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CUSTOMER GUIDE

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 CATERPILLAR FOCUS ON IMPROVING ASSET RELIABILITY
Each year, customers experience financial and productivity losses due to unexpected power outages. For
customers who invest in generators, Caterpillar is dedicated to offering solutions that ensure assets are
running within normal parameters. To reduce financial and productivity loss, the Genset Control Package
offers customer solutions to improve asset reliability through remote monitoring and controlling.

REPLACE OBSOLETE TECHNOLOGIES AND AVOID FAILURES

EMCP I and II generator set control panels are no longer in production and EMCP II+ and EMCP 3 panels,
while still available, may not provide all the capabilities customers need.​ Caterpillar introduces Series 4
EMCP upgrades to replace controllers at or near obsolescence, as well as a free mobile app to help
customers monitor and diagnose equipment for maximum uptime.​
*An additional hardware purchase is required.
• Power OnSite App
• Electronic Modular Control Panel (EMCP) Upgrades
• EMCP 4.1
• EMCP 4.2
• EMCP 4.2B
• EMCP 4.3
• EMCP 4.4
“Unplanned maintenance can
cost up to 3X More
than scheduled maintenance.”
- For Construction Pros.com/True Cost of Unplanned Downtime

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PRODUCT OVERVIEW
Installed on any Cat® or competitive genset,
Series 4 EMCPs improve asset utilization, help
prevent unplanned downtime and provide real-
time performance data. Through condition
monitoring, customers can mitigate costs and
risks associated with power being unavailable.

Cat® Electronic Modular Control Panel

Upgrades

• 24/7 remote genset monitoring and control

for standby and prime power​
• Reduce fail-to-start occurrences​
• Real-time condition-based
maintenance strategies​
• Obsolescence management​
• Latest technology and features​
• Mixed-fleet solution​
• Tiered product offering based on feature
and hardware requirements

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 EMCP Series II have either reached or are near
obsolescence, making them difficult to maintain.
EMCP Series 4 offers the following advantages.

EMCP 4.2 EMCP 4.2B EMCP 4.3 EMCP 4.4

CONTROLS ∙ New user interface
∙ Supports multiple languages
∙ New user interface
∙ Supports multiple languages
∙ Programmable Logic Control
∙ New user interface
∙ Supports multiple languages
∙ Programmable Logic Control
∙ New user interface
∙ Supports multiple languages
∙ Programmable Logic Control
∙ Paralleling Multiple or Single
Gensets to Single Utility

GENERATOR
∙ kW, kVAr, kVA ∙ kW, kVAr, kVA ∙ kW, kVAr, kVA ∙ kW, kVAr, kVA
MONITORING
(Average, Phase, %) (Average, Phase, %) (Average, Phase, %) (Average, Phase, %)
∙ Power Factor (Average, Phase) ∙ Power Factor (Average, Phase) ∙ Power Factor (Average, Phase) ∙ Power Factor (Average, Phase)

ENGINE
∙ Enhanced engine monitoring ∙ Enhanced engine monitoring ∙ Enhanced engine monitoring ∙ Enhanced engine monitoring
MONITORING (with electronic engines) (with electronic engines) (with electronic engines) (with electronic engines)

GENERATOR
∙ Overcurrent (50/51) ∙ Overcurrent (Thermal Damage Curve) ∙ Overcurrent (Thermal Damage Curve) ∙ Overcurrent (Thermal Damage Curve)
PROTECTION
∙ Over/under voltage ∙ Over/under voltage ∙ Over/under voltage ∙ Over/under voltage
∙ Integrated Voltage Regulator ∙ Integrated Voltage Regulator ∙ Integrated Voltage Regulator ∙ Integrated Voltage Regulator

COMMUNICATION ∙ Modbus RTU (RS-485 Half duplex) ∙ Modbus RTU (RS-485 Half duplex) ∙ Modbus RTU (RS-485 Half duplex) ∙ Modbus RTU (RS-485 Half duplex)
PROTOCOLS
∙ Modbus TCP (10BT Ethernet) ∙ Modbus TCP (10BT Ethernet)

INPUTS &
∙ Cat Electronic Technician ∙ Cat Electronic Technician ∙ Cat Electronic Technician ∙ Cat Electronic Technician
OUTPUTS
compatible compatible compatible compatible
∙ 2 programmable digital outputs ∙ 2 programmable digital outputs ∙ 16 programmable digital outputs ∙ 16 programmable digital outputs

