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EJ-C3

CLR-GA
WIRE NAME POS TERM/PLUG
GY-16-KYNAR T858-EJ14
1
YL-16-KYNAR
T958-EJ2
2
ACCESSORY TABLE
QTY
PART NAME
P/N
1
CONNECTOR AS 7E-6513
50mm
TUBE
112-8144

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 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.

INJECTOR 4
CONNECTOR
EJ-C5

INJECTOR 3
CONNECTOR
EJ-C4

EJ-C2
CLR-GA
WIRE NAME POS TERM/PLUG
GY-16-KYNAR T858-EJ13
1
PU-16-KYNAR T957-EJ1
2
ACCESSORY TABLE
QTY
PART NAME
P/N
1
CONNECTOR AS 7E-6513
50mm
TUBE
112-8144

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

EJ-C1
CLR-GA
WIRE NAME POS TERM/PLUG
PU-16-KYNAR T957-EJ1
1
180-9339
YL-16-KYNAR
T958-EJ2
2
180-9339
BR-16-KYNAR T959-EJ3
3
180-9339
BU-16-KYNAR T960-EJ4
4
180-9339
GN-16-KYNAR T961-EJ5
5
180-9339
WH-16-KYNAR T962-EJ6
6
180-9339
GY-16-KYNAR T858-EJ7
7
180-9339
WH-16-KYNAR T859-EJ8
8
180-9339
OR-16-KYNAR T860-EJ9
9
180-9339
10
8T-8737
11
8T-8737
12
8T-8737
ACCESSORY TABLE
QTY
PART NAME
P/N
1
RECEPTACLE AS. 262-6073
1
WEDGE
3E-5180

INJECTOR 6
CONNECTOR
EJ-C7
EJ-C7
CLR-GA
WIRE NAME POS TERM/PLUG
OR-16-KYNAR T860-EJ18
1
WH-16-KYNAR T962-EJ6
2
ACCESSORY TABLE
QTY
PART NAME
P/N
1
CONNECTOR AS 7E-6513
50mm
TUBE
112-8144

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.

C18 Generator Set


with EMCP3
Electrical System

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.

N1C1-UP
N1D1-UP
DKE1-UP
NKK1-UP
M1P1-UP
EKW1-UP
M1Y1-UP
M1Z1-UP

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 278-5657

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.

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


Wire,
Cable,
or
Harness
Assembly Identification: Includes
Harness Identification Letters and
Harness Connector Serialization
Codes (see sample).

Harness Identification Letter(s):


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

L-C12
3E-5179

AG-C4
111-7898

BU-18
BU-16-HV
PK-18
GN-18

BK-18
WH-18
GY-18
PK-18

WH-18
YL-18

PK-18

YL-18
BU-18

BU-18
GY-18

YL-18

WH-18

WH-18

PU-18

OR-16-HV

GY-16-HV
WH-16-HV
BR-16-HV
GN-16-HV
BU-16-HV

WH-16-HV
PU-16-HV
YL-16-HV

QTY
1
200mm

K-C1
WIRE NAME POS TERM/PLUG
K738-K41
1
180-9340
2
8T-8737
3
8T-8737
4
8T-8737
5
8T-8737
6
8T-8737
7
8T-8737
K737-K4
8
180-9340
9
8T-8737
10
8T-8737
11
8T-8737
12
8T-8737
995-K11
13
180-9340
K739-K40
14
180-9340
R746-K18
15
180-9340
16
8T-8737
G829-K2
17
180-9340
18
8T-8737
19
8T-8737
20
8T-8737
21
8T-8737
22
8T-8737
23
8T-8737
24
8T-8737
E963-K23
25
180-9340
G856-K8
26
180-9340
27
8T-8737
994-K10
28
180-9340
29
8T-8737
G833-K7
30
180-9340
31
8T-8737
32
8T-8737
33
8T-8737
34
8T-8737
E964-K22
35
180-9340
G857-K9
36
180-9340
37
8T-8737
38
8T-8737
39
8T-8737
C991-K6
40
180-9340
41
8T-8737
42
8T-8737
43
8T-8737
44
8T-8737
45
8T-8737
E966-K26
46
180-9340
E965-K27
47
180-9340
48
8T-8737
49
8T-8737
50
8T-8737
51
8T-8737
52
8T-8737
53
8T-8737
54
8T-8737
55
8T-8737
C967-K13
56
180-9340
R747-K5
57
180-9340
58
8T-8737
59
8T-8737
60
8T-8737
61
8T-8737
F421-K12
62
180-9340
63
8T-8737
64
8T-8737
T725-K44
65
180-9340
66
8T-8737
67
8T-8737
68
8T-8737
69
8T-8737
70
8T-8737
71
8T-8737
G828-K1
72
180-9340
73
8T-8737
74
8T-8737
75
8T-8737
76
8T-8737
77
8T-8737
78
8T-8737
79
8T-8737
80
8T-8737
81
8T-8737
82
8T-8737
N707-K43
83
180-9340
84
8T-8737
85
8T-8737
86
8T-8737
87
8T-8737
88
8T-8737
89
8T-8737
90
8T-8737
91
8T-8737
92
8T-8737
93
8T-8737
94
8T-8737
95
8T-8737
96
8T-8737
97
8T-8737
98
8T-8737
T860-K14
99
180-9340
100
8T-8737
101
8T-8737
102
8T-8737
103
8T-8737
T858-K15
104
180-9340
T962-K25
105
180-9340
T959-K17
106
180-9340
T961-K16
107
180-9340
T960-K24
108
180-9340
109
8T-8737
110
8T-8737
111
8T-8737
112
8T-8737
113
8T-8737
114
8T-8737
T859-K21
115
180-9340
T957-K20
116
180-9340
117
8T-8737
T958-K19
118
180-9340
119
8T-8737
120
8T-8737
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
227-4002
PAINT/PRO
110-3202

CLR-GA
BU-18
PK-18

ENGINE COOLANT
TEMPERATURE
SENSOR CONNECTOR
K-C10

CLR-GA
WH-18
GN-18
PK-18
QTY
1
200mm

K-C7
WIRE NAME POS TERM/PLUG
G828-K30
1
180-9340
G829-K34
2
180-9340
R746-K18
3
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
237-0227
PAINT/PRO
110-3202

CLR-GA
PU-16-HV
YL-16-HV
BR-16-HV
BU-16-HV
GN-16-HV
WH-16-HV
GY-16-HV
WH-16-HV
OR-16-HV
BR-16-HV
GN-16-HV
BU-16-HV
QTY
1
200mm
1

QTY
1
200mm

K-C13
WIRE NAME POS TERM/PLUG
T957-K20
1
180-9340
T958-K19
2
180-9340
T959-K17
3
180-9340
T960-K24
4
180-9340
T961-K16
5
180-9340
T962-K25
6
180-9340
T858-K15
7
180-9340
T859-K21
8
180-9340
T860-K14
9
180-9340
K737-K4
10
180-9340
K738-K41
11
180-9340
K739-K40
12
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
155-2252
PAINT/PRO
110-3202
WEDGE
155-2258

Plug

CLR-GA
BU-18
PK-18
QTY
1
200mm

SECONDARY ENGINE
SPEED/TIMING
SENSOR CONNECTOR
K-C8

1
2

Deutsch connector: Typical representation


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

1
2

Sure-Seal connector: Typical representation


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

5A
9X-1123

Fuse (5 Amps)

Harness identification code:


This example indicates wire group 325,
wire 135 in harness "AG".

155-2269

CLR-GA
YL-18
PK-18

FUEL HARNESS
CONNECTOR
K-C11

CLR-GA
YL-18
PK-18
WH-18
PU-18
WH-18
GN-18
PK-18

QTY
1
200mm

K-C11
WIRE NAME POS TERM/PLUG
F421-K12
1
180-9340
G833-K37
2
180-9340
T725-K44
3
180-9340
N707-K43
4
180-9340
G828-K28
5
180-9340
G829-K35
6
180-9340
C991-K6
7
180-9340
8
8T-8737
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
231-2295
PAINT/PRO
110-3202

WH-18
GN-18
PK-18

FUEL HARNESS TO
MAIN HARNESS
CONNECTOR
L-C1

QTY
1
200mm

L-C1
WIRE NAME POS TERM/PLUG
F421-L4
1
180-9339
G833-L5
2
180-9339
3
8T-8737
4
8T-8737
G828-L1
5
180-9339
G829-L2
6
180-9339
C991-L3
7
180-9339
8
8T-8737
ACCESSORY TABLE
PART NAME
P/N
RECEPTACLE AS. 231-2300
PAINT/PRO
110-3202

237-0227

230-4011

GRAY
3

231-2295

230-4013

K-S3
(G828 WH-18)
RED
2

K-S2
(G829 GN-18)

CLR-GA
BK-18
WH-18
QTY
1
200mm

K-C6
WIRE NAME POS TERM/PLUG
E963-K23
1
180-9340
E964-K22
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4011
PAINT/PRO
110-3202

CLR-GA
WH-18
YL-18

TIMING
CALIBRATION
PROBE
CONNECTOR
K-C2

QTY
1
200mm
1

K-C2
WIRE NAME POS TERM/PLUG
G856-K8
1
180-9340
G857-K9
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
155-2269
PAINT/PRO
110-3202
WEDGE
155-2261

7E-6513

231-2300

Wire 1

Wire 2

ENGINE CONTROL
MODULE
(ECM) P2
K-C1

PRIMARY ENGINE
SPEED/TIMING
SENSOR CONNECTOR
K-C6

227-4002

CLR-GA
YL-18
PK-18

ATMOSPHERIC PRESSURE
SENSOR CONNECTOR
K-C4

QTY
1
200mm

CLR-GA
WH-18
GN-18
GY-18
QTY
1
200mm

K-C9
WIRE NAME POS TERM/PLUG
G828-K29
1
180-9340
G829-K33
2
180-9340
994-K10
3
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
237-0227
PAINT/PRO
110-3202

Wire Gauge
Wire Color

Printed in U.S.A.

