UENR4692

May 2013

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

(Dimensions: 48 inches x 35 inches)

Inside Breaker
Box
F F F F
ETH 132 131

NEMA PLUG

UENR4692
NEMA PLUG

L1 L4

L2 L5

C4.4 Generator Set with D40 - D50

G
L3 L6

D-BLOCK #3 139 131

N1 N1
EMCP4.2 Mechanical Engine Control
Electrical System
ETH
E 138 131 INTERNAL E E E E E
D-BLOCK #1 D-BLOCK #2 AC FUSE
132 131
:C1
+
BATTERY
- CHARGER
1
ST FIT SHT(2)
LC41-UP
:C2 IF REQUIRED
2
INTERNAL
DC FUSE
ENGINE :14 :11
HEATER 4 3
BKR
:12 AUX
5

36 Page,
+ 5
FIT AUX/PP01
IF REQUIRED
TO STARTER
53C MOTOR
:A1 TO FAULT CHANNEL 23 :96 :95
:1 :3 :5 :7 18 7 6
HC IN CONTROL PANEL PP01
D :2 :4 :6 :8 5 D D D
:A2
24 REF. REF.
C03 C02

5
23

OPTION GROUPING - BASE GROUP C4.4

FUSE FUSE
OPTION NUMBER SET DESCRIPTION DESCRIPTION DESCRIPTION
OPTION 1 JACKET WATER HEATER RECEPTACLE F11 - 15AMP
OPTION 2 ALT HEATER F8 - 4AMP
WHH, AH1H, EBH, L1 L7
OPTION 3 BATTERY HEATER F7 - 2AMP
EOS, PBC10NU
183 183 184 185 132 OPTION 4 SUMP HEATER F10 - 2AMP
OPTION 5 BATTERY CHARGER RECEPTACLE F9 - 10AMP L2 L8
C C C C
F11 F8 F7 F10 F9 F12 F13 L3 L9
138 141 140 172 139 173 174 OPTION GROUPING - BASE GROUP C6.6
N1
FUSE FUSE
OP2 OP3 OP4 OP6 OPTION NUMBER SET DESCRIPTION DESCRIPTION DESCRIPTION © 2013 Caterpillar, All Rights Reserved Printed in U.S.A.
OPTION 1 JACKET WATER HEATER RECEPTACLE F11 - 20AMP
OPTION 2 ALT HEATER F8 - 4AMP E
131 ETH 131 ETH 131 ETH 131 WHH, AH1H, EBH,
OPTION 3 BATTERY HEATER F7 - 2AMP
EOS, PBC10NU
OPTION 4 SUMP HEATER F10 - 2AMP
:C1
OPTION 5 BATTERY CHARGER RECEPTACLE F9 - 10AMP 8
ST FIT SHT(2)
:C2 IF REQUIRED
9
OPTION GROUPING - ADDITION C4.4/6.6
FUSE FUSE :14 :11
OPTION NUMBER SET DESCRIPTION 11 10
DESCRIPTION DESCRIPTION
B B B BKR B
:12
12 AUX
OPTION 6 PROVISION FOR CANOPY SPACE HEATER F12 - 15AMP CABH FIT AUX/PP01
IF REQUIRED

:96 :95
OPTION GROUPING - ADDITION C4.4/6.6
REF. PP01 REF.
FUSE FUSE E03 E02
OPTION NUMBER SET DESCRIPTION DESCRIPTION DESCRIPTION

OP7 OPTION 7 20AMP GFCI CUSTOMER RECEPTACLE F13 - 20AMP GFCI DUAL BREAKER CBRXXX2
OP5 131 IF REQUIRED
131

ETH
ETH
A A A A
GFCI
OP1 CONNECTION

NOTE A
JWH & BATT CHGR NOTE A: REMOVE AND DISCARD METAL LINK.
DUPLEX RECEPTACLE
PAGE 1 PAGE 3
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

