Systems & Components - REHS9132 - Procedure to Upgrade EMCP 1, EMCP 2, EMCP ...

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Shutdown SIS

Previous Screen

Product: GENERATOR SET

Model: C15 GENERATOR SET CYY00784
Configuration: C15 Generator Set CYY00001-UP

Special Instruction
Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to
EMCP 4.4 {4490}
Media Number -REHS9132-04 Publication Date -06/10/2014 Date Updated -29/05/2020

i08029527

Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1,

EMCP 3.2, and EMCP 3.3 to EMCP 4.4 {4490}
SMCS - 4490

Electric Power Generation

All

Introduction
Table 1
Revision History
Revision Summary of Change

04 Updated and added the revision history, schematic 9, 10, 11, 12.

This Special Instruction provides information about upgrading electric power generator set control mounted
panels to the EMCP 4.4 control. The following is a list of the controls that can be upgraded to the EMCP
4.4:

• EMCP engine status control (ESC)

• EMCP1 (per 7C-1000 Control Panel Chart)

• EMCP2

• EMCP2+

• EMCP3.1

• EMCP3.2

• EMCP3.3

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The EMCP4.4 control is intended for applications that require generator paralleling for low voltage
applications less than 1000 V. Cat® floor-standing control or switch gear must be utilized for medium and
high-voltage applications.

Proper application of EMCP4.4 paralleling controllers is critical. In various areas of this document, the
document will refer to the unit as the generator set or engine. These terms are to be used interchangeably.

Reference Section
Reference: Systems Operations Troubleshooting/Testing and Adjusting, UENR1210-01, "EMCP4.3/4.4"

Reference: Application and Installation Guide, LEBE0007, "EMCP 4.3/4.4 Generator Set Control"

Reference: Specification, SENR3130, "Torque Specification"

Reference: Special Instruction, REHS1844, "General Welding Procedure"

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and
you understand this information. Use only proper tools and observe all precautions that pertain to the use of
those tools. Failure to follow these procedures can result in personal injury. The following procedures
should be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure
to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person must also have the necessary training, skills, and
tools to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot
anticipate every possible circumstance of a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive.
Avoid using a tool, a procedure, a work method, or operating technique that is not recommended by
Caterpillar.

Ensure that the product will not be damaged or the product will be made unsafe by the operation,
lubrication, maintenance, or the repair procedures.

Do not operate or work on this product unless you have read and
understood the instruction and warnings in the relevant Operation and
Maintenance Manuals and relevant service literature. Failure to follow
the instructions or heed the warnings could result in injury or death.
Proper care is your responsibility.

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Failure to follow all safety guidelines prescribed in this document and

by governing authorities and regulatory agencies may result in severe
injury or death of personnel or machine damage.

When removing a major component or attachment, ensure that it is

properly blocked or secured before removing mounting hardware. An
assembly that is disconnected without proper blocking may shift or fall,
resulting in serious injury or death of personnel or machine damage.

Personal injury or death can result from improper maintenance

procedures. To avoid injury or death, follow the procedures exactly as
stated below.

Personal injury or death can result from sudden movement.

Prevent possible injury by performing the following procedures before

work begins:

Move the product or equipment to a smooth, level surface.

When applicable, lower equipment/work tools to the ground.

Engage the parking brake, system brakes and/or hydraulic lockout

control. When applicable, stop the engine and remove the ignition key.

Release system pressure from pressurized systems.

If applicable, block the wheels/tracks.

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Turn the battery disconnect switch to the OFF position and if

applicable, remove the battery disconnect key. If not equipped with a
battery disconnect switch, disconnect the battery cables from the battery
and tape the battery clamps.

Attach a “Do Not Operate” or similar warning tag at the battery

disconnect switch location and as defined by site rules and/or local
regulations.

Illustration 1 g06276183

Access to this service point may require climbing on the equipment.

Slipping or falling while climbing on the equipment could result in
personal injury or death. Refer to the Operation and Maintenance
Manual, Mounting and Dismounting topic for safety information.

Failure to use an approved access system during installation and

removal of components could result in slipping and falling which could
result in personal injury or death. To prevent injury or death, use an
approved access system to reach the appropriate mounting locations of
the components. Do not climb on the machine. Maintain three-points of
contact and/or use a safety harness.

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Personal injury can result from improper handling of chemicals.

Make sure you use all the necessary protective equipment required to do
the job.

Make sure that you read and understand all directions and hazards
described on the labels and material safety data sheet of any chemical
that is used.

Observe all safety precautions recommended by the chemical

manufacturer for handling, storage, and disposal of chemicals.

Do not operate the machine if any guards or covers are missing or

inadequately secured. Personnel could be seriously injured or machine
damage may occur.

Observe the safe working load limits of all lifting and blocking devices
and keep a safe distance from suspended/blocked loads. Personnel may
be seriously injured or killed by falling loads.

Hazardous Voltage Information

ELECTROCUTION HAZARD - The electrical system contains

hazardous voltage levels.

DO NOT remove any covers that will expose energized hazardous-voltage

electrical components without shutting down and discharging the
electrical system.

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DO NOT perform any maintenance on the electrical system until after

the electrical system has been shut down and the voltage has been
discharged by qualified personnel.

Read and understand the instructions and warnings found in the

Operation and Maintenance Manual to properly shut down the electrical
system and discharge hazardous-voltage electrical components.

Failure to follow these instructions could result in personal injury or

death.

ELECTROCUTION HAZARD - Ensure proper grounding.

Avoid a buildup of hazardous live voltages on exposed surfaces by

ensuring that all grounding wires/straps are always properly connected.

Disconnected grounding wires, including grounding wires/straps for

hazardous-voltage components and electrical enclosures, must be
properly reconnected before connecting equipment to the power supply.

Failure to follow these instructions could result in personal injury or

death.

When service or maintenance must be performed in a hazardous-

voltage component enclosure, always assume that a hazardous level of
voltage could be present.

Qualified personnel should manually check for hazardous-voltage using

electrical measuring tools that have the capacity to measure the
hazardous-voltage components being checked.

The level of voltage present must be confirmed to be below 50 Volts

before any exposure to the hazardous-voltage components can take
place.

Failure to follow these instructions could result in personal injury or

death.

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There may be government regulations, local regulations, or site-specific rules that govern the operation,
service, and maintenance of high-voltage components and machines. Comply with applicable rules and
regulations for the work place.