ENGINE OIL
PRESSURE SENSOR
CONNECTOR
K-C9

Component
Part Number

INJECTOR
HARNESS
CONNECTOR
K-C13

K-C5
WIRE NAME POS TERM/PLUG
C967-K13
1
180-9340
G833-K38
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4011
PAINT/PRO
110-3202

K-S1
(G833 PK-18)

Receptacle
Pin or Socket Number

325-AG135 PK-14

2012 Caterpillar,All Rights Reserved

INLET MANIFOLD
AIR TEMPERATURE
SENSOR CONNECTOR
K-C5

K-C8
WIRE NAME POS TERM/PLUG
E965-K27
1
180-9340
E966-K26
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4011
PAINT/PRO
110-3202

Part Number: for Connector Receptacle

Volume 1 of 2: Engine

INTAKE MANIFOLD
PRESSURE SENSOR
CONNECTOR
K-C7

CLR-GA
BU-18
YL-18

QTY
1
200mm

L-C12
3E-5179

Part Number: for Connector Plug

K-C10
WIRE NAME POS TERM/PLUG
995-K11
1
180-9340
G833-K36
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4011
PAINT/PRO
110-3202

Harness Connector Serialization Code:


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

CLR-GA
WH-18
GN-18
GY-18
QTY
1
200mm

K-C4
WIRE NAME POS TERM/PLUG
G828-K31
1
180-9340
G829-K32
2
180-9340
R747-K5
3
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4013
PAINT/PRO
110-3202

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 276-4752

L-C3
WIRE NAME POS TERM/PLUG
F421-L4
1
180-9340
G833-L5
2
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
230-4011
PAINT/PRO
110-3202

10

22 21 20 19 18 17

QTY
1
200mm

32 31 30 29 28

27 26 25 24 23
38 37 36 35 34 33

52 51 50 49

48 47 46 45

60 59 58 57

56 55 54 53

68 67 66 65

64 63 62 61

76 75 74 73

72 71 70 69
82 81 80 79 78 77

98 97 96 95 94

93 92 91 90 89

110 109 108 107 106 105

104 103 102 101 100 99


115 114 113 112 111

120 119 118 117 116

L-C2
WIRE NAME POS TERM/PLUG
G828-L1
1
180-9340
G829-L2
2
180-9340
C991-L3
3
180-9340
ACCESSORY TABLE
PART NAME
P/N
PLUG AS.
237-0227
PAINT/PRO
110-3202

44 43 42 41 40 39

88 87 86 85 84 83

CLR-GA
WH-18
GN-18
PK-18

16 15 14 13 12 11

FUEL TEMPERATURE
SENSOR CONNECTOR
L-C3

3E-8969

10 11 12

FUEL PRESSURE
SENSOR CONNECTOR
L-C2
155-2252

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 276-4754

12

11

10

(Dimensions: 39 inches x 24 inches)

INJECTOR 1
CONNECTOR
EJ-C2

INJECTOR
HARNESS
CONNECTOR
EJ-C1

BR-16-HV

SPN/FMI
94-15
94-16
94-00
94-17
94-18
94-01
100-17
100-01
110-15
110-16
110-00
174-15
174-16
174-00
175-15
175-16
175-00
190-15
190-00
1108-31
1636-15
1636-16
N/A
N/A
N/A

Pressure
Symbol

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.

CLR-GA
GN-16-HV

Engine Cross-Reference for SPN-FMI Code to EID


EID
Description of Code
E096-1
High Fuel Pressure Warning
E096-2
High Fuel Pressure Derate
E096-3
High Fuel Pressure Shutdown
E198-1
Low Fuel Pressure Warning
E198-2
Low Fuel Pressure Derate
E198-3
Low Fuel Pressure Shutdown
E360-1
Low Engine Oil Pressure Warning
E360-3
Low Engine Oil Pressure shutdown
E361-1
High Engine Coolant Temperature Warning
E361-2
High Engine Coolant Temperature Derate
E361-3
High Engine Coolant Temperature Shutdown
E363-1
High Fuel Supply Temperature Warning
E363-2
High Fuel Supply Temperature Derate
E363-3
High Fuel Supply Temperature Shutdown
E197-1
High Engine Oil Temperature Warning
E197-2
High Engine Oil Temperature Derate
E197-3
High Engine Oil Temperature Shutdown
E362-1
Engine Overspeed Warning
E362-3
Engine Overspeed Shutdown
E085-3
Engine Shutdown Overridden
E539-1
High Intake Manifold Air Temperature Warning
E539-2
High Intake Manifold Air Temperature Derate
E194-2
High Exhaust Temperature
E255-1
Diagnostic Reset
E264-3
Emergency Stop Activated

EJ-C6
CLR-GA
WIRE NAME POS TERM/PLUG
OR-16-KYNAR T860-EJ17
1
GN-16-KYNAR T961-EJ5
2
ACCESSORY TABLE
QTY
PART NAME
P/N
1
CONNECTOR AS 7E-6513
50mm
TUBE
112-8144

20 Page,

N/A

Symbols

EJ-S3
(T860 OR-16)

EJ-S2
(T859 WH-16)

EJ-S1
(T858 GY-16)

Harness And Wire Electrical Schematic Symbols

RENR9874-04
June 2012

INJECTOR 5
CONNECTOR
EJ-C6

RENR9874-04 VOL 1 of 2

SPN/FMI
91-08
94-03
94-04
100-03
100-04
100-10
108-03
108-04
110-03
110-04
168-00
168-01
168-02
172-03
172-04
174-03
174-04
175-03
175-04
190-08
228-13
234-02
620-03
620-04
651-05
651-06
652-05
652-06
653-05
653-06
654-05
654-06
655-05
655-06
656-05
656-06
723-08
1111-02
1785-03
1785-04
1785-10

Engine Cross-Reference for SPN-FMI Code to CID-FMI


CID/FMI
Description of Code
91-08
Throttle Position signal abnormal
94-03
Fuel Pressure open/short to +batt
94-04
Fuel Pressure short to ground
100-03
Engine Oil Pressure open/short to +batt
100-04
Engine Oil Pressure short to ground
100-10
Engine Oil Pressure Sensor abnormal rate of change
274-03
Atmospheric Pressure open/short to +batt
274-04
Atmospheric Pressure short to ground
110-03
Engine Coolant Temperature open/short to +batt
110-04
Engine Coolant Temperature short to ground
168-00
System Voltage High
168-01
System Voltage Low
168-02
System Voltage intermittent/erratic
172-03
Intake Manifold Air Temp open/ short to +batt
172-04
Intake Manifold Air Temp short to ground
174-03
Fuel Temperature open/ short to +batt
174-04
Fuel Temperature short to ground
175-03
Engine Oil Temperature open/short to +batt
175-04
Engine Oil Temperature short to ground
190-08
Engine Speed signal abnormal
261-13
Engine Timing calibration required
253-02
Personality Module mismatch
262-03
5 Volt Sensor DC Power Supply short to +batt
262-04
5 Volt Sensor DC Power Supply short to ground
1-05
Cylinder #1 Injector open circuit
1-06
Cylinder #1 Injector short
2-05
Cylinder #2 Injector open circuit
2-06
Cylinder #2 Injector short
3-05
Cylinder #3 Injector open circuit
3-06
Cylinder #3 Injector short
4-05
Cylinder #4 Injector open circuit
4-06
Cylinder #4 Injector short
5-05
Cylinder #5 Injector open circuit
5-06
Cylinder #5 Injector short
6-05
Cylinder #6 Injector open circuit
6-06
Cylinder #6 Injector short
342-08
Secondary Engine Speed signal abnormal
268-02
Check Programmable Parameters
1785-03
Intake Manifold Pressure Sensor voltage high
1785-04
Intake Manifold Pressure Sensor voltage low
1785-10
Intake Manifold Pressure Signal abnormal rate of change
Throttle #2 Position Sensor abnormal frequency, pulse
1690-08
width, or period

EJ-C5
CLR-GA
WIRE NAME POS TERM/PLUG
WH-16-KYNAR T859-EJ15
1
BU-16-KYNAR T960-EJ4
2
ACCESSORY TABLE
P/N
QTY
PART NAME
1
CONNECTOR AS 7E-6513
112-8144
50mm
TUBE

