REGULATOR MODULE (R438)

SENSOR MODULE (R731) OVERLOAD CURRENT TRANSFORMERS (CT1, CT2, CT3) GEN SET CONTROL OR
ELECTRONIC MODULAR CONTROL PANEL KENR5917
(EMCP3)
EMERGENCY STOP
PUSH BUTTON (ESPB) SERVICE TOOL September 2007
CONNECTOR

HARNESS 304-7187
(INSIDE CONTROL PANEL BOX)

6A CIRCUIT BREAKER (MCB 12)

OVERLOAD UNIT 2A CIRCUIT BREAKERS (MCB 9 & 11)
HEATER CONTACTOR (HC) FUSES (F6, F7, F8)
6A CIRCUIT BREAKERS (MCB 3, 4, 5)
12 VDC RELAYS (CR & ECMR)
2A CIRCUIT BREAKER (MCB 2)
6A CIRCUIT BREAKER (MCB 1) CIRCUIT BREAKERS

XQ80 and XQ100 Generator Set

M1 THROUGH M6
BACK PANEL OF EMCP3 BOX
50A 125/250V

with EMCP3
CIRCUIT BREAKER CALIFORNIA
MCCB2 208 V OUTPUT TWISTLOCK
RECEPTACLES
(S5) & (S6)

CIRCUIT BREAKER
MCCB1 480 V OUTPUT 20A 125V
Electrical System
DUPLEX
RECEPTACLES
HARNESS 278-6143 (S1) & (S2) D4D1-UP
HARNESS 306-5286
AUXILIARY SUPPLY
120 V AC INLET
SOCKET

POWER
TERMINAL STRIP
Related Electrical Service Manuals
Title Form Number
20A 120/208V
Operation and Maintenance Manual SEBU8132
FLANGED EMCP 3 Systems Operation/ Troubleshooting/
RECEPTACLES RENR7902
(S3) & (S4) Testing and Adjusting
Electrical Schematic for C4.4 Generator Set KENR8281
(See this Schematic for engine component location)
EARTH
CONNECTION
BLOCK

2007 Caterpillar Printed in U.S.A.

REAR VIEW OF GENERATOR SET All Rights Reserved
LEFT SIDE VIEW OF GENERATOR SET

SERVICE TOOL CONNECTOR 24 WAY CONNECTOR FROM ALTERNATOR

27 15 5
PIN WIRE
D 122 1 9
24 WAY PIN WIRE
PIN A (7) 1 2 3 4 PIN 5 (150)
E C PIN 6 (151)
PIN B (5)
SPLICE (131) 3 SPLICE (132) 4 5 6 7 8 9
PIN 7 (152)
F A B PIN C (SCR)
37mm 40mm 62mm 77mm 37mm 40mm 104mm 40mm 60mm 37mm 68mm 71mm 64mm 10 11 12 13 14 15 PIN 8 (153)
G J PIN D (371) 6 PIN 9 (154)
51mm 16 17 18 19 20
H PIN E (372) 79mm 11mm 45mm PIN 10 (155)
6 21 22 23 24
PIN F (62) PIN 11 (156)
29mm 47mm
C50 PIN 12 (157)
PIN G (61) PIN 13 (158)
C60 21mm
SPLICE (156) 3
59mm
54mm 22WAY
50mm
22 WAY ENGINE DC CONNECTOR
47mm
SERVICE TOOL

(Dimensions: 39 inches x 28 inches)

DEUTSCH 66mm
C55 PIN WIRE
21mm 49mm 1
22 23 24 25 2 3 PIN 2 (+)
165mm 67mm 31mm 50mm 420mm
58mm PIN 3 (3A)
1 7 1 1 16 5 4 5 6 7 8
21mm PIN 4 (4)
1 18 9 10 11 12 13 14
55mm C65 6 PIN 5 (5)
28 103mm 15 16 17 18 19
6 4 58mm 47mm PIN 6 (61)
141 ETH 20 21
C130 33mm 22 PIN 7 (62)
C30
12 13 14 11 ETH PIN 8 (371)
C100 138
C40 3 1 1 PIN 9 (372)
10 1
VT1 VT2 38mm
11 75mm
135
36mm 3 WAY DC PIN 10 (YGN)
C35 PIN 13 (5A)
SPLICE (157) 3 34mm
162mm 3 WAY DC CONNECTOR PIN 14 (42)
FROM DISTRIBUION
208 165mm 67mm 31mm PANEL PIN 15 (FL)
12 13 14

