EMG ZW Set Service manual

INSTALLATION INFORMATION
All EMG Pickups and accessories are warranted for a period of two years. This warranty
does not cover failure due to improper installation, abuse or damage. If upon examination the
pickup is determined to be defective, a replacement will be made at no charge. Warranty
replacement products are covered by this same warranty. This warranty covers only those
pickups and accessories sold by authorized EMG Dealers. This warranty is not transferable.
Warranty:
© Copyright EMG Inc. 2007
EMG Model: EMG-ZW
SPECIFICATIONS:MODEL:
roloCogoL Silver Gold
Resonant Frequency (KHz)
2.2.00 2.45
Output Voltage (String)2.0 2.1
Output Voltage (Strum) 4.5 4.5
Output Noise@ 60Hz
-91 -89
Output Impedance (Kohm)10 10
Current@ 9V (Microamps) (System) 160
Battery Life (Hours) (System) 1500
Maximum Supply(VoltsDC)27
81
85
IMPORTANT INSTALLATION NOTES:
1) Only one battery is required for the pickups,
and any active accessories such as the SPC,
RPC, EXG, AB, PA-2, and Pi-2.
2) Use an Alkaline or Lithium batteryfor longest life.
3) The controls included with EMG Systems are 25K
Ohm, Audio Taper. This value of controlisrequired
for the system to work correctly.
4) When installing EMG Active Pickups, DO NOT connect
the bridge ground wire. This wire isusually soldered
to a volume or tone control casing and goes to the
bridge. This wire grounds the strings and uses them
and your body as a shield against hum and buzz. It
also creates a shock hazard. EMG Pickups are
shielded internallyand DO NOTrequire string
grounding. This greatly reduces the possibility of
reverse polarity shock from microphones and other
equipment
5) EMG Active Pickups have very little magnetism
compared to passive pickups. We recommend
you adjust the pickups as close to the strings as
possible. Sustain and string movement will not be
inhibited by close adjustment.
6) If your installation is different from the diagrams in
these instructions or you need additional diagrams
visit our website: emgpickups.com for a complete
listing of available diagrams.
Note: Magnet Type: A (Alnico)
C/S (Ceramic/Steel)
Updated 1/10/07
Magnet Type C/S Alnico
Bridge Neck
Preferred Pickup Placement
0230-0039C

Be sure to unplug your guitar when not in use to avoid current drain on the battery!
Tone
Tone
Volume
Volume
.1
.1
RED
Bottom View
Bridge pickup cable
(Gibson Les Paul
April 1975 and later)
Cable from
3 way switch
Finger Board pickup cable
RED FROM PICKUPS
BLACK
BLACK
Black wire/ Green
wire shrink tubing.
GREEN
WHITE
BLACK
RED
Installation Procedures for Models:
EMG Model: EMG-ZW Set, EMG-81/EMG-85
1) Mount the volume and tone control sets included
with the EMG-ZW as shown in the diagram. Extra hex
nuts are provided to set the height of each control
so the knobs fit nicely on the top of the guitar.
2) Install the pickups in the guitar routing the
pickup cables into the control cavity. Solder the
braid (shield) to the control casing and white wire
to the center terminal of each volume control.
Set the red wires aside for now.
3) Solder the Red wire of the switch cable to the
outside terminal of the rhythm pickup volume control.
4) Solder the White wire of the switch cable to the
outside terminal of the bridge pickup volume control.
5) Solder the Braid (shield) wire of the switch cable to the
casing of the rhythm pickup volume control
6) Install the Output jack/Battery clip set included and
fasten the output jack securely to the jack plate.
7) Solder the Black wire of the switch cable to the Green
wire of the output jack and cover the connection with
the shrink tubing provided.
8) Solder the Black wire of the Output jack to the casing
of the rhythm tone control
9) There is a small black wire included with the System
to ground the two volume control casings together,
Solder one end of this wire to the rhythm pickup volume
control casing and the other end to the bridge pickup
volume control casing.
10) Solder the red wires of the pickups to the red wire of the
battery clip, cover the connection with the heat shrink
tubing provided.
11) This completes the installation. Before stringing up the
guitar, install a 9 Volt battery, plug in the guitar and test
it through an amp. Tap on the pickups lightly with a small
screwdriver and check the operation of the volume and
tone controls. Wrap the battery in some of the packaging
foam provided to insulate from the controls and
reassemble the guitar.
12) String it up and Boogie down Broadway.
4) Remove the knobs and hex nuts from the pots and
the output jack as well. Remove the whole plate as a
single unit. It will not be reused.
a) Red wire at the rhythm pickup volume control
b) White wire at the bridge pickup volume control
c) Black wire at the solder lug terminal in the
center of the control plate
d) Braid (shield) at the solder lug terminal in the
center of the control plate
e) Bridge ground wire soldered to the volume control casing
(Do not reconnect during installation)
3) Unsolder the following wires coming from the
selection switch cable.
2) Unsolder the pickup cables that go to the casing of
the volume controls and the center terminal of the
volume controls. Remove the pickups from the guitar.
Set the guitar aside and mount the EMG Pickups into
the pickup mounting rings using the screws and
springs supplied and set them aside.
1) Remove the control cavity cover (4 screws) and
unscrew the screw(s) that fasten the shielding can.
The ZW Model is designed as a direct replacement into
Gibson Les Paul Guitars. LPGuitars manufactured after
April of 1975 require long shaft pots. Inside the control
cavity the existing electronics are mounted to a metal
control plate, which will be removed as a whole unit,
and will not be reused. If your Les Paul was manufactured
before April of 1975 or is an import model it will not
require long shaft pots. Both pot types have been included
with this system.
Refer to other diagrams included on this sheet for reference.
Diagram 1 shows the installation for the Gibson Les Paul
Guitar (after 1975) which uses the long shaft pots. Start
by removing the strings and loosening the pickup
mounting screws.