EJ-C4
CLR-GA
WIRE NAME POS TERM/PLUG
WH-16-KYNAR T859-EJ16
1
BR-16-KYNAR T959-EJ3
2
ACCESSORY TABLE
QTY
PART NAME
P/N
1
CONNECTOR AS 7E-6513
50mm
TUBE
112-8144

INJECTOR 2
CONNECTOR
EJ-C3

6
K-C12
3E3364

K-C2
1552269

TIMING CALIBRATION(TC) PROBE

SIGNAL
GROUND

G829-K34
G829-K33
G829-K32
G829-K35

GN-18
GN-18
GN-18
GN-18

G828-K30 WH-18
G828-K29 WH-18
G828-K31 WH-18
G828-K28 WH-18

G833-K7 PK-18

T858-EJ13 GY-16-KYNAR
T957-EJ1 PU-16-KYNAR

SIGNAL
GROUND

G829-K2 GN-18

T858-EJ14 GY-16-KYNAR
T958-EJ2 YL-16-KYNAR

K-C13 EJ-C1
1552252 3E8969

K-S3

G828-K1 WH-18

T957-K20 PU-16-HV
T958-K19 YL-16-HV
T959-K17 BR-16-HV
T960-K24 BU-16-HV
T961-K16 GN-16-HV
T962-K25 WH-16-HV
T858-K15 GY-16-HV
T859-K21 WH-16-HV
T860-K14 OR-16-HV
K737-K4 BR-16-HV
K738-K41 GN-16-HV
K739-K40 BU-16-HV

C967-K13 BU-18
G833-K38 PK-18

1
2

994-K10 GY-18
995-K11 BU-18
C967-K13 BU-18
C991-K6 PK-18
E963-K23 BK-18
E964-K22 WH-18
E965-K27 BU-18
E966-K26 YL-18
F421-K12 YL-18
G856-K8 WH-18
G857-K9 YL-18
N707-K43 PU-18
R746-K18 PK-18
R747-K5 GY-18
T725-K44 WH-18

K-C8
2304011
SECONDARY ENGINE SPEED/TIMING SENSOR
2717537

BK-18
WH-18

E965-K27 BU-18
E966-K26 YL-18

1
2

NOTE A

BK-18
WH-18

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

T957-EJ1
T958-EJ2
T959-EJ3
T960-EJ4
T961-EJ5
T962-EJ6
T858-EJ7
T859-EJ8
T860-EJ9

T858-EJ13 GY-16-KYNAR
T858-EJ14 GY-16-KYNAR

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

T859-EJ16 WH-16-KYNAR
T959-EJ3 BR-16-KYNAR

EJ-S2

T859-EJ8 WH-16-KYNAR

T859-EJ15 WH-16-KYNAR
T859-EJ16 WH-16-KYNAR
T860-EJ17 OR-16-KYNAR
T860-EJ18 OR-16-KYNAR

T957-EJ1
T958-EJ2
T959-EJ3
T960-EJ4
T961-EJ5
T962-EJ6

T859-EJ15 WH-16-KYNAR
T960-EJ4 BU-16-KYNAR

PU-16-KYNAR
YL-16-KYNAR
BR-16-KYNAR
BU-16-KYNAR
GN-16-KYNAR
WH-16-KYNAR

1
2

INJECTOR 6
CONNECTOR
EJ-C7

INJECTOR 3

1
2

INJECTOR 4

1
2

INJECTOR 5
CONNECTOR
EJ-C6

INJECTOR 5

1
2

INJECTOR 6

NOTE A

K737-K4 BR-16-HV
K738-K41 GN-16-HV
K739-K40 BU-16-HV
T858-K15 GY-16-HV
T859-K21 WH-16-HV
T860-K14 OR-16-HV
T957-K20 PU-16-HV
T958-K19 YL-16-HV
T959-K17 BR-16-HV
T960-K24 BU-16-HV
T961-K16 GN-16-HV
T962-K25 WH-16-HV

N707-K43 PU-18
R746-K18 PK-18
R747-K5 GY-18
T725-K44 WH-18

994-K10 GY-18
995-K11 BU-18
F421-K12 YL-18
C967-K13 BU-18
C991-K6 PK-18
E963-K23 BK-18
E964-K22 WH-18
E965-K27 BU-18
E966-K26 YL-18
G828-K1 WH-18
G829-K2 GN-18
G833-K7 PK-18
G856-K8 WH-18
G857-K9 YL-18

INJECTOR 4
CONNECTOR
EJ-C5

INJECTOR 3
CONNECTOR
EJ-C4

K-C4
2304013

ATMOSPHERIC PRESSURE SENSOR


2769067

VS
GROUND
SIGNAL

NOTE A
NOTE A

G828-K30 WH-18
G829-K34 GN-18
R746-K18 PK-18

1
2
3

INJECTOR 2

EJ-C6
7E6513

T860-EJ18 OR-16-KYNAR
T962-EJ6 WH-16-KYNAR

K-C7
2370227
VS
GROUND
SIGNAL

1
2

EJ-C7
7E6513

NOTE A

INTAKE MANIFOLD PRESSURE SENSOR


2490096

INJECTOR 1

EJ-C5
7E6513

EJ-S3

T860-EJ9 OR-16-KYNAR

T860-EJ17 OR-16-KYNAR
T961-EJ5 GN-16-KYNAR

E963-K23 BK-18
E964-K22 WH-18

1
2

1
2

EJ-C4
7E6513

EJ-S1

T858-EJ7 GY-16-KYNAR

K-C6
2304011
PRIMARY ENGINE SPEED/TIMING SENSOR
2717538

EJ-C3
7E6513

K-S2

K-C5
2304011
INLET MANIFOLD AIR TEMPERATURE SENSOR
2345013

K-S1

995-K11 BU-18
G833-K36 PK-18

1
2

3
EJ-C2
7E6513

G833-K36 PK-18
G833-K37 PK-18
G833-K38 PK-18

K-C10
2304011
ENGINE COOLANT TEMPERATURE SENSOR
2345012

NOTE A

G856-K8 WH-18
G857-K9 YL-18

1
2

G828-K31 WH-18
G829-K32 GN-18
R747-K5 GY-18

1
2
3

K-C9
2370227

FUEL TEMPERATURE SENSOR


2345013

SIGNAL
GROUND

1
2

T958-K19 YL-16-HV

T859-K21 WH-16-HV
T957-K20 PU-16-HV

GY-16-HV
WH-16-HV
BR-16-HV
GN-16-HV
BU-16-HV
T858-K15
T962-K25
T959-K17
T961-K16
T960-K24

T860-K14 OR-16-HV

N707-K43 PU-18

G828-K1 WH-18

T725-K44 WH-18

C967-K13 BU-18
R747-K5 GY-18

E966-K26 YL-18
E965-K27 BU-18

C991-K6 PK-18

E964-K22 WH-18
G857-K9 YL-18

994-K10 GY-18

G833-K7 PK-18

E963-K23 BK-18
G856-K8 WH-18

G829-K2 GN-18

995-K11 BU-18
K739-K40 BU-16-HV
R746-K18 PK-18

F421-K12 YL-18

INJECTOR 1
CONNECTOR
EJ-C2

INJECTOR 2 COMMON

INJECTOR 3&4 HIGH


INJECTOR 1 COMMON

1&2 HIGH
6 COMMON
3 COMMON
5 COMMON
4 COMMON
INJECTOR
INJECTOR
INJECTOR
INJECTOR
INJECTOR

INJECTOR 5&6 HIGH

FUEL DIFFERENTIAL PRESS SW RETURN

PRESSURE SENSOR +5V

FUEL TEMPERATURE

DIFFERENTIAL FUEL PRESSURE SW

L-C3
2304011

INLET MANIFOLD AIR TEMPERATURE


ATMOSPHERIC PRESSURE

F421-K12 YL-18
G833-K37 PK-18
T725-K44 WH-18
N707-K43 PU-18
G828-K28 WH-18
G829-K35 GN-18
C991-K6 PK-18

SECONDARY ENGINE SPEED/TIMING +


SECONDARY ENGINE SPEED/TIMING -

G828-L1 WH-18
G829-L2 GN-18
C991-L3 PK-18

1
2
3
4
5
6
7
8

FUEL PRESSURE

F421-L4 YL-18
G833-L5 PK-18

K-C11
2312295

PRIMARY ENGINE SPEED/TIMING +


TIMING CALIBRATION PROBE -

L-C1
2312300

ENGINE OIL PRESSURE

J2

TEMPERATURE SENSOR COMMON

G828-L1 WH-18
G829-L2 GN-18
C991-L3 PK-18

PRIMARY ENGINE SPEED/TIMING TIMING CALIBRATION PROBE +

1
2
3

PRESSURE SENSOR COMMON

VS
GROUND
SIGNAL

BRAKE SOLENOID L/H

FUEL PRESSURE SENSOR


2769067

ENGINE COOLANT TEMPERATURE


BRAKE COMMON
INTAKE MANIFOLD AIR PRESSURE

K-C1
2274002

L-C2
2370227

INJECTOR 2
CONNECTOR
EJ-C3

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
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120