NETBITER REMOTE COMMUNICATIONS OIL TEMPERATURE SENDER SPLICED INTO SPLICED INTO SPLICED INTO
GEN RUN RELAY MODULE REM200 ML1 OPTIONS HARNESS OPTIONS HARNESS OPTIONS HARNESS
IF REQUIRED
(GRR) VOLT FREE IF REQUIRED ABBREVIATIONS
F CONTACTS F F F
VDO VIEWLINE HC HEATER CONTACTOR
GAUGE 16 17 15
8 7 23 22 GRR GENERATOR RUN RELAY
5 7 25 5 20A 5 22
:A1 65 66 OIL + 5
7 TEMP CAR COMMON ALARM RELAY
GRR
:A2 13 14 15 16 17 18 19 20 21 22 23 24
- + - +
:12 :14 :11 RS485 NETBITER REMOTE Vin
COMMS MODULE 1 4 A B C
12 14 11 5 8 1 2
1 2 3 4 5 6 7 8 9 10 11 12 FUEL
LEAK
20 SWITCH + 5 22
90 FLS 20A 5
VDO VIEWLINE IF REQUIRED
GAUGE
7
22 CONNECTION
HARNESS LOW
E COOLANT E E E

COMMON ALARM RELAY

TEMP
SWITCH
SYMBOLS
1 4 WC1
(CAR) VOLT FREE
5 8 IF REQUIRED SPILL
CONTACTS
CONTAINMENT
SWITCH SPC
7 IF REQUIRED FUSE
:A1 19 INTERNAL PANEL TERMINAL
CAR
:A2 1 5 2

:12 :14 :11 :A1 131 CUSTOMER AUXILIARY CONNECTION TERMINAL

MALE BLADE :1 :5 :3 :7
12 14 11 TERMINALS HC HEATER CONTACTOR
:2 :6 :4 :8
:A2
21
88 CAT ENGINE 12 CUSTOMER OPTION RELAY CONNECTION TERMINAL
D OPTION D D D
HARNESS
:A1
GRR GENERATOR RUNNING OPTION RELAY
POWER TERMINAL
FEMALE LOCKING :A2
TERMINALS

5 2 1 :A1
CAR COMMON ALARM OPTION RELAY 7 CUSTOMER CIRCUIT BREAKER AUXILIARY/SHUNT TRIP CONNECTION TERMINAL
OT 5 49
:A2

1 4
F14 5 8 8 WAY TYCO CONNECTOR
(3A)

C C C CIRCUIT BREAKER C
OT 5

1 2

AC POWER DUPLEX SOCKET W/ SPLIT CIRCUIT CAPABILITY

1 2
2 WAY DEUTSCH CONNECTOR
S3
5 +

CONNECTED TO A B C 3 WAY DEUTSCH CONNECTOR

STARTER MOTOR
SPLICED INTO
OPTIONS HARNESS AC POWER GFCI SOCKET

B B B B
29 +
OIL - OIL TEMPERATURE GAUGE
21 5 TEMP

:G 7 WAY DISTRIBUTION BLOCK

CAN 2 CONNECTOR
HARNESS
1 2 CCM0005
SPEED ADJUST
IF REQUIRED POTENTIOMETER
PSS1 VOLTS ADJUST
POTENTIOMETER PSV1
21 5 A B G F C IF REQUIRED NEMA PLUG
:1 :3
SCREEN CABLE
7 5 63 64 :2
FL VT1 VT2
314 315 316
A A A A
FUEL LEVEL
SWITCH VOLTS ADJUST
FSS TO ST1,ST2 & ETH WIRES POTENTIOMETER
IF REQUIRED FROM ENGINE HARNESS
22 24 11 10 9 INSIDE PANEL

PAGE 2 PAGE 4
8 7 6 5 4 3 2 1 8 7 6 5 4 3 2 1

OPTIONS SCHEMATIC (380-5925)

 14 13 12 11 10 9 8 7 6 5 4 3 2 1

L1 P1 P2 L4
J L2
S1
P1
S2
P2 L5
J
S1 S2
G L3 P1 P2 L6
S1 S2
(Dimensions: 48 inches x 35 inches)

