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KENR8699
February 2010
3412C Gener at or Set w i t h EMCP 3
El ec t r i c al Syst em
4BZ1-UP
2010 Caterpillar
All Rights Reserved
Printed in U.S.A.
EARTH FAULT RELAY
1
10
30 7
5 8 9
74
30
14
12
13
2
G
E
N
EF1 EF2
CURRENT TRANSFORMER
T3
T2
T1
CORE BALANCE
SWITCH
LEVEL
FUEL
LOW-LOW
72 30
REMOTE CONTACTS
FOR GENERAL ALARM
:11
ALR/3
:9
66 65 64
:8
:10
ALR
:2
6
C C C
2
GRR
:10
:2
33 32 31
87
FOR GENSET RUNNING
REMOTE CONTACTS
C
88
C
89
C
58
:8
87
57
:9
59
88
:11
89
GRR/3
2
38
137
6
:5
6
HC
:A2
131
131
m
m
2
131
:6
6
m
m
2
137 137
:A1
137 137
19
m
m
2
131
WATER
J ACKET
ENGINE
HEATER
139
134
136
CR/1
66
:1
38
:4
17
(2A)
136 136 136
F16
COPPER BUSBAR
131 131 131
(32A)
F19
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO
TERMINALS.
ENTER DIRECTLY ONTO
mm2 6
132
131
6
6
134
mm2
mm2
AC SUPPLY
200V TO 250V
CUSTOMER
C
C
:1
131 131
6
HC
:A1
:A2
137 137 131
66
19
m
m
2
137 137
137
HEATER
2 131
m
m
2
5 .
142
ALTER-
NATOR
2
141
:3
:4
m
m
2
5 .
ENTER DIRECTLY ONTO
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO
AC SUPPLY
TERMINALS.
CUSTOMER
200V TO 250V
COPPER BUSBAR
17
38
CR/1
:4
136
136 136 136 131 131 131
F16
(2A) 6 mm2 131
141
6mm2
C
F18
(4A)
132 mm2 6 C
FOR 5A CHARGER FIT 6A FUSE
FOR 10A CHARGER FIT 10A FUSE
F15 36
49 11 36
2 --
++
CONSTANT
VOLTAGE CHARGER
140
131
HC
:2
131
:A2
131 140
:1 :A1
137
19
m
m
2
6
38
66
17
:4
137
CR/1
:1
136
(2A)
F16 F17
(6A)
136 136 136 131 131 131 135
COPPER BUSBAR
CUSTOMER
200V TO 250V
ENTER DIRECTLY ONTO
mm2 6
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO
6mm2 TERMINALS.
131 C
AC SUPPLY
6 mm2 132 C
DC POSITIVE 1
135
S-SPD
152 151 153 150
LOADSHARING C.T.s
P1
P1
S1
S1
P2
S2
P2
S2
S1
P1
S2
P2
CT6
CT5
CT4
LOAD
6
WARNING INTERNAL CT BURDEN MUST BE CONNECTEDACROSS POWER SOURCE CURRENT TRANSFORMERS AT ALL TIMES TO PREVENT LETHAL HIGH VOLTAGE.
151
152
153
150
108
110
109
106
104
106
105
104 105
151
B0
POTENTIAL
A0
2 1 4
C0
3
CT
5
A0
FOR LOADSHARING OPERATION,
PARALLEL LINES TO BE CONNECTED
ANDSCREEN TO BE EARTHEDONE
ENDONLY (TERMINAL :12).