FUEL JUMPER HARNESS

K737-K4 BR-16-HV

G828-K29 WH-18
G829-K33 GN-18
994-K10 GY-18

1
2
3

BRAKE SOLENOID M/H

VS
GROUND
SIGNAL

K738-K41 GN-16-HV

ENGINE OIL PRESSURE SENSOR


2769067

INJECTOR HARNESS
CONNECTOR
EJ-C1

TOP VIEW
(Injector Harness)

F421-L4 YL-18
G833-L5 PK-18
ENGINE CONTROL MODULE
2267467

SECONDARY ENGINE
SPEED/TIMING SENSOR
CONNECTOR
K-C8

INTAKE MANIFOLD
PRESSURE SENSOR
CONNECTOR
K-C7

INJECTOR
HARNESS
CONNECTOR
K-C13

INLET MANIFOLD
AIR TEMPERATURE
SENSOR CONNECTOR
K-C5

TIMING CALIBRATION(TC)
PROBE CONNECTOR
K-C2

FUEL HARNESS
CONNECTOR
K-C11

(Dimensions: 39 inches x 24 inches)

20 Page,

RENR9874-04 VOL 1 of 2

(-) BATTERY / SENSOR RETURN


SENSOR / ACTUATOR SUPPLY

SIGNAL FROM ECM

SIGNAL TO ECM
CONTROL (POSITIVE) FROM ECM

ENGINE COOLANT
TEMPERATURE SENSOR
CONNECTOR
K-C10

CONTROL (NEGATIVE) FROM ECM


HIGHWAYS

ATMOSPHERIC
PRESSURE SENSOR
CONNECTOR
K-C4

NOTE A:

IDENT

MUST BE TWISTED TOGETHER AT LEAST


1 TURN PER 25mm
PART NUMBER

K
L
EJ
PRIMARY ENGINE
SPEED/TIMING SENSOR
CONNECTOR
K-C6

ENGINE CONTROL
MODULE
(ECM) P2
K-C1

ENGINE OIL
PRESSURE SENSOR
CONNECTOR
K-C9

TIMING CALIBRATION
PORT

LEFT SIDE VIEW

FRONT VIEW

VIEW B-B

00
00
03

NOTE
ENGINE HARNESS
FUEL JUMPER HARNESS (EPG)
(INTERNAL) INJECTOR HARNESS
SYMBOL

COLOR ABBREVIATIONS

PRIMARY ENGINE
SPEED/TIMING SENSOR

276-4752
276-4754
278-5657

CHG

ABBREV

COLOR

RD

RED

WH

WHITE

OR

ORANGE

YL

YELLOW

PK

PINK

BK

BLACK

GY

GRAY

PU

PURPLE

BR

BROWN

GN

GREEN

BU

BLUE

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
SPLICE
BLADE, SPADE, RING OR SCREW
TERMINAL

THIS SCHEMATIC IS FOR THE C18 GENERATOR SET WITH EMCP3 ELECTRICAL SYSTEM
VOLUME 1 of 2: ENGINE
MEDIA NUMBER: RENR9874-04
SCHEMATIC PART NUMBER: 276-4751, CHANGE: 00, VERSION: Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

38

Aftercooler Temperature

52

Starting Air Pressure

82

RTD MODULE

Fuel Pressure

94

40-PIN CONNECTOR

Fuel Filter Differential Pressure

95

RTD #1 - H

Fuel Level (Local Tank)

96

Engine Oil Level

98

RTD
TERMINAL
STRIP
1

RTD #1 - L

99

Engine Oil Pressure

100

RTD #1 - GND

Crankcase Pressure

101

RTD #1 - SHIELD

Intake Manifold 1 Temperature

105

Air Filter Differential Pressure

107

RTD #2 - H

11

Atmospheric Pressure

108

RTD #2 - M

Engine Coolant Temperature

110

RTD #2 - L

Engine Coolant Level

111

Fire Extinguisher Pressure

137

Battery Voltage (switch)

158

Battery Charging System Voltage

167

RTD #3 - H

21

RTD #3 - M

22

13

RTD #2 - GND

14

RTD #2 - SHIELD

15

Exhaust Temperature

173

RTD #3 - GND

24

Fuel Temperature

174

RTD #3 - SHIELD

25

RTD #4 - H

31

441

Auxiliary Temperature 2

442

Generator Rotating Diode Failure

612

32

RTD #4 - L

33

RTD #4 - GND

34

RTD #4 - SHIELD

35

SCADA Data Link Fault

625

Voltage Regulator Failure

628

RTD #5 - H

Primary Data Link (J1939 #1)

639

RTD #5 - M

Event Input Function #1

701

RTD #5 - L

Event Input Function #2

702

RTD #5 - GND

9
10

703

Event Input Function #4

704

RTD #5 - SHIELD

Event Input Function #5

705

RTD #6 - H

16

Event Input Function #6

706

RTD #6 - M

17

Event Input Function #7

707

Event Input Function #8

708

RTD #6 - L

Event Input Function #9

709

RTD #6 - GND

Event Input Function #10

710

RTD #6 - SHIELD

20

Event Input Function #11

711

Event Input Function #12

712

RTD #7 - H

26

Event Input Function #13

713

RTD #7 - M

27

Event Input Function #14

714

RTD #7 - L

28

Event Input Function #15

715
716

Engine Derate Overridden

971

RTD #8 - H

Generator Bearing Temperature #1

1122

RTD #8 - M

37

Generator Bearing Temperature #2

1123

RTD #8 - L

38

Generator Winding Temperature #2

1125

RTD #8 - GND

39

Generator Winding Temperature #3

1126

RTD #8 - SHIELD

40

Intake Manifold 2 Temperature

1131

Intake Manifold 3 Temperature

1132

Intake Manifold 4 Temperature

1133

1138
1139

Exhaust Gas Port 4 Temperature

1140

Exhaust Gas Port 5 Temperature

1141

Exhaust Gas Port 6 Temperature

1142

Exhaust Gas Port 7 Temperature

1143

Exhaust Gas Port 8 Temperature

1144

Exhaust Gas Port 9 Temperature

1145

Exhaust Gas Port 10 Temperature

1146

Exhaust Gas Port 11 Temperature

1147

Exhaust Gas Port 12 Temperature

1148

Exhaust Gas Port 13 Temperature

1149

Exhaust Gas Port 14 Temperature

1150

Exhaust Gas Port 15 Temperature

1151

Exhaust Gas Port 16 Temperature

1152

Exhaust Gas Port 17 Temperature

1153

Exhaust Gas Port 18 Temperature

1154

Exhaust Gas Port 19 Temperature

1155

Exhaust Gas Port 20 Temperature

1156

Main Bearing 1 Temperature (engine)

1157

Main Bearing 2 Temperature (engine)

1158

Main Bearing 3 Temperature (engine)

1159

Main Bearing 4 Temperature (engine)

1160

Main Bearing 5 Temperature (engine)

1161

Main Bearing 6 Temperature (engine)

1162

Main Bearing 7 Temperature (engine)

1163

Main Bearing 8 Temperature (engine)

1164

Main Bearing 9 Temperature (engine)

1165

Main Bearing 10 Temperature (engine)

1166

Main Bearing 11 Temperature (engine)

1167

Turbocharger 1 Compressor Inlet Temperature

1172

Turbocharger 2 Compressor Inlet Temperature

1173

Turbocharger 3 Compressor Inlet Temperature

1174

Turbocharger 4 Compressor Inlet Temperature

1175

Turbocharger 1 Turbine Inlet Temperature

1180

Turbocharger 2 Turbine Inlet Temperature

1181

Turbocharger 3 Turbine Inlet Temperature

1182

Turbocharger 4 Turbine Inlet Temperature

1183

Turbocharger 1 Turbine Outlet Temperature

1184

Turbocharger 2 Turbine Outlet Temperature

1187

Engine Auxiliary Coolant Temperature

1212

Accessory Data Link Fault (J1939 #2)

1231

Emergency Shutdown Override Mode Active


Warning

1237

Ruptured Fuel Basin- Primary Tank

1239

Unexpected Engine Shutdown

1383

Engine Failure to Start Shutdown

1664

Battery 1 Temperature

1800

Battery 2 Temperature

1801

Intake Manifold 5 Temperature

1802

Intake Manifold 6 Temperature

1803

Right Exhaust Temperature

2433

Left Exhaust Temperature

2434

Generator Frequency

2436

Generator AC Voltage

2440

Generator AC Current

2448

Generator Reverse Power (kW)

2452

Generator Reverse Power (kVAr)