N1 N1
EARTH STUD
E E

104 103 102 101 C10 C30 C50 C90

F4 F5 F6
(2A) (2A) (2A)
5 4 3 2 1
BOX 108 109 110 101 C10 C30 C50 C90 ELECTRONIC SERVICE TOOL LINK
UENR4692

REF. A B D E G F C
DOOR
E05
7 5 371 372 61 62
CHASSIS REF.
D07
8 9 14 11 10 9 8 7 6 30 31 32
REF. 13
E06 12
REF.REF. 10 11
C07 D07 120
120
61 62 63 64 65 66 76 77
VOLTAGE SENSING WIRES VOLTAGE SENSING WIRES
13 11 9 7 31 47 57 39 50 34 42 62 64 63 5 3 4 59 49 17
I EMCP4.2 VC IA IB IC I RETURN + - SCRN + - SCRN + - SCRN + - SCRN I
VB CAN1 J1939 CAN2 J1939 RS 485 DISTANT
VA ANNUNCIATOR LCD DISPLAY ACK RESET LOG
OK G LC2000 G LC1500
68 SERIES ALT SERIES ALT
PROG TRANS O/P 2
RUN AUTO STOP
69
PROG TRANS O/P 1
SYMBOLS

F6-

F5+
RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8
OIL ENGINE

+
3
-
2
-
+

2
ENG FUEL GLOW AUDIBLE COMMON GENSET PROG PROG EMERG REMOTE LOW COOLANT PROG PROG PROG PROG PROG PASSIVE MAGNETIC
BATTERY (12Vdc) O/P O/P PRESSURE TEMP FUEL LEVEL ANALOG
CRANK CONTROL PLUG ALARM ALARM RUNNING STOP START LEVEL I/P I/P I/P I/P I/P 5V PICKUP 1 2 3 4 5 6 362-0120 1 2 3 4 5 6 362-0120
PASSIVE PASSIVE PASSIVE RETURN
GND - + I/P A I/P B I/P 1 I/P 2 I/P 3 I/P 4 I/P 5 I/P 6 SUPPLY ANALOG 1+ ANALOG 2+ ANALOG 3+ 1- 2- 3- - + GND PMG AREP FUSE
60 52 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 16 56 38 30 46 37 29 67 66 65
REF REF
REF. 5 7 4 17 3 17 10 17 87 5 88 90 17 24 LCL SP0 SP1 SP2 SP3 SP4 42 41
SA1 3E07 OR 3E06 3E07 OR 3E06
E06
REF. 25 1 EMERGENCY STOP PUSHBUTTON
36 Page,

E04 30
5 24 2 19 18 17 16 15 29
REF. 5 5 5 5 5 12 13 14
B04 16 15 14 :85
23 R RELAY COIL
:86

10 9 12 11 REF REF
3F07 OR 3F06 3F07 OR 3F06
1 2 3 4 351-6706
PANEL REF. REF. SCREEN CABLE
1 2
E-STOP B05 A07
AUDIBLE 1 2 3 4 351-6707 1 2 3 4 5 6 362-0122 1 2 3 4 5 6 362-0122

153
162
154
161
154
153

EXJ
162
154
161
EXJ
153
ALARM 10 9 12 11
4 3 10 LCL DIODE
FIT IF 6
H :85 :85 :85
REQ
88 90 MAGNETIC
PICK-UP
H
ECR FCR GPR 22 21 20 + 5 LCL :30
REF.
R/1 RELAY CONTACT N/O
E04 :86 :86 :86
7 CAR & GRR A B C
:87

ET
7 7 7 7 7 7 17A
19

14
7

15
16

162

162
161

154

153

161

154

153
+ + + 12 9 11 10 :30
R/1 RELAY CONTACT N/C

380V

230V

110V

110V
0V

0V
E-

E+

E-

E+
Z2

X2
X1

Z1
F3 F1 F2 :87
5 (6A) (15A) (20A)
:87A
GPR/1
:30 30
REF. R220/R250/R251
53 51A B06 R438 AVR
RATED AVR
EARTH

1000
TO

3ph

470
5

S1

S2
TO AUX 50AMP 53A 5V OP W W
HEATER :30 :87
ECR/1 LOW WATER LEVEL 17 18
CONTACTOR 53C :87A FCR/1 :30 SWITCH WS1
COIL 26
:87 VT1 VT2 VT1 VT2
4 1 2
1AMP CIRCUIT BREAKER
2 53A 51 58A + CANOPY
REF. 53A E-STOP PSV1 1KW PSV1 1KW
27 1 1 VOLTAGE ADJUST VOLTAGE ADJUST
B05
ET POTENTIOMETER POTENTIOMETER
51 17A IF REQUIRED IF REQUIRED
7 WATTS 17C
15 16 REF. 51W
C04 2 2 5 RESISTOR
28
FIT IF
5V OP P1 P2
REQUIRED
+ 19 CURRENT TRANSFORMER
5 S1 S2
1
5
G 3
5 OP
3 BUZZER / SIREN G
SS
5 REF. REF.
C04 D07 2 FCS SOLENOID
12V
M
5 REF.
A03 GLOW
PLUGS + 1 2
B+ 2 WAY DEUTSCH CONNECTOR
19
E D+

