RENR7902-07

December 2009

Systems Operation
Troubleshooting
Testing and Adjusting
EMCP3
CNB1-Up (Generator Set) NKK1-Up (Generator Set)
D4B1-Up (Machine) YAK1-Up (Generator Set)
G5B1-Up (Generator) CAL1-Up (Generator Set)
X3B1-Up (Generator Set) NKL1-Up (Generator Set)
ZAB1-Up (Generator Set) ZAL1-Up (Generator Set)
CMC1-Up (Generator Set) KNM1-Up (Power Module)
N3C1-Up (Generator Set) NKM1-Up (Generator Set)
NCC1-Up (Generator Set) SLM1-Up (Engine)
NSC1-Up (Generator Set) YAM1-Up (Generator Set)
XYC1-Up (Generator Set) 7RN1-Up (Engine)
D4D1-Up (Machine) FDN1-Up (Generator Set)
GLD1-Up (Generator Set) YAN1-Up (Generator Set)
N4D1-Up (Generator Set) ZAP1-Up (Generator Set)
N6D1-Up (Generator Set) N4R1-Up (Generator Set)
NCD1-Up (Generator Set) PBR1-Up (Generator Set)
XYD1-Up (Generator Set) ZAR1-Up (Generator Set)
ZAD1-Up (Generator Set) YAS1-Up (Generator Set)
GLE1-Up (Generator Set) YAT1-Up (Generator Set)
N4E1-Up (Generator Set) YAW1-Up (Generator Set)
NCE1-Up (Generator Set) N3X1-Up (Generator Set)
ZAF1-Up (Generator Set) N4X1-Up (Generator Set)
ZAH1-Up (Generator Set) G5Y1-Up (Generator)
ZAJ1-Up (Generator Set) 4BZ1-Up (Generator Set)
BRK1-Up (Generator Set) E6M1-Up (Engine)

SAFETY.CAT.COM
 i03684547

Important Safety Information

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 should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels
on the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must
not use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
RENR7902-07 3
Table of Contents

Table of Contents Testing and Adjusting Section

Testing and Adjusting
Electrical Connector - Inspect ............................. 138
Systems Operation Section Wiring Harness (Open Circuit) - Test .................. 138
Wiring Harness (Short Circuit) - Test .................. 139
General Information ................................................ 4
External Potential Transformer Connections ...... 139
Component Location ............................................... 6
Engine Speed Timing Calibration - Setup ........... 144
Electronic Control Module (Generator Set) ............ 11
Speed Sensor (Engine) - Adjust ......................... 145
Data Link .............................................................. 13
Engine Setpoint Verification - Test ...................... 145
Electronic Control Module (Engine) (EUI Engines
Electronic Control Module (Generator Set) -
Only) ................................................................... 14
Replace ............................................................. 147
MUI Engine Monitoring and Control ...................... 15
Electronic Control Module (Generator Set) - Flash
System Operation ................................................. 15
Program ............................................................ 147
Password Entry ..................................................... 17
Electronic Control Module (Generator Set) -
Event Viewing ....................................................... 19
Configure .......................................................... 147
Event Resetting .................................................... 20
Typical Generator Abbreviations ......................... 201
Setpoint Programming .......................................... 23
ECM Connections ............................................... 203
Digital Input Programming .................................... 25
Digital Output Programming ................................. 28
Relay Output Programming .................................. 32 Index Section
Spare Analog Input Programming ........................ 37
Cycle Timer Programming .................................... 38 Index ................................................................... 208
Trip Point Programming ........................................ 40
Text String Programming ...................................... 41
Voltage and Frequency Adjustment ...................... 49
Real Time Clock Programming ............................. 50
Thermocouple Module .......................................... 52
Discrete Input/Output Module ............................... 55
Resistive Temperature Device Module ................. 57
Annunciator Module .............................................. 60
Monitoring Software for Computer ........................ 69

Troubleshooting Section
Introduction
General Information .............................................. 89
Service Tools ........................................................ 90
Diagnostic Capabilities ......................................... 91
Diagnostic Trouble Code List ................................ 92

Diagnostic System Procedures

Engine Cooldown Warning ................................. 108
Engine Overcrank Warning ................................. 108
Engine Speed Warning ....................................... 109
Engine Overspeed Warning ................................. 110
Engine Underspeed Warning ............................... 112
Generator Control Not in Automatic Warning ...... 114
Generator Output Sensing Circuit Fault ............... 115
Generator Overcurrent Warning .......................... 115
Generator Overfrequency Warning ...................... 116
Generator Overvoltage Warning .......................... 119
Generator Reverse Power Warning .................... 120
Generator Underfrequency Warning ................... 121
Generator Undervoltage Warning ....................... 124
Service Maintenance Interval Warning ............... 126
Analog Input Circuit Fault ................................... 127
Charging System ................................................ 128
Data Link Circuit Fault ........................................ 130
Digital Input Circuit Fault ..................................... 132
Digital Output Circuit Fault .................................. 133
Engine Speed Circuit Fault ................................. 134
Unexpected Engine Shutdown ........................... 137
4 RENR7902-07
Systems Operation Section

Systems Operation Section

i03541121

General Information
SMCS Code: 4490

g01237225
Illustration 1
Block diagram of a generator set with EMCP 3 and EUI Engine
RENR7902-07 5
Systems Operation Section

g01237211
Illustration 2
Block diagram of a generator set with EMCP 3 and MUI Engine
6 RENR7902-07
Systems Operation Section

i02989617

Component Location
SMCS Code: 4490

The original “Electronic Modular Control Panel 3”

(EMCP 3) design utilized existing hardware. These
Early Introduction Packages, shown in Illustrations
3 and 4, are still in use today. The newest EMCP
3, shown in Illustrations 5 and 6 uses the Global
Design Package. Both versions of the EMCP 3
have some components, such as the “Start Aid
Switch”, that are optional. Additionally, some of the
components, such as the speed potentiometer, are
only found on certain engines. This optional and
specialized information can be found in the call out
section of the specific Illustration.

g01228802
Illustration 3
Early Introduction EMCP 3 - Face
(1) Electronic Control Module (ECM) for the (4) Start Aid Switch (SAS) (optional) (8) Alarm Acknowledge/Silence Switch
Generator Set (5) Speed Potentiometer (SP) (optional) (9) Alarm Horn
(2) Panel Lights (6) Emergency Stop Push Button (ESPB) (10) Annunciator Module (ALM)
(3) Panel Light Switch (PLS) (7) Lamp Test Switch
RENR7902-07 7
Systems Operation Section

Illustration 4
Early Introduction - EMCP 3 - Subpanel
(11) AC Terminal Strip
(12) DC Terminal Strip
(13) Switchgear Option Terminal Strip
g01228805
(14) Discrete Input Output (I/O) Terminal (15) Discrete Input Output (I/O) Module or
Strip Resistive Temperature Device (RTD)
Module
8 RENR7902-07
Systems Operation Section

Illustration 5
Global Design EMCP 3 - Face
(16) Electronic Control Module (ECM) for
the Generator Set
(18) Annunciator Module (ALM)
g01589889
(19) Lamp Test Switch (22) Emergency Stop Push Button (ESPB)
(20) Alarm Acknowledge/Silence Switch (23) Panel Light Switch (PLS) (optional)
(21) Alarm Horn
RENR7902-07
Illustration 6
Global Design - EMCP 3 - Subpanel
(27) AC Terminal Strip
(28) DC Terminal Strip
(29) DC Terminal Strip
9
Systems Operation Section
g01222139
(30) Relay for MUI engine with Ether Start (32) Service Connector for CAN 2
Aid option (33) Discrete Input Output (I/O) Terminal
(31) Service Connector for CAN 1 Strip
10 RENR7902-07
Systems Operation Section

g01514733
Illustration 7
In Line Six Cylinder Components
RENR7902-07 11
Systems Operation Section

i02970772

Electronic Control Module

(Generator Set)
SMCS Code: 4490

g01211086
Illustration 8
EMCP 3 Control System Panel
(1) Display Screen (7) Auto key (13) Up key
(2) Yellow Warning Lamp (8) Run key (14) Left key
(3) Red Shutdown Lamp (9) Escape key (15) Engine Overview key
(4) Alarm Acknowledge/Silence key (10) Enter key (16) AC Overview key
(5) Lamp Test key (11) Right key
(6) Stop key (12) Down key

General Information • Providing visual and audible indications when

The main component of the “Electronic Modular
Control Panel 3” (EMCP 3) is the “Electronic Control
Module” (ECM). This section discusses the display,
keys, and indicators on the control system panel of
the ECM. The EMCP 3 panel is used for monitoring
and controlling many of the generator set functions.
Some of the functions include:
• Sending start and stop signals to the engine
warning or shutdown events occur
• Displaying Engine information and AC generator
set information
• Displaying Suspect Parameter Number (SPN) and
Failure Mode Identifier (FMI) information for events
• Programming set points for the standard EMCP 3
(The set points for optional modules are set with
the use of Cat ET.)
12
Systems Operation Section
ECM Front Panel Components
The following components can be found on the front
panel of the ECM:
• Information Display
• Alarm Indicators
• Alarm Acknowledge/Silence Key
• Function Keys
• Navigation Keys
• System Overview Keys
Information Display
(1) Display Screen – Information from the EMCP
3 is displayed on the Display Screen. This screen
is used for the following programming and display
functions.
• Displaying AC parameter information of the
generator set
• Displaying Engine parameter information of the
generator set
• Programming set points for the generator
• Displaying Engine Event information
• Displaying Event codes from other modules
• Programming the display preferences of the EMCP
3 holding the lamp test key will cause all of the LED
• Changing password levels of the EMCP 3
Alarm Indicators
(2) Yellow Warning Lamp – A solidly illuminated
Yellow Warning Lamp indicates that there are
acknowledged warnings that are still present. A
flashing Yellow Warning Lamp indicates that there
are unacknowledged warnings that are still present.
In order to verify the warnings, press the Alarm
Acknowledge/Silence key (4). If there are no longer
any active warnings, then the lamp will turn off. If
active warnings still exist, then the lamp will change
from flashing yellow to solid yellow.
RENR7902-07
(3) Red Shutdown Lamp – An illuminated
Red Shutdown Lamp indicates that there are
acknowledged shutdown events that are still active.
A flashing Red Shutdown Lamp indicates that there
are unacknowledged active shutdown events. In
order to verify the shutdown events, press the Alarm
Acknowledge/Silence key (4). If there are no longer
any active shutdown events, then the lamp will turn
off. If active shutdown events still exist, then the lamp
will change from flashing red to solid red.
Note: Any condition that has caused a shutdown
event must be manually reset.
Reference: Systems Operation, “Event Resetting”
Alarm Acknowledge/Silence Key
(4) Alarm Acknowledge/Silence – Pressing the
Alarm Acknowledge/Silence key causes the horn
relay output to turn off, which silences the alarm.
When the alarm acknowledge key is pressed, a
“global acknowledge” command is transmitted on the
CAN data link. Other modules may be configured to
respond to the “global acknowledge” signal. When
the horn relay sounds, one or both of the alarm
lamps (2) or (3) will begin to flash. Depending on the
active status of the alarms when this key is pressed,
the flashing lamp(s) will either turn off or solidly
illuminate. The alarm acknowledge key always sends
out a global acknowledge, however other modules
must be configured in order to listen to the global
acknowledge.
Function Keys
(5) Lamp Test – Pressing the lamp test key and
indicators and the display screen pixels to illuminate.
The LED indicators and the display screen pixels will
remain illuminated until the key is released.
(6) STOP – Pressing the “STOP” key causes the
EMCP 3 to enter the “STOP” mode.
(7) AUTO – Pressing the “AUTO” key causes the
EMCP 3 to enter the “AUTO” mode.
(8) RUN – Pressing the “RUN” key causes the EMCP
3 to enter the “RUN” mode.
(9) Escape Key – The escape key is used during
menu navigation in order to navigate up through the
menu/submenu structure. Each key press causes
the user to move backward (upward) through the
menus. The escape key is also used in order to
cancel out of data entry screens during set point
programming. If the escape key is pressed during
set point programming, then none of the changes
displayed on the screen will be saved to memory.
RENR7902-07
(10) Enter Key – The enter key is used during menu
navigation in order to move forward (downward)
through the menu/submenu structure. The key is also
used during set point programming in order to save
set points changes. Pressing the Enter key during
set point programming causes set point changes to
be saved to memory.
Navigation Keys
(11) Right Key – The right key is used during set
point adjustment. During numeric data entry, the
key is used in order to choose which digit is being
edited. The key is also used during certain set point
adjustments in order to select a check box or to
deselect a check box. If a box has a check mark
inside of it, then pressing the key will cause the check
mark to disappear. If the box does not have a check
mark inside of it, then pressing the key will cause a
check mark to appear inside the box.
(12) Down Key – The down key is used in order
to navigate down through the various menus or
monitoring screens. The key is also used during set
point entry. During numeric data entry, the key is
used in order to decrement the digits (0-9). If the set
point requires selection from a list, then the key is
used to navigate down through the list.
(13) Up Key – The up key is used in order to
navigate up through the various menus or monitoring
screens. The key is also used during set point entry.
During numeric data entry, the key is used in order
to increment the digits (0-9). If the set point requires
selection from a list, then the key is used to navigate
up through the list.
(14) Left Key – The left key is used during set
point adjustment. During numeric data entry, the
key is used in order to choose which digit is being
edited. The key is also used during certain set point
adjustments in order to select a check box or to
deselect a check box. If a box has a check mark
inside of it, then pressing the key will cause the check
mark to disappear. If the box does not have a check
mark inside of it, then pressing the key will cause a
check mark to appear inside the box.
System Overview Keys
(15) Engine Overview – Pressing the engine
overview key displays the first screen of engine
information. This initial information page contains
various engine parameters that summarize the
operation of the engine. Additional engine parameters
can be viewed by pressing the “Down” key (12)
multiple times.
13
Systems Operation Section
(16) AC Overview – Pressing the AC overview
key displays the first screen of AC information
for the generator set. This initial information page
contains various AC parameters that summarize the
electrical operation of the generator set. Additional
AC parameters can be viewed by pressing the down
key (12) multiple times.
i02971361
Data Link
SMCS Code: 4490
Data Links
The EMCP 3 has up to three different data links:
• Primary Data Link
• Accessory Data Link
• System Control And Data Acquisition (SCADA)
Data Link
Note: The “EMCP 3.1” has one Primary Data Link.
The “EMCP 3.2” and “EMCP 3.3” have one Primary
Data Link, one Accessory Data Link, and one SCADA
Data Link.
Primary Data Link - J1939 (CAN 1)
The Primary Data Link is used for local communication
among modules associated with a single genset
such as the Electronic Control Module (ECM) for
the engine (EUI engines only), Caterpillar Digital
Voltage Regulator (CDVR), and the Thermocouple
Module. On MUI engines, the engine sensors are
wired directly to the EMCP 3. The Primary Data Link
utilizes the Society Of Automotive Engineers (SAE)
J1939 protocol and requires Controller Area Network
(CAN) hardware running at 250k bits per second.
The Primary Data Link supports appropriate SAE
J1939 Broadcast Parameter Group Numbers (PGN)
and Suspect Parameter Numbers (SPN) for engine
and genset data.
Accessory Data Link - J1939 (CAN 2)
The Accessory Data Link is used for local
communication among modules associated with a
single genset such as Annunciators, RTD Modules
and Discrete Input Output Modules. It utilizes the
Society Of Automotive Engineers (SAE) J1939
protocol and requires CAN hardware running at 250k
bits per second.
The Accessory Data Link supports appropriate SAE
J1939 Broadcast Parameter Group Numbers (PGN)
and Suspect Parameter Numbers (SPN) for engine
and genset data.
14
Systems Operation Section
SCADA Data Link - Modbus RS-485
The SCADA Data Link is used for communication
with a System Control And Data Acquisition (SCADA)
system.
The SCADA Data Link uses the Modbus Protocol
with an RS-485 half duplex hardware layer operating
at a minimum of 2.4k bits per second. All data items
are accessed as Modbus registers. Data that is less
than 16 bits occupies a single register. Larger data
occupies consecutive registers in order to allow
access using single request.
The SCADA Data Link is a Master/Slave Data Link.
The SCADA controller or customer software will be
the master and the genset controls will be slaves on
the Data Link.
The SCADA controller can connect directly to the
genset control or it may be connected remotely
through a modem using an RS-485 to RS-232
converter. Passwords levels are used in order to
restrict access to the genset control.
Each genset control on the SCADA Data Link has a
unique Modbus Address. A setpoint is available to
select the address for the genset control.
In order to use a modem connection to the SCADA
Data Link, the modem must be pre-configured with
all necessary communication parameters and set to
automatically answer. No modem handshaking or
control is performed by the EMCP 3.
Refer to the Application and Installation Guide,
LEBE5255 for more detailed information about the
SCADA data link.
i02972121
Electronic Control Module
(Engine)
(EUI Engines Only)
SMCS Code: 1901
The electronic control module (ECM) for the engine
controls the operation of the engine. Recently
produced “Electronic Unit Injection” (EUI) engines
utilize a “Common Engine Interface” (CEI). In CEI
applications, the EMCP 3 only sends the engine start
and the engine stop information across the datalink.
Note: For a CEI application, the cooldown timer that
is in the ECMP 3, should be set to zero.
RENR7902-07
The engine ECM controls engine speed and also
enables fuel injection on EUI engines in electric
power generation applications. Both the fuel enable
input and the speed input are configurable using the
service tool.
The fuel enable input to the ECM can be a
“switch-to-ground” or the input can be transmitted
over the primary J1939 data link from the EMCP 3.
The desired engine speed is derived from one of the
two following inputs:
• Input from a converter that converts the analog
speed signal of a speed potentiometer into a pulse
width modulated signal or directly from EMCP 3
over the primary J1939 data link
• The ECM uses feedback from the engine speed
sensors that are mounted on the engine to control
the engine speed
There are primary and secondary throttle inputs.
The throttle inputs can be a pulse width modulated
signal or the speed inputs can be transmitted over
the primary J1939 link (CAN 1).
Note: The Caterpillar service tool is used in order
to configure the throttle inputs as either primary or
as secondary.
If the primary throttle input fails, then the engine ECM
will generate a diagnostic, acknowledge the failure,
and respond to the secondary input. If the primary
throttle input fails and the secondary input is disabled,
then the engine will default to the idle speed setting.
The EMCP 3 receives specific information that it
uses in order to monitor the system for events. If a
particular parameter is not supported by the engine
ECM, then the EMCP 3.3 displays the parameter
name with an associated value of “****”, which
indicates that there is no value associated with that
specific parameter.
Note: Recent versions of software do not display the
parameter name for unsupported parameters.
The information that is shown on the display screen
of the EMCP 3.3 is:
• Engine Oil Pressure (see note 1 that is shown
below)
• Engine Coolant Temperature (see note 2 that is
shown below)
• Left Exhaust Manifold Temperature
• Right Exhaust Manifold Temperature
• Intake Manifold Temperature
RENR7902-07 15
Systems Operation Section

• Oil Temperature Reference: For EMCP 3 settings that are specific to

EUI engine applications, seeTesting and Adjusting,
• Fuel Pressure “Electronic Control Module (Generator Set) -
Configure”, Set Point Tables.
• Boost Pressure
i02973249
• Oil Filter Differential Pressure
MUI Engine Monitoring and
• Fuel Filter Differential Pressure
Control
• Air Filter Differential Pressure
SMCS Code: 4490
• Fuel Consumption
The EMCP 3 can be used for monitoring and control
• Battery Voltage of MUI engines. With the absence of an engine
ECM, the EMCP 3 uses relay outputs to control
• Engine Speed (rpm) start/stop and uses analog resistive sender inputs for
monitoring of critical engine parameters.
• Engine Hours
Reference: For EMCP 3 configuration settings that
• Engine State are specific to MUI engine applications, see Testing
and Adjusting, “Electronic Control Module (Generator
• Service (hrs)/days Set) - Configure”, “Set Point Tables”.