2456

Service Interval Warning

2648

Air Damper Closed

4000

ATS in Normal Position

4001

ATS in Emergency Position

4002
4003

Generator Breaker Closed

4004

Utility Breaker Closed

4005

Engine in Cooldown

4006

Generator Control Not in Automatic Warning

4007

Generator Breaker Failure to Open

4009

Utility Breaker Failure to Open

4010

Generator Breaker Failure to Close

4011

Utility Breaker Failure to Close

4012

Utility to Generator Transfer Failure Warning

4015

Generator to Utility Transfer Failure Warning

4016

Loss of Utility

4017

Earth Fault

4028

Earth Leakage

4029

347

182

WHITE

116

THERMOCOUPLE #5

348

117

THERMOCOUPLE #5

13

349

RED

191

THERMOCOUPLE #6

23

350

THERMOCOUPLE #6

33

351

THERMOCOUPLE #7

352

THERMOCOUPLE #7

14

353

118

RTD
PT100
192

WHITE

RED

163

119

WHITE

55

BATT(-)

CAN_L

CAN2 -

SHIELD

SHIELD

303

INPUT #5

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

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'

134

CHANNEL6 DEFAULT SPN='EXHAUST GAS PORT 6 TEMP'


135

CHANNEL7 DEFAULT SPN='EXHAUST GAS PORT 7 TEMP'

THERMOCOUPLE #8

34

355

THERMOCOUPLE #9

356

THERMOCOUPLE #9

357

122

THERMOCOUPLE #10

358

123

THERMOCOUPLE #10

17

359

THERMOCOUPLE #11

15

OUTPUT #2 (N/C)

15

320

THERMOCOUPLE #11

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

62

J1939 DATA LINK - HIGH


J1939 DATA LINK - LOW

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'

CHANNEL8 DEFAULT SPN='EXHAUST GAS PORT 8 TEMP'

89

141

CHANNEL10 DEFAULT SPN='EXHAUST GAS PORT 10 TEMP'

38

OUTPUT #8 (N/C)

38

338

39

OUTPUT #8 (COM)

39

339

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

OUTPUT 1 DEFAULT SPN='COOLANT TEMP HIGH WARNING'

90

92

OUTPUT 2 DEFAULT SPN='OIL PRESSURE LOW WARNING'

C18 Generator Set


with EMCP3
Electrical System

93
94
95

OUTPUT 3 DEFAULT SPN='COOLANT TEMP LOW WARNING'

96
97
98

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

99

55

BATT(-)

CAN_H

CAN1 +

CAN_L

CAN1 -

18
5

102
103
104 OUTPUT 6 DEFAULT SPN='COOLANT TEMP HIGH SHUTDOWN'
105
106
107 OUTPUT 7 DEFAULT SPN='ENGINE OVERCRANK'
108
109
110 OUTPUT 8 DEFAULT SPN='ENGINE OVERSPEED'
111

27

SHIELD

J1939 DATA LINK - HIGH


J1939 DATA LINK - LOW

31

64

55

BATT(-)

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.

CAN_H

CAN2 +

CAN_L

CAN2 -

SHIELD

SHIELD

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.
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


Wire,
Cable,
or
Harness
Assembly Identification: Includes
Harness Identification Letters and
Harness Connector Serialization
Codes (see sample).

Harness Identification Letter(s):


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

18 BATTERY POSITIVE(12-24V DC)

L-C12
3E-5179

AG-C4
111-7898

BATTERY NEGATIVE (12-24VDC)


29

N1C1-UP
N1D1-UP
DKE1-UP
NKK1-UP
M1P1-UP
EKW1-UP
M1Y1-UP
M1Z1-UP

101 OUTPUT 5 DEFAULT SPN='OIL PRESSURE LOW SHUTDOWN'

BATT(+)
BATTERY POSITIVE(12-24V DC)

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.

100

8-PIN CONNECTOR
1

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.

91

143

THERMOCOUPLE #20

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.

88

140

142

Circuit Breaker
Symbol

Flow
Symbol

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

87

139

CHANNEL9 DEFAULT SPN='EXHAUST GAS PORT 9 TEMP'

Level
Symbol

Symbols and Definitions

86

138

THERMOCOUPLE #20

SHIELD

75

Temperature
Symbol

85

137

121

BATTERY NEGATIVE (12-24VDC)

INPUT 3 DEFAULT SPN='COOLANT LEVEL LOW WARNING'

Pressure
Symbol

84

136

354

BATT(+)

74

133

24

63

31

THERMOCOUPLE #8

BATTERY POSITIVE(12-24V DC)

CAN2 +

INPUT #4

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

127

8-PIN CONNECTOR

BATT(+)

CAN_H

CHANNEL2 DEFAULT SPN='EXHAUST GAS PORT 2 TEMP'

120

RTD
PT100
164

302

62

J1939 DATA LINK - HIGH

63

J1939 DATA LINK - LOW

L-C12
3E-5179

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

Part Number: for Connector Receptacle

64

Plug

Receptacle
Pin or Socket Number

1
2

Deutsch connector: Typical representation


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

1
2

Sure-Seal connector: Typical representation


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

5A
Component
Part Number

9X-1123

Fuse (5 Amps)

325-AG135 PK-14

Volume 2 of 2: EMCP3

CONNECTOR PINOUTS FOR HARNESS 269-8103

CONNECTOR PINOUTS FOR HARNESS 258-4700

155-2264

Related Electrical Service Manuals

160-7689
1

23

14

31

24

39

32

47

40

57

48

70

58

ECM (J1) PLUG


POSITION NO:
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

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

WIRE INDENT
1
1
D+
DSCR
n/a
10
n/a
n/a
20
2
2
n/a
n/a
41
n/a
45
n/a
n/a
18

14 13 12 11 10

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

GENERATOR PLUG
70 WAY
POSITION NO:
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

n/a
n/a
19
n/a
n/a
n/a
8
ESn/a
n/a
21
22
SCR
n/a
SSPD
DSPD
SCR
n/a
CAN1+
CAN1SCR
n/a
n/a
n/a
n/a
11
12
17
34
46
n/a

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

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
SCR

52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

128-2312

103-0213

9X-4391
13

WIRE INDENT
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
8
ES45
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
n/a
CAN1n/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
CAN1+
n/a
B+
B+
n/a
n/a
n/a
n/a
n/a
n/a
n/a
2
n/a
2
n/a
2
SSPD
n/a
DSPD
n/a
10

Wire Gauge
Wire Color

Printed in U.S.A.

2012 Caterpillar,All Rights Reserved

160-7689

Harness identification code:


This example indicates wire group 325,
wire 135 in harness "AG".

13

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

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

10 11 12 13 14

D+
D-

Title

CAN 1-

C
A

RENR7902

2
55

B
J

CAN 1+

Form Number

EMCP 3 Systems Operation/ Troubleshooting/


Testing and Adjusting

E /STOP PLUG
8 WAY
WIRE INDENT
17
30
12
11
46
2
34
4

POSITION NO:
1
2
3
4
5
6
7
8

EMCP 3 PLUG

ELECTRONIC CONTROL
MODULE (ECM)
P1

120

ETHER START
59

SPLICE(2)

30

116

110
SPLICE(7)

115

305

300

SPLICE(4)

SPLICE(5)

105

567

128

190

CAT DIGITAL
VOLTAGE
REGULATOR

385

SPLICE(3)

593

379

220

47

90

78

372

80

72
30

FUEL LEVEL

82

1790

ANALOG
VOLTAGE
REGULATOR

260

440
40

131

30
1500

EF2

8mm2

180
200
245
165
200
200
200
210
180

25

40
1
2

2.5mm

R
30

EARTH
2

21

22

19

OIL TEMPERATURE

L
2

MAGNETIC
PICKUP

2.5mm

25

8mm

180
180

10

2.5mm

E/STOP

SPLICE(6)

8mm2

EF1

CORE BALANCE
CURRENT
TRANSFORMER

SERVICE
CONNECTOR

CONTROL
RELAY CR
1

340

CONTROL PANEL

GENERATOR RECEPTACLE
70 WAY

100

8mm

200

310
310

428
SPLICE(1)

STARTER MOTOR
143

2198

1
B+

90

TERMINAL BOX
8mm2

180
180
180
180

A-10

30

130

ALTERNATOR

360

613

B-2
C-18

8mm

8mm2

30

40
2

ETH
2

COOLANT LOSS
NOTE A: UNLESS OTHERWISE SPECIFIED ALL WIRE SIZES 1.5mm/16 AWG
1595

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 269-8103

8mm2

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
n/a
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

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
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
SSPD
DSPD
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