C
NOTE:
152
153
150
LS1
LS2
LS1
LS2
C
29
PARALLEL
+
10 8
CT
B0
7
CT
C0
9 12
LINES
-
11 13
OPEN FOR DROOP
0
DROOP GAIN
10
AUXILIARY
CONTACT
(SUPPLIED
BY OTHERS)
24102
18-32VDC
AUX CONTACT
15
+
14 16
-
10 0
30
GENERATOR
-
23
LOADSIGNAL
TEST POINT
LOADSENSOR
18 17 22
+
PWM
OUTPUT
26
-
25
+
24
SYNC
INPUT
21 28 27
TRIM
SPEED
19
+
POTENTIOMETER
(10K , 10T)
SPEEDADJ UST
:1 :3
43
CW
42
:2
44S-SPD
W
-
20
D-SPD
2
97 95 5 3 1 O/L
131
33
70
DC POSITIVE 1
210
5
131
2
5 .
m
m
2
2
mm2 5 .
FUEL
PUMP
2
M
.
2
211
6 4
209
131 131
mm2
96 98
4 18
:10
2
PR
83
:2
FUEL
SWITCH
-
+
81
9
LEVEL
FUEL
HIGH
LEVEL
SWITCH
LOW
PR/1
:1
:3
84
10
81
RUN
84
(2A)
F23
PUMP
84
5
203 202
:X1
40
1
:X2
202
RUN
PUMP
203
STOP
131
:X2
TRIP/
PUMP
:X1
42
3
AUX
:14
:13
PUMP
STOP
O/L
:98
:97
131 131 208 203 206 131
131
2
204
PC
131
A2
:11
A1
2 6 4
208
1 5
211
3
O/L
:95
PR/3
205
:96
:9 5 .
m
m
2
2
14
13
131
131
.5
m
m
2m
m
2
6
206
24
64
206
36
207 207
F21
(6A) (2A)
F22
BUSBAR
COPPER
131 131 131
ENTER DIRECTLY ONTO
TERMINALS. mm2 6
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO
AC SUPPLY
CUSTOMER
200V TO 250V
6 132 mm2
131 6 mm2
C
C
HIGH 81
SWITCH
LEVEL
FUEL
83
LOW
SWITCH
LEVEL
FUEL
:3
PR/1
:1
84
10
4
84
85
:6
:7
MV PR
2
:10 -
2
:1
:2 + :2
DC POSITIVE
F23
(2A)
1 84
MV PR
2
2
:10
2
-
:1
84
4
10
84
83
HIGH
:2
SWITCH
LEVEL
FUEL
LOW
SWITCH
LEVEL
FUEL
+ :2
85
:3
PR/1
:1
:6
PR/2
:7
81
9
18
81
RUN
PUMP
mm2
PUMP
FUEL
131 131
70
33
131
m
m
2
2 .5
.5 2
A2
131
O/L
203
:X2
:X1
40
:X2
:X1
202
PUMP
RUN
203
1
202
PUMP
TRIP/
STOP
42
PC
A1
204
:9
205
PR/3
:11
3 :95
O/L
:96
24
203 206
M
131 131
14
97
mm2
98
209 211
2 4 6
210
. 2 5
2
1
4
3
6
5
96
95
131
13
211 208
1 3 5
131
m
m
2
.5
2
m
m
2
5 .2
208 131
m
m
2
131
6
131 131
COPPER
BUSBAR
:97
O/L
207
:98
AUX
:13
:14
207
36
STOP
PUMP
206
64
206
5
F22
(2A) (6A)
F21
mm2
131 131 131
6 131 C
mm2 6 132 C
ENTER DIRECTLY ONTO 200V TO 250V
mm2 AC SUPPLY 6 TERMINALS.