• Reset Service Interval Command MUI engine start/stop control by EMCP 3

• Total Crank (Cranks) • Relay output 1 (non configurable) to energize

starter motor magnetic switch used to crank the
• Total Start (Starts) engine

• Reset Counters • Relay output 2 (non configurable) gives run signal

• Exhaust Temp
• Turbo 1, 2, 3, and 4 Compressor Inlet Temp
• Turbine 1, 2, 3, and 4 Inlet Temp
• Turbine 1, 2, 3, and 4 Outlet Temp
to engine governor
• Additional relay output (configured for “rated
speed”) gives permissive signal to engine governor
to ramp up to rated speed
MUI engine parameters monitored directly by EMCP
3:

• Cylinder Temps • Engine speed (via MPU input)

• Crankcase Pressure
• Total Fuel
• Rate of Fuel
Note: 1) Only the values that are for “Engine Screens
6 through 11”, that are supported by other modules,
and that are on one of the J1939 data links, will be
displayed.
Note: 2) Engine information displayed on the
EMCP 3.1 and EMCP 3.2 includes only “Engine Oil
Pressure” and “Engine Coolant Temperature”.
The EMCP 3 also displays diagnostic codes from the
ECM as a convenience to the operator.
Reference: For information on the management of
diagnostic codes by the EMCP 3 and the ECM, see
Troubleshooting, “Diagnostic Trouble Code List”.
• Oil pressure (via analog input 1)
• Coolant temperature (via analog input 2)
• Spare input (only EMCP 3.3 and EMCP 3.2)
i02973458
System Operation
SMCS Code: 4490
Before putting the engine into service, verify the
following:
• The desired voltage and frequency are correct at
rated engine speed
• Load control devices are functioning properly and
have the load isolated from the generator when
not running
16
Systems Operation Section
• If warning events are present, that is, the yellow
warning lamp (2) is lit, then take corrective action if
necessary
• No shutdown events are active, that is, the red
shutdown lamp (3) is not lit
• For remote initiate operation, the EMCP 3 must
be in AUTO mode
Engine Starting Sequence
1. The EMCP 3 receives an engine start signal under
one of the following conditions:
• The operator presses the “RUN” key
• The control is in “AUTO” and the remote initiate
input (IC) becomes active
• The operator presses the “AUTO” key and a
start command is sent via the RS-485 SCADA
Data Link (Modbus).
• Programmable cycle timer output 1 is “Active”
2. The EMCP 3 checks the following system items
before beginning the cranking sequence:
• There are no shutdowns on any module
• The engine is stopped
3. The EMCP 3 begins the starting sequence.
a. The EMCP3 activates the pre-crank and start
aid outputs, if programmed, for the configured
duration.
b. On MUI engines, the EMCP 3 activates the
starting motor relay (relay output 1) and the
fuel control relay (relay output 2).
c. On EUI engines that do no utilize a common
engine interface, the EMCP 3 activates the
starting motor relay (SMR) and sends a start
signal to the engine ECM via the J1939 primary
data link.
d. On EUI engines that utilize a common engine
interface, the EMCP 3 will send a start signal
to the engine ECM via the J1939 data link and
the ECM will be responsible for cranking the
engine (4) and deactivating the starting motor
relay (5).
RENR7902-07
4. The EMCP 3 cranks the engine for the
programmed crank time or until the engine starts.
If the engine does not start after the crank time
has elapsed, then the starting motor relay will
de-energize for the programmed rest time. After
the rest time has elapsed, then the starting motor
relay will start cranking again for the programmed
crank time.
A cycle consists of a crank time and a rest time. If
the engine has not started after the programmed
number of cycles, then the EMCP 3 will abort the
starting process and will generate an “Engine
Failure to Start Shutdown”.
5. The EMCP 3 deactivates the starting motor relay
when the engine speed reaches the setpoint for
the crank terminate speed.
Engine Stopping Sequence
1. The EMCP 3 will stop the engine under either of
the following conditions:
a. The operator presses the “STOP” key.
b. If the control is in “AUTO” and no longer
receives any of the following:
• the remote initiate input
• the SCADA start signal
• programmable cycle timer output 1
Note: If the control is in “AUTO”, in order for the
engine to stop, the remote initiate must be inactive
AND the Modbus data link must be requesting a stop.
If either the remote initiate is active, that is, an engine
run state is being requested via the Modbus, or the
PCT output 1 is active, then the engine will not stop.
2. After receiving the “Stop” signal, the EMCP 3
checks to ensure that there are no system faults
present.
3. The EMCP 3 begins the cooldown period. In
order to bypass the cooldown, depress and hold
the “STOP” key. The screen displays instructions
to “PRESS ENTER TO BYPASS”, and “PRESS
ESCAPE TO CONTINUE” Press the Enter key in
order to bypass the cooldown sequence or press
the Escape key in order to continue the cooldown
sequence.
Note: For common engine interface applications,
cooldown must be controlled by the engine ECM.
4. After the cooldown cycle, the EMCP 3 initiates an
engine shutdown by turning off the fuel supply.
RENR7902-07
a. On the MUI engines, the EMCP 3 deactivates
the fuel control relay, which in turn, shuts the
engine down.
b. On EUI engines, the EMCP 3 sends a
shutdown signal to the engine ECM over the
primary J1939 data link in order to shut down
the engine.
i02973498
Password Entry
SMCS Code: 4490
There are three levels of password protection on
the EMCP 3 control panel. All of the adjustable
parameters are associated with a specific level
of security that is required in order to make an
adjustment to the parameter.
The passwords only affect changing parameters from
the EMCP 3 control panel. Changing parameters
with the Caterpillar service tool does not require
passwords.
The level of password protection that is required for
each setpoint is identified on the parameter setpoint
entry screen. A security level identification number
“1”, “2”, or “3” next to a padlock symbol is displayed
on the parameter setpoint entry screen. Level 3
security is used for the most secure setpoints and
Level 1 security is used for the least secure setpoints.
If the EMCP 3 is currently at the required level of
security when viewing a parameter, then the padlock
will not appear.
If a parameter is displayed with a padlock, but there
is no security level identification number associated
with it, then the parameter cannot be changed from
the EMCP 3 display.
Level 1 and Level 2 passwords are disabled when
shipped from the factory. If desired, Level 1 and Level
2 passwords can be user defined.
Function and Navigation Keys
Reference: The call outs that are in this section can
be found on the EMCP 3 control system panel in
the Systems Operation, “Electronic Control Module
(Generator Set)” section of this publication.
The keys that are listed below are used for
programming the EMCP 3 and for navigating within
the menu structure.
17
Systems Operation Section
Reference: For a full explanation of the use of the
function keys (enter, escape) and the navigation keys
(left, right, up, and down) that are referenced in this
section, refer to the Systems Operation, “Electronic
Control Module (Generator Set)” section of this
publication.
(9) Escape key – Navigate up (backward) through
the menu structure and also used to cancel out of
data entry screens during setpoint programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Right key – During numeric data entry, choose
the digit to edit. During certain setpoint adjustments,
select or deselect a check box.
(12) Down key – Move down through the main
menu or navigate within a list in order to highlight one
of the items. Also used to decrement digits (0-9).
(13) Up key – Move up through the main menu or
navigate within a list in order to highlight one of the
items. Also used to increment digits (0-9).
(14) Left key – During numeric data entry, choose
the digit to edit. During certain setpoint adjustments,
select or deselect a check box.
Drop to Minimum Security Level
The first option on the security screen is “DROP
TO MIN LEVEL”. This option refers to a process of
placing the EMCP 3 into the lowest level of security
that is authorized. This would be used after the
programming of the control is complete. If “DROP TO
MIN LEVEL” is not initiated manually, then the control
will automatically revert to the minimum level after
ten minutes of non-activity.
1. From the “MAIN MENU”, press the Up key or the
Down key in order to highlight the “CONFIGURE”
menu.
2. Press the ENTER key in order to select the
“CONFIGURE” menu. “SECURITY” will be
highlighted.
3. Press the ENTER key in order to select the
“SECURITY”. The “DROP TO MIN LEVEL” option
will be highlighted.
4. Press the “ENTER” key in order to select the
“DROP TO MIN LEVEL” option.
5. The EMCP 3 will now be at the minimum level of
security.
Note: When the “SECURITY” screen is displayed on
the EMCP 3 control, the current level of security for
the EMCP 3 is shown at the top of the display screen.
18
Systems Operation Section
Enter Level 1 or 2 Password
1. From the “MAIN MENU”, press the Up key or the
Down key in order to highlight the “CONFIGURE”
menu.
2. Press the Enter key in order to select the
“CONFIGURE” menu. “SECURITY” will be
highlighted.
3. Press the Enter key in order to select the
“SECURITY” menu. “DROP TO MIN LEVEL” will
be highlighted.
4. Press the Down key in order to highlight “ENTER
LEVEL 1 OR 2”.
5. Press the Enter key in order to select the “ENTER
LEVEL 1 or 2” menu. “ENTER PASSWORD FOR
DESIRED LEVEL” is displayed. There is also a 16
digit entry field with 0 highlighted at the far right.
6. Press the Up key or the Down key in order to
increment or decrement the highlighted digit to the
desired number.
7. Press the Left key in order to highlight the next
character to be entered and then press the Up
key or the Down key in order to increment or
decrement the highlighted digit to the desired
number.
8. Continue this process until the correct password
has been entered for the corresponding level.
When all digits of the password are correctly
entered, then press the Enter key. This action will
display the current level of password protection
and the parameters can now be set.
Note: The EMCP 3 will go to the highest level of
security authorized by a correctly entered password.
Note: Level 1 and level 2 passwords are entirely
determined by the user and can range from one to
sixteen digits.
Note: If parameters are being changed using a
Caterpillar service tool, then a password is not
required.
Enter Level 3 Password
The level 3 password is intended for situations where
a customer or a dealer wants to do something that
would typically be done with the service tool, but the
service tool is not available.
1. From the “MAIN MENU”, press the Up key or the
Down key in order to highlight “CONFIGURE”.
RENR7902-07
2. Press the Enter key in order to select the
“CONFIGURE” menu. “SECURITY” will be
highlighted.
3. Press the “Enter” key in order to select
“SECURITY”. “DROP TO MIN LEVEL” will be
displayed.
4. Press the Down key in order to highlight “ENTER
LEVEL 3”. Press the Enter key in order to select
“ENTER LEVEL 3”.
5. A sixteen digit number will be displayed and
“ENTER RESPONSE” will be highlighted.
Make a copy of the sixteen digit number that is
displayed. Work through the dealer “Technical
Communicator” to contact the “Dealer Solutions
Network” (DSN) in order to obtain a factory
provided response code. The factory provided
response code will be entered into the EMCP 3.
6. When the factory response is received from the
factory, press the Enter key in order to select
“ENTER RESPONSE”. “ENTER RESPONSE”
will be displayed along with a sixteen digit entry
field where the factory provided password will be
entered.
7. Use the Up key or the Down key in order to
increment or to decrement the highlighted digit
to the corresponding digit of the factory provided
password.
8. Press the Right key or the Left key in order to
highlight the next character that is to be entered,
and use the Up or the Down key in order to
increment or decrement the highlighted digit to
the corresponding digit of the DSN provided
password.
9. Continue the process until all sixteen digits of the
password are entered. Press the “Enter” key after
all sixteen digits of the password are entered .
After the password has been entered and after
the “Enter” key has been pressed, the current
level, “LEVEL 3”, of security will be displayed. The
parameters can be set at this time.
Note: If parameters are being changed using a
Caterpillar service tool, then a password is not
required.
Change Level 1 or Level 2 Password
1. From the “MAIN MENU”, press the Up key or the
Down key in order to highlight the “CONFIGURE”
menu.
2. Press the Enter key in order to select
“CONFIGURE”. “SECURITY” will be highlighted.
RENR7902-07
3. Press the Enter key in order to select
“SECURITY”. “DROP TO MIN LEVEL” will be
highlighted.
4. Ensure that the current level of security is at least
as high as the level of the password that is to be
changed.
5. Press the Down key in order to highlight
“CHANGE LEVEL 1 PSWD”. Press the Enter key
in order to select “CHANGE LEVEL 1 PSWD”.
“CHANGE LEVEL 1 PSWD” is displayed along
with a sixteen digit password entry field that has a
zero highlighted in far right of the field.
6. Press the Up key or the Down key in order to
increment or to decrement the highlighted digit
to the corresponding number of the desired
password.
7. Press the Left key in order to highlight the
next character that is to be entered. Press the
Up key or the Down key in order to increment
or to decrement the highlighted digit to the
corresponding number of the desired number.
8. Continue this process until the desired password
is displayed and then press the Enter key. The
password is now set.
Note: In order to change a level 2 password,
substitute “CHANGE LEVEL 2 PSWD” for “CHANGE
LEVEL 1 PSWD” in step 5 above.
Note: Level 1 and level 2 passwords are entirely
determined by the user and can range from one to
sixteen digits
Note: To disable a password, set the password to a
single zero.
i02973527
Event Viewing
SMCS Code: 4490
Reference: Call outs in this section can be found
on the EMCP 3 Control System Panel Illustration
in Systems Operation, “Electronic Control Module
(Generator Set)”
Event system information from the EMCP 3 is
displayed on the display screen (1). The event
system uses the following terms to describe the
status of an event:
PRESENT – The condition causing the event is
present and is affecting the system behavior.
19
Systems Operation Section
Note: For external modules such as engine ECM
thermocouples, RTD, and discrete I/O, there will be
only active and inactive events. There are no present
events for optional modules.
ACTIVE – The event was previously in a “Present”
state, but it is no longer present. It has been latched
by the event system and needs to be reset before the
engine can be restarted.
INACTIVE – The event was previously in an active
or a present state, but it is no longer in an active or a
present state, and it is not affecting system behavior.
The “ACTIVE EVENTS” menu is used to display
active events for ECMs, including those ECMs that
are connected to the EMCP 3 over the data link.
There is a number in the top right of the “ACTIVE
EVENTS” menu that indicates how many active or
present events are currently in the system. There is
also a number to the right of each listed ECM that
indicates how many active or present events are
currently associated with that particular ECM.
The ECMs listed in Table 1 can have an event log
associated with them:
Table 1
ECM Event Type
Genset Control EMCP 3
Engine Control ADEM
AVR (requires CDVR) Voltage Regulator
Thermocouple (TC) Module(1) Optional TC
Resistive Temperature Device Optional RTD
(RTD) Module
Discrete Input/Output (DI/O) Optional DI/O
Module(1)
(1) There may be more than one module.
Note: On power up, the EMCP 3 displays the “MAIN
MENU” screen. If the EMCP 3 is currently powered
up, and the “MAIN MENU” screen is not displayed,
then press the Escape key (9) as many times as
required in order to return to the “MAIN MENU”. Each
successive press of the Escape key backs you up
one level in the menu structure.
Perform the following steps in order to view an event.
1. Using the Scroll Down key (12) or the Scroll Up
key (13), navigate within the “MAIN MENU” to the
“EVENT LOGS” menu and press the Enter key .
The “ACTIVE EVENTS” menu is displayed listing
the connected ECM.
Note: Events are organized by which ECM originated
the event.
20 RENR7902-07
Systems Operation Section

2. Select an ECM and press the Enter key (10).

All of the Events associated with the ECM are
displayed.