1) Disconnect the existing pickup from its volume and
tone control.
2) Disconnect any existing selection switch wire(s)
from its volume and tone control.
3) Remove the pickup and the volume and tone control.
Place the EMG Volume and Tone Control in the instrument.
Mount the pickup in the mounting ring and install it
routing the cable to the control cavity.
4) Connect the pickup to the volume control as shown
in the diagram, and connect the switch wires as shown.
5) For two-pickup guitars, follow steps 1-4 before continuing.
6) Remove the existing output jack and replace it with
the EMG Output Jack. Solder the output wire to the
jack as shown in the diagram.
7) Solder the RED wire(s) of the pickup(s) to the RED wire
of the battery clip and cover the connection with the
heat-shrink tubing provided.
8) Use some of the packaging foam that comes with the
pickup and surround the battery to insulate it.
Place the battery in the control cavity.
9) We suggest you test the guitar before closing up the
control cavity to make sure everything is working.
For all other installations:
Refer to the following diagrams. Find the diagram of the
volume,tone, and switch type you have in your guitar and
follow that diagram. It is recommended that if you plan to
install other EMG Products, that you do the installation per
the diagram on this sheet and get the system functioning
before adding any accessories.
The diagrams shown are for EMG Active Pickups only.
All diagrams show the Red Wire coming from the pickups
connected to the battery. If you are installing EMG-HZ
Passive Pickups refer to those diagrams. The Red Wire of
the HZ Pickup is NOT for battery power, it is a coil wire.
We recommend you make a simple diagram of your
current wiring scheme and follow it when rewiring with
the EMG 25K Controls.

Bottom View
Red
Black
White
Black
Solder Pickup Braids to pot casings
2 Volume (Independent)
2 Tone
w/ Gibson Style Toggle Switch
Red wires from Pickups
Volume
Pickup Output Cable
Solder Fingerboard Pickup "Hot" lead to this lug
.1uf
104 Tone
Volume
Pickup Output Cable
Solder Bridge Pickup "Hot" lead to this lug
.1uf
104 Tone
Bottom View
Red
Black
White
Black
Solder Pickup Braids to pot casings
2 Volume (Either volume will act as master)
w/ selection switch in middle position)
2 Tone
w/ Gibson Style Toggle Switch
Red wires from Pickups
Volume
Pickup Output Cable
Solder Fingerboard Pickup "Hot" lead to this lug
.1uf
104 Tone
Volume
Pickup Output Cable
Solder Bridge Pickup "Hot" lead to this lug
.1uf
104 Tone
Solder Pickup Braids to pot casing