KENR5917
108 PIN WIRE 3 1 1 PIN 16 (16)
28
C45 A B
PIN A (5) 23 WAY 3 WAY AUX PIN 17 (47)
70mm 1 25mm
28 PIN B (24) 17 18 3 WAY AC AUXILIARY PIN 18 (41)
210 PIN C (88) SUPPLY CONNECTOR
C130 6 63 C 1 17 PIN 19 (19)
FROM DISTRIBUTION
131 152mm PIN 20 (49)
110 64 PANEL
C110 28
PIN 21 (10)
114mm 3 16mm 23 WAY AC SENSING CONNECTOR PIN WIRE
309 70mm PIN WIRE
140mm 6 SRN
K A B PIN A (131)
L X PIN B (132)
120mm 3 28 123mm PIN A (101)
C20 61 M W PIN C (135)
100mm 3 7 20mm 65 B PIN B (C15) C
6 3 61 C J PIN C (C35)
C70 80mm 62 N V
66 61
6 5 162mm 62 PIN D (C55)
66mm 44 D A H
50mm 19 SRN PIN E (C10)
19mm SRN 62 O U
E G (C30)
C60 48 SRN PIN F
C10 123mm F
24mm 28 3 P T PIN G (C50)
182mm SRN
10 C45 153mm
C90 C20 4 Q S PIN H (C90) 5.
25mm 193mm R 14 10mm 2 ETH.
8 C80 60mm 28 6mm 2 6
3A PIN J (YGN) 1 1.5mm2
3A N
109 212mm 9 51. 1 O MEAS PART NO. NAME
C25 C15 PIN K (7) T
ITEM QTY UNIT
2.5mm 2 ETH. E
55mm
308
19mm PIN M (104) 160 145 115 105 6mm 2 PARTS LIST
142mm 132 PIN O (88) CIRCUIT IDENTIFICATION NUMBERS 17 13 1 1 262-4754 PLUG AS.
165mm 67mm 31mm 105
59 FOR 4 WAY FUEL SWITCH SENDER 2 2 1 262-4800 CLAMP AS.
310 PIN P (204) CIRCUIT IDENTIFICATION NUMBERS 1
12mm FOR 4 WAY CONNECTOR CONNECTOR 3 18 266-3230 TERMINAL-SOCKET
102mm 134 44
50mm 16mm C25 PIN R (102) 3 4 43 4 1 268-1167 CONNECTOR
5 123mm 132 1 2 POSITION NO: WIRE IDENT / WIRE GUAGE POSITION NO: WIRE IDENT / WIRE GUAGE
82mm 70mm 1 5 1 7H-1189 TERMINAL AS