CHARGING 5
IF PSS1 REQUIRED
MAGNETIC ALTERNATOR
CONNECT TO REF.
PICK-UP POTENTIOMETER
SPEED ADJUST POT A07
IN PANEL
53A 53A
53A 315 314 316
FCS FLPS 1 4 7 STARTER MOTOR
1 2 M
GE5
5 5
5 5 11 3 MPU-
MPU+
19 INTERNAL PANEL TERMINAL

58
CONTROLLER 70-WAY CONNECTOR

22 PANEL DC SOCKET CONNECTOR

F F
380-5922 POWER TERMINAL

D40 - D50 3P4W ELECT GOV A B C 3 WAY DEUTSCH CONNECTOR

1 2 3 4 4 WAY DEUTSCH CONNECTOR

4 ELECTRONIC GOVERNOR SOCKET CONNECTOR

L1 P1 P2 L4 5 INTERNAL PANEL AC SENSING TERMINAL

S1 S2
G L3 P1 P2 L6
S1 S2
N1 N1
EARTH STUD
E E
E 1 2 3 4 4 WAY MALE MATE N' LOCK ALTERNATOR CONNECTOR E
104 103 101 C10 C30 C90

F4 F5 F6
(2A) (2A) (2A)
1 2 3 4 4 WAY FEMALE MATE N' LOCK ALTERNATOR CONNECTOR
5 4 3 2 1
BOX 108 109 110 101 C10 C30 C50 C90 ELECTRONIC SERVICE TOOL LINK
REF. A B D E G F C
DOOR
E05
7 5 371 372 61 62 1 2 3 4 5 6 6 WAY MALE MATE N' LOCK ALTERNATOR CONNECTOR
CHASSIS REF.
D07
8 9 14 11 10 9 8 7 6 30 31 32
REF. 13
E07 12
REF.REF. 10 11
C07 D07 120 1 2 3 4 5 6 6 WAY FEMALE MATE N' LOCK ALTERNATOR CONNECTOR
120
61 62 63 64 65 66 76 77

13 11 9 7 31 47 57 39 50 34 42 62 64 63 5 3 4 59 49 17
EMCP4.2 VC IA IB IC I RETURN + - SCRN + - SCRN + - SCRN + - SCRN VOLTAGE SENSING WIRES 1 CUSTOMER INTERFACE CONNECTION TERMINAL
VB CAN1 J1939 CAN2 J1939 RS 485 DISTANT
VA ANNUNCIATOR LCD DISPLAY ACK RESET LOG
OK
68
LC1500 OR
PROG TRANS O/P 2
RUN
G LC2000
AUTO STOP
69 SERIES ALT
PROG TRANS O/P 1
D D
RLY1 RLY2 RLY3 RLY4 RLY5 RLY6 RLY7 RLY8
OIL ENGINE PASSIVE
ENG FUEL GLOW AUDIBLE COMMON GENSET PROG PROG EMERG REMOTE LOW COOLANT PROG PROG PROG PROG PROG MAGNETIC
BATTERY (12Vdc) O/P O/P PRESSURE TEMP FUEL LEVEL ANALOG

F6-

F5+
CRANK CONTROL PLUG ALARM ALARM RUNNING STOP START LEVEL I/P I/P I/P I/P I/P 5V PICKUP
PASSIVE PASSIVE PASSIVE RETURN

2
GND - + I/P A I/P B I/P 1 I/P 2 I/P 3 I/P 4 I/P 5 I/P 6 SUPPLY ANALOG 1+ ANALOG 2+ ANALOG 3+ 1- 2- 3- - + GND
60 52 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 16 56 38 30 46 37 29 67 66 65 1 2 3 4 5 6 362-0120
REF. 5 7 4 17 3 17 10 17 87 5 88 90 17 24 LCL SP0 SP1 SP2 SP3 SP4 42 41 PMG AREP
SA1
E06
REF. 25 1 REF
E04 30 3E07 OR 3E06
5 24 2 19 18 17 16 15 29
REF. 5 5 5 5 5 12 13 14
B04
23
16 15 14