NOTE: CUSTOMER CABLE TO NOTE: CUSTOMER CABLE TO CUSTOMER
DC POSITIVE
(2A)
1 F23 84
VOLTAGE
MODULE/NETWORK
STATUS
SPARE
AIR SHUTDOWN
DAMPER
BATTERY CHARGER
AC FAILURE
LOWSTARTING
AIR PRESSURE
VOLTAGE
LOWBATTERY
LOWFUEL LEVEL
CONTROLLING SWITCH
CONTROLLING SWITCH
NOT INAUTO
HIGH BATTERY
EPS SUPPLYING
LOAD
LOWCOOLANT LEVEL
OVERSPEED
ACKNOWLEDGE
ALARM
LOWOIL PRESSURE
LOWCOOLANT TEMPERATURE
HIGH COOLANT TEMPERATURE
EMERGENCY STOP
FAIL TO START (OVER CRANK) TEST
LAMP
CONNECTOR
10
9
8
5
11
12
6
7
6
6 PIN DEUTSCH
4
5
3
1
J 1
2
CAN2+
SCR2
CAN2-
2
55
WARNING
11 10 6 1 2
9 8 7 5 4 3 CR
F2 F1
GRR
11 10 6 1 2
9 8 7 5 4 3
F11F12F13
11 10 6 1 2
9 8 7 5 4 3
-B +B S D
1 2 3 ALR
SECONDARY
SERVICE
CONNECTOR
(FRONT VIEW)
A
1 2 5 6 7
A B C DE F G H I J
set point adjust
read
11 10 6 1 2
9 8 7 5 4 3
DC
1 2 5 6 7
A B C DE F G H I J
set point adjust
read
AC
1 2 5 6 7
A B C DE F G H I J
set point adjust
read
BTR
1 2 5 6 7
A B C DE F G H I J
set point adjust
read
ATR
DC CHASSIS
ATR
11 10 6 1 2
9 8 7 5 4 3
11 10 6 1 2
9 8 7 5 4 3
KWR
ATR
ALR PR
VIEWA-A
CHASSIS ONLY SHOWN
D
C
TER
M
S
AC
TER
M
S
AC CHASSIS
EFR
F22
BC
F17 F16 F19 F18 F21
HC
2 4 6 8
1 3 5 7BF20.4..
OV/UV F32F33
TX
AR
11 10 6 1 2
9 8 7 5 4 3
4 2 6 14
3 1
MC9
5 13
A2
A1
PC
I
O
TEST
on
off
SACE S6 ABB
A
PWM
DC TERMINAL
STRIP
AC TERMINAL
STRIP
DC TERMINAL
STRIP
KILOWATT
RELAY
ALARM
RELAY
PUMP
RELAY
WINDING
TEMPERATURE
RELAYS
BEARING
TEMPERATURE
RELAYS
DC 40 PIN CONNECTOR
AC 40 PIN CONNECTOR
VOLTAGE REGULATOR
AC TERMINAL
STRIP
HEATER
CONTACTOR
ENGINE FAILURE
RELAY
PUMP
CONTACTOR
FUSE BLOCKS
OVER/UNDER
VOLTAGE RELAY
FUSE BLOCKS
BATTERY CHARGER
CUSTOMER
TERMINAL STRIP
GENERATOR
RUNNING
RELAY
ALARMRELAY CRANK RELAY
EARTH LEAKAGE OPTION
5A/10A BATTERY CHARGER OPTION
LOAD SHARE GOVERNOR OPTION
ENGINE HEATER OPTION ALTERNATOR HEATER OPTION
COMMON ALARM/SHUTDOWN
RELAY OPTION
GENERATOR RUNNING
RELAY OPTION
LOW FUEL LEVEL
ALARM OPTION
FUEL TRANSFER SYSTEM 1 OPTION
FUEL TRANSFER SYSTEM 3 OPTION
FUEL TRANSFER SYSTEM 2 OPTION
ANNUNCIATOR OPTION
MARSHALLING BOX
CONTROL PANEL
K
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THIS SCHEMATIC IS FOR THE 3412C EMCP 3 FOR PEEC ENGINES
PART NUMBER: 254-1263, CHANGE: 00, VERSION: DK
Components are shown installed on a fully operable generator set with the key and engine off.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
36
1
15
3
33
19
24 64
70
131
66
137
131
206
137
SP4
63 34
49
31 57
87
88
89
59
58
33
32
36
55
51
N
11
159
70B
54
46
44
1
36
61
42
43
40
203
13
202
131
206
137
SP4
C
C
89
C
88
87
N
36
159
54
C
70B
C
203
61
202
5
13
14
11
29
17
98
36
38
136
34
207
136
28
96
97
91
32
33
31
8
18
39
157
23
31
27
29
25
117
29
158
74
22
21
178
37
4 10
17 17
72
81
18 9
84
RDM
7 7
71
1 16
C
C
207
136
C
98
C
96
97
C
91
157
117
31
158
178
74
72
81
C
RDM
84
71
NOTE: IF 4 POLE BREAKER FITTED
B08
REF.