WIRE
55
2
D+
DCAN 1CAN 1+
n/a
n/a

PIN
A
B
D
E
F
G
H
J

10

41

55

1A

10

55
55

26

GENERATOR
RECEPTACLE

3
90

90

160 160

200

30

20

50

0
16
160
160

20

8
10

30
23A

0
16
160
160

30
37

20
38

0
16
160
160

55

108

59
30
12
0
120
120

109
110

73

0
16
160
160

77

ES20
ES-

SERVICE CONNECTOR
RECEPTACLE

95

0
16
160
160

96

EF2
EF1

30
50

SCN
12
0
120
120

51
52

PANEL
LIGHT
SWITCH

ETHER
START
ES-

1A

CAN1-

0
19
190
190
190
19
0

CAN1+
SCN

160

CAN1CAN1+

CAN1-

CAN1+
80

PANEL
LIGHT

570

570

80

80

80

93

20

94
30

SCN

36

60

ALARM BUZZER

30
200

E/STOP

200

M+

0
19
190
190

M-

17

SCN
30

45

14

30
200
100 100 100

30

E/STOP

120
120
120

34

70

DOOR STUD ETH

200
CONTROLLER ETH

50

30
57
20

53
30
12
0
120
120

101
140
140

80

108

55
10

0
16
160

140

VOLTAGE 82
ADJUST

90

OPTION CHASSIS ETH

91
78

50

CHASSIS ETH
ETH TERM

100
250
180

160-7689
70
57
47
39
31
23
13

SSPD

40

46

58
48
40
32
24
14
1

DSPD
0
16
160

100
SPLICE 50

SPLICE 62

SPLICE 10

SPLICE 30

92
97

0
16
160
160
160
16
0

98
99

0
16 0
16

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

346

32

21

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

73

0
19 0
19
190

Battery Charger Failure

22

THERMOCOUPLE #4

INPUT #3

72

260
260
0
26 0
26

1186

Turbocharger 4 Turbine Outlet Temperature

THERMOCOUPLE #4

RTD
PT100

8-PIN CONNECTOR

1185

Turbocharger 3 Turbine Outlet Temperature

345

36

1124

Exhaust Gas Port 3 Temperature

12

30

RTD #7 - SHIELD

Generator Winding Temperature #1

Exhaust Gas Port 2 Temperature

THERMOCOUPLE #3

115

301

126

RED

181

29

RTD #7 - GND

970

1137

344

19

Emergency Stop Switch

Exhaust Gas Port 1 Temperature

343

18

Event Input Function #16

1135

31

THERMOCOUPLE #3

Event Input Function #3

Engine Oil Temperature 2

THERMOCOUPLE #2

300

11

125

342

114

INPUT #2

SPLICE 108

SCN
100

600
SPLICE 55

SPLICE 2

SPLICE 41

SPLICE 1

CAN2+

SPLICE 17

CAN2-

EMCP3 CONNECTOR
ALL WIRES SIZES 1.5mm/16 AWG UNLESS
OTHERWISE STATED

CONNECTOR AND SPLICE LOCATIONS FOR HARNESS 258-4700

(Dimensions: 39 inches x 24 inches)

Auxiliary Temperature 1

RTD #4 - M

21

113

INPUT #1

20 Page,

190

WHITE

CHANNEL1 DEFAULT SPN='EXHAUST GAS PORT 1 TEMP'

RENR9874-04 VOL 2 of 2

Engine Speed

341

16
0

176

11

16
0

175

THERMOCOUPLE #1

40-PIN CONNECTOR

124

1
19 90
0

Engine Oil Temperature


Turbo Oil Temperature

340

THERMOCOUPLE #2
172

23

RTD #3 - L

1
19 90
0

172

12

RTD
PT100

THERMOCOUPLE #1

16
0

Inlet Air Temperature

112

DISCREET I/O MODULE

1
16 60
0

171

40-PIN CONNECTOR

Symbols

1
16 60
0

168

THERMOCOUPLE MODULE

THERMOCOUPLE
TERMINAL
STRIP

90

Battery Voltage

RED

171

RTD #1 - M

Oil Filter Differential Pressure

Ambient Air Temperature

Harness And Wire Electrical Schematic Symbols

RENR9874-04
June 2012

SPN

Fuel Level (External Tank)

10

Suspect Parameter Number (SPN)


SPN Description

7
NEUTRAL EARTH LINK

AC
GENERATOR

BREAKER

4 POLE BREAKER OR POWER TERMINAL STRIP (PTS) OPTIONAL

T2
T3
N
E

P1

P2

S1
P1

S2
P2

CT1

T2

S2
P2

CT2

T3

S1
P1
S1

S2

L1

10

EARTH FAULT
RELAY
8
9

13

30

14

12

7
1

21

EF1

30

14

14

20

73

EF1
61

62

26

25

GENERATOR
RECEPTACLE
1030213

52

53

CAN 2 SERVICE
CONNECTOR

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

EF2

EF1

T2
F2
(4A)

T3
F3
4A)

101

55

SERVICE
CONNECTOR
108

109

110

SRN

C
G
F

CAN2+

64

CAN2-

63

SRN
CAN2CAN2+

32

21

EMCP3 PLUG
1607689

22

21

22

67

66

AC

2.5 mm 2

52

53

31

47

57

50

39

108

109

110

101

13

11

+
IA

IB

IC

CB3
(15A)

CB2
(20A)

CB1
(60A)

1.5 mm 2

24

CAN1+

VC

I RETURN
VB

65

52

:87

ALT

DC
F5
(10A)

CHARGING
ALTERNATOR

RLY3

FUEL
CONTROL

51

61

EMCP3 PLUG
1607689
14

6 mm 2

-VE SUPPLY

TERMINAL
RAIL LINK

ASR
SWITCH

SRN(CAN1)

55

GFR
SWITCH

55

48

41

58

35

37

43

33

55

41

32

55

36

GRR
SWITCH

40

55

31

27

26

55

38

HARNESS Y
SPLICE CAN1-

27

50

29

CAN 1-

HARNESS Y
SPLICE CAN1+

39

CAN 1+

CAN 1+

PANEL
LIGHT
SWITCH

EMERG
STOP

55

25

90

15

91
57

92

24

97

I/P 1
70

58

59

14

98

60

REMOTE
START
I/P 2
55

17

99

57

18

I/P 4
53

73

21

61

LOW
FUEL
LEVEL
I/P 6
44

I/P 5
45

77

18

CAN1 J1939

20

EMER.
STOP

D+
4

D-

40

PROG
I/P 8

OIL
PRESSURE

I/P 7
36

I/P 8
28

PASSIVE
ANALOG 1+
56

93

62
+

34

52

41

S-SPD

38
36

ENGINE
TEMP

D
+B

10
40

:11
CR/3

27

8
22

-B

28

ES-

42

HARNESS Y
SPLICE 10

10

49

15

11

TERMINAL
RAIL LINK

17

46

17

25

PASSIVE
ANALOG 2+
38

PASSIVE
ANALOG 3+
30

OIL
PRESSURE

ENGINE
TEMP

PASSIVE
ANALOG 146

AWG 12

CAN2 +

SHIELD

AWG 12

MODBUS RS485 COMMUNICATION


MODBUS RS485 COMMUNICATION
SHIELD

AWG 12
AWG 12
AWG 12

AWG 12
AWG
AWG
AWG
AWG
AWG
AWG
AWG
AWG
AWG

12
12
12
12
12
12
12
12
12

68

22

96

23
J1939 SECONDARY COMMUNICATION
J1939 SECONDARY COMMUNICATION
SHIELD
BREAKER AUX N/C
BREAKER AUX COM
BREAKER AUX N/O

EMCP3 PLUG
1607689

AWG
AWG
AWG
AWG
AWG
AWG

12
12
12
12
12
12

PASSIVE
ANALOG 237

46

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

46

10

23A

59

18

20

17

80

E/STOP RECEPTACLE 3E3388


HARNESS X
SPLICE 10

54

55

56

78

:86

RELAY BOX

45

18

2
5

VOLTAGE
ADJUST

AIR
SHUTOFF
AIR

ETHER
START
1

59
SASV
2

COOLANT LOSS

50Hz

ST4
R448

P4
ST2

P2

E+

6 mm 2

ST1

NOTE:E

NOTE:F

ASOS

POT
470ohm

3ph

ALTERNATOR
(GENERATOR)
HEATER

T1
S1 S2

1 F15
24V DC
+ 1
SUPPLY
(*)
(DC
TERMINAL
2
- 5
RAIL)

CUSTOMER
L1-N 220V-250V
AC SUPPLY

J1

S1
STATISME
P2

6 mm 2

131

16

14

36

S2

:X2

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

HIG
HIG HH

A1

13

207

208

131

A2

14

TI04

POWER
WIRING
FROM
GENERATOR

96

95

98

131

211

209

210

203

-132

18

-133

PUMP

131

OW
- L
LOW
LOW

LEVEL
SWITCH
(TOP VIEW)

TERMINAL BOX

19

-139

RUN

20

-148

LEVEL SWITCH
(SIDE VIEW)

SW4 NORMALLY OPEN


:X2

SW2 NORMALLY CLOSED

SW1 NORMALLY CLOSED

(+) BATTERY

SYMBOLS

11

CHASSIS CUSTOMER TERMINAL


LOCATED ON DC TERMINAL RAIL

11

CHASSIS DC TERMINAL
LOCATED ON DC TERMINAL RAIL

CHASSIS AC TERMINAL
LOCATED ON AC TERMINAL RAIL

TABLE: 2
50 HZ VOLTAGE WYE

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

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

(T2
(T2
(T2
(T2
(T2

380)
380)
380)
220)
220)

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

380)
380)
380)
220)
220)

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

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

600V

- (T1,T2&T3 220)

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.
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

