM
MOUNTING
BOLT

ELECTRONIC CONTROL
MODULE (ECM)

RETARDER SOLENOID
MED/HI

INJECTOR
HARNESS
CONNECTOR

ECM
GROUND
STRAP

P300
INJECTOR HARNESS
CONNECTOR

INJECTOR HARNESS
CONNECTOR
J300

A701 GY-16

SPLICE
997

SPLICE
R993

SPLICE
D789

SPLICE
D788

13
23
31
39
47
57
70

PRIMARY ENGINE
SPEED / TIMING
(CRANKSHAFT)
P401

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 122-1486

1
14
24
32
40
48
58

ELECTRONIC
CONTROL MODULE
P2

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 238-1773

SYMBOL

DESCRIPTION
CIRCUIT CONNECTED
CIRCUIT NOT CONNECTED
ELECTRICAL CONNECTION TO
MACHINE STRUCTURE
INTERNAL ELECTRICAL CONNECTION
TO SURFACE OF COMPONENT
CONNECTOR

H#

CIRCUIT GROUPING DESIGNATION


ATCH WIRE, CABLE, COMPONENT
CIRCUIT CONNECTED

JUNCTION
BOX

(+) WH-16

15A
CB3
9M-9085

(+) WH-14

20A
CB1
200-8577

ECM
RELAY
206-9427
30

ENGINE OIL
TEMPERATURE

JUNCTION
BOX

(+) WH-12
60A
CB2
6T-3645

START
RELAY
(SMMS)
9X-8124

87a

SPLICE

EARTH

25

40

BLADE, SPADE, RING OR SCREW


TERMINAL

COOLANT
LEVEL

COLOR ABBREVIATIONS
2

(25) WH-14

10

87
86

85

B+

(25) WH-14
(+) WH-12
(+) WH-14
(+) WH-16

(YGN) WH-16

(40) WH-12

(4) WH-16
(2) WH-16

(B+) WH-16

(10) WH-16
(2) WH-16

(2) WH-16

(2) WH-16

STARTING
MOTOR

MTR

BAT.

R448
ANALOG
VOLTAGE
REGULATOR

RD-00
STARTING
MOTOR

P1
1607689

CAT DATA LINK (+)


CAT DATA LINK (-)

DIGITAL RETURN

ENGINE STOP

J1939 DATA (-)

START/RUN/STOP

+BATTERY (SWITCHED)
J1939 DATA (+)
+BATTERY (SWITCHED)
+BATTERY (SWITCHED)

-BATTERY
-BATTERY
-BATTERY
THROTTLE POSITION SENSOR

+BATTERY (KEYSWITCH)
ELECTRONIC CONTROL MODULE (ECM)

(2) WH-16

(2) WH-16
(2) WH-16

(2) WH-12

(4) WH-16
(B+)
(B+)
(B+)
(B+)

(D+) WH-12
(D-) WH-16

WH-16
WH-16
WH-16
WH-16
(10) WH-16
(10) WH-16

(D+) WH-12
(D-) WH-16
(20) WH-16
(45) WH-16

(20) WH-16

(ATA-)
(ATA+)
SHIELD
(45) WH-16

(1) WH-16
(2) WH-16

(D+) WH-12
(D-) WH-16

(D+) WH-12
(D-) WH-16

(ATA-)
(ATA+)
SHIELD

(ATA-)
(ATA+)
SHIELD

(1) WH-16

(1)
(1)
(D+)
(D-)

WH-16
WH-16
WH-12
WH-16

(10) WH-16

(2) WH-16

(20) WH-16
(45) WH-16
(41) WH-16

(20) WH-16
(45) WH-16
(41) WH-16

(SSPD) WH-12
SHIELD

(SSPD) WH-12
SHIELD

(41) WH-16

(20) WH-16
(2) WH-16
(2) WH-16
(41) WH-16
(45) WH-16

(SSPD) WH-12

(10) WH-16

(10) WH-16
SHIELD

(2) WH-16
(2) WH-16
(2) WH-16

BATTERY
12V

(34)
(46)
(12)
(11)
(17)
(30)

(2) WH-16

WH-16
WH-16
WH-16
WH-16
WH-16
WH-16

(62L)
(18)
(67L)
(620)
(19)
(670)

WH-16
WH-16
WH-16
WH-16
WH-16
WH-16

(ATA-)

11
(41) WH-16

12

17

30

46

34

3E-3388 1552264
WH-16
WH-16
WH-16
WH-16
WH-16
WH-16
WH-16
WH-16

1
2
3
4
5
6
7
8

(17) WH-16
(30) WH-16
(12) WH-16
(11) WH-16
(46) WH-16
(2) WH-16
(34) WH-16
(4) WH-16

(21)
(22)

(4) WH-16
(2) WH-16
(34) WH-16
(46) WH-16
(12) WH-16
(11) WH-16
(17) WH-16
(30) WH-16

SHIELD
(SSPD) WH-12
SHIELD
(ATA+)
(ATA-)
SHIELD

(B+) WH-16
(ATA+)
(B+) WH-16
(B+) WH-16

EMERGENCY STOP SWITCH


206-9509

1552269
ENGINE SPEED SENSOR
6V-2455

SIGNAL(+)
SIGNAL(-)

BK-18
WH-18

(21)
(22)

1
2

SHIELD
1552267

COOLANT LEVEL SENSOR


165-6634

+V
RETURN
SIGNAL

RD
BK
GN

A
B
C

ENGINE OIL TEMPERATURE


134-2252

+V
RETURN
SIGNAL

OR
BK
WH

A
B
C

(2) WH-16
(SSPD) WH-12

(10) WH-16

(67L) WH-16
(62L) WH-16
(18) WH-16

(11)
(12)
(17)
(34)
(46)

WH-16
WH-16
WH-16
WH-16
WH-16

1552267

(2) WH-16
(2) WH-16

CORE BALANCE
CURRENT TRANSFORMER
(IF EQUIPPED)
R448
ANALOG
VOLTAGE
REGULATOR

80

9X4391

(2) WH-16

(10) WH-16

BK-00

82

CORE BALANCE
CURRENT
TRANSFORMER

25

ST4

(670) WH-16
(620) WH-16
(19) WH-16
(EF1) WH-16
(EF2) WH-16
(80) WH-16
(82) WH-16

(80) WH-16
(82) WH-16

(EF1) WH-16
(EF2) WH-16
(30) WH-16

Y/G

EF1 EF2

(1) WH-16

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

BATTERY
12V

BK-00

1
2
3
4

(2) WH-16

(Dimensions: 34 inches x 24 inches)

ALTERNATOR

16 Page,

RENR7934-01 VOL 1 of 3

EMERGENCY STOP
SWITCH

103-0213

ABBREV

COLOR

RD
WH
OR
YL
PK
BK
GY
PU
BR
GN
BU

RED
WHITE
ORANGE
YELLOW
PINK
BLACK
GRAY
PURPLE
BROWN
GREEN
BLUE

ENGINE
SPEED

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

SPLICE(2) #3

ALTERNATOR

40
SPLICE(10)
SPLICE(2) #2

SPLICE(B+)
SPLICE(2) #4

SPLICE(1)
SPLICE(2) #1

(+) BATTERY
(+) BATTERY SWITCHED
STARTING CIRCUIT

REFERENCE GENERATOR SET CONTROL


SCHEMATIC VOL2 AND VOL3

(-) BATTERY / SENSOR RETURN

THRU

SENSOR / ACTUATOR SUPPLY


SIGNAL PLUS TO ECM
SIGNAL MINUS TO ECM
CONTROL PLUS FROM ECM
CONTROL MINUS FROM ECM
CAT DATA LINK
J1939 DATA LINK
HIGHWAYS

CONTROL PANEL

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 244-1172


(FOR EMCPII AND EMCPII+)

ELECTRONIC CONTROL
MODULE (ECM)
P1

THIS SCHEMATIC IS FOR THE C18 GENERATOR SET


S/N: ZKB
G4C
STM
C6C
STD
HARNESS
238-1773
122-1486
244-1172

CHG
00 (J2 / ENGINE HARNESS)
11 (INJECTOR HARNESS)
02 (J1 / GENERATOR SET CONTROL HARNESS FOR EMCPII AND EMCPII+)

NEUTRAL EARTH LINK

HIGH
COOLANT
TEMP

1
2
3
4
5
6
7

LOW
OIL
PRESSURE

LOW
FUEL
LEVEL

SYSTEM
NOT IN
AUTO

8
9
10
11
12
13
14

1
2
3
4
5
6
7

1
2
3
4
5
6
7

8
9
10
11
12
13
14

108

8
9
10
11
12
13
14

33

108

CORE
BALANCE
C.T.

T11

110

34

:A
:B
:C
:D
:E

110

NOTE:

IF 4 POLE BREAKER FITTED


CHANGE N T0

T13

LOW
BATTERY
VOLTAGE

18

35

159

:6/:L3

157

:4/:L1

19

36

F32
(2A)

157

154

F33
(2A)

159

156

TERM. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

L2

T3

L3

43

37

EF1

10

A1

38

EF2

22

12

24

21

`EFU'
A2
BENDER
EARTH FAULT RELAY

30

11

30

14

73

31

(FRONT)
TERM. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

CONNECTION DESCRIPTION
WIRE No. 10 (GSC RM39) & HORN +VE
WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK
JUMPER TO 10
JUMPER TO 11
NOT CONNECTED
NOT CONNECTED
WIRE No. 30 (GSC RM27) & SILENCE SWITCH
LOW FUEL LEVEL SWITCHED -VE INPUT
NOT CONNECTED
LED 7 (SPARE)
LED 8 (SPARE)
LAMP TEST -VE INPUT (IF REQUIRED)
SILENCE SWITCH
HORN -VE

(FRONT)

(REAR)

CONNECTION DESCRIPTION
WIRE No. 10 (GSC RM39) & HORN +VE
WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK
LED 5 SWITCHED -VE INPUT
LED 6 SWITCHED -VE INPUT
LED 7 SWITCHED -VE INPUT
LED 8 SWITCHED -VE INPUT
WIRE No. 30 (GSC RM27) & SILENCE SWITCH
LED 1 SWITCHED -VE INPUT
LED 2 SWITCHED -VE INPUT
LED 3 SWITCHED -VE INPUT
LED 4 SWITCHED -VE INPUT
LAMP TEST
SILENCE SWITCH
HORN -VE

NOTE ON SYNC MODULE:


FOR 208V SYSTEM 108 &
FOR 240V SYSTEM 108 &
FOR 300V SYSTEM 108 &
FOR 380V SYSTEM 108 &
FOR 400V SYSTEM 108 &
FOR 415V SYSTEM 108 &
FOR 480V SYSTEM 108 &
FOR 600V SYSTEM 108 &

(REAR)

CONNECTION DESCRIPTION
WIRE No. 10 (GSC RM39)
WIRE No. 90 (GSC 40 WAY No. 35) ALARM DATALINK
LED 5 SWITCHED -VE INPUT
LED 6 SWITCHED -VE INPUT
LED 7 SWITCHED -VE INPUT
LED 8 SWITCHED -VE INPUT
WIRE No. 30 (GSC RM27)
LED 1 SWITCHED -VE INPUT
LED 2 SWITCHED -VE INPUT
LED 3 SWITCHED -VE INPUT
LED 4 SWITCHED -VE INPUT
LAMP TEST -VE INPUT (IF REQUIRED)
TERMINAL No. 13 ON 1st ALARM MODULE
(ALM MUTE)
TERMINAL No. 14 ON 1st ALARM MODULE
(HORN ON)

TERM. No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14

110
110
110
110
110
110
110
110

SHOULD
SHOULD
SHOULD
SHOULD
SHOULD
SHOULD
SHOULD
SHOULD

BE
BE
BE
BE
BE
BE
BE
BE

CONNECTED
CONNECTED
CONNECTED
CONNECTED
CONNECTED
CONNECTED
CONNECTED
CONNECTED

DC NEG. 2

TO
TO
TO
TO
TO
TO
TO
TO

C18 Generator Set


with EMCPII, EMCPII+, and EMCP3
Electrical System

RESISTOR PIN D
RESISTOR PIN C
RESISTOR PIN B
RESISTOR PIN B
RESISTOR PIN B
RESISTOR PIN A
RESISTOR PIN A
SINGLE RESISTOR

ZKB1-UP
C6C1-UP
G4C1-UP
STM1-UP
STH1-UP (engine)