30 Page,B&W
209 7 PIN T (202) 1 2 1 35
C40 18 27 133 80mm 123mm 132 102 1 N/A 5. 49. A 5. / 0.75mm 2 30 6 1 3T-4697 TERMINAL AS
0.75mm2 0.75mm2 1
62mm 17 C130 40mm 7 PIN V (103) 2 N/A B 47. / 0.75mm 2 1 7 1 247-3241 CONNECTOR
5A 30mm 40MM
PIN X (203) 21 9 18 3 N/A C FL. / 0.75mm 2 128 246MM 8 2 247-3242 TERMINAL
51mm 136 80mm D +. / 0.75mm 2 9 12 246-2009 TERMINAL
C120 123mm 103 5 6 7 8 1 6 2 3 4 4 5B. / 1.5mm 2 SPLICE (+-1) 5 128 30
48 8 9 10 5 246-2010 INSULATOR
C65 6 60mm 7A 15mm 11mm 150 CIRCUIT IDENTIFICATION NUMBERS CIRCUIT IDENTIFICATION NUMBERS 1 11 3 7H-1179 TERMINAL AS.
163mm 7 7 N
C75 O MEAS
PART NO. FOR 8 WAY ENGINE INTERFACE 20 9 FOR GLOW PLUG RELAY 800MM 12 536 CM 134-6258 CABLE-ELECTRICAL
3 5 110 80mm 123mm
T
E ITEM QTY UNIT NAME
MODULE CONNECTOR 50 50
100mm 22 1 1 POSITION NO: WIRE IDENT / WIRE GUAGE 32 13 4 7H-1188 TERMINAL AS
PARTS LIST POSITION NO: WIRE IDENT / WIRE GUAGE 14 1 7H-1181 TERMINAL AS
15mm 151 104 1 30 +. / 10mm 2 1
8 9 A 1 9999 CM 242-4916 WIRE-ELECTRICAL 1 51. / 2.5mm 2 15 2 7H-1187 TERMINAL AS
19mm 203 AC+ 87 58A. / 10mm 2
4 120mm 129mm 53mm 109 80mm E 1 5439 CM 242-4916 WIRE-ELECTRICAL 23 34 16 6 307-6931 TERMINAL
88mm 2 2 3 AC- 2 58. / 1.5mm 2 2 30
53mm SPLICE (+) 152 2 259 CM 242-4917 WIRE-ELECTRICAL 1 1 86 5. / 1.5mm 17 2 7H-1190 TERMINAL AS
21mm 3 53. / 4mm 2 1
123mm 202 153 8 9 3 8900 MM 264-8941 WIRE-ELECTRICAL 25MM 85 58. / 1.5mm 2 250 18 2 128-3117 TERMINAL
109mm 108 80mm 4 10. / 1.5mm 2 135 240MM 19 1 259-5667 PLUG AS
4 1064 CM 134-6258 CABLE-ELECTRICAL 135
SOCKET WIRE 5 32mm 6 6 5 +. / 4mm 2 19 20 1 262-1744 RECEPTACLE AS
58mm 5 27 261-7902 PLUG-CONNECTOR 30 87
15mm 6 4. / 1.5mm 2 29 A.
1 405 21 1 262-1752 RECEPTACLE AS
SOCKET 3 (66) 123mm 154 6 45 240-1407 46 35
TERMINAL-FORK 1 D C
22 1 263-3807 SLEEVE
5 210 80mm 7 5. / 1.5mm 2 1 1
SOCKET 4 (SC2) 204 7 35 240-1405 TERMINAL-BLADE 340MM B. 23 1 263-3808 SLEEVE
35mm 8 3A. / 1.5mm 2 34 40MM
SOCKET 5 (65) 6
30mm
8 26 246-2009 TERMINAL 1 86 85 SPLICE (5-1) 5 24 1 245-1042 PLUG AS-CONN
24mm 22mm 15mm 157
4 15mm 9 26 246-2010 INSULATOR 25MM B 25 1 245-1045 ENDBELL-CONN
SOCKET 7 (101) 7 350 B 26 2 245-1044 LOCK-CONNECTOR
24mm 47mm 31mm 32mm 19mm 19mm 43mm 39mm 8mm 209 80mm 156 10 23 7H-1189 TERMINAL AS.
SOCKET 9 (310) 123mm 31 150 155 150 140 11 45 27 15 245-1047 SOCKET-CONNECTOR
11 11 1 3T-4699 TERMINAL AS. 30
7A 7 1 1 29 2 2 C 28 49 245-1048 PLUG-CONNECTOR
SOCKET 11 (309) 25mm 12 6 9W-0844 SOCKET-CONNECTOR 1 9 10
13mm 170mm 3 1 2 100MM 1 360 58A. 29 29 DM 240-0711 CONDUIT-FLEXIBLE
SOCKET 13 (308) 30mm 6 13 2 155-2261 WEDGE-PLUG LOCK 2 2 405
6 208 80mm 18 1 105 33 33 350MM +. 10mm2 30 60 DM 5N-8360 CONDUIT FLEXIBLE
52mm
7 14 2 3E-3370 RECEPTACLE AS.-CONNECTOR 1 30 58.
SOCKET 31 (C70) 75mm 1 1 10mm2 31 1 301-8319 PIN-ISOLATOR
8 123mm 50 15 1 261-7653 SOCKET AS. 2 3 1 1.5mm2
+ 25mm 5. 32 4 214-3133 CONDUIT-TEE
SOCKET 32 (88) 16 1 267-1337 SOCKET AS. 4 5 6 7 8 295MM 1.5mm2 33 8 214-3164 CONDUIT-TEE
SOCKET 34 (62) 35mm 80mm 17 1 34 15 CM 9X-2506 TUBE-HEAT
+ 17mm 183mm 212-9865 CONNECTOR 9 10 11 12 13 14
18 17
200 145 150 155 305 305 280 275 275 110 100 35 2 DM 6V-2721 TUBE-SHRINKABLE
SOCKET 35 (10) 7A 4 115-1052 PIN-CONNECTOR
75mm 157 15 16 17 18 19 36 303 DM 6V-2648 WIRE-ELECTRICAL