3. In order to scroll through the events, use the

Scroll Up key (11) and the Scroll Down key (12).

4. After highlighting an event, press the Enter key

(10) in order to see information about the event Illustration 9
g01455471

such as the SPN and the FMI.

3. Press the Enter key (10). An “ACTIVE EVENTS”
Press the Scroll Down key (12) in order to see menu will be displayed that will list the ECMs that
additional information such as the following: are connected to the system. The total number of
active events for an ECM is listed to the right of
• Time and date of first occurrence (not on version the ECM. Refer to Illustration 14.
3.1)

• Time and date of last occurrence (not on version

3.1)

• Engine hours at first occurrence

• Engine hours at last occurrence
g01455474
Illustration 10
i02934616
4. Use the Scroll Down key in order to highlight an
Event Resetting ECM that has active events. Refer to Illustration
14.
SMCS Code: 4490

Reference: The call outs that are in this section

can be found on the “EMCP 3 Control System
Panel” illustration that is in the Systems Operation,
“Electronic Control Module (Generator Set)” section.

A flashing red shutdown lamp (3) indicates that there

is an unacknowledged shutdown event. The lamp will
change from flashing red to solid red when the Alarm
Acknowledge key (4) is pressed.
Shutdown events can only be reset when the
shutdown events are described as “Active”. Use
the following procedure in order to reset the active
shutdown events.
Note: The following instructions do not apply to the
EMCP 3 that is listed as “GENSET CONTROL” in
the event log.
Resetting All Events for a Single
Module
g01455480
Illustration 11
5. Press the Enter key in order to display the active
events for the selected ECM. Refer to Illustration
15.
Note: The events are sorted. Present events are
placed at the top of the log, then active events, and
finally inactive events. Within each of these groups,
events are sorted by time and date with the most
recent events at the top of each group. If a real time
clock time stamp is not available, then events are
sorted based on the engine hours.
6. Scroll through the events in order to highlight an
active event.

1. Press the STOP key (6).
Note: The control must be in “STOP” in order to reset
active shutdown events.
2. Use the Scroll Down key (12) in order to navigate
from the “MAIN MENU” to the “EVENT LOG”
menu.
7. Ensure that the condition which caused the event
is no longer present and then press the Enter key.
If the condition that caused the event is no
longer present, and the control is in “STOP”, then
“RESET ALL” will be highlighted.
RENR7902-07 21
Systems Operation Section

g01455527 g01506375
Illustration 12 Illustration 14

8. Press the Enter key again. The fault will clear. If 4. Use the Scroll Down key in order to highlight an
there are no other active shutdown events, then ECM that has active events. Refer to Illustration
the red shutdown lamp will turn off. 14.

Note: Modules other than the EMCP 3 do not

distinguish between “PRESENT” and “Active” events.
If the “RESET ALL” does not reset all of the events
when the “ENTER KEY” is pressed, then the condition
that is causing the event, that is being viewed, may
still be present. For example, if the engine shut down
due to a low coolant level fault, then the “Low Coolant
Level Shutdown” event will not reset until the coolant Illustration 15
g01455480
level has been filled to the required level.
5. Press the Enter key in order to display the active
9. Repeat steps 4 through 8 until there are no active events for the selected ECM. Refer to Illustration
shutdown events remaining. When all active 15.
shutdown events have been reset, then the Red
Shutdown Lamp will be turned off. Note: The events are sorted from top to bottom. For
example, the highest priority events will be listed at
10. Press the Escape key (9) three times in order to the top of the event log.
return to the “MAIN MENU” screen.
The state of the event , the priority level, and the
Reset Individual Events from the event types that are associated with a specific
event are listed in Table 2.
Generator Set Control
Table 2
1. Press the STOP key (6).
Event State Priority Level Event Type
Note: The control must be in “STOP” in order to reset Present (1) Highest Warnings
active shutdown events. Shutdowns
Active Medium Shutdowns
2. Use the Scroll Down key (12) in order to navigate
from the “MAIN MENU” to the “EVENT LOG” Inactive Lowest Warnings
menu. Shutdowns
(1) Does not apply to external modules

6. Scroll through the events in order to highlight an

active event.

7. Ensure that the condition which caused the event

is no longer present and then press the Enter key.
g01455471
Illustration 13 If the condition that caused the event is no
longer present, and the control is in “STOP”, then
3. Press the Enter key (10). An “ACTIVE EVENTS” “RESET” will be highlighted.
menu will be displayed that will list the ECMs that
are connected to the system. The total number of
active events for an ECM is listed to the right of
the ECM. Refer to Illustration 14.
22 RENR7902-07
Systems Operation Section

• Engine Type Configuration

• Engine Control J1939 Data Link Support
Configuration

The functionality that is available for the different

types of engine ECM is shown in Table 3.

Illustration 16
g01506377 Table 3
ECM Functionality
8. Press the Enter key again. The fault will clear. If
there are no other active shutdown events, then Engine Type Engine Control Engine Events
Configuration J1939 Data Functionality
the red shutdown lamp will turn off. Link Support
Configuration
9. Repeat steps 4 through 8 until there are no active
shutdown events remaining. When all active Mechanical None
shutdown events have been reset, then the red No J1939 Can reset all
shutdown lamp will be turned off. Electronic
Support events only

10. Press the Escape key (9) three times in order to Basic J1939 Can view and
Electronic
return to the “MAIN MENU” screen. Support reset all events
Enhanced J1939 Can view and
Resetting All Events for All Modules Electronic
Support reset all and
view additional
event info
1. Ensure that the control is “Stopped”.

2. Execute the following from any screen. Press
the “ACKNOWLEDGE” key and hold the
“ACKNOWLEDGE” key for approximately 5
seconds.
3. A confirmation prompt will appear.
The EMCP 3 GSC has the ability to reset all events
for electronic engines with no J1939 support. The
reset is accomplished by the use of a relay output.
Three conditions must be satisfied in order for the
reset to work.

1. One of the digital selectors must be configured for

“ECU Fault Reset”. Refer to the “Digital Selector
Options” information for a list of options that relate
to the digital selectors.

2. The corresponding relay output must be wired

Illustration 17
g01455626
4. Press the “ENTER” key in order to continue to
“RESET” all events on all of the modules. Press
the “ESCAPE” key in order to “CANCEL” the reset
operation.
Note: “Reset All Events” will not reset “Present”
events! For example, if the “E-Stop” switch is pressed
and an EMERGENCY STOP SWITCH ACTIVATED
SHUTDOWN is present, the event cannot be reset
until the “E-Stop” is pulled out and the event status
changes from “PRESENT” to “ACTIVE”.
Resetting Events for Engines
Without J1939 Support
The EMCP 3 GSC support that is provided for engine
events, depends on the type of engine ECM. The
configuration of the EMCP 3 GSC includes these set
points:
to a corresponding “Fault Reset I/O” pin on the
engine ECM or the relay must be setup to power
cycle the ECM.
3. The EMCP 3 GSC set points that are shown in
Table 3 must be properly set. The “Engine Type
Configuration” must be set to “Electronic”. The
“Engine Control J1939 Data Link Support” must
be set to “NO J1939 SUPPORT”. If the “Engine
Control J1939 Data Link Support” is set to “NO
J1939 SUPPORT”, then the engine control will
not be listed in the EMCP 3 GSC display event
log. However, there will be an option to “RESET
ALL ENGINE EVENTS”. If the “ENTER” key is
pressed with the “RESET ALL ENGINE EVENTS”
option selected, the “ECU FAULT RESET” will be
activated. The “ECU FAULT RESET” will activate
the corresponding relay output. The “ECU FAULT
RESET” will trigger the engine ECU to reset the
faults or will cycle the power for the ECU.
RENR7902-07
i02974035
Setpoint Programming
SMCS Code: 4490
Illustration 18
The engine and generator setpoints are programmed
in the EMCP 3 at the factory. The setpoints that are
stored in the EMCP 3 must match the specified
setpoints of the particular generator set. These
setpoints, which are programmable, affect the proper
operation and serviceability of the engine, as well
as the accuracy of the information that is shown on
the Display Screen (1).
The setpoints may require modification when the
EMCP 3 is moved from one engine to another engine.
The setpoints may also require modification in order
to satisfy the requirements of the installation.
Function and Navigation Keys
The keys listed below are used for programming the
EMCP 3 and navigating within the menu structure.
23
Systems Operation Section
g01233459
Reference: For a full explanation of the use of the
Function keys (Enter, Escape) and the Navigation
keys (Scroll Left, Scroll Right, Scroll Up, Scroll Down)
that are referenced in this section, see Systems
Operation, “Electronic Control Module (Generator
Set)”
(9) Escape – Navigate up (backward) through the
menu structure and also used to cancel out of data
entry screens during setpoint programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Scroll Right key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
(12) Scroll Down key – Move down through the
main menu or navigate within a list in order to
highlight one of the items. Also used to decrement
digits (0-9).
24
Systems Operation Section
(13) Scroll Up key – Move up through the main
menu or navigate within a list in order to highlight one
of the items. Also used to increment digits (0-9).
(14) Scroll Left key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
EMCP 3.x Programming Example
Note: This programming example is not intended
as a standard or as a preferred method of use. It is
presented here only as an example of the logical flow
for programming.
For consistency of terminology, a “normally closed”
switch is a switch that is closed prior to installation,
(not being acted upon). A “normally open” switch is
a switch that is open prior to installation, (not being
acted upon). This example outlines the steps for
wiring a low fuel level shutdown float switch to digital
input 3.
In this example, the “Active Low” configuration will be
used assuming a normally open switch that closes
when the fuel level drops to the low shutdown level,
which in turn shuts off the generator set. When the
switch closes, the EMCP 3 sends a “Batt” signal to
digital input 3.
1. Mount the switch in the desired location and then
route and connect the wiring.
a. Route a wire to the 70 pin connector on pin 54.
This wire is for digital input 3.
b. Route a second wire to a battery negative point
in the system.
c. Connect the two wires to the contacts of the
newly mounted switch.
2. Select the appropriate digital input and the “Active”
state for the mounted switch.
a. Navigate to the DIGITAL INPUTS menu as
follows:
MAIN MENU
.... CONFIGURE
......... SETPOINTS
................. I/O
....................... DIGITAL INPUTS
b. Press the Enter key. The available digital
inputs are displayed.
RENR7902-07
c. Scroll through the available digital inputs until
digital Input 3 is highlighted, and then press the
Enter key
d. Press the Enter key a second time. This action
highlights the current configuration of the
“Active” state for digital Input 3.
e. Set the “Active” state to the “Active LOW”
option using the Scroll Up or the Scroll Down
keys. After the state has been set, then press
the Enter key in order to save the selection.
Note: The selection of “HIGH” or “LOW” for the
Active state is based on the following:
• If a normally closed float switch (I.E. the
switch is open when the fuel level is below
the switch) is used, then set the option to
Active High. This relates to the voltage level
of the digital input pin of the EMCP 3.
• If a normally open float switch (I.E. the
switch is closed when the fuel level is below
the switch.) is used, then set the option to
Active Low. This relates to the voltage level
of the digital input pin of the EMCP 3.
• If a normally closed contact is used, then
the voltage level of the digital input pin is
pulled low when fuel is present. When the
fuel level is below this switch, then the switch
is activated and the contact opens, allowing
the voltage level of the digital input pin to go
high. This action indicates to the EMCP 3
that the switch has been operated.
• If a normally open contact is used, then the
voltage level of the digital input pin is high
when fuel is present. When the fuel level is
below this switch, then the switch is activated
and the contact closes, pulling the voltage
level of the digital input pin low. This action
indicates to the EMCP 3 that the switch has
been operated.
3. Navigate to the EVENT I/P FUNCTIONS SELECT
menu:
Note: Each press of the Escape key backs up
one level in the menu structure. At this point in the
procedure, the Escape key can be pressed twice
until the SETPOINTS menu is highlighted and then
the navigation can be completed. The complete
menu map is:
MAIN MENU
.... CONFIGURE
......... SETPOINTS
................. EVENTS
RENR7902-07
....................... EVENT I/P FUNCTIONS SELECT
Note: Event Input Function #1 corresponds to Digital
Input #3, Event Input Function #2 corresponds to
Digital Input #4, etc.
4. Select Event Input Function #1, and then press
the Enter key in order to configure the settings.
Using the navigation keys, scroll through the
selections until the setting that is to be configured
is highlighted and then press the Enter again in
order to display the current value for that setting.
The settings that can be configured include:
• Active state
• Time delay
• Suspect Parameter Number
• Failure Mode Identifier
5. Set the Active state. This appears in the menu as
ACTIVE STATE CFG. The Active State should
always be set to Active HIGH.
6. Set the Time delay. This appears in the menu as
EVENT DELAY TIME. If a time delay is desired
perform the following steps using the navigation
keys in order to adjust the value to the desired
number of seconds.
a. Press the Enter key (10) in order to highlight
the value.
b. Using the Scroll Right and Scroll Left
navigation keys, highlight each number that is
to be changed. Once the number is highlighted,
use the Scroll Up and the Scroll Down
navigation keys in order to change the selected
value to the desired value.
c. Press the Enter key again in order to save the
new value.
7. Set the “Suspect Parameter Number” (SPN). This
value appears in the menu as “SUSPECT PARM
NUM/”.
a. Press “Enter”.
b. Press the Scroll Down key and navigate to the
LEVELS menu and then press the Enter key in
order to select the menu.
c. Using the “Scroll Down” key, navigate to the“
FUEL LEVEL” parameter, and then press the
“Enter” key in order to select this parameter.
This setting will generate an SPN of “96”.
8. Set the Failure Mode Indicator. This value appears
in the menu as FAILURE MODE ID.
25
Systems Operation Section
a. Using the Scroll Down key, navigate to the
LOW SHUTDOWN parameter, and then press
the Enter key in order to select this parameter.
This setting will generate an FMI of “1”.
In summary, when the fuel level drops below the level
of the float switch, Digital Input #3 is connected to
battery negative through the switch. This generates
an SPN-96, with an FMI-1. This code is translated
by the EMCP 3 to shutdown the engine, turn on
the shutdown LED, and broadcast the code on the
J1939 data link. Any annunciator installed could be
programmed to have a pair of LED indicators to
detect this code and turn on the red LED.
i02974036
Digital Input Programming
SMCS Code: 4490
There are two separate procedures that need to be
performed in order to program the EMCP 3 digital
inputs. The first procedure involves programming
the Active State of the input as either “Active High”
or as “Active Low”. The second procedure involves
programming the Event Input Functions.
Digital Inputs
The main purpose for the digital inputs is to add
additional monitoring capabilities for the engine
or the generator. The inputs can be configured
by navigating to the “EVENT I/P FUNCTIONS”
parameter under the “SETPOINTS” menu.
Note: There are eight digital inputs on “EMCP 3.2”
and “EMCP 3.3”. There are six digital inputs on
“EMCP 3.1”. On all three levels of controls, the first
and second digital inputs are dedicated and cannot
be programmed.
The digital inputs of the EMCP 3 are tied to an
internal pull-up resistor inside the control. Therefore,
if there is no connection to a digital input, then the
digital input will read as a logical high. A ground
or battery negative input should be wired to each
EMCP 3 digital input. If an Active High configuration
is desired, then the ground or battery negative input
should be wired through a normally closed switch.
If an Active Low configuration is desired, then the
ground or battery negative input should be wired
through a normally open switch.
26
Systems Operation Section
Digital Input #1 is dedicated for “Emergency Stop”
and Digital Input #2 is dedicated for “Remote Initiate”.
The other 4 or 6 inputs can be configured to trigger
alarms or shutdowns in the EMCP 3. In the EMCP
3 software, Digital Inputs 3 through 8 (3 through 6
on EMCP 3.1) are linked to functions that are called
“EVENT INPUT FUNCTIONS”. Because Digital
Inputs #1 and #2 are dedicated inputs, Digital Input
#3 is linked to Event Input Function #1, Digital Input
#4 is linked to Event Input Function #2, and so on.
See Illustration 19
g01228372
Illustration 19
Digital Input 1 – Digital input 1 is used for
“Emergency Stop”. This input should be wired to
battery negative through an emergency stop switch.
The input can be set to activate on an active high
(normally closed contact) or an active low (normally
open contact). If the operator wants to enable the
“Reduced Power Mode”, then emergency stop must
be configured for active low.
Reference: Testing and Adjusting , “Electronic
Control Module (Generator Set) - Configure”
RENR7902-07
Activating the Emergency Stop input will either cause
the generator set to stop immediately or else it will
prevent the generator set from starting. Once Digital
Input #1 goes active, the engine will not start until
the event is reset.
Reference: System Operation , “Event Resetting”
Digital Input 2 – Digital Input 2 is used for remotely
starting and stopping the generator set. This input
should be wired to battery negative through a
“Remote Initiate” switch. The input can be set to
activate on an Active High (normally closed contact)
or an Active Low (normally open contact). If the input
is active, and the EMCP 3 is in the “AUTO” mode,
then the engine will attempt to start and run. Once
the input becomes inactive, the engine will enter into
cooldown (if programmed to do so) and will then stop.
All remaining inputs can be configured.
Function and Navigation Keys
Reference: Callouts in this section can be found
on the EMCP 3 Control System Panel in Systems
Operation, “Electronic Control Module (Generator
Set)”
The keys listed below are used for programming the
EMCP 3 and navigating within the menu structure.
Reference: For a full explanation of the use of the
Function keys (Enter, Escape) and the Navigation
keys (Scroll Left, Scroll Right, Scroll Up, Scroll Down)
that are referenced in this section, see Systems
Operation, “Electronic Control Module (Generator
Set)”
(9) Escape – Navigate up (backward) through the
menu structure and also used to cancel out of data
entry screens during setpoint programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Scroll Right key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
(12) Scroll Down key – Move down through the
main menu or navigate within a list in order to
highlight one of the items. Also used to decrement
digits (0-9).
(13) Scroll Up key – Move up through the main
menu or navigate within a list in order to highlight one
of the items. Also used to increment digits (0-9).
(14) Scroll Left key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
RENR7902-07 27
Systems Operation Section

Programming the Active State of ..................... EVENT I/P FUNCTIONS

the Digital Input 2. Set the “Active State”. The Active State should
always be set to Active HIGH. The next setting
Reference: For an example of programming a digital
is the Time Delay. Press the Enter key and then
input for a fuel level switch, see Systems Operation,
enter the desired value using the navigation keys.
“Setpoint Programming”.
3. Set the Time Delay. Press the Enter key and
In order to program the “Active State” of the digital
enter the desired value using the navigation keys.
input, perform the following steps:
4. Set the Suspect Parameter Number (SPN).
1. On the EMCP 3, navigate to the Digital Inputs
Press the Enter key in order to choose the SPN.
menu as follows:
The available parameters are listed in Table 4.
MAIN MENU

.... CONFIGURE

......... SETPOINTS

................. I/O

..................... DIGITAL INPUTS

2. Using the navigation keys, select the Digital Input

that is to be programmed and press the Enter key.
The current configuration will be displayed.