Appropriate high-voltage protective equipment should be worn as defined by local rules and
regulations.

Only qualified service personnel should perform service on high-voltage systems.

DO NOT remove covers, or open enclosures, that will expose energized high-voltage electrical
components.

DO NOT perform service or maintenance on energized high-voltage electrical components.

High voltage can cause electrocution resulting in personal injury or death.

High-voltage components and connections must be properly maintained.

Refer to the Maintenance Section in the Operation and Maintenance Manual for additional information.

Residual energy can remain in high-voltage components even after operation has stopped. Always assume
that a hazardous level of voltage could be present.

Before performing any type of service, repair, or maintenance on high-voltage electrical components,
perform the following:

• Disconnect the electrical power source

• Isolate electrical components

• Discharge residual energy

• Check components for voltage using electrical measuring tools.

Note: Use electrical measuring tools that have the capacity to measure the high-voltage components being
checked. The level of voltage present must be confirmed to be below 50 Volts before any exposure to the
high-voltage components can take place.

Read and understand the instructions and warnings found in Operation and Maintenance Manual,
"Electrical Shutdown and Voltage Discharge" , to shut down the electrical system and discharge high-
voltage electrical components.

Table 2
Required Parts
Qty Part Number Part Name

1 452-9414 Electronic Panel Gp

Overview
Applicability

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Illustration 2 g06552457
Enclosure dimensions
(D1) 323.8 mm (12.7 inch)
(D2) 323.8 mm (12.7 inch)
(D3) 603.2 mm (23.7 inch) to 698.5 mm (27.5 inch)

The kit is intended to replace EMCP control panels that are fitted in a generator-mounted enclosure with
the dimensions shown in Illustration 2. The enclosure included with the kit has three conduit holes in the
bottom while some of the original controls only have two holes. The third hole can be blocked, if
necessary.

In addition to the control replacement, the following sensors must be replaced:

• Oil pressure sensor

• Engine speed sensor

• Coolant temperature sensor

The sensors listed above and the needed electrical connectors are included in the upgrade kit. The EMCP
4.4 control has been pre-configured for the new sensors.

Features

The EMCP 4.4 control offers more features and communication options than what was available with the
older EMCP models. See the Application and Installation Guide, LEBE0007 for a complete description.

The EMCP 4.4 control is able to do dead bus arbitration and load sharing.

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The purpose of hard wired dead bus arbitration (HDBA) is to determine whether a dead bus condition
exists. Also, the purpose of HDBA is to provide dead bus close arbitration in the absence of a multiple
generator set data link.

The EMCP 4.4 control actively monitors the real (kW) and reactive (kVAr) load requirement of all
paralleled generator sets as shown on the load sharing lines. The EMCP 4.4 control adjusts output of the
generator set to maintain a balanced loading of all generator sets.

The EMCP 4.4 control includes logic to sequence generator sets based on the total load requirement of the
system.

Required Documents

The following documents are required prior to any installation work:

• Systems Operations Troubleshooting Testing and Adjusting, UENR1210

• Application and Installation Guide, LEBE0007

The documents are available on the "Caterpillar Service Information System" website. Review the
documents and if needed for reference, print the required portions prior to beginning the upgrade.

Power Requirements
The control is designed to operate on 24 VDC only. Current draw of the control package is less than 2 A.
External solenoids, loads driven by the control relays, and connection of a Cat ET communications adapter,
will add to the current draw.

Note: All ground wires shall connect to terminal blocks labeled 201 through 209. Every device shall have
its own ground wire that runs from the device to one of the ground terminal blocks, do not “Share” a
common ground wire between multiple devices. The connection to Battery (-) shall be made at terminal
block 201.

New Features
As implemented, the EMCP 4.4 control offers more features and communication options than what was
available with the earlier EMCP models. Refer to Application and Installation Guide, LEBE0007, "EMCP
4.3/4.4 Generator Set Control" for a complete description.

Safety
Electrical Safety
Refer to the "Important Safety Information" and "Introduction" sections of Special Instruction, REHS9132
for safety information.

Electrostatic Discharge Awareness

The EMCP 4 control contains components that are sensitive to electrostatic discharge (ESD). An
electrostatic charge can damage the control resulting in EMCP 4 breakdown or improper operation.

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Take the following precautions while installing, removing, and handling the control:

• Handle equipment correctly. Use ESD protective packaging and material handling containers that are
anti-static and provide discharge protection and electric field suppression.

• Use protective devices. ESD - protective workstations and/or work surfaces that include a grounding
mat anti-static wrist strap.

• Keep all plastic items away from the devices. Any plastic item is a potential static generator. The
plastic includes candy wrappers, foam cups, synthetic carpet, and foam cushions.

• The anti-static bag cannot function as a static dissipating mat.

• Do not use an anti-static bag for any other purpose than to enclose a product.

NOTICE

The 120-pin connector and 70-pin connector on the back of the control
is the most vulnerable area to electrostatic discharge (ESD). While
handling the EMCP 4.4, extra attention is required to the back of the
control. The control may become damaged or inoperable if extra care
is not taken.

Note: Consult the Electrostatic Discharge Association for proper procedure during particular situations at
http://www.esda.org.

Accidental engine starting can cause injury or death to personnel

working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.

Turn the battery disconnect switch to the OFF position and lockout the
battery disconnect switch with a safety lock.

Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the

start switch and battery disconnect location to inform personnel that the
machine is being worked on.

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Illustration 3 g03682962
"Do Not Operate" warning tags
(1) Tag Side A
(2) Tag Side B

Note: Illustration 3 is an example of the "Do Not Operate" tags required for lockout and tag out of the unit.

Removal of the Existing Control

Since the original installed control can vary in how the installation was made, the following are general
steps to remove an existing control:

1. Resolve any existing issues with the control, the generator set, or the wiring between the control and
the generator set.

2. Perform voltage and continuity checks to insure that the schematic conforms to the as-built or
corrected schematic of the existing installation.

3. Record the generator set parameters at idle and rated speed.

4. Record the baseline operating parameters of the generator set.

5. Remove the existing panel.

Resolve Existing Issues

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Resolve any existing issues with the control, the generator set, or the wiring between the control and the
generator set.

If the existing installation has generator set or control issues, both must be repaired prior to performing a
control upgrade. Troubleshooting a failure will only become more difficult after the new control is
installed. Performing the following tasks may not be possible if the control has failed.