3 C130 15mm SPLICE (88) 19 1 160-7689 PLUG AS-CONN SPLICE (ETH) 4 SPLICE (5-3)6 30 30 SPLICE (+-2)4
SOCKET 39 (C90) SPLICE (59) 37 1651 CM 242-4916 WIRE-ELECTRICAL
100mm 20 34 126-1766 SOCKET-CONNECTOR 20 21 32 30 1 1 30 30 30
SOCKET 40 (5) 158 22 38 357 CM 242-4917 WIRE-ELECTRICAL
6 21 36 8T-8737 PLUG-SEAL 1 1 600MM 33 270MM 33 1 33 1 32 1 32
210 200 39 33 DM 5P-3960 WIRE-ELECTRICAL
SOCKET 42 (SCR) 5 33mm 130mm 22 1 128-2312 CONNECTOR 30 135MM 1 1 540MM 1 100MM 1 90MM 1 40 819 CM 234-4888 WIRE-BULK
54mm 2 C130 15mm 600
SOCKET 43 (7) SPLICE (3)
4 23 7 8T-8729 PIN-CONNECTOR 1 29 29 130 41 392 CM 242-4918 WIRE-ELECTRICAL
44mm 8 9 137 CIRCUIT IDENTIFICATION NUMBERS
100mm 123mm 24 1 096-0061 STRAP-CABLE 140MM 1 1 42 4789 MM 264-8941 WIRE-ELECTRICAL
SOCKET 45 (49) FOR 22 WAY ENGINE DC CONNECTOR
7 7 25 1 8C-6354 CAP-RECEPTACLE 200MM 190MM 43 1 DM 168-9044 TUBE-BULK
SOCKET 47 (C75) 88 POSITION NO: WIRE IDENT / WIRE GUAGE 29 44 8 CM 7X-2639 TUBE SHRINKABLE
15mm C100 26 1 2L-8075 TERMINAL SPLICE (53)7
48 1 PIN ISOLATOR (ITEM 31) CIRCUIT IDENTIFICATION NUMBERS 34 1 45 4 9W-1795 BOOT
SOCKET 48 (27) C130 156 27 122 8L-8413 STRAP-CABLE 4 FOR 5 WAY MPU CONNECTOR 130
100mm C110 2 +. / 1.5mm 2 1 590MM 46 1 265-5679 RELAY
SOCKET 50 (61) SPLICE (48)3 40mm 28 27 307-6931 TERMINAL 1
3 3A. / 1.5mm 2 POSITION NO: WIRE IDENT / WIRE GUAGE 25MM 4 47 430 CM 203-6282 WIRE-BULK
(18) 5 15mm C120
SOCKET 51 10 217mm VT2 NOTE A: OR EQUIVALENT 4 4. / 1.5mm 2 1 N/A NOTE B: PART NOT SHOWN
134 7 8 3 SPLICE (5-2) 6
SOCKET 52 (7) 1 131 100mm 123mm NOTE E: CONTINUATION TOTAL QTY IS 15438 5 5. / 1.5mm 2 650 650 150 200 2 1
60mm 6 2 N/A 1 2 130 NOTE C: FOR BLANKING OUT EMPTY HOLE POSITIONS
SOCKET 53 (47) 60mm VT1 6 61. / SRN Cable 16 16 5 3 42. / SRN Cable
FL 3 30
141 25mm 133 7 62. / SRN Cable 4 1 4 41. / SRN Cable 5
CONTROLLER 70 WAY CONNECTOR SOCKET 54 (16) 2 CIRCUIT IDENTIFICATION NUMBERS
AC- 8 371. / 0.75mm2 35 1
100mm 26mm AC+ 5 N/A FOR 64 WAY A4:E2 ECM CONNECTOR
SOCKET 55 (24) 9 372. / 0.75mm2 1 380MM
155 135. 131. ETH.
ETH 100mm 131. POSITION NO: WIRE IDENT / WIRE GUAGE
58 70 SOCKET 57 (C80) 148mm 59 138 10 YGN / 1.5mm 2 1.5mm2
1.5mm2 1.5mm 2 1.5mm 2 40MM
8 9 80 1 5. / 0.75mm 2
48 57 SOCKET 58 (7) 11 N/A / 135.
21mm 3A
21mm
7A 1.5mm 2 +. 5. 2 5. / 0.75mm 2
SOCKET 61 (7) 40mm 123mm 4 4 12 N/A / 2
40 47 5
13 5A. / 1.5mm 2 1.5mm 2 1.5mm 24 25 26 27 28 3 5. / 0.75mm 2
32 39 SOCKET 62 (63) 3A 80mm
12mm 1 1 2 15 49 25 32 57 64 7 53. / 0.75mm 2
14 42. / SRN Cable
SOCKET 63 (SC1) 69mm 7A SPLICE (3A)5 8 53. / 0.75mm 2
24 31 44 15 FL. / 0.75mm 2 17 24 49 56
6 9 16 41 48 9 5. / 0.75mm 2
23
SOCKET 64 (64) 3 29mm 16 16. / 0.75mm 2 15 45
14
25mm 30 1 8 33 40 10 5. / 0.75mm 2
SOCKET 65 (5) 2 33mm 17 47. / 0.75mm 2 1 1
1 13 43 80mm 1 15 53. / 0.75mm 2
SOCKET 66 (41) 18 41. / SRN Cable 33 33 33
133mm 136 17 +. 140MM 16 53. / 0.75mm 2
54mm 19 19. / 0.75mm 2 1 1 1
SOCKET 67 (42) 69mm 43 7 1 6mm 2 20 61. / SRN Cable
30mm 20 49. / 0.75mm 2
SOCKET 70 (17) 5 23mm 7 21 62. / SRN Cable
7 SPLICE (C130) 7 21 10. / 1.5mm 2 19.
165 150 260 520 1110
48mm 0.75mm2 22 SRN / SRN Cable
50 5 80mm 6 22 N/A /
23 371. / 0.75mm 2
19 20 21 ETH. 30
100mm
1 30 24 372. / 0.75mm 2
1 34 36 137 51mm 6mm 2 35 29 30
24mm 70mm 59 59mm 250MM 1 40 53. / 0.75mm 2
1 1 430 600 1
143mm ETH 420MM 29 510MM 1100MM
10 15 40MM 220
CAT