PANEL REF. REF. 10 9 12 11 REF REF

1 2 3F07 OR 3F06 3F07
E-STOP B05 A07 1 2 3 4 351-6706
AUDIBLE
ALARM
4 3 10
FIT IF 6
LCL 1 2 3 4 351-6707 1 2 3 4 5 6 362-0122 1 2 3 4 5 6 362-0122 ABBREVIATIONS

154
161
EXJ
153
EXJ
162
153

154
162
154
161

153
REQ 10 9 12 11
88 90 MAGNETIC
:85 :85 :85
PICK-UP
REF. ECR FCR GPR 22 21 20 + 5 LCL
E04 ALT ALTERNATOR
:86 :86 :86
7 CAR & GRR A B C
ET
7 7 7 7 7 7 17A AVR AUTOMATIC VOLTAGE REGULATOR
19 7

C + + + AC ALTERNATING CURRENT C

14
15
16

162

162
161

154

153

161

154

153
F3 F1 F2 :87 12 9 11 10
5 (6A) (15A) (20A) GPR/1
:30 30 DC DIRECT CURRENT

380V

230V

110V

110V
0V

0V
E-

E+

E-

E+
Z2

X2
X1

Z1
REF.
53 51A RATED B06
TO R220/R250/R251
TO AUX 5 50AMP 53A R438 AVR SCRN SCREEN FROM SCREEN CABLE
:87 5V OP AVR
HEATER :30

1000
ECR/1 LOW WATER LEVEL

3ph

470

S1

S2
CONTACTOR :87A 17 18
COIL
53C FCR/1 :30 26 SWITCH WS1 W W
:87 RLY RELAY
4 1 2
1AMP VT1 VT2 VT1 VT2
2 53A 51 58A + CANOPY I/P INPUT
REF. 53A 1 1 E-STOP
27
B05
51 17A ET PSV1 1KW PSV1 1KW
VOLTAGE ADJUST VOLTAGE ADJUST CAR COMMON ALARM RELAY
7 WATTS 17C
15 16 REF. POTENTIOMETER POTENTIOMETER
C04 2 2 5 IF REQUIRED IF REQUIRED
28 GRR GENERATOR RUN RELAY
FIT IF
5V OP
REQUIRED
+ 19
5 FCS FUEL CONTROL SOLENOID
1
5 3
3
5 OP FCR FUEL CONTROL RELAY
SS
5 REF. REF.
C04 12V D07 2
GPR GLOW PLUG RELAY
M
5 REF.
A03 GLOW
PLUGS + ECR ENGINE CRANK RELAY
B B+
19
B
E D+ SS STARTER SOLENOID
CHARGING 5
IF PSS1 REQUIRED
MAGNETIC ALTERNATOR
CONNECT TO REF. FLPS FUEL LIFT PUMP SOLENOID
PICK-UP
SPEED ADJUST POT A07
IN PANEL
53A 53A PMG PERMANENT MAGNET
53A 315 314 316
FCS FLPS 1 4 7
1 2
GE5
5 5
5 5 11 3 MPU-
MPU+

380-5926
D40 - D50 1P3W ELECT GOV
A THIS SCHEMATIC IS FOR THE C4.4 GENERATOR SET WITH D40 - D50 A
EMCP4.2 MECHANICAL ENGINE CONTROL ELECTRICAL SYSTEM
MEDIA NUMBER: UENR4692

(380-5922) (CHG02) D40 - D50 3P4W ELECT GOV (DIAGRAM WIRING)

(380-5926) (CHG02) D40 - D50 1P3W ELECT GOV (DIAGRAM WIRING)
(380-5925) (CHG01) OPTIONS SCHEMATIC (DIAGRAM WIRING)
Components are shown installed on a fully operable generator set.
Refer to the appropriate Service Manual for Troubleshooting, Specifications and Systems Operations.
14 13 12 11 10 9 8 7 6 5 4 3 2 1