Use the documentation appropriate for the control. The documentation should be available on the Service
Information System (SIS ).

Check the control for stored diagnostic codes and repair the issues that are causing the codes.

As much as practical, insure that the control and generator set are working without issues.

Voltage and Continuity Check

An accurate schematic of the existing installation will be required when installing the new control.

1. Connect the negative lead of a voltmeter to ground.

2. Measure the voltage at every point shown on the schematic that is connected to battery (+).

3. Check continuity for every point on the schematic that is connected to ground, terminal block
position 201 through 208.

4. Mark up the latest schematic with any changes that have occurred since the original installation.

Note: The tolerance for the continuity is < 10 ohms. The tolerance for the voltage is the V bat +/- 0.5 V.

Determine Idle, and Rated, Speed Parameters

Record the generator set parameters when the generator is at idle and at rated speed.

The value of the generator set parameters will be needed to verify that there are no problems after the
installation of the new sensors.

Start the generator set and force the generator to remain at idle. The governor must be disconnected or
disabled. When the coolant temperature has stabilized, record the following values listed in Table 3.

Table 3
Value Unit
Engine Idle Speed RPM = ________

Engine Oil Pressure psi / kPa = _______

Engine Coolant Temperature C / F = ________

Enable the generator set to go to rated speed. When the coolant temperature has stabilized, record the
values listed in Table 4.

Table 4
Value Unit

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Engine Rated Speed RPM = ________

Engine Oil Pressure psi / kPa = _______
Engine Coolant Temperature C / F = ________

Baseline Generator Set Operating Parameters

Illustration 4 g03557376

Record the existing baseline operating parameters of the generator set.

Use documentation found in the service information system website to determine how to access the
generator set parameters. The parameters will be needed to program the new control. Record the data for
the list of parameters that are shown in Illustration 4.

Remove the Existing Panel

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Use the following procedure to remove the existing panel.

Accidental engine starting can cause injury or death to personnel

working on the equipment.

To avoid accidental engine starting, disconnect the battery cable from

the negative (−) battery terminal. Completely tape all metal surfaces of
the disconnected battery cable end in order to prevent contact with
other metal surfaces which could activate the engine electrical system.

Place a Do Not Operate tag at the Start/Stop switch location to inform

personnel that the equipment is being worked on.

Bodily contact with electrical potential can cause bodily injury or death.

To avoid the possibility of injury or death, ensure that the main power
supply has been disconnected before performing any maintenance or
removing any modules.

Working with electrical circuits is hazardous. Bodily contact with

electrical potential will cause personal injury or death. Ensure that
personnel are trained in proper operating procedures in order to ensure
safe operation.

1. Insure that the generator has been disconnected and/or isolated from any other power source and the
load. Ensure that the unit has been appropriately locked out and tagged.

2. Disconnect the AC power from the battery charger.

3. Disconnect the battery charger from the battery.

4. Disconnect the battery from the generator set.

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5. Inspect the wiring coming out of the conduit that enters the bottom of the panel. All the wires must
be labeled with the number of the terminal blocks that the wires are connected to. Make sure to
match the wire numbers shown on the schematic for the existing installation. The labeling is shown
on the schematic for the existing installation. The wire numbers are critical in determining where to
connect the wires in the EMCP 4.4 panel. When all the wires have been labeled, disconnect the wires
from the terminal blocks.

6. Leave the wires that are in the conduit or spiral wrap and remove the wires from the bottom of the
panel.

7. If the governor/speed control is going to be reused in the new panel, remove the governor/speed
control from the old panel. After removal, set the governor/speed control aside, for installation in the
new panel.

8. Remove the old panel from the generator enclosure.

Installation of the EMCP 4.4 Control

Installation Overview
The following steps are an overview of the process to install the EMCP 4.4 control:

1. Install the new EMCP 4.4 panel.

2. Install wiring from the generator set to the EMCP 4.4.

3. Install the new engine speed sensor, coolant temperature sensor, oil pressure sensor, and the required
new wiring.

4. Perform power off electrical tests.

5. Perform power on electrical tests.

6. Install the control parameter configurations that are required.

7. Perform the idle speed engine parameter verification.

8. Perform the E-Stop validation.

9. Perform the rated speed validation.

Install EMCP4.4 Panel

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Illustration 5 g03712294
EMCP 4.4 control panel hole location information - top view of enclosure
(5) Existing holes in the generator enclosure

If replacing an EMCP 2 or EMCP 2+, the conduit holes will line up. However, four new mounting holes
may need to be drilled for the vibration isolation mounts. The conduit entry holes on the bottom of the
enclosure are standard in all three enclosure sizes.

Refer to Illustration 5 for dimensions information to mark the location of the mounting holes for the EMCP
4.4 control panel.

Install Wiring from the Generator Set to EMCP 4.4

The corrected schematic for the existing installation and the EMCP 4.4 schematic will be required to install
the wiring for the EMCP 4.4. The EMCP 4.4 related schematics in this publication are Illustration 10,
Illustration 12, Illustration 13, and Illustration 15.

Since the EMCP 4.4 can replace many different controls, the existing wire numbers will likely not
correspond with the EMCP 4.4 terminal blocks.

The wire numbers on the existing wiring along with the schematic for the existing control will help to
identify the function for each wire. Use the schematic for the EMCP 4.4 to find the corresponding function
and the terminal block number. Connect each wire to the correct terminal block. In many installations there
will be wiring that is not used. If the wire will not be used, the wire can be pulled out of the conduit and
discarded.

Fuel Control Valve Operation

If the fuel control valve was originally wired for "Energize to Run", no changes to the EMCP 4.4 control
are required. If the fuel control valve was originally wired for "Energize to Stop", then the wire from

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terminal block 7 to terminal 7 of the fuel control relay (FCR), must be moved to terminal 3 of the FCR.
Refer to Table 5.

Table 5
Fuel Control Valve Function Connect To
Energize to Run Terminal Block 7 FCR, terminal 7 As shipped

Energize to Stop Terminal Block 7 FCR, terminal 3 Optional

Potential Winding Rating

The EMCP 4.4 control can directly monitor generator voltages up to 600 V. Voltages more than 600 V
must use potential transformers (PT). The purpose of the PT is to scale the generator voltage to less than
600 V. If potential transformers are used, the voltage ratio is set in the EMCP 4.4 parameter settings.