G
N
4
E
E
T2
T3
T1
CHANGE N T0
N
E
T2
T3
T1
REMOTE TERMS
OPEN & CLOSED
(IF REQUIRED)
FOR BREAKER
POSITIONS
231 C
C 232
C 233
POWER
WIRING FROM
GENERATOR
POWER
WIRING TO
BREAKER N
REF.E02
2
6
E
T2
T3
T1
6 22 6
REF. F02/F03
GENERATOR
POWER
WIRING FROM
OPEN & CLOSED
FOR BREAKER
POSITIONS
REMOTE TERMS
:C2
:12
BREAKER
AUXILIARY
:11
:14
SHUNT
TRIP
ST
:C1
24V DC
N
E
L2
L3
L1
:C12
BREAKER
AUXILIARY (IF REQUIRED)
233
232 C
C
C 231
:14 :13
:11 :12
Q/2
Q/1
:C11
ST
N
REF.E02
6
2
E
T2
T3
T1
24V DC
SHUNT
TRIP
4 POLE BREAKER OPTIONAL
(SEE NOTE REF.F08)
4 POLE BREAKER OPTIONAL
(SEE NOTE REF.F08)
N
E
L2
L3
L1
ENCLOSURE
STOP
EMER.
STOP
EMER.
BATTERY (+)
BATTERY (-)
2
2
11
12
2
BATTERY
REMOVABLE
ISOLATOR
30
KEY
SWITCH
(OPTIONAL)
-
24V
+
DC MARSHALLING BOX
AC MARSHALLING BOX
CONTROL PANEL BODY
CONTROL PANEL TOP COVER
CONTROL PANEL REAR COVER
CONTROL PANEL DOOR
CONTROL PANEL CHASSIS
REF.
C07
E
E
E
68 21
E
21 47
E
E
E
E
E REF.
E05
F08
SMMS1/1
PS1
2 2 20 2
PS1
SM1
25
PS2
50 REF.
SM2
PS2
26
SMMS2/1
mm 2 6
40
ALT CHARGING
ALTERNATOR
2 19
13 P+
CB3
(15A)
2.5
2.5mm 2
24
CB2
(20A)
mm 2
+
mm 2 2.5
24
mm 2 6
2
1
1
1
+
mm 2
(60A)
CB1
6
:30
PEECR/1
:87
ESDR
PEECR
:30 :86
:86
:85
10
9 5
2
SATS
60
1
SASV
2
60
59
1
59
33
44 43 42
:3 :1
:2
ADJ. POT.
(1K , 10T) W
SPEED
R
4
5
7
D-SPD
S-SPD
1
2
10
E
ENGINE SHUTDOWN
DROOP
:31
ENGINE
MOUNTED
C
:37
27 14
REF.
B06 10
3
FUEL SHUTOFF
SOLENOID
GROUND
PRIMARY THROTTLE
IDLE/RATED
P
E
:21 :22
:8
:33
:1 :17
PEEC
FSOS
45A 1
9
6 45
B08
REF.
7 41
20
REF.
:87a
27
:85
10
10
B05
45A B04
REF.
45
C05
REF. 41
41
20
S-SPD
S
10
D-SPD30
D +B -B
CONTROL
SPEED 1 2 3
23A 23A
39
SWITCH
START
ETHER
59 59
:1
:2
(OPTIONAL)
ON
CR
2
:10
30
4
30
B06
REF.