DC POS.
38

39

2
:5

22

3456

HORN

+
10

DC

:7 -

LINK

:11

SPARE FAULT INPUT (LED 8)


72

:8

SILENCE
SWITCH
ALARM
DATALINK

SPARE FAULT INPUT (LED 7)

:4

:1 +

30

HORN

LINK

:10

LOW FUEL LEVEL

10

90

17

:2

20

:12

:14

+
10

:1 +

30

:7 -

SILENCE
SWITCH

LAMP
TEST

:13

SPARE FAULT INPUT (LED 1)

:9

SPARE FAULT INPUT (LED 2)

:10

:12

HORN ON

SPARE FAULT INPUT (LED 3)

:11

DC

:13

LAMP TEST
(IF REQUIRED)

38

:8

SPARE SHUTDOWN INPUT (LED 5)

:4

SPARE SHUTDOWN INPUT (LED 6)

:5

SPARE SHUTDOWN INPUT (LED 7)

:6

SPARE SHUTDOWN INPUT (LED 8)

:2

90

17

FIRST
ALARM
MODULE

SPARE FAULT INPUT (LED 4)

:3

69

:14

10

:1 +

30

:7 -

68

:13

ALARM MUTE

:14

ALARM
DATALINK

ALARM DATALINK

17

DC

:13

90

:8

SPARE FAULT INPUT (LED 1)

:9

SPARE FAULT INPUT (LED 2)

:10

3456

ES-

:30

:87

23

:86
EPIR
:85

ETHER
START
SWITCH

:30

59

ASOR/1
:87

59
:86 AIR
ASOR
SHUT-OFF
:85 RELAY

:2

SPARE FAULT INPUT (LED 3)

SASV

SPARE FAULT INPUT (LED 4)


SPARE SHUTDOWN INPUT (LED 5)

:4

SPARE SHUTDOWN INPUT (LED 6)

:5

SPARE SHUTDOWN INPUT (LED 7)

:12

2
2

FV

-VE SUPPLY

-VE SUPPLY

ETHER
START
SWITCH

3 :2

13

:1

37

ACT+

:3

40

:1

59

ACTMPU-

44

NOTE:
IF CONTROL PANEL IS SGCP THEN
SWITCH IS MOUNTED REMOTELY.

28

MOT1

MPU+

10
11
12

MAGNETIC
PICK UP No.2

58

60

4
3
13

43

SASV
57

35

:2
:1

:3

14

42

8
1

59

MOT2

59

36

SPEED ADJUST
POTENTIOMETER
(2K W, 10 TURN)

LINK
WOODWARD
ELECTRONIC
LINK FUEL
GOVERNOR
(ISOCHRONOUS)

SATS

SPARE SHUTDOWN INPUT (LED 8)


38

37
(OPTIONAL)
FLAP
VALVE

23A

:2

:4

27

:3

20

(16A)

F27

ASOR+
:1 MAN
:2 AUTO

STD1-UP
PDH1-UP (engine)

EPIR/1

51

SPEED
LOWER/RAISE
SWITCH

:11

:6

10

SASV - START AID SOLENOID VALVE

:6
:3

3406C

27
68

ACTUATOR

:14

73

11

SP2

17

3406C

73

12

(REAR)

CONNECT TO ALARM MODULE


SPARE SHUTDOWN CHANNEL

(FRONT)

L1

T2

ALARM
SILENCE

T1

42

LAMP
TEST

ALARM
SILENCE

4 POLE BREAKER OPTIONAL


(SEE NOTE REF.A01)

CORE BALANCE
CURRENT TRANSFORMER

TO
BREAKER
BOX

T2
T3
N
E

SLR/2

LOW
COOLANT
TEMP

T1

RENR7934-02
October 2008

SLR/1

:A
:B
:C
:D
:E

23

LAMP TEST
(IF REQUIRED)

24

MOT1

MOT2

SASV - START AID SOLENOID VALVE


SATS - START AID TEMPERATURE SWITCH

-VE SUPPLY

Volume 2 of 3: EMCPII AND EMCPII+


GENERATOR
SYNCHRONIZING
MOTOR

Printed in U.S.A.

2008 Caterpillar
All Rights Reserved

ALTERNATOR TERMINAL BOX

PUMPED FUEL SUPPLY FROM BELOW FLOOR LEVEL BULK TANK TO BASETANK
FUEL SYSTEM No. 1

D
+

74

P
+

E
7

S
2

75

D
+

74

30

S
2

30

30

75

6 mm 2

6 mm 2
:3

:5

HC
:A2

:14

:2

:4

:6

202

203

10
142
9
NOTE A

131

CONSTANT
VOLTAGE CHARGER

7
+

75
30

30

TO
STARTER
MOTOR

131
140

13

10

NOTE A

143

131

205

ENGINE
JACKET
WATER
HEATER

75

75

14

32

75

75

206

148

:X2

16

74

74

13

6 mm

132

SP1
25

74

74

CONNECT TO ALARM MODULE SPARE ALARM CHANNEL

12

F17
(6A)

F16
(2A)
136

131

F19
NOTE:A

F18
(4A)
135

6 mm

131

T2

:A1

BATTERY CHARGER
& HEATERS

T3

131

135
:1

O/L 1

13

14

97

141

:3

:5

:4

:6

23
2 .5 mm

10

208
PUMP
STOP

23

ALREADY
FITTED AS
STANDARD

205

:9

81

SW3

PUMP
RUN

NORMALLY OPEN

SW2

83

SW1

PR
:10

NORMALLY CLOSED

204

208 211 131

A1

A2
131

NORMALLY CLOSED

NORMALLY CLOSED

13

84

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

:6
PR/2
:7
36

85

14

O/L 1

97

:2
MV
:1 MOT.

95

98

-VE SUPPLY

23
2 .5 mm

131

:3
PR/1
:1
20

81

81

83

96

2 .5 mm

:2

PR
:10

:A2

:2

131

131

140

WHITE

RED
P
+

- 3

164

164

S
2

NOTE:

D
+

71

(*)
2

140

131

131

131

ENGINE
JACKET
WATER
HEATER

36

ALTERNATOR
HEATER

6 mm

F15

2 .5 mm

+ 1
24V DC
SUPPLY

163

NOTE:A
IF 120V
IF 230V
IF 120V
IF 230V

JACKET WATER
JACKET WATER
BLOCK HEATER
BLOCK HEATER

24V

COPPER BUSBAR

F17
(6A)
136

131

T2

137

33

76

14

132

131

:A2

71

10

SP1
+ 1
1

71

71

CONNECT TO ALARM MODULE SPARE ALARM CHANNEL


- 3

F15

36

NOTE: ADD FUSE F41,


REMOVE LINK AND
CONNECT WIRE 111A
TO 3RD PHASE IF
VOLTAGE IS 240V L-L

135

131

:1

:1
:3
UVT/1

107

111A

POWER SUPPLY
REF. B03 BREAKER
DRAWING

117

SW1

NORMALLY CLOSED

POWER
WIRING FROM
GENERATOR

:4

:6

107

LINK

402A

:6

:7

OPEN SIGNAL
REF. C03
BREAKER DRAWING

402

BAR/2

NEUTRAL REF. C03


BREAKER DRAWING

2
5

:5

:1

T2

L2

T3

L3

SW2

SW1

LOW

LOW
LOW

CABLE

SW3

45

CONNECT TO ALARM MODULE SPARE ALARM CHANNEL


1

1 F23

:3

159

CLOSE SIGNAL
REF. C03 BREAKER
DRAWING

159

BCR/1

LEVEL SWITCH
(TOP VIEW)

30

84
HIG
HIG HH

H
HIG

17

72
72

11

72

F40

178B

:1

178

:3

LEVEL SWITCH
(SIDE VIEW)
ST

24V DC
SHUNT
TRIP

CONNECT TO ALARM MODULE SPARE ALARM CHANNEL


SW1

65

72

30

LOW
LEVEL
FUEL
SWITCH

LOW
FUEL
LEVEL
SWITCH

TERMINAL BOX

:C2

REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

B
B
B

233

:14

231

:12

232

72

:11

SW4

157

SW1

NORMALLY CLOSED

CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL

158

20

T1

L1

FUSED DC
POSITIVE

410
COPPER BUSBAR

26

F31
(2A)
157

220

F32
(2A)
411

158

F16

30

F18
(4A)

412

6 mm

136

F19
NOTE:A

131

6 mm

141

D-

14

31

131

12

22

56

T2

L2

T3

L3

LOW-LOW
FUEL
LEVEL
SWITCH

51

52

16

TERMINAL BOX

36

LEVEL SWITCH
(SIDE VIEW)

85
:2
MV
:1 MOT.
VALVE

TERMINAL BOX

:2

PR
:10

-VE SUPPLY

54

MODE/
CLEAR
SWITCH
`MCS'

:3
:2

:1

:3 :6
:2

:4

:5

BREAKER
OPEN

REF.
B05

BREAKER
CLOSED

REF.
B05

:C11
ST

24V DC
SHUNT
TRIP

:C12

29

2
REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

55

HARNESS CODE 18

6 mm
141

99

31

SCROLL
SWITCH
`SS'

57
53

99

B
B
B

231

:11

:12

233

:13

:14

232
BREAKER
AUXILIARY

ABB ACB

134

Q/1

31

35

46

54

Q/2

Related Electrical Service Manuals


9

11

:13
BKRR
:14

:A1

:3

:5

54

:A2

:4

:6

:3
BAR/1
:1

416

46

:6

426

47

:11

414

437

48

217
14

218
15

:1

:13
BUSR
:14

NOTE:
IF NO ALARM MODULE FITTED THEN
RELAY WILL ACTIVATE ON SHUTDOWN ONLY.

SECONDARY
120V AC L-L

:5
8

ALTERNATOR
HEATER

415

ENGINE
JACKET
WATER
HEATER

131

131

6 mm

SYNCHRONIZE
SWITCH

139
19

:14 :13 :15

142
20

:4 :5 :8 :10

16

221

131

2 .5 mm

219

BLACK/WHITE

30

131

ORANGE

30

NOTE
PT PRIMARY WIRE COLORS
- WHITE
= 240V AC
- GREEN
= 380V AC
- BROWN
= 480V AC
- RED
= 600V AC
- BLACK
= COMMON

38

NOTE:A
IF 120V
IF 230V
IF 120V
IF 230V

JACKET WATER
JACKET WATER
BLOCK HEATER
BLOCK HEATER

HEATER IS
HEATER IS
IS FITTED
IS FITTED

FITTED FUSE F19


FITTED FUSE F19
FUSE F19 SHOULD
FUSE F19 SHOULD

SHOULD BE 30A
SHOULD BE 16A
BE 16A
BE 10A

:2
GRR
:10

GRR/3
:8

:9

6
:11
87
32

BKRR/1

88
33

89

:2
ALR
:10

34

REMOTE CONTACTS
FOR GENERATOR RUNNING

2
3

ALR/3
:8

26

:11

:9

64

65
30

:4
BKKR/4
:12

66
31

REMOTE CONTACTS
FOR GENERAL ALARM

24
37

25

31

26A

:3

:9
:11

29

SP4

146

BKRR/3

19

29
38

30
8

145
41

:9
BUSR/1
:1

:2
ALR
:10

144
40

AUXILIARY CONTACTS
REF. A03 BREAKER
DRAWING

REF.
B02

54A
:10
BAR
:2

:2
GCR
:10

10

REF.
A02

18

HC

98

Title
54

REF.
G08

HIG

:7

17

23 SRV

33 CLR

CATERPILLAR
MONITORING
SYSTEM
2

137

32

EMSII

D+

46

DC NEGATIVE

2 .5 mm

6 mm

HEATERS

BLACK

B12

412
WHITE

B11

411

F37
(2A)