100mm 66mm 66mm 66mm 67mm 44mm 44mm 77mm 13mm 47mm 56mm 24mm 83mm 37mm 33mm 30mm 30mm 44mm 63mm 63mm
1 34 34 1
SPLICE (C90) 5 SPLICE (5-1) 8 SPLICE (7) 8 SPLICE (ETH)10 SPLICE (7A) 5 SPLICE (5-2) 8 2
235mm 1 590MM
1
25MM 25MM 29
130mm
30 100 34 1
430mm ETH
SLEEVING 1 210MM
25MM
11 45
ETH 13 58A.
70 WAY 10
1
HARNESS 304-7187 2
ETH.
ETH.
6mm 2 16. 5. 9
10mm 2
10
1 1

6mm 2
0.75mm2 53. 0.75mm2 3 3
0.75mm 2

HARNESS 306-5286
 6 5 4 3 2 1 SYMBOLS
ABBREVIATIONS
AC-
VT1 AC
MCCB1 ALTERNATING CURRENT
AC+
VT2 A.V.R.
135
AUTOMATIC VOLTAGE REGULATOR FUSE
VOLTAGE ADJUST 11 CUSTOMER TERMINAL
POTENTIOMETER L1 L7
CR CONTROL RELAY
P1 P2 C
Cut Links ST9 and ST1 3ph 470 W S1 S2 S2 S1 + - POT
POT TI TI CT S1 S2 132
DC DIRECT CURRENT
SENSOR MODULE L2 P1 P2 L8
REGULATOR MODULE (R438) (R731) MCB9 MCB11 MCB12 B
ECM ENGINE CONTROL MODULE
S1 S2 AUXILIARY SUPPLY EMERGENCY STOP
U V W (2A) (2A) (10A)
F L3 P1 P2 L9 480V OUTPUT 131 120V AC INLET F ECMR ENGINE CONTROL MODULE RELAY PUSHBUTTON INTERNAL PANEL TERMINAL