2
4 TO 34
45A TO 46
12 TO 11
FITTED
THEN LINK
:2
12
IF NOT
11
30 30
30 17
REF.B06
41
17
20
LIGHTS
PANEL 9 9
45
9
SWITCH
PANEL
LIGHT
:3
:2
45A 2
45 46
56
35 15
16
2 2 2
C
C
6
2
17
MARSHALLING BOX CUSTOMER AC TERMINAL
MARSHALLING BOX CUSTOMER DC TERMINAL
MARSHALLING BOX 40 WAY AC CONNECTOR
MARSHALLING BOX 40 WAY DC CONNECTOR
PANEL 70 WAY CONNECTOR 12
SATS 2 WAY CONNECTOR
SASV 2 WAY CONNECTOR
2
C
1
18
ENGINE TEMPERATURE ENGINE CONNECTOR
A.C. CONNECTOR FROM ALTERNATOR (GREEN)
D.C. CONNECTOR No.1 FROM ENGINE (BLACK)
D.C. CONNECTOR No.2 FROM ENGINE (GREY)
INTERNAL PANEL TERMINAL
POWER TERMINAL
OIL TEMPERATURE ENGINE CONNECTOR
MAGNETIC PICK-UP ENGINE CONNECTOR
24 WAY PEEC ENGINE CONNECTOR
COOLANT LOSS ENGINE CONNECTOR
OIL PRESSURE ENGINE CONNECTOR
MARSHALLING BOX TERMINAL
OUTGOING/INCOMING PANEL TERMINAL
3
2
3
11
1
SYMBOLS
C
B
C
B
A
NOTE A: ALL WIRE SIZES 1.5mm UNLESS OTHERWISE STATED
22 21 CAN1+
55 2
120
1 3 2
53 51 52
12 10 11
B08
REF. 50
50 50 50
METERING C.T.s
P1
P1
S1
S1
S1
P1
P2
S2
P2
S2 CT3
CT2
S2
P2
CT1
6
4
4
34
IF REQUIRED
SMMS1 SMMS2
55
:9
CR/3
:11
REF.
B06/B07
10
10
45
12
10
C
55
REF.
B06
15
30
START
C
CONTACT
C
REMOTE
30
COOLANT
LOSS
C B A
10
18
8
62
10
18
10
RATED
SPEED
RLY5
GFR
RLY4
SWITCH
32 41 33 43 40
ASR
SWITCH
RLY3
58 35
FUEL
RLY2
_
52
ENG
CRANK
RLY1
+
61 48 51 DC
CONTROL
BATTERY (12/24Vdc)
31
IA
AC 47
IB
66
+ -
67
PICKUP
MAG
65
EARTH (MOUNTING SCREW)
SINK O/P 1
44
I/P 6
SPARE
INPUT 1
I/P 5
45
I/P 4
53
EMERG
STOP
REMOTE
START
70
I/P 1 I/P 2
55
COOLANT
LOW
I/P 3
LEVEL
54
O/P
PROG
RLY8
24 1 15 14
PROG
O/P
RLY7
25 2 27
GRR
RELAY
RLY6
26
OIL
TEMP
29 37
PASSIVE
OIL
PRESSURE
46
ANALOG 1-
PASSIVE
30
TEMP
ENGINE
38
ANALOG 2+
PASSIVE PASSIVE
TEMP
ANALOG 3+
OIL TEMP
ENGINE
ANALOG 2-
OIL
I/P 8
PROG
28
I/P 8
36
I/P 7
I/P 7
PROG PRESSURE
ANALOG 1+
PASSIVE
56
PASSIVE
ANALOG 3-
11
VB
VA
VC
13 7 9 39 57
IC I RETURN
LCD DISPLAY
4 5
+
63
SRN -
62
+
42
SRN
CAN2 J1939
64 3
-
RS485
SRN
34
-
50
+
CAN1 J1939
EMCP3.2
69
8 6 108 108
(2A) (2A) (2A)
110 108 109 101
9
F13
T1 T2
7 5
T3
F11 F12
8
TO
12
109
110
10
109
110 10
8
14
101 101 38
38 6 37
2
6 2
REF.