GREEN

J1-1 J1-2 J1-3 J1-4


217
218
98

B22

RED

BREAKER
CLOSE

REF.
B02

131

B2

B1
B21
F36
(2A)

CUSTOMER
100V TO 250V
AC SUPPLY

31

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

CR/1
:1

LINK

BROWN

219

BUS
TRANSFORMER
BOX
(BTB+)

CAT
DATA
LINK

45

10

134

:4
BREAKER
OPEN

132

HC5

158

HC4

HC3

157

HC1

HC2

:2
BCR
:10

REF.
B02
REF.
E04

POWER
WIRING FROM
GENERATOR

LOW

:6

4 POLE BREAKER OPTIONAL


(SEE NOTE REF.A02)

111

410

HC0

ENTRY

SP2

30

10

30

SW3

PR/2

REF. CO5 BREAKER DRAWING


6

SW2

35
17

72
NORMALLY CLOSED

10

:3
PR/1
:1

HIGH
LEVEL
FUEL
SWITCH

65

NORMALLY CLOSED

SW2

72

21

83

131

111

11

LOW
LOW

84

30

NORMALLY OPEN

64

ABB MCCB

:2
UVT
:10

17

72

BREAKER
AUXILIARY

UV COIL SUPPLY
REF. C03 BREAKER
DRAWING

178

2CR/1

FOR 5A CHARGER FIT (6A) FUSE


FOR 10A CHARGER FIT (10A) FUSE

CABLE

SW4

10

30

64

SW3

107

DC CIRCUIT

(2A)

FUEL
LEAK
SWITCH

ENTRY

TERMINAL BOX

:C1

140
111

131

77

CR/2
117

111

26

28

GCR/1

178
F41
(6A)

(6A)

117

REF.
D10

117

REF.
F02

:2
131

117

IF REQUIRED

140

(*)

131

407

71

CONSTANT
VOLTAGE CHARGER

111B

:1

:A1

CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL

F42
(6A)

46

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

131

NOTE: IF VOLTAGE IS 240V L-L CONNECT 111A TO


3RD PHASE, FOR 480V USE TRANSFORMER

406
E

CUSTOMER
100V TO 250V
AC SUPPLY

HC

16

77

L1

T1

45

6 mm

BATTERY CHARGER
76

NORMALLY CLOSED

HIG
HIG HH

4 POLE BREAKER OPTIONAL


(SEE NOTE REF.A02)

T3

135

CR/1
:1
8

6 mm

6 mm

:4

15

30

T1

F16
(2A)

76

77

SW4

76

SHOULD BE 30A
SHOULD BE 16A
BE 16A
BE 10A

30

SW2

FUEL SYSTEM No. 2

131

LEVEL SWITCH
(TOP VIEW)

THERMOCOUPLE
RELAY

30

FITTED FUSE F19


FITTED FUSE F19
FUSE F19 SHOULD
FUSE F19 SHOULD

76
30

HEATER IS
HEATER IS
IS FITTED
IS FITTED

IF 4 POLE BREAKER FITTED


CHANGE N
T0

FOR 5A CHARGER FIT (6A) FUSE


FOR 10A CHARGER FIT (10A) FUSE

2
E
-

NORMALLY CLOSED

139
19

142
20

CONSTANT
VOLTAGE CHARGER

RTD
PT100

NOTE:
WIRE DIRECTLY ONTO
RELAY TERMINALS.

SW3

GRAVITY FUEL SUPPLY FROM HIGH LEVEL BULK TANK TO BASETANK


FUEL SYSTEM No. 2

WT1

NORMALLY OPEN

SW4

HC

N1

163

LEVEL SWITCH
(SIDE VIEW)

TERMINAL BOX

21

HIGH
LEVEL
FUEL
SWITCH

ALREADY
FITTED AS
STANDARD

35

24

FUEL
PUMP

LOW
LEVEL
FUEL
SWITCH

VALVE

211 209 210

6 mm 2
46
131

PC

35

:2

131

204
:X1
PUMP
TRIP/
STOP
:X2

:X2

96

18

:95
O/L
:96
:X1

TERMINAL BOX

15

PR/3
:11

81

ENTRY

H
HIG

12

203

21

LEVEL SWITCH
(SIDE VIEW)

LOW

LOW
LOW

22

SW3

SW2

SW1

PUMP
RUN

205

SW4

95

98

2 .5 mm

20

84

AC SUPPLY
CUSTOMER
100V TO 250V

11
J

CABLE

SW4

24

131

24

FUEL
PUMP

134

:3
PR/1
:1

HIGH
LEVEL
FUEL
SWITCH

211 209 210

46

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

6 mm

137

2 .5 mm

T1

6 mm

ALTERNATOR TERMINAL BOX

A1

A2
131

131

203

HIG
HIG HH

16

TERMINAL BOX

21

LOW
LEVEL
FUEL
SWITCH

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

134

141

CR/1
:1

208 211 131

206

6 mm 2
46
131

PC

CUSTOMER
100V TO 250V
AC SUPPLY

:4

45

204

2 .5 mm

COPPER BUSBAR

74

131

204
:X1
PUMP
TRIP/
STOP
:X2

PUMP
RUN

ENTRY

202

TERMINAL BOX

18

:95
O/L
:96

12

207

202

:9

NOTE:A
IF 230V JACKET WATER HEATER IS FITTED MCB M2 SHOULD BE 16A
IF 230V BLOCK HEATER IS FITTED MCB M2 SHOULD BE 10A

CONNECT TO ALARM MODULE SPARE SHUTDOWN CHANNEL

13

LOW
LOW

:97
O/L
:98

H
HIG

15

PR/3
:11

20

LOW

:13
AUX
:14

12

203

21

ALTERNATOR
(GENERATOR)
HEATER

SW2

SW1

PUMP
RUN

202

E
-

84

AC SUPPLY
CUSTOMER
100V TO 250V

23

205

:X1
75

208
PUMP
STOP

SW3

CABLE

LEVEL SWITCH
(TOP VIEW)

ALREADY
FITTED AS
STANDARD

SW4

24

11

139
19

D
+

74
30

:1

:97
O/L
:98

HIG
HIG HH

16

22

P
+

:13

192

2
E
-

:A1

F21
(6A)
84

13

207
M

:13
AUX
:14

F22
(2A)

84

13

138

AC CIRCUIT

DC CIRCUIT

SP3

Form Number

EMCPII Troubleshooting/
Systems Operation / Testing and Adjusting

RENR2483

EMCPII+ Troubleshooting/
Systems Operation / Testing and Adjusting

RENR2484

SW4

NORMALLY OPEN

SW3

NORMALLY CLOSED

SW2

NORMALLY CLOSED

SW1

NORMALLY CLOSED

(Dimensions: 39 inches x 28 inches)

134

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6mm 2 TERMINALS.

6 mm 2

LEVEL SWITCH
(TOP VIEW)

84

6 mm 2
45
132

30 Page,

S
-

191

147

141

138

(2A)

COPPER
BUSBAR

ALREADY
FITTED AS
STANDARD

P
+

182

137

134

F21
(6A)

24V

147

181

CR/1
:1

BATTERY CHARGER 140


& HEATERS
(120V Charger,
240V Heaters)

141

6 mm 2

172

:4

F22
(2A)

6 mm

3
2

171

136

:5

AC CIRCUIT

6 mm 2
45
132

2 .5 mm

NOTE:
WIRE DIRECTLY ONTO
RELAY TERMINALS.

135

CR/2
:6

WHITE

RED

RED

RED

RTD
PT100

WHITE

RTD
PT100

WHITE

RTD
PT100

2 .5 mm 2

BT3

2 .5 mm 2

BT2

14

1 F23

DC CIRCUIT

84

(2A)

COPPER
BUSBAR

NOTE A

AC CIRCUIT

1 F23

M2
NOTE:A
MCB

M1
2P 6A
MCB

F16
(2A)

2 .5 mm 2

BT1

F17
(10A)

AC CIRCUIT

120

AC SUPPLY
(AC TERMINAL
RAIL)

6 mm

131

240
18

133

2 .5 mm

6 mm 2

CUSTOMER
100V TO 250V
16

132

N1

6 mm 2

2 .5 mm

COPPER BUSBAR

T3

mm
2.5

FUEL PUMPED FROM FREE STANDING BULK TANK


FUEL SYSTEM No. 3

mm
2.5

T2

RENR7934-02 VOL 2 of 3

T1

40

REF.
4
DK

10

REF.
2
D-8

REF.
31
E-3

D+

REF.
32
E-2

D-

65

ATA-

39

REF.
ENGINE SCHEMATIC
VOL1

64

ATA+

METERING C.T.s

G
E

T1

P1

P2

T2

S1
P1

S2
P2

CT1

T3

S1
P1

S2
P2

CT2

S1

S2

CT3

L1

L2

10

L3

11

12

E
13

71

17

72

31

73

25

74

32

75

SERVICE CONNECTOR
41

51

SCR

SPEED
ADJ. POT.
(1K ohm, 10T)

:x
:x

EMCPII

:x

82

:1

98

:2

REF.
D-2

50

50

T1

T2

T3

101

14

93

:2
EMCPII+

10

13

12

14

28

92

82
34

80

80

35

44

82

SPEED
CONTROL

36

43

33

91

15

52

53

50

LINK

AC TRANSFORMER BOX
(ATB)

J1-3

92

51

J1-4

93

50

J1-5

94

REF.
C-9

J1-6

95

94

J1-7

96

95

:1

50

1. IF THE FAULT SHUTDOWN INDICATOR IS


FLASHING THEN THE LINK SHOULD BE
TEMPORARILY FITTED.
THE GSC SETPOINTS
MUST BE PROGRAMMED IN OFF/RESET WHEN
A FAULT SHUTDOWN IS ACTIVE.
IF THE
FAULT ALARM INDICATOR IS FLASHING THE
GSC CAN BE PROGRAMMED WITH THE CONTROL
SWITCH IN ANY POSITION.

J1-8

16

97

96

(1K ohm , 1 TURN)

98

(EMCPII)

97

:3

82

80

80

:3

53

VOLTS ADJUST
POTENTIOMETER

:2
:3

52

33

76

71

72

73

74

LINK

LINK

T1

T2

T3

H23
F11
(2A)

H21
F12
(2A)

H22
F13
(2A)

101

101

110

110

28

57

MOT1

58

MOT2

63

KWR/3

:8

T12

109

109

T11

108

108

J1-1

42

:9

EMCPII

26

:11

47

EMCPII

48

42

27

84

EMCPII

T13

J1-2

91

16

18

81

49

7
EMCPII

50

REMOTE CONTACTS
FOR KW LEVEL

76

EMCPII

81

84

51
EMCPII

52

56

EMCPII

D +B -B

29

OFF/RESET
S-SPD

30

10

D-SPD

57

REF.
C-5
30

31

REF.
C-3

:8
AUTO
START
:9
COOLDOWN/STOP :10

:6

D+

CONTROL
MODE SWITCH
REF.
C-2

32

P2/2

35

EMCPII+

13

EMCPII+

37

SEE NOTE A

EMCPII+

EMCPII+

EMCPII+

27

25

26

18

20
EMCPII+

17

61

15

99

63

35

15

217

32

31

CCM+

218
P

52

EMCPII+

18

61

50

CCM-

51

REF.
F-8

RDM

17

99

90

EMCPII+

REF.
F-8

19

D-

B+
POST

RM

RM

RM

RM

RM

RM

RM

RM

RM

31

35

30

33

32

34

36

RM

46

47

416

63

F6
(10A)

F3
(10A)

F1
(10A)

CTR

RM

RM

RM

RM

FCR

RR

RM
12

F7
(10A)

F5
(10A)

RM
5

35

KW

36

ALARM

18

SPARE

D+

20
D+

48

426

RR

15

EMCPII+

GFR
F10
(10A)