R448 VOLTAGE REGULATOR


DIAGRAM

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

IDENT
Y
X

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

START AID SOLENOID VALVE


SOCKET

OIL TEMPERATURE SENSOR


SOCKET

HARNESS

CHG

258-4700
269-8103

07
06

58

CHASSIS TO DOOR DC SOCKET


30

GENERATOR SOCKET
5
E/STOP CHASSIS TO DOOR SOCKET

POWER TERMINAL

CONNECTION

:2
:3

:1

EMERGENCY STOP
PUSHBUTTON

PANEL LAMP
:10

EMCP3 HARNESS
J1/GENERATOR SET CONTROL HARNESS

RELAY COIL
:2

TRANZORB
(SURGE SUPPRESSOR)

SCREEN CABLE

:1
131

R/1

6(-)

RELAY CONTACT N/O


:3

F2 CONNECTION

F2
5(+)

VOLTS ADJUST
POTENTIOMETER
(MOUNTED IN
CONTROL PANEL)

T3

T2

4 POLE BREAKER OPTIONAL

REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

65
67
66

S1

POLARITY
MARKS

T2

L2

T2

L2

T3

L3

T3

L3

F1

TO
EXCITER

:3

:3 :2
10k
0.5W

F30
(10A)

NOTE F
5

NOTE E

82
NOTE H 6A

30

30

28

28

26

26

:1
80

3
8

16

4 80
6

233

:13

:14

232

Q/2

REMOTE TERMS
FOR BREAKER
OPEN & CLOSED
POSITIONS

67
65
66

16
26

NOTE G

5A

S2

F26
(10A)

15

ST
:C2

233

:14

231

:12

232

:11

14

16

CONNECTION
TO
PMG

15

30

11

28

12

26

F26
(10A)

CONNECT FOR AREP


EXCITATION GENERATORS

L2

L3

NOTE D

22
22

22
24

24V DC
SHUNT
TRIP

24

24
20

GND

20

22

T1

T2

T3

CONNECTION TO
GENERATOR
TERMINALS
(LINE PTS)

30
24
28
20
26

T4

T5

T6

CONNECTION TO
GENERATOR
TERMINALS
(CENTER PTS)

VR6-B
240V OR BELOW:
(PARALLEL CONNECTION)

ABOVE 240V:
(SERIES CONNECTION)

CIRCUIT BREAKER

NOTE:B
CONNECT 1A DROOP CT BETWEEN TERMINALS 5 AND 6
CONNECT 5A DROOP CT BETWEEN TERMINALS 5A AND 6
NOTE:C
FOR SE GENERATOR JUMPER
TERMINAL 20 TO 28
TERMINAL 22 TO 30
TERMINAL 24 TO 36
REMOVE JUMPERS FOR PM OR AREP GENERATOR
NOTE:D
CONNECT VAR/PF CONTROL TO TERMINALS 2 AND 3
JUMPER TERMINALS 2 AND 3 WHEN NOT USING VAR/PF CONTROL
NOTE:E
FACTORY DEFAULT IS 2V/Hz UNDER FREQUENCY SLOPE. FOR 1V/Hz
UNDER FREQUENCY SLOPE, ADD JUMPER TO TERMINALS 6A AND 8.
NOTE:F
FACTORY DEFAULT IS THREE PHASE SENSING. FOR SINGLE PHASE
SENSING REMOVE JUMPER BETWEEN TERMINALS 6A AND 9.
NOTE:G
JUMPER 4 AND 7 WHEN USING INTERNAL VOLTAGE ADJUST, REMOVE
WHEN USING REMOTE VOLTAGE ADJUST RHEOSTAT.
NOTE:H
CONNECT REMOTE ADJUST RHEOSTAT (10, 0.5w)

MCCB

ACB

CONNECTION
TO
AREP

9
26

BREAKER
AUXILIARY

BREAKER
AUXILIARY

EARTH

11
12

CONNECT FOR PMG


EXCITATION GENERATORS

20

Q/1

14

10
10

30

:C1

:C12

F30
(10A)

30

L1

24V DC
SHUNT
TRIP

:12

PANEL LAMP SWITCH


:2

NOTE B

POWER
WIRING
FROM
GENERATOR

:C11

:11

VR6-B VOLTAGE REGULATOR DIAGRAM

BETWEEN TERMINALS 6A AND 7.

THIS SCHEMATIC IS FOR THE C18 GENERATOR SET WITH EMCP3 ELECTRICAL SYSTEM
VOLUME 2 of 2: EMCP3
MEDIA NUMBER: RENR9874-04
SCHEMATIC PART NUMBER: 265-7864, CHANGE: 11, VERSION: DK (EMCP3.1)
SCHEMATIC PART NUMBER: 265-7865, CHANGE: 11, VERSION: DK (EMCP3.2)
SCHEMATIC PART NUMBER: 265-7866, CHANGE: 11, VERSION: DK (EMCP3.3)
SCHEMATIC PART NUMBER: 261-5834, CHANGE: 14, VERSION: DK (OPTIONS)
SCHEMATIC PART NUMBER: 354-8363, CHANGE: 03, VERSION: DK (VR6-B)
Components are shown installed on a fully operable machine with the key and engine off, transmission shifter
in neutral and with parking brake set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.

131

L1

231

POTENTIOMETER

FUSE

FOR 5A CHARGER FIT (6A) FUSE


FOR 10A CHARGER FIT (10A) FUSE

ST

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

T1

ENTRY

HIG

TERMINAL BOX

:X1

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

L1

SW3

97

O/L

-132

NOTE:A
50/60 Hz SELECTION

NOTE:H

S1

131

140

CABLE

207

R731

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

T1

HEATERS

SW2

SW1

PC

CHASSIS
AC TERMINAL
RAIL

SW4

131

204

NOTE:I

82

ENGINE
JACKET
WATER
HEATER

6 mm 2

P1

470ohm
POT

TENSION
P1

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2

12

NOTE:B
IF M2 IS NOT AVAILABLE THEN INSERT WIRES INTO M1
ENSURE WIRE IDENTS MATCH

BLACK
BLUE

P1
QUADRATURE DROOP ADJUST

14

20
131

FUEL LEVEL SWITCH DRAWING

F1

19

148

12

203

:11

AH2

NOTE:A
IF 240V JACKET WATER HEATER IS FITTED MCB M2 SHOULD BE 16A
IF 240V BLOCK HEATER IS FITTED MCB M2 SHOULD BE 10A

:X1

TRIP/

17

50 HZ VOLTAGE WYE

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)

ALTERNATOR
WINDING
CONNECTIONS

RFI UNIT
ALTERNATOR
WINDING
CONNECTIONS

DROOP CT

139

TABLE: 1

BLACK

380

T1

:6

:5

131

ENGINE
JACKET
WATER
HEATER

15

PR/3

J2

134

6 mm 2

6 mm 2

6 mm 2
6 mm 2

131

20
140

NOTE:C

220

ST9

CONSTANT
VOLTAGE CHARGER

15

BLACK

110

NOTE:D

110

143

CUSTOMER
100V TO 250V
NOTE A

PUMP
205

16

OPTIONAL RFI KIT CONNECTIONS

CONNECTION
TO EXCITER

NOTE:B

230

:A1
HC
:A2

16

207

PUMP
STOP

P2

4 POLE BREAKER OPTIONAL

AH1
AH2

E-

72

TH2

142
9

13

207

132

208

PMG

ST6

110

TH1

NOTE: CUSTOMER CABLE TO


ENTER DIRECTLY ONTO
6 mm 2 TERMINALS.

FUEL LEAK DETECTOR

AC SUPPLY

F21
NOTE:B

131

15

X1
Z2

LOW
FUEL
LEVEL

SHUT-OFF
SOLENOID

X1

9/GREEN

X2
1/2 PHASE
T1- T4 OR
T8 - T11

S2

132

13

30

ABBREVIATIONS

Z2

ANALOG
VOLTAGE
REGULATOR

400

148

F22
(2A)

14

X1

P3

400

:6

139
19

134

X2

10/YELLOW

12/BLACK

230

:4

6 mm 2

120 OHM
RESISTOR
BETWEEN
62 & 63

SUPPLY STATOR PMG

Z1

230

CR/2

(DC TERMINAL RAIL)


30

AC CIRCUIT

PMG

SHUNT
SUPPLY 140V MAX 50/60HZ

X2

LINK

:6

:11

:5 138

L1-N

:5

:8

9/GREEN

10A FUSE

6 mm 2

21

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

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.

10/YELLOW

ST4

16

F19
(16A)
136

141

15

77

CAT DATA LINK

60Hz

110

131

F16
(2A)

SW3 NORMALLY CLOSED

AREP

400

HC
:A2

132

L1-N

CR/3
134

6 mm 2

COPPER BUSBAR
F18
(4A)

PR
:10

-5O EARTH

SUPPLY - AUXILIARY WINDING

CONSTANT
VOLTAGE CHARGER

CUSTOMER
L1-L2: 208V to 250V
L1-N: 120V
AC SUPPLY

:2

77

16

51

REMOTE CONTACTS
FOR GENERATOR RUNNING

NOTE:A

EXCITATION
CEILING
P5
ADJUST

HARNESS X
SPLICE 45

45

CR/1
:1

:3

50

-VE SUPPLY

82

:85

SMMS1

COPPER BUSBAR

:A1

49

89

11/RED

SR

:4

137

L1 AWG 8
L2 AWG 8

-131

FUEL
LEAK
SWITCH

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

15

PR
:10

(-) BATTERY / SENSOR RETURN

BATTERY CHARGER

CR/2

48

88

J3

45

135
136

138

87

ST3

UNDER
SPEED
ADJUST
STABILITY
ADJUST

F17
(6A)

134

AWG 8

53

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

70

80

FOR
USE
WITH
CDVR

E/STOP PLUG
1552264

COPPER BUSBAR

CR/1
:1

:9

:2

83

VALVE

-VE SUPPLY

VALVE

HIGHWAYS

23A

59

:4

CHASSIS
DC TERMINAL
RAIL

-93
-94
-M+
-M-SRN
-S-SPD
-D-SPD
-SRN
-10

:2
MV
:1 MOT.