Use Cat® Electronic Technician (Cat ET ) Service Tool to perform the following steps to access the
parameters.

Illustration 6 g03692434
Generator potential transformer primary winding current parameters on Cat ET

1. Navigate to the EMCP 4.4 screen.

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2. Click "Generator AC Monitor".

3. Click "Generator Potential Transformer Primary Winding Rating".

4. Type the desired value in the "Values" field. Cat ET will automatically update the control.

Use the following steps to access the "Generator Potential Transformer Secondary Winding Rating" using
Cat ET.

Illustration 7 g03692406
Generator potential transformer secondary winding current parameters on Cat ET

1. Navigate to the EMCP 4.4 screen.

2. Click "Generator AC Monitor".

3. Click "Generator Potential Transformer Secondary Winding Rating".

4. Type the desired value. Cat ET will automatically update the control.

Note: Fuse protection is needed if the generator is wired directly to the EMCP 4.4 or if potential
transformers are used. Fuses with rating of 5 amps or less, with the appropriate voltage rating, must be
installed immediately after the connection to the generator.

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The EMCP 4.4 control must use current transformers to measure generator output current. The current
transformers must scale the generator output current from 0 A to 5 A for use by the EMCP 4.4. The current
transformer ratio is set in the EMCP 4.4 parameter settings.

Note: Refer to Special Instruction, M0107220, "Procedure to upgrade EMCP 1, EMCP 2, EMCP 2+,
EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.3/4.4"

Use the following steps to access the primary winding rating parameters using Cat ET.

Illustration 8 g03707532

1. Navigate to the EMCP 4.4 screen. Click "Generator AC Monitor".

2. Click "Generator Current Transformer Primary Winding Rating".

3. Type the desired value. Cat ET will automatically update the control.

Use the following steps to access the secondary winding rating parameters using Cat ET.

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Illustration 9 g03707533

1. Navigate to the EMCP 4.4 screen. Click "Generator AC Monitor".

2. Click "Generator Current Transformer Secondary Winding Rating".

3. Click the desired value.

Install New Sensors

New sensors have been provided in the kit, to insure compatibility with the EMCP 4.4 control.

Install the three new sensors and related wiring. The new sensors are as follows:

• Coolant temperature, 102-0050 Temperature Sensor Gp

• Oil pressure, 216-8684 Pressure Sensor Gp

• Engine speed, 318-1181 Speed Sensor Gp

The oil pressure and coolant temperature sensors are active pulse width modulated (PWM) sensors. The
sensors require a supply voltage and ground. The sensor output is a pulse width modulated signal that is
read by the EMCP 4.4 control. A three wire 371-6415 Electrical Cable is included with the sensor kit. The
cable has a red (+8 V), a black (negative), and a white (analog input positive) wire.

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The oil pressure sensor is an "absolute" sensor, as opposed to a "gauge" sensor. An absolute pressure sensor
measures pressure using vacuum as a reference. The sensor will read atmospheric pressure of 101.35 kPa
(14.7 psi) when there is no apparent pressure being applied to the gauge. When the generator set is not
running, this gauge will read 101.35 kPa (14.7 psi) even though the generator set has no oil pressure.

The oil pressure settings for idle speed, oil step, and rated speed must each be increased by 101.35 kPa
(14.7 psi) to be valid. Therefore, the calculation for "psi" is 14.7 psi + normal gauge reading (psi) =
absolute pressure gauge in psi.

For metric readings, the calculation would be 101.35 kPa + normal gauge reading (kPa) = absolute pressure
gauge in kPa.

The following is an example. If the idle speed oil pressure was measured at 117 kPa (17 psi), the absolute
pressure gauge reading will be 117 kPa (17 psi) + 101.35 kPa (14.7 psi) = 219.35 kPa (31.82 psi).

When configuring the oil pressure transducer parameters in the EMCP 4.4 control, use the following data:

• 5% duty cycle = 13.4 kPa (2 psi)

• 90% duty cycle = 844.4 kPa (122 psi)

When configuring the coolant temperature sensor parameters in the EMCP 4.4 control, use the following
data:

• 5% duty cycle = −7.93707° C (17.71327° F)

• 95% duty cycle = 119.0560° C (246.30080° F)

On some installations, the Governor shares the engine speed magnetic pickup unit (MPU) with the EMCP
control. A new MPU has been included with the kit to allow the EMCP 4.4 and the Governor to each have
a dedicated MPU.

Refer to Systems Operation, SENR3535, "Service Procedure F - Speed Sensor Adjustment" for installation
and setup of the new MPU.

The MPU engine speed sensor uses only two wires (white and black) of the supplied cable.

Install the sensors at the appropriate points on the generator set. Connect the sensors to the EMCP 4.4
control as per the schematic shown in Illustration 12, Illustration 13, and Illustration 15.

Electrical Tests of the EMCP 4.4 Control

The following is a general list of electrical tests used to validate the operation of the EMCP 4.4 control:

• Power off electrical tests

• Power on electrical tests

• Control parameter configuration

• Idle speed generator set parameter verification

• E-Stop validation

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• Rated speed validation

Power Off Tests

The battery must be disconnected.

"TB" designates the terminal blocks in the EMCP 4.4 control.

Note: The engine speed sensor MPU white wire, terminal 2 to TB 302, in Table 6, is used by the EMCP 4.4
control.

Note: The engine speed sensor MPU white wire, terminal 2 to TB 323, listed in Table 6, is for use by the
electronic governor only.

Note: Prior to checking for continuity of the wiring from the generator output to the EMCP 4.4, ensure that
no voltage is present. Remove the three fuses that isolate the wiring from the generator output to the EMCP
4.4. Fuse removal will allow continuity checks of the wiring. Replace the fuses after the continuity checks
have been completed.

Note: The validation assumes that potential transformers are not being used.

Check for continuity between the following points that are listed in Table 6.