380

230

110

400
230
110
400
230
110
400
230
110
X2
SOCKET

Z1

X1

Z2

E+

E-
S1 S2

N
N1 N1 136 131 133 134 A
HC HEATER CONTACTOR :10
150 151 152 153 154 I/P INPUT R
E E
155 156 157 158 RELAY COIL
EXCITER 2U1 2V1 2W1 :5 MCB MINIATURE CIRCUIT BREAKER :2 OUTGOING/INCOMING PANEL TERMINAL
5 6 7 8 9 10 11 12 13
FIELD 7 :3 CR/2
REF.E06 MCCB
104 103 102 101 C10 C30 C50 C90 :6
MOULDED CASE CIRCUIT BREAKER
158 4 ST SHUNT
PMG 6
- 88 :1 TRIP MPU MAGNETIC PICKUP
REF. REF.E06
157 9 E05 58
14 15 16 O/P OUTPUT SCREEN CABLE
156 8 CONTROLLER 70-WAY CONNECTOR
5 137

+
MCCB2 155 7 M V R A E F G H K O PMG PERMANENT MAGNET GENERATOR
EXTERNAL BATTERY CHARGER :1 :5
:A1
RLY RELAY
HC
2U2 +
L10 P2 P1 L4 REF. 135 :A2 :2 :6 SRN SCREEN FROM SCREEN CABLE 30
C06
+ DIODE
L 22 WAY ENGINE DC CONNECTOR
S2 S1 SS STARTER SOLENOID
L11 P2 P1 L5 2V2
5 131
REF. REF. REF. 141 138 ST
S2 S1 B06
- N SHUNT TRIP :1
L12 P2 P1 L6 2W2 B05 B04
208V OUTPUT
S2 S1
R/1 RELAY CONTACT N/O
REF.
N2 N2 POWER TERMINAL
B06 :3
REF. C50 C130 C130
D06 2P2 S1 ENGINE
C90 C55 C35 C15 204 203 202 C60 C100 ALTER- JACKET
E REF.
EARTH
STUD REF. C55
2P1
1P2
S2
C100 5 6 NATOR WATER E EARTH
:3 7 E05 HEATER HEATER
M 23-WAY AC SENSING CONNECTOR
D C B P X T
F03 REF. C65 1P1
OVERLOAD (IF REQD.)
(IF REQD.)