53

HIGH
LEVEL
FUEL
SWITCH

:2
MV
:1 MOT.

85

SIGNAL PLUS TO ECM


SIGNAL MINUS TO ECM

64

10

143

52
55

81

:3
PR/1
:1
81

55

131

:7

82

NOTE:G

18

PR/2

:7

52

83

54

LOW
LEVEL
FUEL
SWITCH

:6

:6
PR/2

HIGH
LEVEL
FUEL
SWITCH

30

84

84

72

59

6 mm 2 133

120 OHM
RESISTOR
BETWEEN
27 & 29

:3
PR/1
:1

RS-232/RS-485 DATA LINK

E/STOP RECEPTACLE 3E3388

ETHER
START

GENERATOR
RECEPTACLE
1030213

84

PUMP
RUN

23A

ES-

84
54

LOW
LEVEL
FUEL
SWITCH

(2A)

-SRN

-131

84

(+) BATTERY SWITCHED

HARNESS X, SPLICE 30

M2
NOTE: A
MCB

66

L1-L2

GRR/3

:1

HARNESS X
SPLICE 2-1

136

:8

82

30

16

CUSTOMER SUPPLY FROM 2 POLE


BREAKER IN EMERGENCY
PANEL POWERS:
JW HEATER, UNIT MOUNTED
CHARGER AND OPTIONAL
GENERATOR SPACE HEATER

GENERATOR RUNNING

REMOTE CONTACTS
FOR GENERAL ALARM

80

E/STOP RECEPTACLE
3E3388

TERMINAL RAIL LINK

F16
(2A)

47

1 F23

85

14

(2A)

DC CIRCUIT

STOP

PASSIVE
ANALOG 329

F23

J1939 DATA LINK


34

10
GENERATOR
PLUG
9X4391

6 mm 2 132

65

FUEL PUMPED FROM FREE STANDING


BULK TANK - FUEL SYSTEM NO. 3

-CAN1+

-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

DC CIRCUIT

:9

:9

64

OR

OIL
TEMP

This pin
does not
exist on
EMCP3.1

:2
:3

78

78

65

2.5 mm 2

J1939 PRIMARY COMMUNICATION

12

59

30

48

50

12

2 .5 mm 2

J1939 PRIMARY COMMUNICATION

CAN2 -

95

69

SINK O/P 2

This pin
does not
exist on
EMCP3.1

:87

19

14

TERMINAL
HARNESS Y RAIL LINK
SPLICE 30
13
30
30

ASOR/1

EMERGENCY STOP
ON ENCLOSURE

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

11

SINK O/P 1

VOLTS ADJUST
POTENTIOMETER
(2K W, 10 TURN)

FOR
USE
WITH
CDVR

:30

E/STOP PLUG 1552264

{ENGINE MOUNTED}

131

CAN2 SRN

:11

E/STOP RECEPTACLE
3E3388

PWM SPEED CONTROL

ES-

ENGINE
ELECTRONIC
CONTROL
MODULE(ECM)

10

-3
-6
-8
-10 x2
-10
-23A
-30
-30
-37
-38
-55 x2
-55
-59
-73
-77
-95
-96
-ES-EF1
-EF2
-CAN1-

GRAVITY FUEL SUPPLY FROM HIGH


LEVEL BULK TANK TO BASETANK
FUEL SYSTEM No. 2

E/STOP PLUG 1552264

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

SPEED CONTROL

13

24

140

RS485

ALR/3

23A

45

42

10

10

AWG 12

4
SRN

(16A)

:87

E/STOP PLUG
1552264

:3

21

NC

ECM POWER LINK


REMOTE START FROM ATS
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

COMMON ALARM

23

EPIR/1

:9

34

:2

43

30

24V DC
1
SUPPLY
(DC
TERMINAL
2
RAIL)

:30

44

61

ALTERNATOR
(GENERATOR)
HEATER

The below does


not function
on EMCP3.1

OIL
TEMP

34

57

30

REMOTE
START
CONTACT

:1

D-SPD

39
37

AH1

-1
-1
-2 x2

35

D-SPD

65

17

46

TERMINAL
RAIL LINK

41

GENERATOR
PLUG 9X4391

68

63

41

GENERATOR
RECEPTACLE
1030213

S-SPD

HARNESS X
SPLICE 2-2

ECM
POWER
LINK

HARNESS Y
SPLICE 41

HARNESS Y
SPLICE 2

15

66

53

142
9

5
+

F27

44

PANEL
LIGHT

10

HARNESS X
SPLICE B+

:6

BATT -

:11
45

45

48

GEN
RUNNING

55

:2
CR
:10

70

BATTERY CHARGER
& HEATERS
(Both use the
same voltage)

63
SRN

:8

23
ECM PLUG
P1 1607689

:5

64

CAN2 J1939

94

33

10

D-

41

HARNESS Y
SPLICE 17

3 COMMON
ALARM

141

37

The above does


not function
on EMCP3.2 or
EMCP3.1

PROG
I/P 7

72

ETHER
START

43

D+

140

AIR
SHUTOFF

38
:2
GRR
:10

ALR ALARM
RELAY
:10
2

ALARM

J
8

(Dimensions: 39 inches x 24 inches)

EARTH
FAULT

16

6 :2

20 Page,

FUEL
LEAK

LOW
COOLANT
LEVEL
I/P 3
54

:2

M1
2P 6A
MCB

AWG 12

38

36

37 :86
AIR
ASOR SHUTOFF
RELAY
:85
2

TERMINAL
RAIL LINK
:3

15

1A

40
CAN 1-

F17
(10A)

FUEL LEAK DETECT

# 1

The above does not function on EMCP3.1

55

55

17

CAN 1+

41

34

RENR9874-04 VOL 2 of 2

RLY6

56

SERVICE CONNECTOR
RECEPTACLE 1282312
CAN 1-

ECM
PLUG P1 1607689

BATT +

E/STUD 2

RELAY BOX

RLY5

RLY4
AUDIBLE
ALARM

30

42
SRN

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

HARNESS Y
SPLICE 55

F4
(10A)

J16
1

M-

M+

EMCP 3.3
or 3.2
or 3.1

B+

OPTIONAL
BATTERY
ISOLATOR
SWITCH
KEY
REMOVABLE

E/STUD 1

RLY2

ENG
CRANK

40

PS1

36

RLY1

25

35

BATTERY (12/24Vdc)
55

SR/1

RELAY BOX

SM1

34

:30

64

CAN2-

CAN2+

LCD DISPLAY

6 mm 2

A+

SMMS1/1

63

AWG 12
AWG 12

120
OHMS

CAN1-

50
+

+
PS1

62

SPARE BATTERY +
SPARE BATTERY +

EARTH (MOUNTING SCREW)

EMCP3 PLUG
1607689
2

24V

120
OHMS

VA

TERMINAL
RAIL LINK

2.5 mm 2

+VE SUPPLY

51

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

AWG 12

ECM POWER LINK

PICKUP

HARNESS Y
SPLICE 1

CHASSIS CHASSIS
STANDARD OPTIONAL
STUD
STUD

MAG
6 mm 2

108

HARNESS Y
SPLICE 108

HARNESS X
SPLICE 1

33

101

SRN(CAN1)

50

31

DOOR

22

CAN 1+

21

GENERATOR
PLUG 9X4391

HARNESS Y
SPLICE 101

GENERATOR
RECEPTACLE
1030213

CAN 1-

62

GENERATOR
RECEPTACLE
1030213

AWG
AWG
AWG
AWG

AIR SHUTOFF RELAY

ANNUNCIATOR

1
2

101

HARNESS Y
SPLICE 50
GENERATOR
PLUG
9X4391

P16

55

18

43

ANNUNCIATOR

1 EARTH

MAGNETIC
PICK UP No.1

GENERATOR
PLUG 9X4391

T1
F1
(4A)

50

PUMPED FUEL SUPPLY FROM BELOW


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

WIRE IDENT:-

CT3

EF1

EF2

EF2

JUMPER PLUGS

L3

51

BATTERY
BATTERY
BATTERY
BATTERY

L2

EF2
24

22

SPARE
SPARE
SPARE
SPARE

METERING C.T.s

T1

10

3
CUSTOMER CONNECTIONS:

T1

CORE
BALANCE
C.T.

CORE BALANCE
CURRENT TRANSFORMER
IF REQUIRED