SET OP6 SETPOINT SP17 TO 6


SET OP6 SETPOINT SP18 TO 7

ASR

21

37

EMCPII+

21

23

24

RDM

CCM-

19

30

22

EMCPII+

EMCPII+

EMCPII+

20

RDM

CCM DATALINK

EMCPII+

20

D-

LOW OIL PRESSURE


EMERGENCY STOP
HIGH WATER TEMPERATURE
ENGINE OVERSPEED
LOW COOLANT LEVEL
OVERCRANK
FAULT SHUTDOWN
FAULT ALARM

97

16

94

93

12

RM

RM

RM

RM

RM

27

15

24

17

16

13

14

28

(Dimensions: 39 inches x 28 inches)

REF.
F-8

30 Page,

RENR7934-02 VOL 2 of 3

RM

GPLO
RM

13

39

38
39

37

15

20

41

11

30

38

23

24

38

17

RM

RM

RM

18

21

39

42

38

38

11

20

41

30

17

34

50

27

28

29

27

11

REF.
F-6

25

26

RM

33

5
34

ASOR+

SD-PWR

SD-RTN

23A

ASOR+

39

SD-RTN

37

44

LCL
13

EMCPII

62

15

16

67

6
39

23

24

25

29

SP1

SP2

SP3

SP4

40

41

42

55

43

40

33

56

40

54

55

21

34

56

44

37

36

49

57

60

22

SP1

61

16

62

SP2
17

63

SP3
18

:2
:3
:4
:5

SP4
19

REF.
E-7
D-7

EMCPII+

30
6

62

66

67

16

15

67

62

18

67

62

67

19

OFF/RESET
AUTO
START
COOLDOWN/STOP

MOT2

SP4

26A

70A

RDM

CCM+

CCM-

16

22

PANEL
LIGHTS

37

25

EMCPII

26

EMCPII

18

EMCPII

:3
PANEL LAMP SWITCH
:2

25

EMCPII

26

EMCPII

27

EMCPII

EARTH

:1

:2
:3
:4
:5

11

ENGINE CONTROL SWITCH

117

202

203

205

207

131

117

217

220

10

35

402

108

110

157

159

218

220

402

108

110

157

159

10

11

12

CIRCUIT BREAKER
13

14

EMCPII

15

EMCPII

:2
:3

:1

POTENTIOMETER

16

11

CHASSIS CUSTOMER TERMINAL

11

CHASSIS DC TERMINAL

CHASSIS AC TERMINAL

28

DOOR TERMINAL

17

18

37
7

30

CHASSIS TO DOOR DC SOCKET

ENGINE SOCKET

30

57

CHASSIS TO DOOR AC SOCKET

38

ES-

EF1

59

EF2

POWER TERMINAL

4
12

REMOTE
START
CONTACT
8

:2
ASOR+

23A

2
11

12

SD-RTN

SD-PWR

51

52

ASOR+

51

REF. ENGINE
SCHEMATIC VOL1

NOT CONNECTED

REF. ENGINE SCHEMATIC VOL1

23A

53

EMCPII+

52

GSC RELAY MODULE TERMINAL

SD-RTN

SD-PWR

REF.
D-2

CR
1
2

GSC 40 WAY HARNESS CONNECTOR

30

:10

RELAY CONTACT N/O

:3

62
30

54

R/1

EMCPII

57

P1/2 REF.
E-5

30

31

19

:1

58

SCR

24

CONTROL MODE
SWITCH

BODY

SCREEN CABLE

23

58

:1

59

21

19

18

REF.
E-7

53

32

DOOR

37

EMCPII+

22

59

:2

45

CHASSIS

41

29

SD-PWR

37

36

10

23A

43

LOP

131

EMCPII

91

22

EMCPII

28

EMCPII+

TRANZORB

20

:3

10

EMCPII+

22

REF.
F-4
REF.
F-2

46

25

:9

EMCPII

45

26A

CR/3

EMCPII

REF.
F-8

45

:11

EMCPII

PANEL
LIGHT
SWITCH

EMER.
STOP

EMCPII+

HET

V+
31

10

EMCPII+

V-

21

26A

14

REF.
C-3

207

AUX. ALARMS/SHUTDOWNS
SWITCHED -VE
POST
B-

92

19

GPHI
RM

205

95

10

EGR

203

EMCPII

EMCPII

RM

EMCPII+

15

30

96

EMCPII+

19

REF.
B-3

98(EMCPII)

17

202

D+

DATA LINK

GENERATOR SET CONTROL (GSC)

LOW OIL PRESSURE


EMERGENCY STOP
HIGH WATER TEMPERATURE
ENGINE OVERSPEED
OVERCRANK
(SPARE 1)
LOW COOLANT LEVEL
HIGH OIL TEMPERATURE
(SPARE 2)
SPARE 3
FAULT SHUTDOWN
FAULT ALARM

19

D-

437

26

EMCPII+

SPARE

GENERATOR SET CONTROL (GSC+)

RM
9

RM
7

17

SPARE

SMR

SMR

CTR

F4
(10A)

34

23

FCR
F2
(10A)

EMCPII+

RELAY COIL

:2

21

21

EMCPII+

CCM+

EMCPII+

14

EMCPII+

14

14

90

43

46

22

:10

13

D-

:2
EMCPII+
KWR
:10

36
1

EMCPII+

48

67

PANEL LAMP
12

29
MOT1

EMCPII+

REF.
ENGINE SCHEMATIC
VOL1

11

R
75

55

EMERGENCY STOP PUSHBUTTON

10

24

(1K ohm, 10 TURN)

:1

FUSE

4 POLE BREAKER OPTIONAL

ATA+

29

22

ATA-

30

23

12
6

53

47

11

10

15

REF. ENGINE
SCHEMATIC VOL1

NOT CONNECTED
EMCPII

30

20

41

46

65

30
25

17
48

34
49

45
17

46
50

10
7

ES27

21

59

28

59

31

22
32

33

62T

67T

42

43

REF. ENGINE SCHEMATIC VOL1

REF. ENGINE SCHEMATIC VOL1

16

15
14

13

67P

62P

44

45

18
20

67L

62L

21

19

NOT CONNECTED

19
23

67O

62O

EF1

EF2

D-

D+

22

61

62

24

ATB TERMINAL
5

REF. ENGINE SCHEMATIC VOL1

EMCPII+

EMCPII

NOT CONNECTED
EMCPII

ANALOG VOLTAGE REGULATOR


DIAGRAM
(3 PHASE SENSING)
NOTE:A

AREP

ST3

10/YELLOW

50Hz

60Hz

60 HZ VOLTAGE WYE
480/277V - (T2 380)
440/254V - (T2 380)
380/220V - (T2 380)
240/139V - (T2 220)
220/127V - (T2 220)
208/120V - (T2 220)
600V
- (T2 220)

(T1,T2&T3
(T1,T2&T3
(T1,T2&T3
(T1,T2&T3
(T1,T2&T3

60 HZ VOLTAGE WYE
480/277V - (T1,T2&T3
440/254V - (T1,T2&T3
380/220V - (T1,T2&T3
240/139V - (T1,T2&T3
220/127V - (T1,T2&T3
208/120V - (T1,T2&T3
600V

R448

ST6

AREP

16

NOTE:C

380

T1
S1 S2

J1

1
4

S2

S1
STATISME
P2
S2

470ohm
POT
TENSION
P1

P1

STABILITY ADJUST
P3
W

VOLTAGE ADJUST
P2

ALTERNATOR
WINDING
CONNECTIONS

NOTE:I

W
N

110

230

110

400

400

230

230

110

400

4
2
1

415/240V
400/230V
380/220V
220/127V
600V

NOTE:A
50/60 Hz SELECTION

(T2
(T2
(T2
(T2
(T2

380)
380)
380)
220)
220)

9/GREEN

14

X2

PMG

15

X1

16

Z2

X1

E+

R448

ST6

E-

ST9

NOTE:E

NOTE:F
3ph

BLACK

POT
470ohm

T1
S1 S2

NOTE:G
3

220

NOTE:C

380

RFI UNIT
ALTERNATOR
WINDING
CONNECTIONS

60 HZ VOLTAGE WYE
480/277V - (T2 380)
440/254V - (T2 380)
380/220V - (T2 380)
240/139V - (T2 220)
220/127V - (T2 220)
208/120V - (T2 220)
600V
- (T2 220)

BLACK

ALTERNATOR
WINDING
CONNECTIONS

(+) BATTERY
(+) BATTERY SWITCHED

STARTING CIRCUIT
N

(-) BATTERY / SENSOR RETURN

SIGNAL PLUS TO ECM


SIGNAL MINUS TO ECM

NOTE:A
50/60 Hz SELECTION

S2
S1

NOTE:B
REMOVE LINK FOR REMOTE VOLTAGE ADJUSTMENT POTENTIOMETER
NOTE:C
REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V)
NOTE:D
ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK NOTE:E
ST9 - AREP AND SHUNT - FULL LINK - . PMG SPLIT LINK NOTE:F
ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT
NOTE:G
FIT 5VA TRANSFORMER FOR 600V OPERATION
NOTE:H
OPTION TI04 FOR PARALLEL OPERATION.

P2

TI04

SENSOR / ACTUATOR SUPPLY

NOTE:H

P1
N

BLACK

P1
QUADRATURE DROOP ADJUST

AIR SHUT-OFF RELAY


AC TRANSFORMER BOX
CONTROL RELAY
CRANK TERMINATION RELAY
ELECTRONIC GOVERNOR RELAY
FUEL CONTROL RELAY
GROUND POST HIGH
GROUND POST LOW
GENERATOR SET CONTROL
HIGH ENGINE TEMPERATURE
HIGH OIL TEMPERATURE
KILOWATT
LOW COOLANT LEVEL
LOW OIL PRESSURE
POTENTIOMETER
SCREEN
STARTER MOTOR RELAY

BLUE

J1

J2

ST4

ASR
ATB
CR
CTR
EGR
FCR
GPHI
GPLO
GSC
HET
HOT
KW
LCL
LOP
POT
SCR
SMR

OPTIONAL RFI KIT CONNECTIONS

CONNECTION
TO EXCITER

NOTE:D

ST1

X1

NOTE:B

NOTE:C
REFERENCE TABLE 2 FOR CONNECTION BETWEEN ALTERNATOR AND R731
NOTE:D
ST6 - 5000 AND 6000 ALTERNATOR FRAME SIZES FULL LINK. 7000 FRAME SIZE REQUIRES SPILT LINK.
NOTE:E
ST9 - AREP AND SHUNT - FULL LINK. PMG SPLIT LINK.
NOTE:F
ST1 - FULL LINK. FOR 3 PHASE SENSING LINK MUST BE SPLIT.