3. Press the Enter key a second time. The current

configuration will be highlighted.

4. Use the navigation keys in order to change the

current configuration to the desired setting.

5. Press the Enter key in order to save the setting.

Programming the Event Input

Functions
Note: Event Input Function #1 corresponds to Digital
Input #3, Event Input Function #2 corresponds to
Digital Input #4, etc. See Illustration 19

Note: It is possible to set the Event Input function to

a value for which no event response configuration
exists, such as High Oil Pressure Warning or High Oil
Pressure Shutdown. If this occurs, and the event is
made Active, then no events will be triggered.

In order to program the “Event Input” functions,

perform the following steps:

1. On the EMCP 3, navigate to the EVENT I/P

FUNCTIONS menu as follows:

MAIN MENU

.... CONFIGURE

......... SETPOINTS

................. EVENTS
28 RENR7902-07
Systems Operation Section

Table 4 Table 5
Available Parameters Custom Event Setpoint Value for Event Input
Functions cVue Block
Pressures
Air Filter Differential Pressure Block Setpoint Description
Engine Oil Pressure Instance Value
Fire Extinguisher Pressure
Fuel Filter Differential Pressure 1 701 Custom Event (Instance
Oil Filter Differential Pressure 1 only)
Starting Air Pressure 2 702 Custom Event (Instance
Gas Pressure 2 only)
Temperatures 3 703 Custom Event (Instance
Ambient Air Temperature 3 only)
Engine Coolant Temperature
Engine Oil Temperature 4 704 Custom Event (Instance
Exhaust Temperature 4 only)
Rear Bearing Temperature
Right Exhaust Temperature 5 705 Custom Event (Instance
Left Exhaust Temperature 5 only)
Generator Winding 1 Temperature 6 706 Custom Event (Instance
Generator Winding 2 Temperature 6 only)
Generator Winding 3 Temperature
7 707 Custom Event (Instance
Levels 7 only)
Engine Coolant Level
Engine Oil Level 8 708 Custom Event (Instance
Fuel Level 8 only)
External Tank Fuel Level
Other 5. Set the Failure Mode Identifier (FMI). The
Air Damper Closed following FMI's are available:
ATS in Normal Position
ATS in Emergency Position • High Warning (example: High Temperature
Battery Charger Failure Warning)
Battery Charging System Voltage
Battery Voltage
Fuel Leak Detected • Low Warning (example: Low Temperature
Custom Event Warning)
Earth Fault
Earth Leakage • High Shutdown
Generator Frequency
Generator Voltage • Low Shutdown
Generator Current
Generator Power • Status (Condition Exists)
Generator Circuit Breaker Closed
Utility Breaker Closed
Generator Circuit Breaker Open i02935049
Utility Breaker Open
Loss of Utility Digital Output Programming
Utility to Generator Transfer Failure
Generator to Utility Transfer Failure SMCS Code: 4490
Engine Inlet Manifold Charge Combustion
EPS Supplying Load
Custom Event(1)
Note: The EMCP 3.1 does not have any digital
outputs. The EMCP 3.2 has one digital output. The
(1) For the Input Function setpoint value name “Custom Event”, EMCP 3.3 has two digital outputs.
the corresponding setpoint value will be dictated by the
information in Table 5.
Each digital output is capable of sinking 300 mA.
The outputs have diagnostics for a short to battery
when the driver is on, as well as diagnostics for an
open circuit when the driver is off. If a short to battery
persists for five seconds, then the driver will be
disabled until the condition is no longer present.
RENR7902-07 29
Systems Operation Section

There are two separate procedures that need to be Programming the Active State of
performed in order to program the digital outputs.
The first procedure involves programming the Active
the Digital Output
State of the output as either “Active High” or else
Note: The outputs are internally controlled in the
as “Active Low”. The second procedure involves
EMCP 3. The active state is programmable but
programming the Digital Selectors.
should always be set to “Active High”.

Function and Navigation Keys
Reference: The call outs that are in this section can
be found on the “EMCP 3 Control System Panel”
in Systems Operation, “Electronic Control Module
(Generator Set)”
In order to program the “Active State” of the digital
output, perform the following steps:
1. Navigate to the Digital Outputs menu.
a. At the “Main Menu”, click “Configure”.

The keys that are listed below are used for b. Select “Setpoints” from the menu.
programming the EMCP 3 and navigating within the
menu structure. c. Click “I/O”.

Reference: For a full explanation of the use of d. Click “Digital Outputs”.

the function keys and the navigation keys that are
referenced in this section, refer to the information 2. Using the navigation keys in order to select the
in Systems Operation, “Electronic Control Module digital output that is to be programmed. Press the
(Generator Set)”. Enter key.

Note: The “Enter” and “Escape” keys are considered 3. Press the Enter key a second time. The current
as function keys. The “Scroll Left”, “Scroll Right”, configuration will be highlighted.
“Scroll Up”, and “Scroll Down” keys are considered
as navigation keys. 4. Use the navigation keys in order to change the
current configuration to the desired setting.
(9) Escape – The “Escape” key is used in order to
navigate up (backward) through the menu structure. 5. Press the Enter key in order to save the setting.
The “Escape” key is also used in order to back out of
any data entry screen during set point programming
before any changes to the existing data are accepted.
Programming the Digital Selectors
The digital outputs that are available with the
(10) Enter key – The “Enter” key is used in order to
EMCP 3.2 control and the EMCP 3.3 control are
select a highlighted menu item or in order to save a
programmable. The digital outputs can be set to
programmed value.
operate based on different conditions. There are
functions that are called “Digital Selectors”. There
(11) Scroll Right key – Used during numeric data
are digital selectors that are associated with each
entry in order to choose the digit to edit. Also used
digital output. There are eight digital selectors. The
during certain set point adjustments in order to select
digital selectors determine the conditions that are
or deselect a check box.
required in order to cause specific digital outputs to
become “Active”. Only “Digital Selector 7” and “Digital
(12) Scroll Down key – Used in order to move
Selector 8” are associated with digital outputs.
down through the main menu or to navigate within a
list in order to highlight one of the items. Also used
The digital selector is a software function that acts
to decrement digits (0-9).
like a 12 position switch. For each output there are
11 different options or conditions that can make the
(13) Scroll Up key – Used in order to move up
output go active, and one condition to disable the
through the main menu or navigate within a list in
output altogether. The digital selector is used in
order to highlight one of the items. Also used to
order to determine which one of those conditions will
increment digits (0-9).
actually be associated with each digital output. This
relationship is shown in Illustration 20. In addition to
(14) Scroll Left key – Used during numeric data
the ten options shown in the Illustration, the digital
entry in order to choose the digit to edit. Also used
selectors can be configured to receive their activation
during certain set point adjustments in order to select
commands over the SCADA data link.
or deselect a check box.
30 RENR7902-07
Systems Operation Section

g01505580
Illustration 20

Perform the following steps in order to program the Table 6

digital selectors. Digital Selector #7 Configuration Options
1. Navigate to the Digital Selectors menu. Display Text Condition
Disabled Disabled
a. Start at the “Main Menu”. Click “Configure”.
Use Input 1(1) Disable Aux AC Supply(1)
b. Click “Other” from the menu selection. Use Input 2 Start Aid
c. Click on “Digital Selectors”. Use Input 3 Breaker Trip 1
Use Input 4 Breaker Trip 2
2. Using the navigation keys, select the digital
selector that is to be programmed. Press the Use Input 5 Auto Mode
Enter key. Use Input 6 Event Output Function #1
3. Press the Enter key a second time. The current Use Input 7 In Cool down
configuration will be highlighted. Use Input 8 Trip Point #1
4. Use the navigation keys in order to change the Use Input 9 Reserved for future use
current configuration to the desired setting.
Use Input 10 Reserved for future use
5. Press the Enter key in order to save the setting. Use Data Link Input Use SCADA Data Link
Command
Available Digital Selectors (1) Default

Digital Selector 7 Digital Selector 8

“Digital Selector 7” controls “Digital Output 1”. The “Digital Selector 8” controls “Digital Output 2”. The
available configuration options for “Digital Selector available configuration options for “Digital Selector
7” are shown in Table 6. 8” are shown in Table 7.
RENR7902-07 31
Systems Operation Section

Table 7
Digital Selector #8 Configuration Options NOTICE
This output does not control a circuit breaker unless
Display Text Condition the user makes the connections to do so. This output
Disabled(1) Disabled(1) type should be viewed as having a generic name be-
cause the name does not necessarily imply the action
Use Input 1 Breaker Trip 1 that is performed.
Use Input 2 Breaker Trip 2
Use Input 3 Common Alarm Common Alarm
Use Input 4 Auto Mode
• Activated any time that the EMCP 3 initiates and/or
Use Input 5 Run Mode detects either a shutdown event or a warning event
Use Input 6 V & Hz Within Limits
• Deactivates when no warnings or shutdowns are
Use Input 7 Reserved for future use present or active
Use Input 8 Reserved for future use Disable Aux AC Supply
Use Input 9 Reserved for future use
The “Disable Aux AC Supply” is intended to be used
Use Input 10 Reserved for future use in order to disconnect the battery charger, heaters
Use Data Link Input Use SCADA Data Link etc when the engine is running.
Command
(1) Default • Activated when engine start is initiated
• Deactivates when the engine is stopped: RPM=0
Description of Digital Selector Inputs
Used to Activate the Digital Outputs Event Output Function #1

Auto Mode • Requires set point configuration for “Event Output

Function 1”
Activated after the Auto key has been pressed or a
Modbus command is given to set engine operating • Activated while “Event Output 1” is active
mode to auto (register 302) and while the EMCP 3
remains in the auto mode. Trip Point #1

Breaker Trip 1 Activated when “Programmable Trip Point 1” is

active. “Programmable Trip Point 1” is activated
• Activated when any event occurs that has an event based on the high percent kW, according to the user
response configuration set for “breaker trip 1” configurable thresholds.

• Deactivates when the event is neither present nor In Cooldown

active
NOTICE
This output does not control a circuit breaker unless
the user makes the connections to do so. This output
type should be viewed as having a generic name be-
cause the name does not necessarily imply the action
that is performed.
Breaker Trip 2
• Activated when any event occurs that has an event
response configuration set for “breaker trip 2”
• Deactivates when the event is neither present nor
active
• Requires that the “Cooldown Duration” setpoint is
to be set greater than zero
• Activated when an engine stop has been initiated
and the cooldown cycle begins
• Deactivates when the cooldown timer has expired
and remains deactivated any time the genset is
not in cooldown
Run Mode
Activated after the Run key has been pressed or a
Modbus command is given to set *Engine Operating
Mode* to “Run” (register 302) and while the EMCP 3
remains in the “Run” mode
32
Systems Operation Section
Start Aid
• Requires that the set point for “Start Aid Activation
Time” is to be set greater than zero
• Activated when the engine start is initiated. The
engine start also starts the timer.
• Deactivates after “Start Aid Activation Time”
expires
V&Hz Within Limits
Note: The normal operating range is defined as
being neither above the “high” warning or shutdown
thresholds, nor below the “low” warning or shutdown
thresholds.
• Activated when measured generator voltage and
frequency (that is calculated as a percentage of
rated voltage and frequency) are both within the
normal operating range.
• Deactivates when either the measured generator
voltage or the frequency are outside the normal
operating range.
i02978888
Relay Output Programming
SMCS Code: 4490
Note: The EMCP 3.1 has six programmable Type
A relays. The EMCP 3.2 and EMCP 3.3 have eight
programmable relays. Six of these are Type A
relays and the other two are Type C relays. Type A
relays contain a common and one normally-open
contact. Type C relays contain a common and two
contacts, one that is normally-open and one that is
normally-closed.
Each relay is capable of handling 2A @ 30VDC. The
relays are “volt free” meaning that the commons are
not referenced to anything within the control. The
relay contacts are not protected against shorts to
battery or ground. Two of the relays are dedicated
and cannot be programmed. Relay Output #1 is
dedicated to controlling the starter motor. Relay
Output #2 is dedicated to fuel enable. The six
remaining Relay Outputs on the EMCP 3.3 and
EMCP 3.2 and four remaining Relay Outputs on
the EMCP 3.1 are programmable and can be set to
operate based on different conditions.
In order to program the Relay Outputs, the Digital
Selectors must be programmed.
RENR7902-07
Function and Navigation Keys
Reference: Call outs in this section can be found
on the “EMCP 3 Control System Panel” in Systems
Operation, “Electronic Control Module (Generator
Set)”
The keys listed below are used for programming the
EMCP 3 and navigating within the menu structure.
Reference: For a full explanation of the use of the
Function keys (Enter, Escape) and the Navigation
keys (Scroll Left, Scroll Right, Scroll Up, Scroll Down)
that are referenced in this section, see Systems
Operation, “Electronic Control Module (Generator
Set)”
(9) Escape – Navigate up (backward) through the
menu structure and also used to cancel out of data
entry screens during setpoint programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Scroll Right key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a check box.
(12) Scroll Down key – Move down through the
main menu or navigate within a list in order to
highlight one of the items. Also used to decrement
digits (0-9).
(13) Scroll Up key – Move up through the main
menu or navigate within a list in order to highlight one
of the items. Also used to increment digits (0-9).
(14) Scroll Left key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a check box.
Digital Selector Programming
There are eight digital selectors. The digital selectors
determine which conditions cause the Relay Outputs
to become active. Only six of the digital selectors are
associated with Relay Outputs.
The digital selector is a software function that acts
like a 12 position switch. For each output there are
11 different options or conditions that can make the
output go active, and one condition to disable the
output altogether. The digital selector is used in
order to determine which one of those conditions will
actually be associated with each digital output. This
relationship is shown in Illustration 21. In addition to
the ten options shown in the Illustration, the digital
selectors can be configured to receive their activation
commands over the SCADA data link.
RENR7902-07 33
Systems Operation Section

g01506813
Illustration 21
Digital Selectors being used to program Relay Outputs
34
Systems Operation Section
In order to program the digital selectors, perform the
following steps:
1. On the EMCP 3, navigate to the DIGITAL
SELECTORS menu as follows:
MAIN MENU
.... CONFIGURE
......... SETPOINTS
................. OTHER
......................... DIGITAL SELECTORS
2. Select the digital selector that is to be programmed,
and then press the Enter key.
3. Press the Enter key again a second time. The
current configuration will be highlighted.
4. Use the navigation keys in order to change the
current configuration to the desired setting
5. Press the Enter key in order to save the setting.
Digital Selector Input Descriptions
Air Shutoff
• Activated by the Emergency Stop condition while
the engine is running
• Activated by an Over speed condition
• Automatically deactivates after a five second delay
Start Aid
• Requires that the setpoint for “Start Aid Activation
Time” is to be set greater than zero
• Activated when engine start is initiated. Engine
start also starts the timer
• Deactivates after Start Aid Activation Time expires
Common Warning
• Activated whenever the EMCP 3 initiates a warning
event or detects a warning event
• Deactivates when there are no warnings present
Common Shutdown
• Activated whenever the EMCP 3 initiates a
shutdown event or detects a shutdown event
• Deactivates when there are no active or present
shutdowns
RENR7902-07
Common Alarm
• Activated whenever the EMCP 3 initiates a
shutdown event or detects a shutdown event
• Activated whenever the EMCP 3 initiates a warning
event or detects a warning event
• Deactivates when no warnings and no shutdowns
are active or present
Crank Alert
• Requires that the “Crank Alert Activation Time” be
set to a value greater than zero
• Activated when the engine start is initiated. This
action also starts the timer.
• Deactivates after the Crank Alert Activation Timer
expires
Engine Start Initiated
• Activates whenever the engine start is initiated
• Deactivates when engine stop is initiated or the
cool down cycle begins
Engine Started
• Activated whenever the engine has reached its
“crank terminate speed”
• Deactivates when the engine has stopped
Rated Speed
• Activated any time that rated speed is permitted
Note: Intended to provide a rated speed permissive
signal to a governor on an MUI engine
Horn Control
• Activated when any event occurs that has an event
response configuration set for “audible alert”
• Deactivates whenever the event is neither present
nor active
• Deactivates whenever the acknowledge/horn
silence key is pressed
ECU Fault Reset
• Activated when the EMCP 3 is in STOP mode and
any event reset is being initiated.
RENR7902-07 35
Systems Operation Section

Note: This output is intended for resetting events
in an ECM when there is no J1939 communication
available in the ECM, such as in the case of an
ADEM II controller. The engine type must be set to
“Electronic” and J1939 support must be set to “No
J1939 Support”.
Disable Aux AC Supply
• Deactivates when either the measured generator
voltage or the frequency are outside the normal
operating range.
In Cooldown
• Requires that the “Cooldown Duration” setpoint is
to be set greater than zero

• Activated when engine start is initiated
• Deactivates when the engine is stopped
Breaker Trip 1
• Activated when any event occurs that has an event
response configuration set for “breaker trip 1”
• Deactivates when the event is neither present nor
active
• Activated when an engine stop has been initiated
and the cooldown cycle begins
• Deactivates when the cooldown timer has expired
Auto Mode
Activated after the Auto key has been pressed and
while the EMCP 3 remains in the auto mode
Run Mode

NOTICE
This output does not control a circuit breaker unless
the user creates the connections for this function. This
output type should be viewed as having a generic
name because the name does not necessarily imply
the action that is performed.
Activated after the Run key has been pressed and
while the EMCP 3 remains in the run mode
Programmable Cycle Timer Output #2
The output is activated any time “Output 2” of the
programmable cycle timer is active.