Table 6
FROM PIN TO PIN

Battery (+) lug TB 101

Battery (-) lug TB 201

Remote Initiate Contact 1 (IC) TB 14 (Optional Feature)
Remote Initiate Contact 2 (IC) TB 201 (Optional Feature)

Remote Shutdown Contact 1 (PSS) TB 22 (Optional Feature)

Remote Shutdown Contact 2 (PSS TB 201 (Optional Feature)
Battery Charger (+) terminal TB 3

Battery Charger (-) terminal TB 201

Starter Motor (+) terminal TB 24
Starter Motor (S) terminal TB 25
Engine Failure remote monitor TB 13 (Optional Feature)

Air Shut Off Relay coil 1 TB 6 (Optional Feature)

Air Shut Off Relay coil 2 TB 201 (Optional Feature)
Fuel Solenoid coil 1 TB 7
Fuel Solenoid coil 2 TB 201

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Start Aid Solenoid coil 1 TB 10 (Optional Feature)

Start Aid Solenoid coil 2 TB 201 (Optional Feature)

Governor Synchronizer Motor (+) terminal TB 9 (Optional Feature)
Governor Synchronizer Motor (-) terminal TB 8 (Optional Feature)

Electronic Governor Enable terminal TB 11 (Optional Feature)

Engine Speed MPU white wire (terminal 2) TB 302

Engine Speed MPU black wire (terminal 1) TB 303

Oil Pressure Sensor orange wire (terminal A) TB 307
Oil Pressure Sensor yellow wire (terminal B) TB 306
Oil Pressure Sensor green wire (terminal C) TB 305

Coolant Temperature Sensor orange wire (terminal 1) TB 311

Coolant Temperature Sensor black wire (terminal 2) TB 310
Coolant Temperature Sensor white wire (terminal 3) TB 309

Engine Speed MPU white wire (terminal 2) TB 323

Engine Speed MPU black wire (terminal 1 TB 324

Electronic Governor Actuator (EGA) (+) terminal TB 327

Electronic Governor Actuator (EGA) (-) terminal TB 326

Speed Adjust Potentiometer (terminal 1) TB 43

Speed Adjust Potentiometer (terminal 2 and 3) TB 42

Fuse T1 protected terminal TB 401

Fuse T2 protected terminal TB 402
Fuse T3 protected terminal TB 403

Generator Enclosure TB 50 TB 408

Generator Enclosure TB 51 TB 405
Generator Enclosure TB 52 TB 406
Generator Enclosure TB 53 TB 407

Power On Tests

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Working with electrical circuits is hazardous. Bodily contact with

electrical potential will cause personal injury or death. Ensure that
personnel are trained in proper operating procedures in order to ensure
safe operation.

Connect the battery terminals to the battery. Connect the battery charger to the battery and insure the
battery charger is connected to an AC source.

Refer to Illustration 12 schematic for fuse terminal block identification. Use terminal block 201 as ground.
Check that there is battery (+) voltage on the following points:

• Fuse 9 terminal 2

• Fuse 8 terminal 2

• Fuse 7 terminal 2

• Fuse 6 terminal 2

• Fuse 5 terminal 2

• Fuse 4 terminal 2

• Fuse 2 terminal 2

• Fuse 1 terminal 2

Verify that the EMCP 4.4 control and annunciator panels have powered up.

Control Parameter Configuration

Program the parameters into the EMCP 4.4 control by using the parameter data that was obtained in
"Baseline Generator Set Operating Parameters".

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Password Entry" for
information about EMCP 4.4 implemented security passwords.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Real-Time Clock
Programming" for information about how to set the time and date on the EMCP 4.4 control.

The EMCP 4.4 control does not have inputs for battery charger fault detection. Refer to Systems Operation
Troubleshooting Testing and Adjusting, UENR1210, "Digital Input Programming" for instructions on how
to set up digital inputs to monitor the battery charger status.

Control Operation Validation

The following tests are to confirm the proper operation of the controls of the unit.

Generator Set Start and Idle Checkout

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Cranking Cycle Tests

The following steps provide information to conduct cranking cycle tests.

1. Remove Fuse 6. Removing the fuse will prevent the fuel control relay (FCR) from:

◦ Activating and causing the fuel control valve from opening

◦ Generator set from starting

◦ Allow full testing of the cranking cycle

2. If the observed generator set cranking cycle is not what is desired, review the times that have been set
in the "Cycle Crank Time" configuration.

3. The battery charger is to be disconnected while the generator set is cranking. Observe the battery
charger and note that the battery charging current drops to zero when the generator set is cranking.

4. Acknowledge the cranking cycle faults and reset the EMCP 4.4 control.

Cranking Cycle and E-Stop Test

The following are steps to conduct the "Cranking Cycle" and "E-Stop" tests.

1. The E-Stop test will verify that the generator set cranking cycle can be stopped with the E-Stop
button. The generator set should not start, since the FCR has been previously disabled.

2. Press the "RUN" button and allow the generator set to go through the first crank/rest cycle. When the
second crank cycle begins, press the E-Stop button to verify that the generator set can be stopped.

3. Acknowledge the cranking cycle faults and reset the EMCP 4.4 control.

4. Replace "Fuse 6" to allow the fuel control relay (FCR) to function.

Idle Speed Tests

Disconnect or disable any speed governor, to prevent the generator set from running at rated speed.

Idle Speed, E-Stop Test

The idle speed and E-stop test will verify that the generator set can be stopped at idle speed with the E-Stop
button.

1. Press the "RUN" button and allow the generator set to start and run at idle speed.

2. Press the E-Stop button to verify that the generator set will come to a controlled stop.

Idle Speed Parameter Validation

1. Press the "RUN" button on the EMCP 4.4 control panel. The generator set will start and run at idle
speed.

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Note: Check the coolant temperature as the generator set starts and verify that temperature is close to
the block temperature of the generator set. The check is to determine if the coolant temperature
sensor and related wiring are functional.

2. Allow the coolant temperature to stabilize and then read the following parameters from the "EMCP"
display.

◦ Engine speed (RPM)

◦ Battery voltage (Volts)

◦ Engine oil pressure (kPa / psi)

◦ Engine coolant temperature (°C / °F)

3. All parameters values must be near the values recorded from "Baseline Generator Set Operating
Parameters". Any parameter value that is not close to the original parameter value data will need to
be investigated and resolved before proceeding.

Note: Regarding this section, the "Idle Speed Parameter Determination" must be investigated and
resolved before proceeding.

4. Press the "Stop" button on the EMCP 4.4. The generator set should come to a controlled stop.

5. Correct any issues that prevented the generator set from starting, idling, or verification of the idle
speed parameters.

Engine Speed Sensor Loss Test

The engine speed sensor loss test will verify that the generator set will stop if the engine speed sensor fails.