OVERLOAD UNIT
ST F03 CURRENT C110
:1 88 REF. 3 4
TRANSFORMER 131
SHUNT F03 (CT3)
TRIP
REF. C15 C120 1 2
C30 2P2 S1 C130 1 24-WAY A.C. CONNECTOR FROM ALTERNATOR
D03
C35 1U2 1V2 1W2 C40 C110
THE 269-5219 PLUG IS PART OF THE 278-6143 HARNESS
REF. 2P1 S2
E03 REF. 5 98 97 88
L4 C35 1P2
REF. C55 E05
E03 F6 F7 F8 C45 1P1
OVERLOAD
REF. F01 L5 CURRENT CIRCUIT BREAKER LAMP
(6A) (6A) (6A) REF.
SHEET 03 TRANSFORMER
MCB3 MCB4 MCB5 B04
N2 N1 (CT2)
L6 (6A) (6A) (6A) N 5 A C
C10 2P2 S1 C130
N2 208 209 210 108 109 110 101 C20 2P1 S2 C120 REF. A 3 WAY D.C. CONNECTOR FROM DISTRIBUTION PANEL
REF. C01 ALTERNATOR TERMINAL BOX B06 5 88
SHEET 03 REF. REF. C15
E 1P2
E05 MAGNETIC
E04 C25 1P1
OVERLOAD
J CURRENT MICRO PICK-UP
TRANSFORMER SWITCH 1
(CT1) REF. 51W
B03 RESISTOR
REF.
B 4 WAY FUEL SWITCH SENDER CONNECTOR
B06
SYMBOL DESCRIPTION
ELECTRONIC SERVICE TOOL LINK D CIRCUIT CONNECTED
D ENGINE
INTERFACE
C25 C45 C65 C20 C40 C60 C90 A B D E G F C P1 P2
MODULE
CIRCUIT NOT CONNECTED
S1 S2 CURRENT TOGGLE SWITCH
ELECTRICAL CONNECTION TO TRANSFORMER
CON2 9 5 3 16 14 10 7 5 371 372 61 62
2 3 MACHINE STRUCTURE
VOLTAGE/CURRENT INTERNAL ELECTRICAL CONNECTION
SENSING SELECTOR REF.
5A 4 1 63 64 SC1 65 66 SC2 TO SURFACE OF COMPONENT
SWITCH REF. REF. B06
B05 B05 14 18 TERMINAL LINK
3 REF. BATTERY CHARGER TERMINAL
53 3 (25A) 8 3A REF. B06
B05 26 22 20 27 23 21 7 6 1 18 13 12
21 REF.
58 2 (15A) 4 10 REF. B06
A04
5 7 6 4
4 FCS SOLENOID C 3-WAY AC AUXILIARY SUPPLY CONNECTOR FROM DISTRIBUTION PANEL
REF. 25 24 19 8 4 2 17 15 11
:85 A05 120 120
GPR 51 1 (20A) 5 +
:86
+
CON1 61 62 63 64 65 66 42 41
308 309 310 101 C70 C75 C80 C90 -
2 MCB1 PUSH SWITCH
+ + 7A PANEL GAUGE
6A 13 11 9 7 31 47 57 39 50 34 42 62 64 63 5 4 3 67 66
REF.
A02
REF.
E02 MCB2 7A EMCP3 VC IA IB IC I RETURN + - SCRN + - SCRN + SCRN - - + :G
50 CAN1 J1939 CAN2 J1939 ** RS 485 ** MAG
VB
C 2 2A MODULE VA
PICKUP C
POWER
OFF/ON REF. EARTH (MOUNTING SCREW)
:87
B06 POTENTIOMETER
GPR/1
:30
B+ 19
19
E
D+
PROG
LCD DISPLAY
SS 69 SINK O/P 1 **
CHARGING MINIATURE CIRCUIT
7A 7A 7A
ALTERNATOR BREAKER
58A
REF. :3
12V PANEL FUEL ECM
A03 ECMR/1
GLOW
M PLUGS
LIGHT
OFF/ON
GAUGE ON
:1 5
- NOTE: ANY PINS WITH ** AGAINST THEM
65 ARE ONLY AVAILABEL FOR EMCP3.2
59 48 3A 3A BATTERY (12/24Vdc)
7
+
52
REF.
PANEL B04 RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8
REF.
REF. REF. REF. LIGHTS D03 ENG FUEL GLOW PROG COMMON PROG PROG PROG
E02 A03 D02 CRANK CONTROL PLUG O/P SHUTDOWN O/P O/P ** O/P **
5 EMERG REMOTE LOW COOLANT LOW FUEL FUEL
5 5 STOP START PROG PROG PROG OIL ENGINE PROG OIL ENGINE PROG
LEVEL LEVEL LEAK I/P I/P ** I/P ** PRESSURE TEMP I/P ** PRESSURE TEMP I/P **
REF.
D02 10
REF.
D02 I/P 1 I/P 2 I/P 3 PASSIVE PASSIVE PASSIVE PASSIVE PASSIVE PASSIVE
THIS SCHEMATIC IS FOR THE
I/P 4 I/P 5 I/P 6 I/P 7 I/P 8 ANALOG 1+ ANALOG 2+ ANALOG 3+ ANALOG 1- ANALOG 2- ANALOG 3-
REF. REF.
51 61 48 58 35 43 33 41 32 40 26 27 2 25 15 1 24 14 70 55 54 53 45 44 36 28 56 38 30 46 37 29 XQ80 AND XQ100 GENERATOR SET
B 5A
REF.
D06 E03