Breaker Trip 2 High Percent kW

• Activated when any event occurs that has an event
response configuration set for “breaker trip 2”
• Deactivates when the event is neither present nor
active
High percent kW is activated when “Programmable
Trip Point 1” is active. The “Programmable Trip Point
1” is activated based on the high percent kW. The
high percent kW is determined by the thresholds that
are configured by the user.

NOTICE Digital Selector Configuration Options

This output does not control a circuit breaker unless
the user creates the connections for this function. This Digital Selector #1
output type should be viewed as having a generic
name because the name does not necessarily imply Digital Selector #1 controls Relay Output #3. Table
the action that is performed. 8 lists the configuration options that are available for
Digital Selector #1.
Event Output Function

• Requires setpoint configuration for Event Output 1

• Activated while Event Output 1 is active
Voltage & Hertz Within Limits

Note: The normal operating range is defined as

being neither above the “high” shutdown threshold,
nor below the “low” shutdown threshold.

• Activated when measured generator voltage and

frequency, which is calculated as a percentage of
rated voltage and frequency, are both within the
normal operating range.
36 RENR7902-07
Systems Operation Section

Table 8 Table 10
Digital Selector #1 configuration Options Digital Selector #3 Configuration Options
Display Text Condition Display Text Condition
Disabled Disabled Disabled(1) Disabled(1)
Use Input #1(1) Air Shutoff (1) Use Input #1 Common Alarm
Use Input #2(2) Start Aid (2) Use Input #2 Common Warning
Use Input #3 Common Warning Use Input #3 Overcrank Shutdown
Use Input #4 Common Shutdown Use Input #4 Engine Started
Use Input #5 Crank Alert Use Input #5 Crank Alert
Use Input #6 Auto Mode Use Input #6(2) Rated Speed(2)
Use Input #7 Breaker Trip 1 Use Input #7 Disable Aux AC Supply
Use Input #8 Event Output Function #1 Use Input #8 Auto Mode
Use Input #9 Trip Point #1 Use Input #9 Breaker Trip 1
Use Input #10 Reserved for future use Use Input #10 Reserved for future use
Use Data Link Input Use SCADA Data Link Use Data Link Input Use SCADA Data Link
Command Command
(1) Default for MUI (1) Default for EUI
(2) Default for EUI (2) Default for MUI

Digital Selector #2 Digital Selector #4

Digital Selector #2 controls Relay Output #4. Table Digital Selector #4 controls Relay Output #6. Table
9 lists the configuration options that are available for 11 lists the configuration options that are available for
Digital Selector #2. Digital Selector #4.

Table 9 Table 11
Digital Selector #2 Configuration Options Digital Selector #4 Configuration Options
Display Text Condition Display Text Condition
Disabled Disabled Disabled(1) Disabled(1)
Use Input #1 Horn Control Use Input #1 Common Warning
Use Input #2 Common Alarm Use Input #2 Common Shutdown
Use Input #3 Common Warning Use Input #3 Engine Started
Use Input #4(1) Common Shutdown(1) Use Input #4 Crank Alert
Use Input #5 Engine Started Use Input #5 ECU Fault Reset
Use Input #6 Run Mode Use Input #6 (2) Disable Aux AC Supply (2)
Use Input #7 Breaker Trip 2 Use Input #7 Engine Start Initiated
Use Input #8 In Cooldown Use Input #8 Run Mode
Use Input #9 Reserved for future use Use Input #9 Breaker Trip #2
Use Input #10 Reserved for future use Use Input #10 Reserved for future use
Use Data Link Input Use SCADA Data Link Use Data Link Input Use SCADA Data Link
Command Command
(1) Default (1) Default for EMCP 3.2 and EMCP 3.3
(2) Default for EMCP 3.1
Digital Selector #3
Digital Selector #5
Digital Selector #3 controls Relay Output #5. Table
10 lists the configuration options that are available for Digital Selector #5 controls Relay Output #7. Table
Digital Selector #3. 12 lists the configuration options that are available for
Digital Selector #5
RENR7902-07 37
Systems Operation Section

Table 12 i02978806

Digital Selector #5 Configuration Options Spare Analog Input

Display Text Condition Programming
Disabled(1) Disabled (1)
SMCS Code: 4490
Use Input #1 Common Shutdown
Use Input #2 Engine Started The “Spare Analog Input” is intended to be connected
to a resistive sender such as the Coolant Temperature
Use Input #3 Crank Alert Sensor or the Oil Pressure Sensor. Each analog
Use Input #4 ECU Fault Reset input is capable of reading a zero to 2k ohm resistive
sender.
Use Input #5 Rated Speed
Use Input #6 Disable Aux AC Supply Note: The EMCP 3.1 does not have a Spare Analog
Input. The EMCP 3.2 and the EMCP 3.3 each have a
Use Input #7 Auto Mode single Spare Analog Input.
Use Input #8 Breaker Trip 1
Note: The R/T map in the EMCP 3 for the Spare
Use Input #9 V&Hz Within Limits Analog Input differs between EUI engines, where the
Use Input #10 Reserved for future use input is reserved for user defined purposes, and MUI
engines which use the input for oil temperature.
Use Data Link Input Use SCADA Data Link
Command The spare analog input can be configured for six
(1) Default specific temperatures. In addition to temperatures,
this input can be factory set to monitor pressures and
Digital Selector #6 to monitor levels. Consult the factory for information
about applications that use the Spare Analog Input.
Digital Selector #6 controls Relay Output #8. Table
13 lists the available configuration options for Digital
Selector #6.
Menu Navigation
Table 13 The EMCP 3 Spare Analog Input menu, which is
used for programming the input, can be navigated to
Digital Selector #6 Configuration Options as follows:
Display Text Condition
MAIN MENU
Disabled(1) Disabled (1)

Use Input #1 Engine Started .... CONFIGURE

Use Input #2 Crank Alert ......... SETPOINTS
Use Input #3 ECU Fault Reset
................. I/O
Use Input #4 Rated Speed
Use Input #5 Start Aid ..................... SPARE ANALOG INPUT
Use Input #6 Common Alarm
Parameters that can be Configured
Use Input #7 Run Mode
Use Input #8 Breaker Trip 2 Parameters that can be configured for the Spare
Analog Input include:
Use Input #9 Programmable Cycle
Timer Output #2 • Enable/Disable
Use Input #10 Reserved for future use
• Suspect Parameter Number
Use Data Link Input Use SCADA Data Link
Command • Thresholds and time delays
(1) Default
Enable/Disable
• If the Spare Analog Input is used, then the
Enable/Disable setpoint must first be enabled
38 RENR7902-07
Systems Operation Section

• If the Spare Analog Input is not used, then the i02936494

Enable/Disable setpoint must be disabled
Cycle Timer Programming
• If the Spare Analog Input is enabled, but is not
being used, then diagnostic codes will be logged SMCS Code: 4490

The “Programmable Cycle Timer” (PCT) feature

Suspect Parameter Number (SPN) provides the option to program the control to perform
seven independently timed tasks. The output from
The following temperature SPN's are available for
the timers are called “PCT Outputs”. The tasks will
configuration:
be automatically activated or deactivated during the
week.
• Air Filter Differential Pressure
The PCT feature is useful in situations that involve
• Ambient Air Temperature paralleling two or more generators. The PCT feature
is useful in situations that require that the generators
• Engine Coolant Level automatically share the duty of supplying power for a
load throughout the week.
• Engine Oil Temperature
The use of the PCT will allow each generator set to
• Exhaust Temperature be programmed to start and stop at preset times in
order to meet the needs of various situations.
• Right Exhaust Temperature
The following scenario is one example of a PCT
• Left Exhaust Temperature application. If a standby generator set does not have
access to a utility supply in order to power a trickle
• Fire Extinguisher Pressure charger, then the PCT can be preset to start and
stop for one hour per week. The running time for the
• Fuel Filter Differential Pressure generator set will then be able to keep the generator
start battery well charged.
• Fuel Level
• External Tank Fuel Level NOTICE
The co-operation of a transfer switch is required in
• Generator Rear Bearing Temperature order to ensure that the generator sets are not stopped
on load.
• Oil Filter Differential Pressure
The PCT feature consists of seven independent
• Starting Air Pressure timers. The set points that are shown below are for
“PCT 1”. Each timer has the following set points:
Additional Parameters
Programmable Cycle Timer 1, Activation Day
The following threshold and time delay parameters of the Week – This set point permits independent
are numerical value entries. selection of each day, Sunday through Saturday, that
the timer will activate.
• High Warning Threshold
Programmable Cycle Timer 1, Activation of the
• High Warning Time Delay start time – This set point determines the time of
day, in hours and minutes, that the timer will activate.
• High Shutdown Threshold
Programmable Cycle Timer 1, Active Time –
• High Shutdown Time Delay This set point determines the duration, in hours and
minutes, for which the timer will be active. This set
• Low Warning Threshold point can be set for up to 24 hours.

• Low Warning Time Delay Programmable Cycle Timer 1, Output 1 Activation

Configuration – This set point determines whether
• Low Shutdown Threshold the PCT first output will be activated when this timer
is active.
• Low Shutdown Time Delay
RENR7902-07
Programmable Cycle Timer 1, Output 2 Activation
Configuration – This set point determines whether
the PCT second output will be activated when this
timer is active.
Outputs
Internal Outputs
The PCT has two internal outputs. The two internal
outputs must not be confused with the physical
outputs of the control. The internal outputs are
connected internally to the control module.
In the standard configuration, “PCT Output 1” is
connected to a “Remote Initiate” command. “PCT
Output 2” is connected to digital selector 6 in order to
potentially control relay output 8.
g01457594
Illustration 22
(1) Programmable Cycle Timers 1, 2, 3, 4, 5, 6, and 7
(2) Output 1 Status
(3) Output 2 Status
The capability allows the operator to configure a
timed relay for external connectivity. The status of
the PCT can be found within the menu structure.
Refer to Illustration 22. The top row (1) displays all
seven PCTs. The middle row (2) displays the status
of “Output 1”. The bottom row (3) displays the status
of “Output 2”.
1. From the “Main Menu”, press the scroll down key
until “Control” is highlighted.
2. Press the enter key.
3. Use the scroll down key in order to cursor down
until “Prog Cycle Timer” is highlighted.
4. Press the enter key in order to enter the edit
mode for the information that is relative to the
programmable cycle timer.
The PCT has two outputs. The two internal outputs
must not be confused with the physical outputs of the
control. The internal outputs are connected internally
to the control module.
39
Systems Operation Section
Output Control
The status of each output is indicated by a one (1), a
zero (0), or a hyphen (-). The output status is shown
in each column below each of the “Prog Cycle”
numbers 1 through 7. The number “One (1)” means
that this PCT is driving that output to be “TRUE”.
The number “Zero (0)” means that this PCT is NOT
driving this output to be true now, but, this output is
programmed in order to be true at another time.
A hyphen means that the PCT is NOT programmed
to activate the specified output.
The following is an explanation of the outputs as
shown in Illustration 23.
• PCT 1 is active (1). Output 1 is logic true or active.
The hyphen (-) that is in the bottom row shows that
output 2 is never enabled.
• PCT 2 is not active (0). If PCT 2 becomes active
(1), then PCT 2 will activate output 1 and output
2. The two zeroes that are shown below PCT 2
indicate that PCT 2 will “ENABLE” output 1 and
output 2 as soon as PCT 2 becomes active.
• PCT 3 is not active. If PCT 3 becomes active, only
output 2 will be enabled. Output 1 is disabled.
• PCT 4, PCT 5, PCT 6, and PCT 7 are “DISABLED”,
therefore, output 1 and output 2 will never be
active.
g01457600
Illustration 23
(6) Program Cycle Timer 1 is selected, activates Output 1, and
output 1 is currently active
(7) Program Cycle Timer 2 activates Output 1 and Output 2, but is
currently inactive
(8) Program Cycle Timers 4, 5, 6, and 7 are not active and the
outputs are disabled
The set points that are associated with the PCT are
configured at the PCT screen. In order to change the
values, use the scroll left key or the scroll right key
until the desired “PCT” is within the selection box (6).
Press the “ENTER” key in order edit the PCT related
information. Perform the following steps in order to
edit the cycle timer information:
40
Systems Operation Section
1. Ensure the edit box is around the timer that is to
be programmed.
2. Press the enter key in order to access the timer
information. The EMCP 3 screen will appear with
one of the choices as highlighted.
3. Use the scroll up key or scroll down key in order
to highlight the desired choice. For example, if an
output needs to be set, then use the proper scroll
key in order to highlight either of the desired timer
outputs.
4. Press the enter key. The EMCP 3 screen will
display the current setting for the output which will
be either “Active” or “Inactive”. The setting will be
highlighted.
5. If the output is set to “Inactive” and the desire is
to change the output to “Active”, then press the
scroll down key in order to change the output to
“Active”. If the output is set to “Active” and the
desire is to change the output to “Inactive”, then
press the scroll up key in order to change the
output to “Inactive”.
Note: On the EMCP 3.3, only the specified keys will
change the output.
6. Press the enter key in order to accept the changes.
7. Press the escape key in order to navigate back
to previous menus.
After the output has been set, the output status that
is shown on prog cycle timer screen should change
to reflect the change that was just made for that
specific timer.
i02936504
Trip Point Programming
SMCS Code: 4490
The standard configuration for the EMCP 3.2 and
for the EMCP 3.3 has only one “Programmable Trip
Point” function block. The “Programmable Trip Point”
is configured to respond to the %KW of the generator
set.
Note: The “Programmable Trip Point” feature is not
available on the EMCP 3.1 control. The EMCP 3.1
does not monitor power.
Note: The “Programmable Trip Point” function cannot
be configured to act upon a different parameter from
%kW. If a different capability is desired, a custom
flash file must be ordered. Contact the Caterpillar
dealer for details.
RENR7902-07
The set points of the “Programmable Trip Point” are
configured by default. If the %kW exceeds 90 percent
for 10 seconds, then the output of the “Programmable
Trip Point” will become true and remain true until the
%kW drops below 85 percent for 1 second.
The output of the “Programmable Trip Point” function
can be configured through “Digital Selector 2” to
“Relay output 4” or through “Digital Selector 7” to
“Digital (transistor) Output 1”.
The set points in the “Programmable Trip Point”
function can be changed with the use of the display.
Programmable Trip Point Function Trigger
Condition (Default = Trip Above Threshold) –
Selects whether the output will be active if the value
is above or below the threshold.
Programmable Trip Point Function Percentage
Threshold (Default = 90%) – The threshold that the
measured parameter must pass in order to change
the state of the output. In the default case for %kW,
this value is 90 percent of rated kW.
Programmable Trip Point Function Hysteresis
Percentage (Default = 5%) – Once the output is on,
the value must exceed the threshold by the default
value before the output turns off again. In the case
of the default %kW, the 5 percent value causes the
relay to not turn off again until 85 percent of rated kW
is reached. Therefore, if the rated kW is 90 percent,
then the output will not switch off until 85 percent
is reached. This hysteresis is used to ensure that
a value close to the threshold does not cause the
output to toggle on and off.
Programmable Trip Point Function Trip Activation
Delay Time (Default = 10 seconds) – The time
that the value must exceed the threshold before the
output of the block becomes active. The activation
delay time is used in order to ensure that the
momentary transients do not trip the relay.
Programmable Trip Point Function Trip
Deactivation Delay Time (Default = 1 second) –
The time that the value must return past the
hysteresis threshold before the output of the block
becomes inactive again. The deactivation delay
time is used in order to ensure that the momentary
transients do not deactivate the realy.
RENR7902-07 41
Systems Operation Section

i02936488

Text String Programming

SMCS Code: 4490

Text String Programming

The EMCP 3 supports the option to customize the
custom event names that are in the event log. The
option is referred to as “Modifiable Text Strings”. The
“Modifiable Text Strings” feature uses events that are
called “Custom Events”. “Custom Events” are special
events that can be configured to display a custom text
string in the event log. “Custom Events” are useful if
an existing “Suspect Parameter Number” (SPN) and
text string does not exist for the required event.

These events can be configured and these events

can be triggered similar to other events. However,
these events are unique in that their displayed text
strings can be customized with the use of Caterpillar
Service Tool. The text strings can be customized
with the use of any character that is in the supported
character set of the EMCP 3 software flash file.

Caterpillar Service Tool has the capability to upload

a “Modifiable Text Strings” configuration file from
a computer or download a configuration from the
EMCP 3 to a computer. The “Modifiable Text Strings”
configuration file can contain previously saved
custom event text strings.