1. Push the "RUN" button and allow the generator set to start and run at idle speed.

2. Jumper terminal 302 to terminal 303. The generator set should shut down immediately. Loss of
engine speed results in an "Unexpected Engine Shutdown" fault. To recover from the fault, press the
RESET button that is on the front of the EMCP 4.4.

3. Restart the generator set and allow the generator to run at idle speed.

4. Disconnect the engine speed sensor from either terminal 302 or 303. The generator set should shut
down immediately. Reconnect the engine speed sensor and cycle the power on the EMCP 4.4.

5. Reconnect or enable the governor to allow the generator set to run at rated speed.

Rated Speed Tests

1. Push the "RUN" button on the EMCP 4.4. The generator set should crank, start, and run at idle speed
while building oil pressure. The EMCP 4.4 and governor will bring the generator set to rated speed
once idle speed and oil pressure conditions have been met.

2. After the generator set comes up to rated speed, monitor the coolant temperature as the temperature
rises. When the coolant temperature has stabilized, check the engine rated speed operating

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parameters. Compare the engine rated speed operating parameters listed below against the values
recorded in "Determine Idle, and Rated, Speed Parameters".

◦ Engine rated speed

◦ Engine oil pressure

◦ Engine coolant temperature

3. Put the EMCP 4.4 into the "Stop Mode". Observe that the engine speed is reduced to idle while the
generator set cools down for the period recorded as "Cooldown Duration".

4. Reconnect or enable any previously disconnected or disabled speed governor. Correct any issues that
prevented the generator set from starting, idling, running at rated speed, cooling down or recording
the rated speed parameters.

Remote Operation Tests

The remote operation tests will validate the control capability to start and stop the generator set using the
remote control inputs.

Each of the following tests will require a jumper wire connected to ground. Connect a wire to terminal 201
to use for this purpose.

E-Stop Test

1. Use the EMCP 4.4 run button to start the generator set and allow the generator to come up to speed.
Do not wait for the generator set to warm up.

2. Using the ground wire, touch terminal 22 and verify that the generator set stops running.

3. If a remote "E-Stop" switch is part of the installation, connect the switch to the control using terminal
22 in the EMCP 4.4 control panel. Start the generator set and allow to come up to rated speed. Press
the remote "E-Stop" switch to verify that the switch works as intended.

4. Correct any issues that prevented the generator set from starting, idling, running at rated speed,
cooling down or stopping.

Remote Initiate Test

1. With the generator set stopped, and the EMCP 4.4 control in "Auto", touch the ground wire to
terminal 14. The generator set should crank, start, idle, and run at rated speed.

2. If a "Remote Initiate" switch is part of the installation, connect the switch to the control using
terminal 14 in the EMCP 4.4 panel. Press the "Remote Initiate" switch to verify that this switch
works as intended.

3. Stop the generator set using the "Stop" button on the EMCP 4.4 control panel.

4. Correct any issues that prevented the generator set from starting, idling, running at rated speed,
cooling down or stopping.

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Engine Set Point Verification

The engine set point verification procedure verifies that the EMCP 4.4 operates correctly when a "Low Oil
Pressure" or a "High Coolant Temperature" event occurs. The engine set point verification procedure also
verifies that the EMCP 4.4 operates correctly when an "Engine Overspeed" event occurs.

Low oil pressure and high coolant temperature each have two events, "Warning" and "Shutdown". The
EMCP 4.4 will issue a warning whenever the warning threshold is reached. The EMCP 4.4 will issue a
shutdown whenever the shutdown threshold is reached. The verification procedure will modify
configuration set points used in normal operation. The following information outlines how to perform a
"Low Oil Pressure Shutdown" and a "High Coolant Temperature Shutdown" procedure. A similar process
can be used for a "Low Oil Pressure Warning" or a "High Coolant Temperature Warning", along with Low
Idle, Low Oil Pressure.

During the procedure, each configuration set point must be recorded prior to adjustment. Each
configuration set point must be returned to the original setting after the set point has been verified.

The following conditions are required before the engine set points are verified:

• The set points must be correct for the generator set application.

• No shutdown events should be present. If necessary, troubleshoot, correct, and reset any shutdown
events.

Low Oil Pressure Verification

Note: The low oil pressure shutdown is disabled during start-up and while the generator set is not running
by the "Fault Protection Timer" (FPT). The fault protection timer starts timing when crank terminate rpm is
reached during the starting sequence. The fault protection timer will then run for a programmed time. The
time is determined by the "Engine Start Fault Protection Activation Delay Time" set point. Make sure that
the fault protection timer has elapsed before starting the "Low Oil Pressure Verification".

1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Analog Input #1 Low Shutdown Event Threshold" to a value that is
above the oil pressure at which the generator set is operating. The shutdown event will occur after the
programmable time delay. The time delay is referred to as the "Analog Input #1 Low Shutdown
Event Delay Time" set point.

3. View the event by going to the EMCP 4.4 event log. Reset the event.

4. Return the set point value for "Analog Input #1 Low Shutdown Event Threshold" to the original
value.

High Coolant Temperature Verification

Note: "Analog Input #2 High Shutdown" is disabled during start-up and while the generator set is not
running by the "Fault Protection Timer" (FTP). The fault protection timer starts timing when the "Crank
Terminate" rpm is reached during the starting sequence. The fault protection timer will then run for a
programmed time (the "Engine Start Fault Protection Activation Delay Time" set point). Make sure that the
fault protection timer has elapsed before starting the "High Coolant Temperature Verification".

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1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Analog Input #2 High Shutdown Event Threshold". Set the parameter
to a value that is below the engine coolant temperature that the generator set is operating at. The
minimum value for the set point is 49° C (120° F). The generator set may have to run for a few
minutes to get the temperature above the minimum value. The shutdown event will occur after the
programmable time delay which is the "Analog Input #2 High Shutdown Event Delay Time" set
point.

3. View the event by going to the EMCP 4.4 control event log. Reset the event.

4. Return the set point value for "Analog Input #2 High Shutdown Event Threshold" to the original
value.

Over Speed Verification

1. Start the generator set and run the generator set at rated speed.

2. Adjust the set point value for "Engine Over Speed Setpoint" to a value that is below the speed that
the generator set is running at. An engine over speed set point event will occur immediately after the
set point is changed. The generator set will shut down.

3. View the event by going to the EMCP 4.4 control event log. Reset the event.

4. Return the set point value for the "Engine Overspeed Set point" to the original value.

Illustration 10 g06519236
Schematic for the EMCP4.4 application (With Terminal Block Relay). Refer to Illustration 15 for the legend.