9/GREEN
X2

1/2 PHASE
T1- T4 OR
T8 - T11

Z2

ST2

50 HZ VOLTAGE WYE

NOTE:H

10/YELLOW

12/BLACK

TABLE: 1

NOTE:G
REMOVE FOR OPTIONAL VOLTAGE ADJUST POT.
NOTE:H
OPTION TI04 FOR PARALLEL OPERATION. WITHOUT 3 PHASE SENSING CONNECT TO S1 AND S2 ON R448 ONLY. STANDARD POSITION ON PHASE U.
FOR CT PARALLEL OPERATION ON PHASE V - MODIFY R731 VOLTAGE SENSING AS FOLLOWS - U(R731) -> V(ALT) . V(R731) -> W(ALT) . W(R731) -> U(ALT).
NOTE:I
FIT 2 x 5VA TRANSFORMERS FOR 600V OPERATION

10A FUSE

110

X2

SUPPLY STATOR PMG

Z1

NOTE:B
REFERENCE TABLE 1 FOR CONNECTION BETWEEN ALTERNATOR (V) AND R448

BLUE

P2

TI04

S1

R731
U

RFI UNIT

BLACK
BLACK

NOTE:G

BLACK

P1
QUADRATURE DROOP ADJUST

380)
380)
380)
220)
220)
220)

OPTIONAL RFI KIT CONNECTIONS

ALTERNATOR
WINDING
CONNECTIONS

J2

ST4

60Hz

EXCITATION CEILING ADJUST


P5

SUPPLY 140V MAX 50/60HZ

11/RED

UNDER SPEED ADJUST


P4

220

ST9

NOTE:E

POT
470ohm

3ph

NOTE:B

NOTE:D

380)
380)
380)
220)
220)

10/YELLOW

50Hz

CONNECTION
TO EXCITER

PMG

SHUNT

SUPPLY - AUXILIARY WINDING

J3

E-

- (T1,T2&T3 220)

Z2

PMG

15

ST3

E+

NOTE:F

50 HZ VOLTAGE WYE

X1

14

X1

ST1

415/240V
400/230V
380/220V
220/127V
600V

X2

Z2

ST2

TABLE: 2

380)
380)
380)
220)
220)

9/GREEN

1/2 PHASE
T1- T4 OR
T8 - T11

NOTE:A

110

(T2
(T2
(T2
(T2
(T2

10/YELLOW

12/BLACK

VOLTAGE ADJUST
P2

SUPPLY STATOR PMG

Z1

STABILITY ADJUST
P3

50 HZ VOLTAGE WYE

X1

X2

UNDER SPEED ADJUST


P4

415/240V
400/230V
380/220V
220/127V
600V

X2

9/GREEN

10A FUSE

EXCITATION CEILING ADJUST


P5

TABLE: 1

SUPPLY 140V MAX 50/60HZ

11/RED

J3

ANALOG VOLTAGE REGULATOR


DIAGRAM
(SINGLE PHASE SENSING)

PMG

SHUNT

SUPPLY - AUXILIARY WINDING

ABBREVIATIONS

CAT DATA LINK


J1939 DATA LINK

OR FOR 3 PHASE SENSING.


AND R448
. 7000 FRAME SIZE REQUIRES SPILT LINK - - -

This schematic is for the C18 Generator Set


S/N: ZKB
G4C
STM
C6C
STD
Part Number 247-5088 DK01 (EMCP II+)
Part Number 247-5087 DK02 (EMCP II)

RENR7934-02
October 2008

SPN
38
52
82
94
95
96
98
99
100
101
105
107
108
110
111
137
158
167
168
171
172
173
174
175
176
190
441
442
612
625
628
639
701
702
703
704
705
706
707
708
709
710
711
712
713
714
715
716
970
971
1122
1123
1124
1125
1126
1131
1132
1133
1135
1137
1138
1139
1140
1141
1142
1143
1144
1145
1146
1147
1148
1149
1150
1151
1152
1153
1154
1155
1156
1157
1158
1159
1160
1161
1162
1163
1164
1165
1166
1167
1172
1173
1174
1175
1180
1181
1182
1183
1184
1185
1186
1187
1212
1231

RTD MODULE

RTD
TERMINAL
STRIP

40-PIN CONNECTOR
RTD #1 - H
RTD #1 - M
RTD #1 - L
RTD #1 - GND
RTD #1 - SHIELD
RTD #2 - H
RTD #2 - M

11

RTD #2 - SHIELD

15

RTD #3 - H

21

RTD #3 - M

22

RED

181

WHITE

RED

191

24

RTD #3 - SHIELD

25
31

RTD #4 - M

32

RTD #4 - L

33

RTD #4 - GND

34

RTD #4 - SHIELD

35

RTD #5 - H

RTD #5 - M

RTD #5 - L

RTD #5 - GND

RTD #5 - SHIELD

10

RTD #6 - H

16

RTD #6 - M

17

RED

163

WHITE

RTD #7 - H

26

RTD #7 - M

27

RTD #7 - L

28

RTD #7 - GND

29

36

RTD #8 - M

37

RTD #8 - L

38

RTD #8 - GND

39

RTD #8 - SHIELD

40

55

BATT(-)

CAN_H

304

INPUT #6

12

305

INPUT #7

22

306

INPUT #8

32

307

INPUT #9

308

INPUT #10

13

309

INPUT #11

23

310

INPUT #12

33

311

INPUT COMMON #1

312

INPUT COMMON #2

14

313

INPUT COMMON #3

24

314

INPUT COMMON #4

34

315

OUTPUT #1 (N/O)

316

OUTPUT #1 (N/C)

317

OUTPUT #1 (COM)

318

OUTPUT #2 (N/O)

17

319

OUTPUT #2 (N/C)

15

320

16

OUTPUT #2 (COM)

16

321

THERMOCOUPLE #12

27

OUTPUT #3 (N/O)

27

322

THERMOCOUPLE #12

25

OUTPUT #3 (N/C)

25

323

THERMOCOUPLE #13

26

OUTPUT #3 (COM)

26

324

THERMOCOUPLE #13

37

OUTPUT #4 (N/O)

37

325

THERMOCOUPLE #14

35

OUTPUT #4 (N/C)

35

326

THERMOCOUPLE #14

36

OUTPUT #4 (COM)

36

327

THERMOCOUPLE #15

10

OUTPUT #5 (N/O)

10

328

THERMOCOUPLE #15

OUTPUT #5 (N/C)

329

THERMOCOUPLE #16

OUTPUT #5 (COM)

330

THERMOCOUPLE #16

20

OUTPUT #6 (N/O)

20

331

THERMOCOUPLE #17

18

OUTPUT #6 (N/C)

18

332

THERMOCOUPLE #17

19

OUTPUT #6 (COM)

19

333

THERMOCOUPLE #18

30

OUTPUT #7 (N/O)

30

334

THERMOCOUPLE #18

28

OUTPUT #7 (N/C)

28

335

THERMOCOUPLE #19

29

OUTPUT #7 (COM)

29

336

THERMOCOUPLE #19

40

OUTPUT #8 (N/O)

40

337

THERMOCOUPLE #20

38

OUTPUT #8 (N/C)

38

338

THERMOCOUPLE #20

39

OUTPUT #8 (COM)

39

339

BATT(+)

55

BATT(-)

CAN_H

CAN2 +

CAN_L

CAN2 -

SHIELD

SHIELD

343

114

THERMOCOUPLE #3

344

115

THERMOCOUPLE #3

12

345

THERMOCOUPLE #4

22

346

THERMOCOUPLE #4

32

347

116

THERMOCOUPLE #5

348

117

THERMOCOUPLE #5

13

349

THERMOCOUPLE #6

23

350

THERMOCOUPLE #6

33

351

THERMOCOUPLE #7

352

119

THERMOCOUPLE #7

14

353

120

THERMOCOUPLE #8

24

354

121

THERMOCOUPLE #8

34

355

THERMOCOUPLE #9

356

THERMOCOUPLE #9

357

122

THERMOCOUPLE #10

358

123

THERMOCOUPLE #10

17

359

THERMOCOUPLE #11

15

THERMOCOUPLE #11

8-PIN CONNECTOR
BATT(+)

INPUT #5

31

30

RTD #8 - H

303

THERMOCOUPLE #2

19

RTD #6 - SHIELD

31

113

18

20

INPUT #4

342

RTD
PT100
164

302

21

118

WHITE

21

THERMOCOUPLE #2

RTD
PT100
192

INPUT #3

341

RTD
PT100
182

301

11

23

RTD #3 - GND

RTD #7 - SHIELD

WHITE

300

11

THERMOCOUPLE #1

12

14

RTD #6 - GND

172

INPUT #2

340

RTD
PT100

40-PIN CONNECTOR
INPUT #1

124

CHANNEL1 DEFAULT SPN='EXHAUST GAS PORT 1 TEMP'

125
126

CHANNEL2 DEFAULT SPN='EXHAUST GAS PORT 2 TEMP'

127
128

CHANNEL3 DEFAULT SPN='EXHAUST GAS PORT 3 TEMP'

129
130

CHANNEL4 DEFAULT SPN='EXHAUST GAS PORT 4 TEMP'

131
132

CHANNEL5 DEFAULT SPN='EXHAUST GAS PORT 5 TEMP'

133
134

CHANNEL6 DEFAULT SPN='EXHAUST GAS PORT 6 TEMP'

135
136

CHANNEL7 DEFAULT SPN='EXHAUST GAS PORT 7 TEMP'

137
138

CHANNEL8 DEFAULT SPN='EXHAUST GAS PORT 8 TEMP'

139
140

CHANNEL9 DEFAULT SPN='EXHAUST GAS PORT 9 TEMP'

141
142

CHANNEL10 DEFAULT SPN='EXHAUST GAS PORT 10 TEMP'

143

8-PIN CONNECTOR

8-PIN CONNECTOR
BATTERY POSITIVE(12-24V DC)

CAN2 +

CAN_L

CAN2 -

SHIELD

SHIELD

BATTERY NEGATIVE (12-24VDC)

62

J1939 DATA LINK - HIGH

63

J1939 DATA LINK - LOW

64

BATT(+)

55

BATT(-)

CAN_H

CAN1 +

CAN_L

CAN1 -

SHIELD

SHIELD

5
2

DISCREET I/O MODULE

THERMOCOUPLE
TERMINAL
STRIP

THERMOCOUPLE #1

112

13

RTD #6 - L

40-PIN CONNECTOR

RTD #2 - GND

RTD #4 - H

RED

171

THERMOCOUPLE MODULE

RTD #2 - L

RTD #3 - L

18

BATTERY POSITIVE(12-24V DC)

BATTERY NEGATIVE (12-24VDC)


29
27

J1939 DATA LINK - HIGH


J1939 DATA LINK - LOW

31

72

INPUT 1 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW WARNING'

73

INPUT 2 DEFAULT SPN='PRIMARY FUEL TANK LEVEL LOW SHUTDOWN

74

INPUT 3 DEFAULT SPN='COOLANT LEVEL LOW WARNING'

75

INPUT 4 DEFAULT SPN='COOLANT LEVEL LOW SHUTDOWN'

76

INPUT 5 DEFAULT SPN='AIR SHUTOFF DAMPER CLOSED'

77

INPUT 6 DEFAULT SPN='GEN BREAKER CLOSED'

78

INPUT 7 DEFAULT SPN='UTILITY BREAKER CLOSED'

79

INPUT 8 DEFAULT SPN='ATS IN NORMAL POSITION'

80

INPUT 9 DEFAULT SPN='ATS IN EMERGENCY POSITION'

81 INPUT 10 DEFAULT SPN='SPARE'


82

INPUT 11 DEFAULT SPN='SPARE'

83

INPUT 12 DEFAULT SPN='SPARE'

84
85
86
87
88
89

OUTPUT 1 DEFAULT SPN='COOLANT TEMP HIGH WARNING'

90

C18 Generator Set


with EMCPII, EMCPII+ and EMCP 3
Electrical System

91
92

OUTPUT 2 DEFAULT SPN='OIL PRESSURE LOW WARNING'

93
94
95

OUTPUT 3 DEFAULT SPN='COOLANT TEMP LOW WARNING'

96
97
98

OUTPUT 4 DEFAULT SPN='GENERATOR CONTROL NOT IN AUTO'

ZKB1-UP
C6C1-UP
G4C1-UP
STM1-UP
STH1-UP (Engine)

99
100
101 OUTPUT 5 DEFAULT SPN='OIL PRESSURE LOW SHUTDOWN'
102
103
104 OUTPUT 6 DEFAULT SPN='COOLANT TEMP HIGH SHUTDOWN'
105

STD1-UP
PDH1-UP (Engine)
Control Panel Callouts
Description
Electronic Modular Control Panel (EMCP)
Panel Lights (optional)
Panel Lights Switch (PLS) (optional)
Annunciator Module
Spare Slot (for additional annunciator module)
Emergency Stop Push Button (ESPB)
Start Aid Switch (SAS) (optional)
Speed Potentiometer (SP) (optional)
Voltage Adjust Toggle Switch

106
107 OUTPUT 7 DEFAULT SPN='ENGINE OVERCRANK'
108

Callout
1
2
3
4
5
6
7
8
9

109
110 OUTPUT 8 DEFAULT SPN='ENGINE OVERSPEED'
111

18 BATTERY POSITIVE(12-24V DC)


5

62

J1939 DATA LINK - HIGH

63

J1939 DATA LINK - LOW

64

Related Electrical Service Manuals

Volume 3 of 3: EMCP 3

Title

Form Number

EMCP 3 Systems Operation/ Troubleshooting/


Testing and Adjusting

RENR7902

Printed in U.S.A.