DISPLAY ∙ 5.5 inch, white backlit, high ∙ 5.5 inch, white backlit, high
visibility graphical display visibility graphical display
∙ Text alarm and event ∙ Text alarm and event
descriptions descriptions
∙ Set points ∙ Set points
∙ Monitor engine and generator ∙ Monitor engine and generator
Contact local
Caterpillar: Cat Dealer
Confidential for complete feature list comparison.
Green health conditions health conditions
 Panel Only Part Numbers Description
503-4411 Panel only
EMCP 467-4168 Panel and harness only
4.2 465-6747 Complete kit with enclosure
533-0545 CDL to J1939 Converter – for use with 4.2

503-4421 Panel only

Panel and Harness Only EMCP
533-1388 Complete kit with enclosure
4.2B
533-0545 CDL to J1939 Converter – for use with 4.2B

503-4406 Panel only

EMCP 581-6553 Panel and harness only
4.3 447-3803 *Panel and harness only
439-5044 Complete kit with enclosure
Complete Kit with Enclosure
503-4417 Panel only
EMCP
447-3804 *Panel and harness only
4.4 452-9414 Complete kit with enclosure

*For upgrading from EMCP 4.2B to 4.3 or 4.4

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WHAT IS THE DIFFERENCE BETWEEN PANEL, PANEL AND

HARNESS KIT, AND COMPLETE KIT?
The EMCP panel is the lowest cost solution for customers who already have a 2.X or 3.X controller
or are looking to upgrade from 4.1 to 4.2B.

Some customers have an enclosure in good condition and a location to mount kit parts, where the
panel and harness kit is the best solution.

The complete kit enclosure includes the panel, harness, and enclosure. This kit is for customers
who have an enclosure/box in poor condition and want to standardize their genset controls across
all units.

DO I NEED TO PURCHASE AN EMCP PANEL UPGRADE IF I

ALREADY HAVE ASSETIQ?
In Genset AssetIQ, an EMCP is the ECM. You would need one if the current Genset controller does not have J1939
or a competitive equipment controller.

IS CAT PRODUCT LINK REQUIRED FOR EMCP?

Remote monitoring requires a telematics system such as Product Link to be installed, or an existing network can be
used to receive the data.

ARE CATERPILLAR EMCP UPGRADES AN OPTION FOR MIXED FLEETS?

All current EMCP kits can be retrofitted on competitive equipment. Contact your local Cat dealer to learn more details.

DOES THE AGE OF MY EQUIPMENT AFFECT MY ABILITY TO

INSTALL EMCP?
No, the only requirement is a 12V or 24V system. Contact your local Cat dealer to learn more details.
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CAN I UPGRADE TO EMCP 4.4 FROM AN EMCPII OR EMCP

3?
Yes, these upgrade kits are compatible with all previous EMCP versions and with
Caterpillar’s electro-mechanical controllers.

CAN I MONITOR EMCP DATA REMOTELY WITH MY SMART

PHONE?
Yes. With an active Product Link™ subscription, data will be visible off-site in Cat Remote Asset
Monitoring (RAM).

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PRODUCT OVERVIEW
The Power OnSite App is an easy way to display and
manage priorities for any asset. The App uses Bluetooth®
technology to connect directly to the asset without the need
of internet coverage. Up to (16) genset and (30) engine
parameters can be monitored.

DISPLAYS CRITICAL
ASSET DATA ON
MOBILE DEVICES
Key benefits of the Power OnSite App:
• Can respond to safety issues quickly
• Schedule service
• Order parts
• Avoid unplanned downtime
• View live ECM data
The Power OnSite App is free through Cat
Parts Store. An additional hardware
purchase is required.
Part Number
572-8499 Power Onsite Bluetooth Transceiver

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 IS PRODUCT LINK REQUIRED FOR THIS SYSTEM?
When installed on engines and power generation equipment, A5:S4 hardware is required to connect for the
Power OnSite App. Product Link is not required for the Cat Power OnSite to function.

WILL THIS DEVICE WORK ON COMPETITIVE ENGINES AND GENSETS?

Yes, the device can read Public J1939 fault codes and parameters of competitive equipment that support Public J1939.

DOES THE AGE OF MY EQUIPMENT AFFECT MY ABILITY TO

USE THE BLUETOOTH DEVICE?
• 2011 and newer model years with ADEM 4 engine ECMs fully supports Cat Power OnSite
• 2010 and older model years have a limited data and may not support Cat Power OnSite
All models require Public J1939 or Proprietary J1939 data link.

WHAT ELSE CAN THE POWER ONSITE APP DO?

The Cat Power OnSite App can provide a list of required parts based on the fault code and offers the ability to request
service from a local Cat dealer.

WHY ARE SOME PARAMETERS NOT AVAILABLE IN CAT POWER

ONSITE?
Cat Power OnSite uses a master list of channels. Very few engines support all the parameters in the Master List. Some
parameters are specific to Tier IV engines, while some parameters like exhaust temperatures are only supported by larger
engines such as C32, 3500 and/or C175 engines.

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