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Illustration 11 g06552226
Schematic for the EMCP4.4 application (With hermetically sealed relay Relay).

Illustration 12 g06519244
Schematic for the EMCP4.4 application. Refer to Illustration 15 for the legend.

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Illustration 13 g06519397
Wiring diagram for the EMCP4.4application.

Illustration 14 g06552236
Hermetically sealed relay

Illustration 15 g06519264
Wiring diagram for the EMCP4.4 application.

Installation notes for Illustration 15. Illustration 15 is an example of the wiring of the original EMCP 1
drawings. The current transformers are wired so the current is 180 degrees out of phase with the voltage
causing a power factor of -1. The solution is to swap the white 51, 52, and 53 leads with the black leads that
are all labeled as 50.

Parameter Configurations Using Cat ET

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Illustration 16 g03557494

The parameters discussed in this section are accessed with Cat ET. The factory default values that are
provided are programmed into the EMCP 4.4.

Crank Attempt/Successful Start Counter Configuration

Illustration 17 g03557496

The parameter indicates the level of security required to modify configuration parameters. The default
value is set to "0 - No Security", which means that everyone has access to the parameters.

Engine Serial Number

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Illustration 18 g03557498

Click "Configuration Data" to display the "Engine Serial Number" information.

Engine Service Hours

Illustration 19 g03557501

Configuration of the "Engine Service Hours" is done by selecting the "Information" tab. Then, from the
drop-down menu, click "Current".

Display Preferences

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Illustration 20 g03557502

Service Maintenance Interval

Illustration 21 g03557504

Analog Inputs

During normal operation, there are two analog inputs from the generator set to the EMCP. The inputs are
listed as "Analog Input #1" for the engine oil pressure, and "Analog Input #2" for the engine coolant
temperature.

Each of the two analog inputs triggers an event code when the set values are exceeded. The nominal default
values for the two analog inputs are set at the factory prior to shipping.

"Analog Input #1" is associated with a "Low Shutdown Threshold" event, and "Analog Input #2" is
associated with a "High Coolant Temperature Shutdown" event.

Low Oil Pressure Shut down Event Threshold

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A "Low Shutdown Event Threshold" is listed as "Analog Input #1 Low Shutdown Event Threshold". The
range of the parameter is 13.4 kPa (2 psi) to 880 kPa (128 psi). The factory default value is set at 150 kPa
(22 psi).

High Coolant Temperature Shut down Event Threshold

Illustration 22 g03731251

Note: The Minimum and Maximum Data Range units for pressure are kilo Pascals (kPa). The Minimum
and Maximum Data Range units for temperature are Centigrade Degrees. All configuration parameters
are entered in SI (Metric) units even though the display may show English units.

A "High Coolant Temperature Shutdown" is listed as "Analog Input #2 High Shutdown Event Threshold".
The range of the parameter is 95° C (203° F)to 120° C (248° F). The factory default value is set at 108° C
(226° F).

Automatic Start/Stop

Configuration of the automatic start/stop parameters is done using Cat ET. The parameters are discussed in
the following sections.

Cycle Crank Configuration

The "Cycle Crank Configuration" is listed as "Crank Duration". The range of the parameter is 1 to 60
seconds. The default value is set at 10 seconds.

Cycle Crank Rest Interval

The range of the parameter is 1 to 60 seconds. The default value is set at 5 seconds.

Maximum Number of Crank Cycles

The range of the parameter is 1 to 99. The default is set to 1.

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Cool down Configuration

The "Cool down Configuration" is listed as "Cool down Duration". The range of the parameter is 0 to 30
minutes. The default value is set at 5 minutes.

Crank Termination Speed Configuration

The "Crank Termination Speed Configuration" is listed as "Crank Terminate RPM". The range of the
parameter is 100 to 1000 rpm. The default value is set at 300 rpm.

Engine Fuel Type Configuration

Illustration 23 g03565819

The "Engine Fuel Type Configuration" value will always read "Diesel", cannot be changed, and will not
affect the operation of a gas generator set.

Battery Voltage Monitor

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Illustration 24 g03565797

Engine Oil Pressure Monitor

Idle Speed Oil Pressure Shutdown

The "Idle Speed Oil Pressure Shutdown" is listed as "Low Idle Low Engine Oil Pressure Shutdown Event
Threshold". The range of the parameter is 20 kPa (3 psi) to 420 kPa (61 psi).The default value is set at
207 kPa (30 psi).

Low Idle Low Engine Speed Oil Pressure Warning Event Threshold

The range of the parameter is 22 kPa (3.2 psi) to 462 kPa (67 psi). The default value is set at 241.3 kPa
(35 psi). The value of the parameter must be set at least 110% of the value of the "Idle Speed Oil Pressure
Shutdown" parameter.

Oil Step Speed

Illustration 25 g03557512

The "Oil Step Speed" parameter is listed as "Low Engine Oil Pressure Step Speed". The range of the oil
step speed parameter is 400 to 1800 RPM. The default value is set at 400 RPM.

Engine Speed Monitor

Ring Gear Teeth

The "Ring Gear Teeth" parameter is listed as "Flywheel Teeth". The range of the ring gear teeth parameter
is 110 to 260. The default value is set at 183.

Over Speed

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Illustration 26 g03557513

The "Over Speed" parameter is listed as "Engine Overspeed Setpoint". The default value is set at 1540
RPM. The engine over speed set point value is generator set-specific.

Enhanced Engine Monitor

Illustration 27 g03557514

The default value for "Number of Engine Cylinders" is set at 1.

Maintenance and Operation

CAN Annunciator Operation

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Illustration 28 g03707582
Cat service tool CAN 2 annunciator default configuration values dialog

The EMCP CAN annunciator serves to display system alarm conditions and status indications. The CAN
annunciator has been designed for use on the EMCP accessory CAN data link. The CAN annunciator may
be used in either local or remote applications. The CAN annunciator provides customers with enhanced site
flexibility.

In local application, the CAN annunciator may be mounted on the package generator set with the EMCP to
provide a complete package-mounted monitoring solution.

The CAN annunciator also may be mounted separately from the generator set. A remotely mounted
annunciator provides remote indication of system operating and alarm conditions.

Refer to Systems Operation Troubleshooting Testing and Adjusting, UENR1210, "Annunciator Module"
for annunciator features, specifications, wiring, and comprehensive discussion of annunciator features.