13 D06 CHASSIS 3A
18 7 27 7 10 7 88 5 17 24 16 47 49
B S/N D4D1-UP
REF.
DOOR 7
E03
REF.
REF. C05 BOX
:2
B05
ECMR REF. 5A REF.
D02
309-3754 (CHG00) WIRING DIAGRAM
B06
:10
306-5286 (CHG01) HARNESS ASSEMBLY
(Dimensions: 39 inches x 28 inches)

16 47 49
5 24
43
REF. REF.
D02 D03
19 B 16 17 20
278-6143 (CHG00) HARNESS ASSEMBLY
ECM EMER
OFF 51
7 WATTS
STOP 5 4 3
REF. REF. 304-7187 (CHG00) HARNESS ASSEMBLY
E03 D02
44
61 62 371 372 CUSTOMER
3A 60 48 START
6 7 8 9 :4 :2 SIGNAL
CR/1 CR +
FROM DISTRIBUTION
:1 :10 5 PANEL
1 AMP 1 AMP - FUEL
1 AMP LEVEL
16

53 53 53 53 53 5 5 5 5 5 61 62 371 372 3 48 :G LOW 49 47

5 87 53 REF.
WATER 32 30 A
KENR5917

LEVEL C06 B
31
A 7 8 15 16 40 1 2 3 9 10 20 21 22 23 24
SWITCH
FUEL SWITCH
D
48 FL + REF.
4 10 FUEL SENDER
15 C06
REF. LEAK
A4:E2 ECM REF.
C06
REF.
C06
B05 REF.
B06 A C
RADIATOR 32
PROBE 5 FL

DIAGRAM-WIRING
(EMCP3 XQ80/100) 309-3754 SHEET 2
6 5 4 3 2 1

L4 L4 L4
208V OUTPUT

F L5 L5 L5
FROM TOP
F
OF MCCB2
REF. E06/D06
SHEET 02
L6 L6 L6
30 Page, B&W,

L4 L5 L6
2
3 x 8 AWG (10MM )
M3 PER PHASE
3P 20A
MCB

L5 L6 L15 L16 L17 20A

13 AWG 13 AWG 13 AWG 120/208V
2 2 2
(2.5MM ) (2.5MM ) (2.5MM )
E FLANGED RECEPTACLE
E
M1 M2 (S3)
1P 20A MCB 1P 20A MCB
Z SILVER
COPPER
L4 L5 L6 L4 L5 L4 L6
Y
COPPER
E
X
L13 L14 COPPER M4 M5 M6
13 AWG 13 AWG 3P 20A 3P 50A 3P 50A
2 2
(2.5MM ) (2.5MM ) MCB MCB MCB
20A 20A
(S1) 125V (S2)
125V
DUPLEX DUPLEX
L24 L25 L26 L27
E E
L18 L19 L20
20A 50A 50A
13 AWG 13 AWG 13 AWG 120/208V 8 AWG 8 AWG 125/250V 8 AWG 8 AWG 125/250V
2 2 2 2 2 2 2
(2.5MM ) (2.5MM ) (2.5MM ) FLANGED RECEPTACLE (10MM ) (10MM ) CALIFORNIA TWISTLOCK (10MM ) (10MM ) CALIFORNIA TWISTLOCK

(S4) (S5) (S6)

SILVER/ SILVER/ Z SILVER Y Y D
BLACK BLACK
D WHITE WHITE COPPER COPPER COPPER

Y X X
COPPER COPPER COPPER
E E E
X W W
COPPER SILVER SILVER

8 AWG 8 AWG 8 AWG 8 AWG

2 2 2 2
(10MM ) (10MM ) (10MM ) (10MM )

13 AWG 13 AWG 13 AWG 13 AWG 13 AWG 13 AWG 13 AWG 13 AWG

2 2 2 2 2 2 2 2
(2.5MM ) (2.5MM ) (2.5MM ) (2.5MM ) (2.5MM ) (2.5MM ) (2.5MM ) (2.5MM )
CHASSIS
PERMANENT
EARTH

COVER
E E E E E EARTH
FROM TOP
OF MCCB2
BOX
C REF. D06 C
N2 N2 SHEET 02
N2 N2 N2 NEUTRAL

B
B DIAGRAM-WIRING A
A (EMCP3 XQ80/100) 309-3754 SHEET 3
6 5 4 3 2 1