Perform the following instructions in order to display

a custom text string for an event.

1. One of the “Event Input Functions” must be

configured with one of the following.

a. a SPN of “Custom Event”

b. a “Failure Mode Identifier” (SPN) of “Status

Condition Exists”.

2. A custom string must be entered, using the

“Modifiable Text Strings” tool that is in the
Caterpillar Service Tool.

3. The language must be set to the customer

language, not to “Technician English”. Refer to
Illustration 24 for an example that shows the event
as the event appears in Caterpillar Service Tool.
42
Systems Operation Section
Illustration 24
Illustration 25 shows the “Technician English” version
as “Custom Event #1” and the customized version of
the event log text string is referred to as “Building
Fire Detected”.
Note: The “Technician English” version is the basic
version of the text string format before the text string
is modified. The “Technician English” version is
offered for the use of troubleshooting by a technician.
g01455906
Illustration 25
RENR7902-07
g01455905
The functionality for the “Modifiable Text Strings”
differs between the EMCP 3 platforms and the
language sets. The EMCP 3.1 supports up to six
custom events. The EMCP 3.2 and EMCP 3.3
support up to eight custom events. Due to the
differences in screen resolution, the display platforms
also differ in the number of pixels that are allowed in
the custom event name.
Different language sets support a different set
of characters. Due to all of the differences, the
“Modifiable Text String” configuration files have
limited portability between the “EMCP 3” modules.
Language Support
The primary language for the “EMCP 3” control will
always be “U.S. (Technician) English”. The user will
always be able to revert back to “Technician English”
from the selected language that is supported by the
flash file. However, if the EMCP 3 display is viewed in
“Technician English”, then the user will not be able to
view the custom text strings. Also, the user will only
be able to view the default strings for a given input.
Refer to the “Before Customizing the Text String”
field information in Illustration 25.
The EMCP 3 has the capability of supporting one
flash file that contains one secondary language at
any particular time. If there is a desire to select a
different secondary language, then a new flash file is
required in order to configure the new language. The
new flash file must be installed.
The user will not be allowed to install multiple
flash files that support different languages. The
EMCP 3 supports Unicode characters from the
English character set. The EMCP 3 also supports
the character set from the local language that is
supported by the file.
RENR7902-07 43
Systems Operation Section

The responsibility of the user includes the installation

of the preferred flash file with the correct language
support that will allow the modification of text strings.
The user is also responsible for choosing the
appropriate operating system or Unicode text entry
system for the chosen language. The Caterpillar
Service Tool software will accept input from a
personal computer keyboard. If, the PC keyboard
setting is for U.S. English (USA), then difficulty may
be experienced in order to enter other non English
characters.

Modifiable Text Strings Configuration File

The user will have the capability to transfer the
custom text string data to the EMCP 3 and from
the EMCP 3 by use of the Caterpillar Service Tool.
The user will have the capability to modify the
configuration file offline.

When not connected to the EMCP 3, the user has

the ability to make changes to a saved configuration
file. The user must navigate to the “File” menu. Click
on “Open”, and then click on “Modifiable String Data
File”. Refer to Illustration 26.

g01456282
Illustration 26
44 RENR7902-07
Systems Operation Section

The user will be prompted to select a previously

saved file to edit. The file selection will be in an “XML”
format. Refer to Illustration 27 and to Illustration 28.

g01456283
Illustration 27

g01456284
Illustration 28
RENR7902-07 45
Systems Operation Section

Any offline changes must save before attempting

to connect the “Service Tool” to the EMCP 3. The
changes will not be saved as shown in Illustration 28.

Other features include the capability to upload and

download a configuration data when online. The
configuration file will be the same file that is used for
editing offline or that is used for editing online. The
configuration file will include, but is not limited to, the
following data:

• The language ID
• Parameter value name current strings that can be
configured

• List of Unicode characters that the EMCP 3

supports

• Pixel width of each Unicode character

Programming Modifiable Text Strings

with Cat Service Tool
The modifiable text strings that are programmable
with the use of Caterpillar Service Tool, version
2005B v2.0 or later.

Note: Remember that the modifiable text string data

can ONLY be updated when the EMCP 3 is in the
STOP position.

Use the following instructions in order to update or to

change the modifiable text string values.

1. Connect Caterpillar Service Tool to the EMCP 3.

2. Navigate to the “Service” menu.

3. Click “Modifiable Strings” (10). Refer to Illustration

29.

g01456352
Illustration 29
46 RENR7902-07
Systems Operation Section

After the “Modifiable String” appears, there will be two

options that are made available (20) and (21). There
are two options that are accessible from dialog. The
options that are available are “Load from ECM” and
“Load from File”.

g01509224
Illustration 30

Note: After the Load From File or the Load From

Display application has been enterned, then the other
two options, (22) and (23) will become available.

One of the options must be selected before editing

the modifiable text strings. Consideration must be
made that programming a “Modifiable Text String” is
completed upon initial setup. The “Load from ECM”
option should be selected. The service tool will collect
the information from the control. The control will
display the following message, “Loading Data From
ECM”. Refer to Illustration 30.

g01456367
Illustration 31

The modifiable text strings can be entered after the
data from the EMCP 3 is downloaded to the service
tool. The modifiable text strings are considered to
be a pair of strings for each event. The user has the
option to customize the pair of text strings.
Note: The modifiable text string parameter value
field is initially blank until it is replaced with a custom
text string parameter value. The custom text string
parameter value entered will replace the default
strings.

Two lines of custom text can be entered as shown in The “Save To ECM” command must be used in order
Illustration 31. The custom text strings can be saved to upload the changes to the EMCP 3 and in order
to the ECM or a file. allow the changes to become effective.

The field in Illustration 31 shows the entered text in

the final font, character spacing, and also indicates
how much space is remaining on the EMCP 3 display
line. The second line has less available space due
to the event log index that is also displayed on that
same line.
RENR7902-07
The custom text string parameter value(s) will
be displayed, that are in the flash file secondary
language, after the changes have been uploaded to
the EMCP 3. The custom text string parameter(s) are
displayed only when an FMI 31 event for the custom
event is triggered. The user will only have access
to the default strings when viewing the display in
“Technician English”. Since the modifiable text strings
are offered as a string pair, the default strings will
be displayed as “Custom Event 1” on the first line
and as “Status” on the second line. The custom text
strings will be displayed in the secondary language.
If the service tool does not support the secondary
language, then “U.S. English (USA)” will be used.
Problems with Modifiable Text Strings
Unable to View the Custom Event
1. Check for wiring problems.
a. At the “Main Menu”, select “I/O Status”.
b. Activate the input. Does the appropriate input
indicator change? If the input indicator does
not change, check the wiring.
Note: The input should be wired between the
appropriate digital input pin and ground (-BATT).
c. Expected Result:
The “I/O Status” should change from a hyphen
(-) to the number of the input that is being
switched.
d. Results:
OK - the “I/O Status” does change. Proceed to
the next heading that is titled “Is the Event Input
Function Configured for the Custom Event?”.
Not OK - the “I/O Status” does not change.
Determine the wiring fault and correct. Stop
and Repair.
2. IS THE EVENT INPUT FUNCTION CONFIGURED
FOR THE CUSTOM EVENT?
In order to show the custom text string in the
event log, the “Event Input Function” number
(SPN) must be configured for a special type of
event. The event is called “Custom Event”. The
“Failure Mode Identifier” (FMI) code must be set to
“Condition Exists” (Status).
Note: Cat ET uses the terminology “Condition Exists”
where the EMCP 3 display uses the terminology
“Status”. The terms are interchangeable.
47
Systems Operation Section
Note: There is a numbering offset. “Digital Input 3”
triggers “Event Input Function 1”. If “Event Input
Function 1” is configured properly, then “Custom
Event 1” will be triggered. For higher numbered
digital inputs, the numbers increase correspondingly.
a. Expected Result:
The “Event Input Function 1” SPN, if using
digital input 3, is configured for “Custom Event”
and that the “Event Input Function 3” FMI code
is configured for “Condition Exists” (Status).
Note: “Status” is referred to as “Condition Exists” by
the Cat Service Tool (CST).
b. Results:
OK - The set points are configured correctly.
Proceed to Step 3.
NOT OK - The set points need to be changed.
In order to change the set points, a security
level 2 access or CST is required. In order
to change the SPN set point from the control
panel display, select the category “Others”,
then click “Custom Event”.
Note: The menu items are not in alphabetical order.
3. IS THE EVENT RESPONSE ENABLED?
Each type of event, such as “Custom Event 1
Condition Exists”, has an associated “Event
Response Configuration”. The “Event Response
Configuration” must be enabled in order for the
event to appear in the event log.
a. Expected Result:
The particular custom event that is being
triggered, should be set to “Warning”, “Soft
Shutdown”, “Hard Shutdown” or “Active Only”.
Note: Other settings are optional.
b. Results:
OK - The set point is already configured as a
“Warning”, “Soft Shutdown”, “Hard Shutdown”
or “Active Only”. Call the customer support
representative for further assistance.
NOT OK - The set point needs to be changed.
In order to change the set point, a security
level 2 access or CST is required. Make sure
the ECS is set to “STOP” before attempting to
change the set point.
48
Systems Operation Section
The Custom Event is Viewable But the Default
Text is Shown on the EMCP 3 Display Instead of
the Custom String
1. VERIFY THAT THE CONTROL PANEL DISPLAY
IS SET TO THE PRIMARY LANGUAGE.
The control panel display supports various
languages. One of the languages that is included
is referred to as “Technician English”. If the primary
language is “US English (USA)”, the display may
be set to “Technician English”.
Note: The “U.S. English (USA)” and “Technician
English” look nearly identical.
The language can be changed. In order to change
the language from the “Main Menu”, select
“Preferences”, then select “Language”.
Note: “Preferences” is the bottom item in the “Main
Menu”. The “Language” choice is the bottom item
that is in listed in the “Preferences” menu. The menu
structure facilitates the ability to change from a
language the user does not understand to a language
the user does understand.
a. Expected Result:
Check the language setting. “Technician
English” should NOT be selected.
b. Results:
OK - The language is not set to “Technician
English”. Proceed to “VERIFY A CUSTOM
STRING”.
NOT OK - Scroll down to the primary language.
Press the “Enter” key that is on the EMCP 3
display in order to change the language. Go
back into the event log in order verify that
the custom string is being displayed for the
“Custom Event” when the corresponding input
is activated.
2. VERIFY A CUSTOM STRING
Verify that a custom string was created. Verify that
a custom string was uploaded by the use of the
Caterpillar Service Tool. Verify that the “Modifiable
Text Strings” command was used. Navigate to the
“Modifiable Text Strings” tool. Press the button
that is labeled “Load from ECM”.
Note: The button may read “Load from Display”.
Verify that the “Custom Event” that is to be
displayed with a custom text string, has the
custom string that is to be displayed.
a. Expected Result:
RENR7902-07
There is a text string shown to the right of the
custom event that is being configured. For
example, in Illustration 28, “Custom Event” 1,
5, and 6 DO NOT have a custom string that is
defined. However, “Custom Event” 2, 3, and 4
DO have custom strings that are defined.
b. Results:
OK - There is a custom string that is defined for
the “Custom Event” that is being configured.
Proceed to Step 3.
NOT OK - A custom string needs to be entered.
Double click to the right of either line 1 or line
2 of the “Custom Event”. Type in the desired
custom string. When finished, press the button
that is labeled “Save To ECM”. The process will
upload the changes to the EMCP 3.
3. VERIFY THAT A STATUS EVENT IS BEING
TRIGGERED
The “Event Input Function” FMI code, that
corresponds to the “Custom Event” that is being
triggered, should be set to “Condition Exists” or
to “Status”.
Note: The code should be set to “Condition Exists” or
to “Status” even though the custom event setting is a
“High Warning”, a “Low Warning”, or a “Shutdown”.
a. Expected Result:
Check the event log entry for the “Custom
Event”. Does entry read “Status” on the
second line? The other settings such as “Low
Warning”, “Low Shutdown”, “High Warning”, or
“High Shutdown” cannot be displayed with the
custom text.
Note: This does not mean that a custom event to
trigger a warning or shutdown cannot be configured.
If needed, configure the “Custom Event” number for
the “Condition Exists Event Response Configuration”
to trigger a “Warning”, a “Soft Shutdown”, or a “Hard
Shutdown”. A user may want to indicate the type
of action taken in a custom text string. “BUILDING
FIRE DETECTED WARNING” or “BUILDING FIRE
DETECTED SHUTDOWN” are examples of the types
of action that can be described in a custom text string.
Note: The set point name may or may not include the
words “Condition Exists”.
b. Results:
OK - The event does read “Custom Event” on
line 1 and “Status” on line 2. Call the customer
support representative for further assistance.
RENR7902-07
NOT OK - Configure the desired “Event Input
Function” FMI code to “Condition Exists” or
“Status”.
i02932987
Voltage and Frequency
Adjustment
SMCS Code: 4490
Function and Navigation Keys
Reference: The call outs that are in this section
can be found in the “EMCP 3 Control System
Panel” information that is in the Systems Operation,
“Electronic Control Module (Generator Set)” section.
The keys that are listed below are used for
programming the EMCP 3 and are used for
navigating within the menu structure.
Reference: For a full explanation of the use of the
“Function” keys such as “Enter” or “Escape” and the
“Navigation” keys such as “Scroll Left”, “Scroll Right”,
“Scroll Up”, and “Scroll Down”, that are referenced
in this section, refer to the Systems Operation,
“Electronic Control Module (Generator Set)” section.
(9) Escape – Navigate up (backward) through the
menu structure and also used to cancel out of data
entry screens during set point programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Scroll Right key – During numeric data entry,
choose the digit to edit. During certain set point
adjustments, select or deselect a check box.
(12) Scroll Down key – Move down through the
main menu or navigate within a list in order to
highlight one of the items. Also used to decrement
digits (0-9).
(13) Scroll Up key – Move up through the main
menu or navigate within a list in order to highlight one
of the items. Also used to increment digits (0-9).
(14) Scroll Left key – During numeric data entry,
choose the digit to edit. During certain set point
adjustments, select or deselect a check box.
Adjustment
Use the following procedure in order to adjust the
voltage and frequency of the generator output.
1. From the MAIN MENU, use the Scroll Down key
or the Scroll Up key in order to navigate to the
“CONTROL” menu.
49
Systems Operation Section
a. Press the Enter key in order to select the
CONTROL menu. “SPEED” or “VOLTAGE” will
be displayed.
Note: The voltage can only be controlled from the
EMCP 3 if a CDVR is installed on the generator.
Speed can only be controlled if there is an ADEM 3
or newer ECM on the engine.
b. Press “Enter”.
c. Press the Scroll Up key in order to increase
the voltage and press the Scroll Down key in
order to decrease the voltage.
Note: When adjusting the voltage using the Scroll
Up and Scroll Down keys, an offset is applied to
the set point value for “Generator Nominal Output
Voltage”. This set point is transmitted over the J1939
primary data link to the CDVR voltage regulator and
is retained until battery power is cycled to the EMCP
3. Cycling the battery power to the EMCP 3 will
remove the offset. Once the offset is removed, the
transmitted value reverts back to the set point value
for “Generator Nominal Output Voltage”.
d. Press the Scroll Left key in order to decrease
the engine speed and press the Scroll Right
key in order to increase the engine speed.
Note: When the scroll left and scroll right keys are
used to adjust the frequency, an offset is applied to
the set point value for “Generator Nominal Output
Frequency”. This data is transmitted over the J1939
primary data link to the engine controller and is
retained until battery power is cycled to the EMCP
3. Cycling the battery power to the EMCP 3 will
remove the offset. Once the offset is removed, the
transmitted value reverts back to the set point value
for “Generator Nominal Output Frequency”.
Idle Speed and Rated Speed
The engine speed can be toggled between the “LOW
IDLE” and the “RATED SPEED” with the use of the
control display.
1. From the “MAIN MENU”, select “CONTROL”.
2. Press the “DOWN ARROW” in order to highlight
“IDLE/RATED”.
3. Press the “ENTER” key. The “IDLE/RATED”
screen will be displayed. The current state will be
displayed.
4. In order to change the state, press the “Enter” key,
then press the “UP ARROW” or press the “DOWN
ARROW” in order to select the desired value.
5. Press the “ENTER” key in order to accept the
change.
50
Systems Operation Section
i02920507
Real Time Clock Programming
SMCS Code: 4490
The real time clock provides accurate information for
the time and the date of an automatic time based
start/stop control. The real time clock provides a
mechanism for time stamps in the event log.
Note: The EMCP 3.1 does not utilize a real time
clock for time stamping.
The EMCP 3 keeps track of the time and the date
using an internal real time clock with an internal
battery backed up memory. The time and the date
will be maintained by the internal battery even when
the control battery power is disconnected.
After the internal battery fails, the real time clock will
continue to keep time only when the control battery
power is connected. If the control battery power
is disconnected, then the real time clock must be
reprogrammed when the EMCP 3 is powered up
again.
Function and Navigation Keys
Reference: Callouts in this section can be found
on the EMCP 3 Control System Panel in Systems
Operation, “Electronic Control Module (Generator
Set)”
The keys listed below are used for programming the
EMCP 3 and navigating within the menu structure.
Reference: For a full explanation of the use of the
Function keys (Enter, Escape) and the Navigation
keys (Scroll Left, Scroll Right, Scroll Up, Scroll Down)
that are referenced in this section, see Systems
Operation, “Electronic Control Module (Generator
Set)”
(9) Escape – Navigate up (backward) through the
menu structure and also used to cancel out of data
entry screens during setpoint programming.
(10) Enter key – Select a highlighted menu item or
save a programmed value.
(11) Scroll Right key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
(12) Scroll Down key – Move down through the
main menu or navigate within a list in order to
highlight one of the items. Also used to decrement
digits (0-9).
(13) Scroll Up key – Move up through the main
menu or navigate within a list in order to highlight one
of the items. Also used to increment digits (0-9).
RENR7902-07
(14) Scroll Left key – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
Programming the Time and Date
The EMCP 3 allows the time and the date to be
changed. If the time and the date are changed, then
the time and the date will change the timestamp on
all future events. However, the time and the date will
change will not for existing events.
Programming the time and date must be performed
on the EMCP 3 display. Caterpillar® Service Tool
cannot be used in order to update the time or the
date. A “Level 1 Access” is required in order to
perform the the date and the time changes. Refer
to the “Password Entry” section of this document in
order to enter “Level 1 Access”.
Perform the following steps in order to access and in
order to change the time and the date.
Change the Time
1. From the “MAIN MENU”, press the Scroll Up
key or the Scroll Down key in order to highlight
“CONFIGURE”.
2. Press the Enter key in order to select
“CONFIGURE”.
3. Press the Scroll Down key in order to highlight
“TIME/DATE”.
4. Press the Enter key in order to select
“TIME/DATE”. The “SET TIME/DATE” screen will
appear. The time that is currently programmed will
have a box around the time that is shown on the
“TIME/DATE” screen.
Note: The current date that is programmed into
the EMCP 3 will also be displayed within the “SET
TIME/DATE” screen.
5. Press the Scroll Down key in order to place the
box, that is on the screen, around the time. Refer
to Illustration 32.
g01451976
Illustration 32
6. With the box placed around the time, press the
Enter key in order to begin editing the time. A
screen will appear that is similar to Illustration 33.
The entire clock time will be highlighted.
RENR7902-07
Illustration 33
g01452052
7. Press the “Enter” key in order to edit the time.
8. Use the Scroll Right key or the Scroll Left
key in order to highlight the digit that is to be
programmed. The seconds are highlighted in
Illustration 34.
g01452040
Illustration 34
9. Press the Scroll Up key or the Scroll Down key
in order to increment or decrement the highlighted
digit to the desired number.
10. Continue until the correct time has been entered.
When all digits of the time are correctly entered,
press the Enter key in order to accept the
changes. The “SET TIME” screen will appear with
a box around the newly programmed time.
Note: In order to reject the changes, press the
“Escape” key instead of the Enter key.
11. After the time has been set, press the Escape
key twice in order to return to the main menu.
Change the Date
1. If the control does not have the “Set Time/Date”
screen shown, then follow the procedures in Steps
1 through 4 of the “Change the Time” section in
order to access the “Set Time/Date” screen.
2. Press the Scroll Right key in order to place the
box around the currently programmed date in the
“Set Time/Date” screen.
3. Press the Enter key in order to edit the date. An
eight digit display is shown. The year is highlighted
at the far right.
4. Use the Scroll Right key or the Scroll Left
key in order to highlight the digit that is to be
programmed.
51
Systems Operation Section
5. Press the Scroll Up key or the Scroll Down key
in order to increment or decrement the highlighted
digit to the desired number.
6. Continue until the correct date has been entered.
When all eight digits of the date are correctly
entered, press the Enter key. The newly
programmed “Set Date” will have a box around
the date.
7. Press the Enter key in order to accept the
changes.
Note: In order to reject the changes, press the
“Escape” key instead of the Enter key.
8. Press the Escape key in order to return to the
“MAIN MENU” screen.
Changing the Date Format
The date format can be set to display in the
“Month/Day/Year” format or the “Day/Month/Year”
format. The procedure in order to change that date
format must be performed using the EMCP 3 display.
The date format change cannot be done with the use
the Caterpillar® Service Tool.
Note: The date format preference does not affect
operation of the EMCP 3 or the data as viewed in
the Caterpillar® Service Tool. The date format only
affects how the date is displayed on the EMCP 3
display.
Perform the following steps in order to change the
date format.
1. From the “MAIN MENU”, press the Scroll Up key
or the Scroll Down key in order to highlight the
“CONFIGURE” menu.
2. Press the Enter key in order to select
“CONFIGURE”.
3. Press the Scroll Down key in order to highlight
“TIME/DATE”.
4. Press the Enter key in order to select
“TIME/DATE”. “SET TIME/DATE” is displayed.
Also shown is the current time and date
that is programmed into the EMCP 3. The
currently programmed time is highlighted on the
“TIME/DATE” screen.
5. Press the Scroll Down key in order to highlight
“FORMAT MM/DD/YY”.
52
Systems Operation Section
g01451712
Illustration 35
1. Press the Enter key.
2. Use the Scroll Right key or the Scroll Left key in
order to the desired format.
3. Press the Enter key.
4. Press the Escape key in order to return to the
“MAIN MENU” screen.
i02981395
Thermocouple Module
SMCS Code: 7490
[ OPTIONAL USE]
This is not a required module.
General Information
Thermocouples, which consist of a probe that is
connected to two wires, are devices that are used for
measuring relatively high temperatures. The probe is
placed a specific distance away from the heat source
that is to be measured. The wires are connected to a
measuring device.
The wires are made up of dissimilar metals that are
connected at two different junctions. The first junction
is for measuring the temperature and the second
junction, which is attached to the thermocouple
module, is used as a reference. When the two metals
are joined, a voltage is generated that relates to the
difference in temperature between the two junctions.
The Thermocouple Module reads the voltage and
then calculates the temperature in “Celsius”. After
the calculations are complete, the Thermocouple
Module broadcasts the information onto the “J1939”
data link. Once on the data link, the EMCP 3 reads
the information and displays it on the display screen,
eliminating the need for a pyrometer or similar
separate display unit.
Thermocouples are given a “Type” designation
that is based on the range of temperatures that
the thermocouple can accurately measure. The
Thermocouple Module is capable of reading twenty
reference inputs from either “Type-J” or “Type-K”
thermocouples.
RENR7902-07
Diagnostics
The thermocouple module is capable of generating
events and diagnostics and can store up to twenty
diagnostic log entries that can be viewed from the
EMCP 3. The generated events and diagnostics are
maintained in non-volatile memory in order to ensure
availability after a power loss. The format for each of
the log entries is listed in Table 14.
Table 14
Diagnostic Log Entry Format
Suspect Parameter Number (SPN)(1)
Failure Mode Indicator (FMI) (2)
Time of Last Occurrence
Date of Last Occurrence
Time of First Occurrence
Date of First Occurrence
Engine Run Hours First Occurrence
Engine Run Hours Last Occurrence
Number of Occurrences
Security to Clear Log Entry
(1) Refer to Table 16 for possible code numbers.
(2) Refer to Table 15 for possible code numbers.
Twenty thermocouple inputs can be connected to a
thermocouple module. The module can detect both
open circuits and short circuits for any of the twenty
inputs.
Additionally, the module detects overtemperature
warnings and shutdowns, as well as
undertemperature warnings. These warnings
are detected by comparing the measured
temperature to the “low warning”, “high warning”,
and “high shutdown temperature” thresholds that are
programmed in the module.
The diagnostic messages listed in Table 15 are
broadcast on the “J1939” data link. The EMCP 3
controller reads these messages and can provide
both an annunciation for the operator and can also
perform a soft shutdown of the engine as appropriate.
Any of the inputs can be disabled in order to prevent
unnecessary diagnostic faults.
RENR7902-07 53
Systems Operation Section