Illustration 29 g03558919

Illustration 29 provides the location of the status light indicators for the module network system on the
annunciator. Refer to Table 7 for an explanation of the status lights.

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Table 7
Module Network Status

Status Light Explanation

CAN 2 data link diagnostic. The module is wired wrong (Data Link), wrong cable,
Red solid
or no terminating resistor.
Green solid CAN 2 data link OK
Green flashing No CAN 2 data link diagnostic, but no communication detected.
Red/Green
No application software loaded
alternating

Icon List

Illustration 30 g03558842

General kit information

The EMCP 4.4 supports flashing (field-programming) of software for all the modules. The flashing is done
by using the Cat Service Tool software and a Cat communication adapter. The primary datalink (CAN 1)
service connector must be used for modules connected to the primary data link. The accessory datalink
(CAN 2) service connector must be used for modules connected to the accessory data link. Refer to the
generator set package documentation for the location of the service connectors.

Software and Hardware Required

The following hardware and software are required to flash the EMCP 4.4:

• Cat Service Tool software installed and licensed on a PC

• Cat communication adapter

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• A 9-pin Deutsch connector, for the service connection to the "Primary Datalink (CAN 1)"

• A 9-pin Deutsch connector, for the service connection to the "Accessory Datalink (CAN 2)"

• The new application software flash file for the EMCP 4.4

Use the following files to flash or configure the appropriate component.

EMCP 4.4 ECM

The flash file name is 5947239.fls.

Note: The new software is available in the form of a flash file through the Caterpillar Service Information
System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.

The configuration file name is Not Programmed_FLTCFG_2013-08-16 _14.02.06.xml.

Note: The configuration file is the most recent .xml file and is subject to change.

Annunciator ECM Information

The flash file name is 2978331.fls

Note: The new software is available in the form of a flash file through the Caterpillar Service Information
System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.

The configuration file name is 1003B183HW_ECMREP_2013-08-16 _13.53.14.xml.

Note: The configuration file is the most recent .xml file and is subject to change.

Programming New Configurations

EMCP 4.4 Control

Illustration 31 g03560896

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1. Connect to the EMCP 4.4, using the Cat Service Tool, to the CAN 2 port.

The message, "No data is available. Load from the ECM now?", will appear. Click "No".

a. Select the "Service" tab.

b. Select "Copy Configuration"

c. Select "Fleet Configuration".

Illustration 32 g03560898

2. After the desired changes are completed, click "Load from File" at the "Fleet Configuration" dialog
to save the file.

Illustration 33 g03560916

3. Navigate to the .xml file. Click "Open". Refer to the "General Kit Information" for the most recent
(.xml) configuration file . A dialog will appear to confirm that the file was loaded. Refer to
Illustration 33.

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Illustration 34 g03560917

4. Select which control configuration data is to be programmed into the EMCP 4.4 by clicking the box
to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a
parameter is not desired, do not click that parameter. If the box has a check mark, but that parameter
is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration
33 as an example of having the boxes checked next to the desired parameters. After any selection
changes are completed, click "Program ECM" from the bottom of the ECM Replacement dialog to
load the file into the EMCP 4.4.

Illustration 35 g03560918

The dialog in Illustration 35 will appear to confirm that programming the ECM is completed.

Annunciator Control

The annunciator control is only accessible through the CAN 2 port/Accessory datalink. In the case of the
annunciator, ECM replacement should be used via the CAN 2 port/Accessory datalink only.

Saving the Current Annunciator Control Configuration

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Illustration 36 g03560920
Cat Service Tool EMCP 4.4 summary dialog

1. Connect to the EMCP 4.4, using the Cat Service Tool, to the CAN 2 port. From the "Cat Service
Tool" menu, select the following.

a. Select the "Service" tab.

b. Select "Copy Configuration"

c. Select "ECM Replacement".

Refer to Illustration 36.

Illustration 37 g03560922

2. The Cat ET dialog shown in Illustration 37 will appear. The dialog will have the message "No data is
available. Load from the ECM now?". Click "Yes" .

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Illustration 38 g03560923

3. Select "Alarm Module #1" from the ECM list. The alarm module will allow the software to connect
to the annunciator.

Illustration 39 g03560924

4. The system will load the annunciator configuration.

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Illustration 40 g03560928

5. After the data is loaded, the current file parameters will be displayed.

6. Select which control configuration data is to be programmed into the EMCP 4.4 by clicking the box
to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a
parameter is not desired, do not click that parameter. If the box has a check mark, but that parameter
is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration
33 as an example of having the boxes checked next to the desired parameters.

Illustration 41 g03560998

7. After the desired changes are completed, click "Save to File" to save .xml the file. Make sure to note
where the file is stored.

Programming New Configurations on the Annunciator Control

1. Connect to the EMCP 4.4, using the Cat Service Tool, to the CAN 2 port. From the "Service Tool"
menu, select the following.

a. Select the "Service" tab.

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b. Select "Copy Configuration"

c. Select "ECM Replacement".

Refer to Illustration 36.

Illustration 42 g03561017

2. After the desired changes are completed, click "Load from File" to save the file.

Illustration 43 g03561019

3. Navigate to the desired file and click "Open". Refer to the "General Kit Information" for the most
recent configuration file (.xml). The software will confirm that the file has been opened. Refer to
Illustration 43.

4. Select which control configuration data is to be programmed into the EMCP 4.4 by clicking the box
to the left of the parameter. A check mark must appear next to the parameter that is to be added. If a
parameter is not desired, do not click that parameter. If the box has a check mark, but that parameter
is not desired, click the box again to remove the check mark for that parameter. Refer to Illustration
33 as an example of having the boxes checked next to the desired parameters.

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Illustration 44 g03561020

5. After the desired changes are completed, click "Program ECM" to load the file into the EMCP 4.4.

Illustration 45 g03561022

6. The dialog in Illustration 45 will appear.

7. Click "Yes".

Illustration 46 g03561023

8. Next, select "Alarm Module #1" from the list of controls.

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Illustration 47 g03561026

9. Allow the software to configure the set parameters to the annunciator.

Illustration 48 g03561028

10. The software will confirm the programming of the control.

Copyright 1993 - 2024 Caterpillar Inc. Thu Jan 25 21:00:28 UTC-0400 2024
All Rights Reserved.
Private Network For SIS Licensees.

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