C02
C05
REF.
PRIMARY SERVICE CONNECTOR
C E H G F A B D
SECONDARY SERVICE CONNECTOR
55 2
A B D E F H G C
1
1 56
REF.
C06
REF.
B04
A
B
C
D
E
F
8 7 6 5 4 3 2 1
A
B
C
D
E
F
8 6 7 5 2 4 3 1
MAGNETIC
PICK UP No.1
22
2 1
21
22 21
19
9
16 15
REF.
D03
B07
REF.
REF.
B07
C06
REF. 55
2
REF.
D03
15 16 19 62 62 62
19 16 15
SP3 74 72 SP4 SP5 55 55 55 55 41 20 14 39
2
55
37 38 6 17 57 18
CAN1-
CAN2+
CAN2-
M+M-
CAN1+
CAN1-
CAN2+
CAN2-
18 2
120
CAN1+
CAN1-
INPUT 2
SPARE
INPUT 3
SPARE
30
52 51 53 50
53 52 51 50 101 110 109 108
SCR1
SCR2
SCR3
SCR1
SCR2
SCR1
30
57
57
10 14 39
OP3
OP4
OP5 (2A)
F1
(10A)
F2
206
SP4
89
88
87
36
202
203
74
72
81
84
71
B06
REF.
REF.
A04
62
7 6
A03
REF.
B08
REF.
12 11 3
8 10
SP2
61
SP2 14 SP2
4 SP1
60
SP1 SP1
SP3
62
SP3 24 SP3
55
PRESS
OIL
TEMP
ENG OIL
TEMP
POTENTIOMETER
VOLTS ADJUST
(10K , 5 TURN)
80 82
:3
80
:1
82
:2
VOLTS
RAISE/LOWER
SWITCH
CONNECT
TO DVR
RAISE
9-5 9-6 9-4
LOWER
FITTED IF REQUIRED
OP1
OP2
REF.
B02
55 55
NOTE B: WIRING REQUIRED FOR EMCP3.2 CONTROLLERS
FOR SETS WITH DVR
FOR SETS WITH AVR
MCCB ACB
NOTE B
NOTE B
NOTE B
NOTE B
NOTE B NOTE B
IF REQUIRED
AC ALTERNATING CURRENT
ACRONYMS
ACB AIR CIRCUIT BREAKER
ALR ALARM RELAY
ASR AIR SHUTOFF RELAY
ATR ALTERNATOR TEMPERATURE RELAY
AVR ANALOG VOLTAGE REGULATOR
BC BATTERY CHARGER
CT CURRENT TRANSFORMER
DC DIRECT CURRENT
DVR DIGITAL VOLTAGE REGULATOR
EFR ENGINE FAILURE RELAY
FSOS FUEL SHUTOFF SOLENOID
GFR GENSET FAULT RELAY
GRR GENERATOR RUNNING RELAY
HC HEATER CONTACTOR
KWR KILOWATT RELAY
ESDR ENGINE SHUTDOWN RELAY
MV MOTORIZED VALVE
OV/UV OVER VOLTAGE/UNDER VOLTAGE
PC PUMP CONTACTOR
PEEC PROGRAMMABLE ELECTRONIC ENGINE CONTROL
PR PUMP RELAY
MCCB MOLDED CASE CIRCUIT BREAKER
PS PINION SOLENOID
PWM PULSE WIDTH MODULATION
SASV START AID SOLENOID VALVE
SATS START AID TEMPERATURE SWITCH
SM STARTING MOTOR
SMMS STARTING MOTOR MAGNETIC SWITCH
CR CRANK RELAY
CIRCUIT CONNECTED
GENERATOR (CHASSIS) GROUND
CIRCUIT NOT CONNECTED
ENGINE GROUND
ADDITIONAL WIRES
LOCATED IN MARSHALLING
BOX/ PANEL CONNECTING
LOOMS FOR OPTIONS.