Table 15 (Table 16, contd)

FMI Codes - Thermocouple Module SPNs Available for Configuration of

Temperature Inputs
FMI Description
SPN Description
0 Thermocouple Input #n High Temperature
Shutdown 1123 Alternator Bearing 2 Temperature
4 Thermocouple Input Sensor #n Short Circuit 1124 Alternator Winding 1 Temperature
5 Thermocouple Input Sensor #n Open Circuit 1125 Alternator Winding 2 Temperature
15 Thermocouple( Input #n) High Temperature 1126 Alternator Winding 3 Temperature
Warning
1131 Intake Manifold 2 Temperature
17 Thermocouple (Input #n) Low Temperature
1132 Intake Manifold 3 Temperature
Warning
1133 Intake Manifold 4 Temperature

Monitoring Features 1135 Engine Oil Temperature 2

1137 Exhaust Gas Port 1 Temperature
Thermocouples are given a “Type” designation
that is based on the range of temperatures that 1138 Exhaust Gas Port 2 Temperature
the thermocouple can accurately measure. The 1139 Exhaust Gas Port 3 Temperature
thermocouple module monitors twenty “Type-J” or
“Type-K” thermocouple inputs. 1140 Exhaust Gas Port 4 Temperature
1141 Exhaust Gas Port 5 Temperature
Each input can be configured and can be set to any
SAE J1939 “Suspect Parameter Number” (SPN) that 1142 Exhaust Gas Port 6 Temperature
is listed in Table 16. An SPN is an internationally 1143 Exhaust Gas Port 7 Temperature
recognized code that is designated with a specific
meaning. For example, SPN 174 is designated as 1144 Exhaust Gas Port 8 Temperature
“Fuel Temperature”. 1145 Exhaust Gas Port 9 Temperature

The display units are selectable at the EMCP 3 1146 Exhaust Gas Port 10 Temperature
controller as either degrees fahrenheit or as celsius. 1147 Exhaust Gas Port 11 Temperature
All monitored values are available on the data link as
read-only information. Temperatures are configured 1148 Exhaust Gas Port 12 Temperature
to indicate the SPN that is transmitted by each 1149 Exhaust Gas Port 13 Temperature
temperature input.
1150 Exhaust Gas Port 14 Temperature
Table 16
1151 Exhaust Gas Port 15 Temperature
SPNs Available for Configuration of
Temperature Inputs 1152 Exhaust Gas Port 16 Temperature

SPN Description 1153 Exhaust Gas Port 17 Temperature

52 Engine Intercooler Temperature 1154 Exhaust Gas Port 18 Temperature

105 Intake Manifold 1 Temperature 1155 Exhaust Gas Port 19 Temperature

110 Engine Coolant Temperature 1156 Exhaust Gas Port 20 Temperature

171 Ambient Air Temperature 1157 Main Bearing 1 Temperature (engine)

172 Air Inlet Temperature 1158 Main Bearing 2 Temperature (engine)

173 Exhaust Gas Temperature 1159 Main Bearing 3 Temperature (engine)

174 Fuel Temperature 1160 Main Bearing 4 Temperature (engine)

175 Engine Oil Temperature 1 1161 Main Bearing 5 Temperature (engine)

176 Turbo Oil Temperature 1162 Main Bearing 6 Temperature (engine)

441 Auxiliary Temperature 1 1163 Main Bearing 7 Temperature (engine)

442 Auxiliary Temperature 2 1164 Main Bearing 8 Temperature (engine)

1122 Alternator Bearing 1 Temperature 1165 Main Bearing 9 Temperature (engine)

(continued) 1166 Main Bearing 10 Temperature (engine)
(continued)
54 RENR7902-07
Systems Operation Section

(Table 16, contd) Table 17

SPNs Available for Configuration of Thermocouple Input Configuration parameters
Temperature Inputs
Description Default Range
SPN Description Value
1167 Main Bearing 11 Temperature (engine) Input #n – Suspect Parameter 0 Any SPN
Number (SPN) listed in
1172 Turbocharger 1 Compressor Inlet Temperature Table 16
1173 Turbocharger 2 Compressor Inlet Temperature Not Not Installed
Input #n - Type
1174 Turbocharger 3 Compressor Inlet Temperature Installed Type-J
Type-K
1175 Turbocharger 4 Compressor Inlet Temperature
Input #n – High Temperature 95 °C 0 °C (32 °F)
1180 Turbocharger 1 Turbine Inlet Temperature Shutdown Threshold (203 °F) to 1735 °C
(3155 °F)
1181 Turbocharger 2 Turbine Inlet Temperature
Input #n – High Temperature 85 °C 0 °C (32 °F)
1182 Turbocharger 3 Turbine Inlet Temperature
Warning Threshold (185 °F) to 1735 °C
1183 Turbocharger 4 Turbine Inlet Temperature (3155 °F)

1184 Turbocharger 1 Turbine Outlet Temperature Input #n – Low Temperature −200 °C −200 °C
Warning Threshold (−328 (−328 °F)
1185 Turbocharger 2 Turbine Outlet Temperature °F) to 800 °C
(1472 °F)
1186 Turbocharger 3 Turbine Outlet Temperature
Input #n – High Temperature 1 0 to 120
1187 Turbocharger 4 Turbine Outlet Temperature
Shutdown Delay Time seconds
1212 Engine Auxiliary Coolant Temperature
Input #n – High Temperature 1 0 to 120
1800 Battery 1 Temperature Warning Delay Time seconds
1801 Battery 2 Temperature Input #n – Low Temperature 1 0 to 120
Warning Delay Time seconds
1802 Intake Manifold 5 Temperature
1803 Intake Manifold 6 Temperature
Specifications
2433 Right Manifold Exhaust Gas Temperature
2434 Left Manifold Exhaust Gas Temperature Table 18 lists the specifications for the thermocouple
module.

Configuration Table 18

Thermocouple Module Specifications

• The thermocouple module will remain fully Valid Thermocouple Types Type-J and Type-K
functional during single setpoint configuration and
also during communications on the data link Operating Voltage Range 9 VDC to 32 VDC
Nominal Voltage Range 12 VDC or 24 VDC
• Even if the communication link is terminated, the
Thermocouple Module will continue to operate Overvoltage Capability 32 VDC for one hour at
normally 85 °C (185 °F)
Ambient Storage Temperature −50 °C (−58 °F) to
• All configured values and error codes are stored 125 °C (257 °F)
in non-volatile memory allowing retention of all
parameter values and error codes when the Ambient Operating −40 °C (−40 °F) to
Thermocouple Module is de-energized Temperature Range 120 °C (248 °F)
(see notes)
• The thermocouple module is configured on
the secondary data link (CAN2) by using the Note: If the ambient temperature exceeds 85 °C
Caterpillar service tool which has the capability to (185 °F), then the thermocouple module may deviate
configure any parameter that is programmable or in accuracy +/- 1° C
configurable
Note: If the ambient temperature exceeds 120 °C
Table 17 lists the configuration parameters for the (248 °F), then the thermocouple module may not
thermocouple inputs. return to proper operation
RENR7902-07 55
Systems Operation Section

i02981487 Table 20

Discrete Input/Output Module EMCP 3 Supported Suspect Parameter Numbers

SPN SPN Description Input Output
SMCS Code: 7490
38 Fuel Level-Secondary
X X
Tank
[ OPTIONAL USE ]
52 Engine Aftercooler
X
Temperature
This module is not required.
82 Starting Air Pressure X
General Information 94 Fuel Pressure X

The Discrete Input/Output (I/O) Module is a device 95 Fuel Filter Differential

X
Pressure
that is capable of reading twelve discrete inputs
and operating eight relay outputs. The Discrete I/O 96 Fuel Level (Primary
X X
Module can be mounted on the genset package or Tank)
else the module can be mounted remotely away from 98 X
Engine Oil Level
the genset package.
99 Oil Filter Differential
X
Pressure
Inputs
100 Engine Oil Pressure X
The Discrete I/O Module has twelve inputs with four 101 Crankcase Pressure X
return channels. The inputs can be activated by
either switching to a return or by switching to battery 107 Air Filter Differential
X
negative. Each of the inputs can be configured to Pressure
signal one of many possible events. The Caterpillar 110 Engine Coolant
Service Tool is used in order to configure the Discrete X
Temperature
I/O Module inputs.
111 Engine Coolant Level X X
Inputs that generate a warning message will reset 137 Extinguisher System
automatically whenever the input returns to a X X
Pressure
non-active state. Inputs that generate a shutdown
message will continue until the input returns to a 167 Battery Charging
X X
non-active state and a reset message is received by System Voltage
the module on the J1939 data link. 168 Battery Voltage X

The input configuration parameters are shown in 171 Ambient Air

X
Temperature
Table 19.
172 Inlet Air Temperature X
Table 19
173 Exhaust Temperature X
Configuration Parameters for Each Input
174 Fuel Temperature X
Setpoint Parameter Range Default
175 Engine Oil Temperature X
Input #inn Active Active Low Active
State Configuration Active High State 190 Engine Overspeed X
Low
612 Gen Rotating Diode
X
Input #nn Time Delay 0 to 120 seconds 0 Failure

Input #nn Suspect Any SPN (see Table N/A 628 Voltage Regulator
X
parameter Number 20 supported by Failure
(SPN) EMCP 3
970 Emergency Stop
X
Input #nn Failure Any FMI supported by N/A Shutdown (1)
Mode Identifier (FMI) EMCP 3
971 Engine Derate
X
Overridden
Table 20 lists the Suspect Parameter Numbers (SPN) 1084 Gen Overexcitation X X
that the EMCP 3 supports for inputs and outputs.
An SPN is an internationally recognized code that is 1122 Generator Bearing
X
assigned a specific meaning. For example, SPN 110 Temperature #1
relates to the Engine Coolant Temperature. 1124 Generator Winding
X
Temperature #1
(continued)
56 RENR7902-07
Systems Operation Section

(Table 20, contd) (Table 20, contd)