2008 Caterpillar
All Rights Reserved

CONNECTOR PINOUTS FOR HARNESS 269-8103

CONNECTOR PINOUTS FOR HARNESS 258-4700

155-2264

160-7689
128-2312

23

14

31

24

39

32

47

40

57

48

70

58

ECM (J1) PLUG

1239
1383
1664
1800
1801
1802
1803
2433
2434
2436
2440
2448
2452
2456
2648
4000
4001
4002
4003
4004
4005
4006
4007
4009
4010
4011
4012
4015
4016
4017
4028
4029

FMI
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
31

PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

WIRE
n/a
n/a
n/a
n/a
n/a
n/a
n/a
D+
Dn/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
20
n/a
n/a
n/a
n/a
45
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
ATAn/a
n/a
n/a
n/a
n/a
41
n/a
n/a
n/a
n/a
n/a
n/a
n/a
B+
n/a
ATA+
B+
B+
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
2
n/a
2
n/a
2
SSPD
n/a
n/a
n/a
10

9X-4391
14 13 12 11 10 9

28 27 26 25 24 23 22

21 20 19 18 17 16 15

42 41 40 39 38 37 36

35 34 33 32 31 30 29

56 55 54 53 52 51 50

49 48 47 46 45 44 43

70 69 68 67 66 65 64

63 62 61 60 59 58 57

WIRE
1
1
D+
Dn/a
n/a
10
n/a
n/a
20
2
2
n/a
n/a
41
n/a
45
n/a
n/a
18
n/a
n/a
19
n/a
n/a
n/a
n/a
n/a
n/a
n/a
21
22
SCR
n/a
SSPD
n/a
SCR
n/a
ATA+
ATASCR
n/a
n/a
n/a
n/a
11
12
17
34
46
n/a
n/a
n/a
78
80
82
n/a
n/a
59
n/a
EF1
EF2
n/a
72
30
n/a
n/a
n/a
n/a
n/a

23

14

31

24

15 16 17 18 19 20 21

22 23 24 25 26 27 28

39

32

29 30 31 32 33 34 35

36 37 38 39 40 41 42

9 10 11 12 13 14

47

40

43 44 45 46 47 48 49

50 51 52 53 54 55 56

57

48

57 58 59 60 61 62 63

64 65 66 67 68 69 70

70

58

EMCP 3 PLUG

WIRE
17
30
12
11
46
2
34
4

PIN
1
2
3
4
5
6
7
8

SPLICE(2) #4

ETHER
START
59

30

SPLICE(2) #2

SPLICE(1,2) #1

SPLICE(45) #7

SPLICE(B+) #5

CONTROL
PANEL
ELECTRONIC CONTROL
MODULE (ECM)
P1

SPLICE(10) #6

260

72
30

FUEL
LEVEL

30

25

2
E/STOP
2
4

230
230
245
245
360
360
250
210
180

EARTH
25
40
+

10

215
215

10

21

CAT DIGITAL
VOLTAGE
REGULATOR

SPLICE(2) #3

E /STOP PLUG
8 WAY

GENERATOR PLUG
70 WAY
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

13

R
30

19

ENGINE OIL
TEMPERATURE

22

ENGINE
SPEED

1
290

STARTER MOTOR

(EARLIER HARNESSES MAY HAVE


MULTIPLE, SMALLER DIAMETER #1
AND #2 WIRES)

400

2
78

ANALOG
VOLTAGE
80
REGULATOR
82

270
270
270

B+
TERMINAL BOX

EF1

EF2
CORE BALANCE
CURRENT
TRANSFORMER
40
B
30

C
A

COOLANT
LOSS
A-10
B-2
C-18

ALTERNATOR
2

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 269-8103

ETH
30

PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

WIRE
97
90
MSRN
M+
n/a
101
n/a
110
n/a
109
n/a
108
99
92
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
98
91
38
55
94
62
19
51
6
36
CAN 137
93
62
16
50
55
55
SRN
55
72
73
62
52
41
n/a
CAN 1+
14
55
77
18
57
15
53
2
n/a
n/a
55
CAN 2+
SRN
CAN 22
22
21
96
95
17

D+
D-

WIRE
1
1
D+
DSRN
n/a
10
3
23a
n/a
2
2
15
16
41
41
45
n/a
62
18
n/a
n/a
19
n/a
30
n/a
8
ESn/a
n/a
21
22
SRN
n/a
S-SPD
D-SPD
YEL
SRN
CAN 1+
CAN 1SRN
n/a
n/a
n/a
n/a
n/a
n/a
17
34
46
n/a
n/a
n/a
78
80
82
n/a
n/a
59
n/a
EF1
EF2
n/a
72
30
n/a
n/a
n/a
n/a
SRN

2
55
CAN 1CAN 1+

CAN 1+

CAN 1-

SERVICE
CONNECTOR

GENERATOR RECEPTACLE
70 WAY
PIN
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

WIRE
55
2
D+
DCAN 1+
CAN 1CAN 1+
CAN 1-

PIN
A
B
D
E
F
G
H
J

GENERATOR
RECEPTACLE

SERVICE CONNECTOR
RECEPTACLE
PANEL LIGHT

10

55

55
1

1A
41

CONTROL
RELAY CR

55

3
6
10
10
23A
30
30
37
38
55
55
59
73
77
95
96
ESEF1
EF2
CAN1CAN1+
SCREEN
93
94
M+
MSCREEN
CAN2+
CAN2SCREEN
10

ETHER START
ES-

36

ALARM BUZZER
2
1A

PANEL LIGHT
SWITCH

EMCP 3 PLUG

EARTH

E/STOP

45

E/STOP

30

17

1
2

34

14

46

55
57
30

108
109
110

50
51
52
53
101
108

90
91
92

80

VOLTAGE 82
ADJUST

97
98
99
D-SPD
S-SPD
SCREEN

79

SPLICE(62)

SPLICE(55)

SPLICE(50)
SPLICE(10)

EARTH

SPLICE(2)
SPLICE(41)

SPLICE(45)
SPLICE(ES-)

SPLICE(30)
SPLICE(1)
SPLICE(CAN1-)

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 258-4700

SPLICE(108)
SPLICE(17)
SPLICE(CAN1+)

(Dimensions: 39 inches x 24 inches)

20 Page,

103-0213
13

RENR7934-02 VOL 3 of 3

160-7689

1237

Failure Mode Identifier (FMI) Codes


Description
Data Valid but Above Normal Operational Range- Most Severe Level
Data Valid but Below Normal Operational Range- Most Severe Level
Data Erratic, Intermittent or Incorrect
Voltage Above Normal or Shorted to High Source
Voltage Below Normal or Shorted to Low Source
Current Below Normal or Grounded Circuit
Current Above Normal or Grounded Circuit
Mechanical System Not Responding or Out of Adjustment
Abnormal Frequency, Pulse Width or Period
Abnormal Update Rate
Abnormal Rate of Change
Unexpected Engine Shutdown
Bad Intelligent Device or Component
Out of Calibration
Special Instructions
Data Valid But Above Normal Operational Range- Least Severe Level
Data Valid But Above Normal Operational Range- Moderately Severe Level (Derate)
Data Valid But Below Normal Operational Range- Least Severe Level
Data Valid But Below Normal Operational Range- Moderately Severe Level (Derate)
Received Network Data In Error
Not Available or Condition Exists

4
2

CAT

Suspect Parameter Number (SPN)


SPN Description
Fuel Level (External Tank)
Aftercooler Temperature
Starting Air Pressure
Fuel Pressure
Fuel Filter Differential Pressure
Fuel Level (Local Tank)
Engine Oil Level
Oil Filter Differential Pressure
Engine Oil Pressure
Crankcase Pressure
Intake Manifold 1 Temperature
Air Filter Differential Pressure
Atmospheric Pressure
Engine Coolant Temperature
Engine Coolant Level
Fire Extinguisher Pressure
Battery Voltage (switch)
Battery Charging System Voltage
Battery Voltage
Ambient Air Temperature
Inlet Air Temperature
Exhaust Temperature
Fuel Temperature
Engine Oil Temperature
Turbo Oil Temperature
Engine Speed
Auxiliary Temperature 1
Auxiliary Temperature 2
Generator Rotating Diode Failure
SCADA Data Link Fault
Voltage Regulator Failure
Primary Data Link (J1939 #1)
Event Input Function #1
Event Input Function #2
Event Input Function #3
Event Input Function #4
Event Input Function #5
Event Input Function #6
Event Input Function #7
Event Input Function #8
Event Input Function #9
Event Input Function #10
Event Input Function #11
Event Input Function #12
Event Input Function #13
Event Input Function #14
Event Input Function #15
Event Input Function #16
Emergency Stop Switch
Engine Derate Overridden
Generator Bearing Temperature #1
Generator Bearing Temperature #2
Generator Winding Temperature #1
Generator Winding Temperature #2
Generator Winding Temperature #3
Intake Manifold 2 Temperature
Intake Manifold 3 Temperature
Intake Manifold 4 Temperature
Engine Oil Temperature 2
Exhaust Gas Port 1 Temperature
Exhaust Gas Port 2 Temperature
Exhaust Gas Port 3 Temperature
Exhaust Gas Port 4 Temperature
Exhaust Gas Port 5 Temperature
Exhaust Gas Port 6 Temperature
Exhaust Gas Port 7 Temperature
Exhaust Gas Port 8 Temperature
Exhaust Gas Port 9 Temperature
Exhaust Gas Port 10 Temperature
Exhaust Gas Port 11 Temperature
Exhaust Gas Port 12 Temperature
Exhaust Gas Port 13 Temperature
Exhaust Gas Port 14 Temperature
Exhaust Gas Port 15 Temperature
Exhaust Gas Port 16 Temperature
Exhaust Gas Port 17 Temperature
Exhaust Gas Port 18 Temperature
Exhaust Gas Port 19 Temperature
Exhaust Gas Port 20 Temperature
Main Bearing 1 Temperature (engine)
Main Bearing 2 Temperature (engine)
Main Bearing 3 Temperature (engine)
Main Bearing 4 Temperature (engine)
Main Bearing 5 Temperature (engine)
Main Bearing 6 Temperature (engine)
Main Bearing 7 Temperature (engine)
Main Bearing 8 Temperature (engine)
Main Bearing 9 Temperature (engine)
Main Bearing 10 Temperature (engine)
Main Bearing 11 Temperature (engine)
Turbocharger 1 Compressor Inlet Temperature
Turbocharger 2 Compressor Inlet Temperature
Turbocharger 3 Compressor Inlet Temperature
Turbocharger 4 Compressor Inlet Temperature
Turbocharger 1 Turbine Inlet Temperature
Turbocharger 2 Turbine Inlet Temperature
Turbocharger 3 Turbine Inlet Temperature
Turbocharger 4 Turbine Inlet Temperature
Turbocharger 1 Turbine Outlet Temperature
Turbocharger 2 Turbine Outlet Temperature
Turbocharger 3 Turbine Outlet Temperature
Turbocharger 4 Turbine Outlet Temperature
Engine Auxiliary Coolant Temperature
Accessory Data Link Fault (J1939 #2)
Emergency Shutdown Override Mode Active
Warning
Ruptured Fuel Basin- Primary Tank
Unexpected Engine Shutdown
Engine Failure to Start Shutdown
Battery 1 Temperature
Battery 2 Temperature
Intake Manifold 5 Temperature
Intake Manifold 6 Temperature
Right Exhaust Temperature
Left Exhaust Temperature
Generator Frequency
Generator AC Voltage
Generator AC Current
Generator Reverse Power (kW)
Generator Reverse Power (kVAr)
Service Interval Warning
Air Damper Closed
ATS in Normal Position
ATS in Emergency Position
Battery Charger Failure
Generator Breaker Closed
Utility Breaker Closed
Engine in Cooldown
Generator Control Not in Automatic Warning
Generator Breaker Failure to Open
Utility Breaker Failure to Open
Generator Breaker Failure to Close
Utility Breaker Failure to Close
Utility to Generator Transfer Failure Warning
Generator to Utility Transfer Failure Warning
Loss of Utility
Earth Fault
Earth Leakage

TO
STARTER
MOTOR

HC
:A2

:2

131

6 mm 2

2 .5 mm 2

141

137

BATTERY CHARGER
& HEATERS
(Both use the
same voltage)

:6

131

135
:1

:3

:5

HC
:A2

:2

:4

:6

131

140

142
9

F16
(2A)

NOTE A

24V DC +
SUPPLY
(DC
TERMINAL
RAIL)

20
148

1 F15

36

140

131

CR/1
:1

137

12

F17
(6A)

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

NOTE A

15
131

131

6 mm 2
135
136

BATTERY CHARGER

:4

16

HEATERS

1 F15

24V DC
+ 1
SUPPLY
(DC
TERMINAL
2
- 5
RAIL)

36

(*)
2

14

CUSTOMER
100V TO 250V
AC SUPPLY
(AC TERMINAL
RAIL)

T1

L1

T2

L2

T3

L3

REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

131

67

231

:11

:12

233

:13

:14

15
NOTE A

POWER
WIRING
FROM
GENERATOR

20

73

T2

S1
P1

S2
P2

CT1

T3

S1
P1

S2
P2

CT2

S1

S2

61

62

26

25

GENERATOR
PLUG
9X4391

EF2

GENERATOR
RECEPTACLE
1030213

GENERATOR
RECEPTACLE
1030213

21

GENERATOR
PLUG 9X4391

EMCP3 PLUG
1607689

6 mm 2

24

1.5 mm 2

6 mm 2

22

21

22

RELAY BOX

52

MAG

AC

66

31

47

IA

50

IB

53

ALT

DC
F5
(10A)

EMCP3 PLUG
1607689

6 mm 2
F4
(10A)

55
ECM
PLUG P1 1607689
34

57

50

RLY3
ASR
SWITCH

110

40

RLY4
AUDIBLE
ALARM

31
27

39

CAN 1+

HARNESS Y
SPLICE CAN1- CAN 1-

28

101
108

HARNESS Y
SPLICE 108

108

109

110

101

13

11

120
OHMS

CAN1+

CAN 1+

29

5
8

VB

40
23
ECM PLUG
P1 1607689
70

48
52

66

HARNESS X
SPLICE B+
68

53

D+

RLY5

RLY6
GRR
SWITCH

EMERG
STOP

D-

35

S-SPD

38
36

20 Page,

22
65

27
28

ES-

S
D
+B

10

14

55

41

37

55

36

55

55

38

55

90

91

92

97

55

ALARM

30
8

SPEED CONTROL

13

HARNESS Y
SPLICE 2

I/P 1
70

ENGINE
ELECTRONIC
CONTROL
MODULE(ECM)

58

59

60

14

98

99

I/P 2
55

17

HARNESS Y
SPLICE 41

PANEL
LIGHT

6 :2
ALR ALARM
RELAY
:10
2

38
:2
GRR
:10

3 COMMON
ALARM

GEN
RUNNING

61

42

16

:X1

203

NOTE A

46

17

:X2

13

207

208

131

CAN2+

BATT -

NC

CAN2 SRN

CAN2 -

CAN2 +

64

35

36

63
SRN
CAN2 J1939

62
+

HARNESS Y
SPLICE 45

10

11

TERMINAL
RAIL LINK

23A

:7

64

RELAY COIL
:2

55

HIGH
LEVEL
FUEL
SWITCH

85

TRANZORB
(SURGE SUPPRESSOR)

:2
MV
:1 MOT.

83

:2

PR
:10

207

SCREEN CABLE

+
-

-VE SUPPLY

:1
R/1

RELAY CONTACT N/O


:3

95

98

131

211

209

210

203

:3
PANEL LAMP SWITCH

:X1
PUMP
RUN

:2
:X2

77

30

M
77

EARTH

21

(DC TERMINAL RAIL)


13

30

CIRCUIT BREAKER

M-

5
+

4
SRN

RS485

The below does


not function
on EMCP3.1
SINK O/P 1

69

95

SINK O/P 2

68

96

I/P 8
28

PASSIVE
ANALOG 1+
56

93

94

PASSIVE
ANALOG 2+
38

OIL
TEMP
PASSIVE
ANALOG 3+
30

OIL
PRESSURE
PASSIVE
ANALOG 146

ENGINE
TEMP
PASSIVE
ANALOG 237

SPARE
SPARE
SPARE
SPARE

EMCP3 PLUG
1607689

This pin
does not
exist on
EMCP3.1

17

18

48

50

78

:2
80

:1

46

10

17

COMMON ALARM
78

80

ALR/3

82
:8

20

65

23A

59

18

59

72
64

AWG
AWG
AWG
AWG

WIRE IDENT:1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67

12
12
12
12

AIR SHUTOFF RELAY

AWG 12

SPARE BATTERY +
SPARE BATTERY +

AWG 12
AWG 12

FUEL LEAK DETECT

AWG 12

J1939 PRIMARY COMMUNICATION

AWG 12

J1939 PRIMARY COMMUNICATION

AWG 12

SHIELD

AWG 12

MODBUS RS485 COMMUNICATION


MODBUS RS485 COMMUNICATION
SHIELD

AWG 12
AWG 12
AWG 12

ECM POWER LINK

AWG 12

82

23A

59

ECM POWER LINK


REMOTE START FROM ATS
REMOTE START FROM ATS
COMMON SHUTDOWN RELAY - N/C
COMMON SHUTDOWN RELAY - COMMON
COMMON SHUTDOWN RELAY - N/O
GENERATOR RUNNING RELAY - N/C
GENERATOR RUNNING RELAY - COMMON
GENERATOR RUNNING RELAY - N/O

:9

AWG
AWG
AWG
AWG
AWG
AWG
AWG
AWG
AWG

12
12
12
12
12
12
12
12
12

:11
54

55

56

70

30

64

65

66

47

48

REMOTE CONTACTS
FOR GENERAL ALARM
23A

59

E/STOP PLUG
1552264

BATTERY
BATTERY
BATTERY
BATTERY

ATS

30
25

VOLTS ADJUST
POTENTIOMETER

:3

JUMPER PLUGS

CUSTOMER CONNECTIONS:

23

PASSIVE
ANALOG 329

This pin
does not
exist on
EMCP3.1

34

22

OIL
TEMP

12

19

14

17

46

:87

:87

TERMINAL
HARNESS Y RAIL LINK
SPLICE 30
13
30
30

ASOR/1

EPIR/1

45

42

HARNESS Y
SPLICE 10

I/P 7
36

ENGINE
TEMP

GENERATOR RUNNING

:8
78

80

GRR/3

:9

82

J1939 SECONDARY COMMUNICATION


J1939 SECONDARY COMMUNICATION
SHIELD
BREAKER AUX N/C
BREAKER AUX COM
BREAKER AUX N/O

AWG
AWG
AWG
AWG
AWG
AWG

12
12
12
12
12
12

E/STOP RECEPTACLE 3E3388


HARNESS X
SPLICE 10

87

E/STOP PLUG 1552264


4

FOR
USE
WITH
CDVR

E/STOP PLUG
1552264

10

49

88
50

1
2
3
4
5
6
7
8
9
10
11
12
13

89
51

REMOTE CONTACTS
FOR GENERATOR RUNNING

ST4
R448

45

:86
:85

SMMS1

RELAY BOX

45

45

HARNESS X
SPLICE 45
18
2

AIR
SHUTOFF
AIR

ETHER
START
1

10
2
3

-1
-1
-2
-2
-2
-2
-3
-6
-8
-10
-10
-23A
-30
-30
-37
-38
-55
-55
-59
-73
-77
-95
-96
-ES-EF1
-EF2
-CAN1-CAN1-CAN1+
-CAN1+
-SRN
-93
-94
-M+
-M-SRN
-S-SPD
-D-SPD
-SRN
-10
-10
-55
-57
-30
-64
-65
-66
-87
-88
-89
-81
-83
-84
-85
-90
-91
-92
-97
-98
-99
-CAN2+
-CAN2-SRN
-231
-232
-233

ABBREVIATIONS

120 OHM
RESISTOR
BETWEEN
27 & 29

CHASSIS
DC TERMINAL
RAIL

COOLANT LOSS

59
SASV
2

SHUT-OFF
SOLENOID

AUTOMATIC
VOLTAGE
REGULATOR (AVR)
72
LOW FUEL
LEVEL

ASOS

HARNESS X
SPLICE 2-1

30

HARNESS X, SPLICE 30
2

AIR CIRCUIT BREAKER


AIR SHUT-OFF RELAY
AIR SHUT-OFF SOLENOID
ALARM RELAY
AUTOMATIC VOLTAGE REGULATOR
CONTROL RELAY
CURRENT TRANSFORMER
CRANK TERMINATION RELAY
CAT DIGITAL VOLTAGE REGULATOR
ENGINE CONTROL MODULE
ELECTRONIC MODULAR CONTROL PANEL
ETHER POWER INJECTOR RELAY
EMERGENCY STOP
GENSET FAULT RELAY
GENERATOR RUNNING RELAY
LIQUID CRYSTAL DISPLAY
MOLDED CASE CIRCUIT BREAKER
MOTORIZED VALVE
OVERLOAD
PUMP CONTACTOR
POTENTIOMETER
PUMP RELAY
POWER TERMINAL STRIP
PULSE WIDTH MODULATED
RESISTIVE TEMPERATURE DETECTOR
STARTER AID SOLENOID VALVE
STARTER MOTOR MAGNETIC SWITCH
SCREEN

(+) BATTERY
(+) BATTERY SWITCHED
STARTING CIRCUIT
120 OHM
RESISTOR
BETWEEN
62 & 63

(-) BATTERY / SENSOR RETURN


SENSOR / ACTUATOR SUPPLY
SIGNAL PLUS TO ECM
SIGNAL MINUS TO ECM
CONTROL PLUS FROM ECM
CONTROL MINUS FROM ECM
CAT DATA LINK
J1939 DATA LINK
DATA LINK

NOTE: SEE AVR DIAGRAM ON


VOLUME 2

CUSTOMER 120/240VAC
SUPPLY FROM 2 POLE
BREAKER IN EMERGENCY
PANEL POWERS:
JW HEATER, UNIT MOUNTED
CHARGER AND OPTIONAL
GENERATOR SPACE HEATER

N
L1

AWG 8

AWG 8

L2 AWG 8

-50
-51
-52
-53
-101
-108
-209
-210
-142
-140
-131
-131
-143

14

-131

15

-131

16

-132

17

-132

18

-133

19

-139

20

-148

OPTIONAL WIRING

CHASSIS
AC TERMINAL
RAIL

-5O EARTH

ACB
ASOR
ASOS
ALR
AVR
CR
CT
CTR
CDVR
ECM
EMCP
EPIR
E/STOP
GFR
GRR
LCD
MCCB
MV
O/L
PC
POT
PR
PTS
PWM
RTD
SASV
SMMS
SRN

:11
E/STOP RECEPTACLE
3E3388

TERMINAL RAIL LINK

FUEL LEAK DETECTOR

The above does


not function
on EMCP3.2 or
EMCP3.1
OIL
PRESSURE

FOR
USE
WITH
CDVR

EMERGENCY STOP
ON ENCLOSURE

:10

:6
PR/2

52

37

M+

CAN2-

CAN2+

42
SRN
CAN1 J1939

PROG
I/P 8

23
:30

:30

:9

E/STOP RECEPTACLE 3E3388

:3
PR/1
:1

LOW
LEVEL
FUEL
SWITCH

VALVE
14

(16A)

SR

PANEL LAMP

84

53

E/STOP RECEPTACLE
3E3388

:86
:1 MAN
EPIR
:2 AUTO
:85
ETHER
START SWITCH

84
54

97

96

EMERGENCY STOP
PUSHBUTTON

F23
(2A)

131

10

57

30

REMOTE
START
CONTACT

E/STOP PLUG 1552264

ETHER
START

POTENTIOMETER

FUSE

DC CIRCUIT

100V TO 250V
14

NOTE: CUSTOMER
CABLE TO ENTER
DIRECTLY ONTO
6 mm 2 TERMINALS.

TRIP/
STOP

AC SUPPLY
CUSTOMER

207

120
OHMS

34

PROG
I/P 7

33

20

F27

63

46

:2

SPEED
ADJ. POT.
(2K , 10T)

132

:1

GRAVITY FUEL SUPPLY FROM HIGH


LEVEL BULK TANK TO BASETANK
FUEL SYSTEM No. 2

ES-

GENERATOR
RECEPTACLE
1030213

72

HARNESS Y
SPLICE 17

:11

16

34

12

GENERATOR
PLUG
9X4391

73

21

CR/3

10

49

77

18

57

ETHER
START

TERMINAL
RAIL LINK

34

I/P 5
45

16

45

ECM
POWER
LINK

I/P 4
53

LOW
FUEL
LEVEL
I/P 6
44

44

43

F21
NOTE:B

207

AIR
SHUTOFF

55

41

PWM SPEED CONTROL

ES-

57

24

EARTH
FAULT

38

36

10

11

15

FUEL
LEAK

LOW
COOLANT
LEVEL
I/P 3
54

44

:3

-B

24

{ENGINE MOUNTED}

25

:1

D-SPD

39

37 :86
AIR
ASOR SHUTOFF
RELAY
2 :85

GENERATOR
PLUG 9X4391

40
21

27

:2
CR
:10

10

61
63

26

41

37

HARNESS X
SPLICE 2-2

40

18

GENERATOR
RECEPTACLE
1030213

D-SPD

32

45

S-SPD

41

41

15

41

33

D-

D-

43

34

CAN2-

POWER TERMINAL

The above does not function on EMCP3.1

REMOTE
START

43

D+

D+

62

The below does


not function
on EMCP3.1

The items below do not


RLY7 function on RLY8
EMCP3.1
PROG
PROG
O/P
O/P

35

EMER.
STOP

:2

63

EMCP 3.3
or 3.2
or 3.1

58

15

CAN 1-

PANEL
LIGHT
SWITCH

CAN2-

SRN

# 1

E/STOP CHASSIS TO DOOR SOCKET

:3

BATT +

GENERATOR SOCKET

CONNECTION

205

J16
1

30

SW1 NORMALLY CLOSED

PUMP

CHASSIS TO DOOR DC SOCKET

FUEL
LEAK
SWITCH

CAN1-

50
+

VC

48

TERMINAL
RAIL LINK

HARNESS Y
SPLICE CAN1+

64

CAN2+

101

HARNESS Y
SPLICE 101

61

1A

:3

SRN

C
J

39

GFR
SWITCH

55

62

51

55

CAN 1+

109

I RETURN

56

17

41

CAN 1-

HARNESS Y
SPLICE 55

2
SERVICE CONNECTOR
RECEPTACLE 1282312

CAN 1+

SRN(CAN1)

TERMINAL
RAIL LINK
CAN 1-

E/STUD 2

RELAY BOX

108

50

IC

P16

OIL TEMPERATURE SENSOR


SOCKET

PUMP
STOP

ANNUNCIATOR

SW2 NORMALLY CLOSED

208

55

18

43

55

SERVICE
CONNECTOR

B+

-VE SUPPLY

30 2

RLY2
FUEL
CONTROL

RLY1
ENG
CRANK

CHARGING
ALTERNATOR

:11

ANNUNCIATOR

:87

(Dimensions: 39 inches x 24 inches)

67

52

101

40

PS1

E/STUD 1

CAN 2 SERVICE
CONNECTOR

BATTERY (12/24Vdc)
55

25

SM1

BOTH OF THESE
WIRES CONNECT
TO THE STANDARD
STUD IF THE
OPTIONAL STUD
IS NOT SUPPLIED

CHASSIS CHASSIS
STANDARD OPTIONAL
STUD
STUD
51

T3
F3
(2A)

HARNESS Y
SPLICE 50

:30

24V

PR
:10

O/L

LCD DISPLAY

65

SR/1

SMMS1/1

PS1

131

BREAKER
AUXILIARY

START AID SOLENOID VALVE


SOCKET

EARTH (MOUNTING SCREW)

EMCP3 PLUG
1607689
2

A+
+

232

F22
(2A)

A2

VA

2
CB1
(60A)

:12

:2

PC

TERMINAL
RAIL LINK

CB3
(15A)

66

:14

231

1 EARTH

33

T2
F2
(2A)

PICKUP

HARNESS Y
SPLICE 1

2.5 mm 2

CB2
(20A)

RENR7934-02 VOL 3 of 3

DOOR

32

21

OPTIONAL
BATTERY
ISOLATOR
SWITCH
KEY
REMOVABLE

T1
F1
(2A)

50

53

22

31

+VE SUPPLY

52

EF1

2.5 mm 2

65

233

HARNESS X
SPLICE 1

67

SW3 NORMALLY CLOSED

6 mm 2

L3

CT3

MAGNETIC
PICK UP No.1

GENERATOR
PLUG 9X4391

:C2

CHASSIS AC TERMINAL
LOCATED ON AC TERMINAL RAIL

:2

L2

EF1

GENERATOR
RECEPTACLE
1030213

24V DC
SHUNT
TRIP

ST

58

NOTE:B
IF 120V FUEL TRANSFER PUMP IS FITTED FUSE F21 SHOULD BE 10A
IF 230V FUEL TRANSFER PUMP IS FITTED FUSE F21 SHOULD BE 6A

:C1

CHASSIS DC TERMINAL
LOCATED ON DC TERMINAL RAIL

LEVEL SWITCH
(SIDE VIEW)

AC CIRCUIT

A1

EF1

L1

P2

EF2

14

EF2

11

TERMINAL BOX

SW4 NORMALLY OPEN

:11

SRN(CAN1)

14

ENTRY

H
HIG

TERMINAL BOX

PR/3

CAN 1+

EF1

30

CHASSIS CUSTOMER TERMINAL


LOCATED ON DC TERMINAL RAIL

204

P1

51

11

L3

METERING C.T.s

12

24

EARTH FAULT
A2
RELAY
k
l

30

14

21

T3

53

This circuitry
applies to fuel
system No. 3
only.
It does not exist
in fuel system
No. 1.

4 POLE BREAKER OR POWER TERMINAL STRIP (PTS) OPTIONAL

T2
T3
N
E

T1

EF2
22

A1

L2

W
2 S

11

CABLE

83

:9

BREAKER

10

T2

81

W
1 S

W
- LO
LOW
LOW

LEVEL
SWITCH
(TOP VIEW)

HIGH
LEVEL
FUEL
SWITCH

VALVE

-VE SUPPLY

L1

:3
PR/1
:1
81

52
55

MCCB

10

:7

T1

T1

CAN 1-

AC
GENERATOR

PR/2

4 POLE BREAKER OPTIONAL

REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

CORE BALANCE
CURRENT TRANSFORMER
IF REQUIRED

54

LOW
LEVEL
FUEL
SWITCH

85
:2
MV
:1 MOT.

CORE
BALANCE
C.T.

84

ACB

NEUTRAL EARTH LINK

Q/2

HEATER

14

84

Q/1

FOR 5A CHARGER FIT (6A) FUSE


FOR 10A CHARGER FIT (10A) FUSE

84

PUMP
RUN

:6

131

SW

SW

(2A)

BREAKER
AUXILIARY

1 F23

232

66

HIG
HIG HH

DC CIRCUIT

:C12

65

SYMBOLS

FUEL PUMPED FROM FREE STANDING


BULK TANK - FUEL SYSTEM NO. 3

24V DC
SHUNT
TRIP

ST

FUEL LEVEL SWITCH DRAWING

OR

:C11

PUMPED FUEL SUPPLY FROM BELOW


FLOOR LEVEL BULK TANK TO BASETANK
- FUEL SYSTEM No. 1

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

140

CONSTANT
VOLTAGE CHARGER

131

POWER
WIRING
FROM
GENERATOR

131

CR/1
:1

139
NOTE A
19

132

14

:6
142
9

6 mm 2

COPPER BUSBAR

:5

:4
131

CUSTOMER
100V TO 250V
AC SUPPLY
(AC TERMINAL RAIL)

ALTERNATOR ENGINE
(GENERATOR) JACKET
HEATER
WATER

FOR 5A CHARGER FIT (6A) FUSE


FOR 10A CHARGER FIT (10A) FUSE

131

16

134

:3

HC
:A2

NOTE A

134

141

131

:A1

HEATER

14

6 mm 2

141

ALTERNATOR ENGINE
(GENERATOR) JACKET
HEATER
WATER

(*)

F19
NOTE:A

131

:4

131

ENGINE
JACKET
WATER
HEATER

NOTE A

F18
(4A)

132

136

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

139
19

6 mm 2

COPPER BUSBAR

134

:A1

131

14

134

141

CONSTANT
VOLTAGE CHARGER

ALTERNATOR
(GENERATOR)
HEATER

10

131

CUSTOMER
100V TO 250V
AC SUPPLY
(AC TERMINAL
RAIL)

139
19

143
2

:5

:4

13

140

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6mm 2 TERMINALS.

6 mm

135

CR/1
:1

138

:3

142
9
NOTE A

131

138

134

:1

:14

131

147

:13

:A1

CONSTANT
VOLTAGE CHARGER
+

141

137

134

6 mm 2

6 mm 2

CR/1
:1

147

F19
NOTE:A

2 .5 mm 2

CR/2
:6

131

6 mm 2

:4

BATTERY CHARGER 140


& HEATERS
(120V Charger,
240V Heaters)

141

6 mm 2

:5

14

F18
(4A)

136
:4

6 mm 2

136

2 .5 mm 2

135

NOTE A

M2
NOTE:A
MCB

M1
2P 6A
MCB

F16
(2A)

2 .5 mm 2

F17
(10A)

120

F17
(6A)

6 mm 2

131

F16
(2A)

16

4 POLE BREAKER OPTIONAL

6 mm 2

18

132

2 .5 mm 2

133

6 mm 2

COPPER BUSBAR

AC SUPPLY
(AC TERMINAL
RAIL)

240

2
2 .5 mm

6 mm 2

16

6 mm 2

132

CUSTOMER
100V TO 250V

6 mm 2

6 mm 2

COPPER BUSBAR

NOTE:A
IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A
IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A

NOTE:A
IF 230V JACKET WATER HEATER IS FITTED FUSE F19 SHOULD BE 16A
IF 230V BLOCK HEATER IS FITTED FUSE F19 SHOULD BE 10A

2 .5 mm 2

NOTE:A
IF 230V JACKET WATER HEATER IS FITTED MCB M2 SHOULD BE 16A
IF 230V BLOCK HEATER IS FITTED MCB M2 SHOULD BE 10A

NOTES:
WIRE SIZES ARE MAXIMUM TERMINAL CAPABILITIES.
208VAC IS ACCEPTABLE VOLTAGE FOR AC FEED, BUT THE JW HEATER WILL DERATE.
DO NOT TURN ON AC POWER UNTIL FIELD TECHNICIAN HAS CHECKED WIRING.
SEE SEPARATE DRAWINGS FOR INTERCONNECT POINTS ONTO OPTIONAL SHIP LOOSE ITEMS.
SEE SEPARATE SHEET FOR THE LOCATION OF THE TERMINAL STRIP ON THE GENSET.

SECTION BORDER

THIS SCHEMATIC IS FOR THE C18 GENERATOR SET


(S/N ZKB, C6C, G4C, STM, STD)
Diagram Part Number
Diagram Part Number
Diagram Part Number

269-3119 DK07 (EMCP3.1)


260-5248 DK07 (EMCP3.2)
260-5249 DK07 (EMCP3.3)

IDENT
Y

HARNESS
258-4700

CHG
06

269-8103

05

EMCP3 HARNESS
J1 / GENERATOR SET CONTROL HARNESS