EMCP 3 Supported Suspect Parameter Numbers EMCP 3 Supported Suspect Parameter Numbers
SPN SPN Description Input Output SPN SPN Description Input Output
1125 Generator Winding User Range
X
Temperature #2 Defined 701-716 X
Input #3
1126 Generator Winding
X
Temperature #3 User Range
Defined 701-716 X
1237 Emergency Shutdown Input #4
Override Mode Active X X
Warning User Range
Defined 701-716 X
1239 Ruptured Fuel Input #5
X X
Basin-Primary Tank
User Range
1383 Unexpected Engine x Defined 701-716 X
Shutdown Input #6
1664 Engine Failure to Start User Range
X
Shutdown Defined 701-716 X
2433 Right Exhaust Input #7
X
Temperature User Range
2434 Left Exhaust Defined 701-716 X
X Input #8
Temperature
2436 Generator Frequency X User Range
Defined 701-716 X
2440 Generator Voltage X Input #9
2448 Generator AC Current X User Range
Defined 701-716 X
2452 Generator Reverse Input #10
X
Power (kW)
User Range
2456 Generator Reactive Defined 701-716 X
X
Power (VAR) Input #11
2648 Service Interval User Range
X
Warning Defined 701-716 X
4000 Air Shutoff Damper Input #12
X X
Close (1) Input configured as “Emergency Stop Shutdown” (SPN 970)
will not perform a shutdown when activated. Use only to create
4001 ATS in Normal Position X X an event log message in the EMCP 3 if desired.
4002 ATS in Emergency
X X
Position Outputs
4003 Battery Charger Failure X X
The discrete I/O module has eight “Form C” relay
4004 Gen Breaker Closed X X outputs. Each output can be configured to signal
4005 Utility Breaker Closed X X one of many possible events. Each output can be
configured for either general events or for specific
4006 Engine in Cooldown X events. The Caterpillar Service Tool (CST) is used in
4007 Generator Control Not order to configure the discrete I/O module outputs.
X
in Auto
For general events, each output activates whenever
4028 Earth Fault X X any “Alarm Condition”, “Shutdown Condition”, or any
4029 Earth Leakage X X combination of the two conditions exist.
User Range For specific events, each output activates whenever
Defined 701-716 X
Input #1
the diagnostic message contains the SPN and Failure
Mode Identifier (FMI) combination that matches the
User Range SPN and FMI combination that is programmed for
Defined 701-716 X that particular output.
Input #2
(continued)
RENR7902-07 57
Systems Operation Section

The FMI defines the nature of the event, such as Table 22

above range or below range. This includes events Input/Output Module Specifications
such as High or Low alarms, Shutdowns, or Condition
Exists. Nominal Voltage 9 VDC to 32 VDC
Operating Voltage 12 VDC
The output configuration parameters are shown in Range 24 VDC (external power supplies)
table 21.
Ambient Operating -40 degrees Celsius to 70
Table 21 Temperature degrees Celsius
Configuration Parameters for Each Output Output Relay 2A @120 VAC
Contact Ratings 2A @ 30 VDC
Setpoint Parameter Range 2A @ 277 VAC
Output #nn SPN Any SPN supported by EMCP 3
Output #nn Trigger Disabled
i02981520
Condition
Specific Condition Exists Resistive Temperature Device
Open Circuit
Diagnostic
Module
High Shutdown
High Warning SMCS Code: 7490
Low Shutdown
Low Warning [ OPTIONAL USE ]
Warning or Shutdown
Warning, Shutdown,
This module is not required.
or Short Circuit
Diagnostic
General Open Circuit
General Information
Diagnostic
Shutdown The resistance of a given material changes as the
Warning temperature of the material changes. A “Resistive
Warning, Shutdown, Temperature Device” (RTD) uses this principle
or Short Circuit in order to accurately measure temperature. An
Diagnostic RTD is a passive device that requires an external
excitation current. Once the current is supplied to the
RTD, the voltage is read across the RTD terminals
Configuration Behaviors and converted into a temperature using a simple
mathematical algorithm.
The discrete I/O module exhibits the following
configuration behaviors. Although RTD are more costly than Thermocouples,
they are widely used because of their excellent
• Maintains functionality with no loss in performance stability. Additionally, RTDs exhibit the most linear
during single setpoint configuration signal with respect to temperature of any electronic
temperature sensor. The typical metallic elements
• Maintains functionality with no loss in performance used in RTD are nickel, copper, and platinum.
while communicating on the data link Platinum is one of the more commonly used metals
in RTD because of its wide temperature range,
• Retains all configured values in non-volatile accuracy, and stability.
memory

• Configured on the secondary data link (CAN2) Module Overview

using the CST.
The RTD Module is a temperature scanner that is
capable of reading eight platinum RTD inputs. The
Specifications eight platinum RTD inputs can have two, three, or
four wire configurations. The four wire is the most
Table 22 lists the specifications for the Input/Output accurate because it uses one pair of wires for the
Module. excitation current and a separate pair of wires to
measure the voltage.
58 RENR7902-07
Systems Operation Section

The RTD Module will read the inputs, apply the
algorithm, and then calculate the temperature in
degrees celsius. The RTD module will then broadcast
the information onto the J1939 data link. The EMCP
3 will read the information from the RTD module and
display the information on the display screen.
The RTD module is also capable of generating
diagnostics. The diagnostics that are generated
by the RTD module are maintained in non-volatile
memory in order to ensure that they are available
following a power loss.
Table 24
RTD Module Diagnostics - FMI Codes
FMI Description
0 RTD Input #n High Temperature Shutdown
4 RTD Input Sensor #n Short Circuit
5 RTD Input Sensor #n Open Circuit
15 RTD Input #n High Temperature Warning
17 RTD Input #n Low Temperature Warning

Diagnostics Monitoring Features

The RTD module is capable of storing the twenty
event log entries that can be viewed from the ECM
and that are broadcast on the J1939 data link.
Each of the eight inputs have sensor diagnostics
in order to detect open or short circuits that go
to the RTD sensors. Overtemperature warnings
and shutdowns, as well as undertemperature
warnings, are detected by comparing the measured
temperature to the low warning, the high warning,
and the high shutdown temperatures that are stored
in the module. The EMCP 3 reads the messages
and annunciates and/or performs engine shutdown
appropriately. Any of the inputs can be disabled in
order to prevent unnecessary diagnostic faults.
The RTD Module monitors eight Platinum RTD
inputs. All monitored values are available on the
communication data link as read-only information.
Temperatures are configured in order to indicate
the SAE J1939 Suspect Parameter Number (SPN)
transmitted by each temperature input. An SPN
is a internationally recognized trouble code that is
assigned a specific meaning. For example, SPN 171
relates to the Ambient Air Temperature.
Each input is fully configurable and can be set to
any SPN that is listed in Table 25. The display
units are selectable at the “EMCP 3” controller as
either Fahrenheit or Celsius. CST is used in order to
configure the inputs of the RTD module.

Table 23 shows the format for the log entries. Table 25 shows the SPNs that are available for
configuration of temperature inputs.
Table 23
Table 25
Diagnostic Log Entry Format Table
SPNs Available for Configuration of
Suspect Parameter Number (SPN)(1) Temperature Inputs
Failure Mode Indicator (FMI )(2) SPN Description
Time of Last Occurrence 52 Engine Intercooler Temperature
Date of Last Occurrence 105 Intake Manifold 1 Temperature
Time of First Occurrence 110 Engine Coolant Temperature
Date of First Occurrence 171 Ambient Air Temperature
Engine Run Hours First Occurrence 172 Air Inlet Temperature
Engine Run Hours Last Occurrence 173 Exhaust Gas Temperature
Number of Occurrences 174 Fuel Temperature
Security to Clear Log Entry 175 Engine Oil Temperature 1
(1)See Table 25 for possible code numbers.
(2) See Table 24 for possible code numbers.
176 Turbo Oil Temperature
441 Auxiliary Temperature 1
Table 24 shows the RTD Module diagnostics.
442 Auxiliary Temperature 2
1122 Alternator Bearing 1 Temperature
1123 Alternator Bearing 2 Temperature
1124 Alternator Winding 1 Temperature
1125 Alternator Winding 2 Temperature
(continued)
RENR7902-07 59
Systems Operation Section

(Table 25, contd) (Table 25, contd)

SPNs Available for Configuration of SPNs Available for Configuration of
Temperature Inputs Temperature Inputs
SPN Description SPN Description
1126 Alternator Winding 3 Temperature 1174 Turbocharger 3 Compressor Inlet Temperature
1131 Intake Manifold 2 Temperature 1175 Turbocharger 4 Compressor Inlet Temperature
1132 Intake Manifold 3 Temperature 1180 Turbocharger 1 Turbine Inlet Temperature
1133 Intake Manifold 4 Temperature 1181 Turbocharger 2 Turbine Inlet Temperature
1135 Engine Oil Temperature 2 1182 Turbocharger 3 Turbine Inlet Temperature
1137 Exhaust Gas Port 1 Temperature 1183 Turbocharger 4 Turbine Inlet Temperature
1138 Exhaust Gas Port 2 Temperature 1184 Turbocharger 1 Turbine Outlet Temperature
1139 Exhaust Gas Port 3 Temperature 1185 Turbocharger 2 Turbine Outlet Temperature
1140 Exhaust Gas Port 4 Temperature 1186 Turbocharger 3 Turbine Outlet Temperature
1141 Exhaust Gas Port 5 Temperature 1187 Turbocharger 4 Turbine Outlet Temperature
1142 Exhaust Gas Port 6 Temperature 1212 Engine Auxiliary Coolant Temperature
1143 Exhaust Gas Port 7 Temperature 1800 Battery 1 Temperature
1144 Exhaust Gas Port 8 Temperature 1801 Battery 2 Temperature
1145 Exhaust Gas Port 9 Temperature 1802 Intake Manifold 5 Temperature
1146 Exhaust Gas Port 10 Temperature 1803 Intake Manifold 6 Temperature
1147 Exhaust Gas Port 11 Temperature 2433 Right Manifold Exhaust Gas Temperature
1148 Exhaust Gas Port 12 Temperature 2434 Left Manifold Exhaust Gas Temperature
1149 Exhaust Gas Port 13 Temperature
1150 Exhaust Gas Port 14 Temperature Configuration Behaviors
1151 Exhaust Gas Port 15 Temperature The RTD module exhibits the following configuration
1152 Exhaust Gas Port 16 Temperature behaviors:
1153 Exhaust Gas Port 17 Temperature
• Maintains functionality with no loss in performance
1154 Exhaust Gas Port 18 Temperature during single setpoint configuration
1155 Exhaust Gas Port 19 Temperature
• Maintains functionality with no loss in performance
1156 Exhaust Gas Port 20 Temperature during communications on the data link
1157 Main Bearing 1 Temperature (engine)
• Will continue to operate normally if the
1158 Main Bearing 2 Temperature (engine) communication data link is terminated
1159 Main Bearing 3 Temperature (engine)
• Retains all configured values in nonvolatile memory
1160 Main Bearing 4 Temperature (engine) so that no information is lost when the module is
de-energized
1161 Main Bearing 5 Temperature (engine)
1162 Main Bearing 6 Temperature (engine) • Configured on the secondary data link (CAN 2)
using the CST
1163 Main Bearing 7 Temperature (engine)
1164 Main Bearing 8 Temperature (engine) Each RTD input has the configuration parameters
that are shown in Table 26.
1165 Main Bearing 9 Temperature (engine)
1166 Main Bearing 10 Temperature (engine)
1167 Main Bearing 11 Temperature (engine)
1172 Turbocharger 1 Compressor Inlet Temperature
1173 Turbocharger 2 Compressor Inlet Temperature
(continued)
60 RENR7902-07
Systems Operation Section

Table 26 Specifications
Configuration Parameters for Each Input
Table 27
Description Range Default RTD Specifications
Value
Operating voltage range 9 VDC to 32 VDC
Input #n Any SPN that is listed
– Suspect in Table 25 Nominal voltage 12 VDC or 24 VDC
0
Parameter
Number (SPN) Overvoltage capability 32 VDC for one hour at
85 °C (185 °F)
Input #n - RTD IEC Platinum (0.00385)
Temperature JIS Platinum Ambient storage −50 °C (−58 °F) to 125 °C
Coefficient (0.003916) temperature (257 °F)
Configuration US Platinum Ambient operating −40 °C (−40 °F) to 120 °C
(0.003902) IEC temperature range (see (248 °F)
Legacy US Platinum notes)
(0.003920)
SAMA Platinum
(0.003923) Note: If the ambient temperatures exceed 85 °C
(185 °F), the RTD module may deviate in accuracy
Input #n – RTD Not Installed
Sensor Type 2-wire RTD Not +/- 1°C
3-wire RTD Installed
4-wire RTD Note: If the ambient temperature exceeds 120 °C
(248 °F), the RTD module may not return to proper
Input #n – High operation.
Temperature 0 °C (32 °F) to 1735 °C 95 °C
Shutdown (3155 °F) (203 °F)
Threshold i02981958

Input #n – High
Temperature 0 °C (32 °F) to 1735 °C 85 °C
Annunciator Module
Warning (3155 °F) (185 °F)
Threshold SMCS Code: 4490
Input #n – Low
Temperature −200 °C (−328 °F) to −200 °C [ OPTIONAL USE]
Warning 800 °C (1472 °F) (−328 °F)
Threshold This module is not required.
Input #n – High
Temperature
0 to 120 seconds 1
General Information
Shutdown Delay
Time The EMCP 3 annunciator module is used in order to
Input #n – High indicate various system events and status conditions.
Temperature The annunciator module uses indicator lights and an
0 to 120 seconds 1 audible horn in order to provide the operator with
Warning Delay
Time information about the current status of the system.
The annunciator module can be used in order to
Input #n - Low announce faults and status signals to the operator.
Temperature
Warning Delay
0 to 120 seconds 1 The annunciator module also allows the operator to
Time silence the horn or to acknowledge the system faults.

There are seventeen pairs of LED indicators on

the annunciator's front panel. Sixteen of these
indicator pairs are used in order to announce events,
diagnostics, and status signals. The seventeenth
indicator pair (25) is used as a combined network and
module status LED to alert the operator of problems
with the J1939 data link connection.

Table 28 lists the color scheme associated with the

data link connections status LED.
RENR7902-07 61
Systems Operation Section

Table 28 Table 29
Annunciator Module Status LED Alarm Conditions and System Status LED
Color Combinations
Solid Green Data link is OK
Row LED 1 LED 2
No CAN data link diagnostic, but no
Flashing
communication detected. Hooking the 1 Red Amber
Green
Annunciator up with the power on.
2 Red Amber
CAN data link diagnostic. For example:
Solid Red the module is wired wrong (Data Link), 3 Red Amber
wrong cable, or no terminating resistor. 4 Red Amber
Red/Green No application software loaded 5 Red Amber
Flashing
6 Red Amber
7 Red Amber
8 Red Amber
8 Red Amber
9 Red Amber
11 Red Amber
12 Red Amber
13 Green Amber
14 Green Amber
15 Red Green

Illustration 36
g01509455
Basic Operation
Each pair of LED indicators on the annunciator
consist of two of the following three colors: green,
amber, and red. The color choices allow for custom
configuration of Status, Warning, and Shutdown
indicators. For example, a pair of red and amber LED
indicators may be configured for engine oil pressure.
If a low engine oil pressure Warning is read over the
data link, the Annunciator will flash the amber LED
and the audible horn will sound. If the low engine oil
pressure shutdown is read over the data link, the
annunciator will flash the Red LED and the audible
horn will sound.
16 Red Green
17 Amber Green
Configuration
The annunciator is field programmable with the use
the CST. The annunciator is also flash programmable
in order to update the software with the use of CST.
The service tool software must be installed on a
Windows based PC. The Caterpillar communication
adapter must be connected between the PC and
the J1939 data link that the target annunciator is
connected to. When the PC is connecting to the
annunciator, the user will first see the “Module
Summary” screen. Refer to Illustration 37.

In order to acknowledge the shutdown and alarm Note: The service tool may be connected to the
conditions or to silence the horn, press the Alarm EMCP 3 accessory data link service connector.
Acknowledge button that is located near the middle
of the annunciator. Illustration 37 shows the module information such as
serial number, part number, software group number,
In order to test the LED indicators, or in order to test and software release date.
the horn, press the Lamp Test button and hold the
Lamp Test button that is located near the top of the
annunciator.

Table 29 lists the available color combinations for the

seventeen pairs of LEDs that are on the annunciator.
62 RENR7902-07
Systems Operation Section

g01510103
Illustration 37

The annunciator module can be customized in order
to signal many different system related conditions.
The supported data link parameters are shown in
Table 30 in the form of “J1939 Suspect Parameter
Numbers” (SPNs).
Global Acknowledge
The annunciator can be configured to initiate an
event acknowledge message and to respond to an
event acknowledge message over the J1939 data
link. If the “Global Acknowledge” set point is enabled,
then the annunciator events may be acknowledged
directly on the annunciator. The annunciator events
may be acknowledged by pressing the:
Electronic Control Unit (ECU) Instance
Number
The module description possesses the capability to
indicate a number that identifies the annunciator
uniquely from any other annunciator modules that are
on the primary or accessory J1939 data link. In the
example that is shown in Illustration 38, the service
tool is connected to “Alarm Module 2”.
The unique number that identifies the annunciator is
called the “Electronic Control Unit (ECU) Instance”.
The “ECU Instance” is programmable. In order to
program the annunciator to a different ECU instance
number:

• “Alarm Acknowledge” button 1. Navigate to the “Service” dialog.

• “Alarm Acknowledge” button on the EMCP 3 (This 2. Click on “Configuration”.

is considered to be a “Remote” acknowledgement.)

• “Acknowledge” button on another annunciator that

is on the same data link. (This is considered to be
a “Remote” acknowledgement.)

Note: Acknowledging the events also silences the

horn.

The default setting for this set point is “DISABLED”.

The default setting can be enabled by the use of the
“Service” dialog. The user will need to navigate to
the “Configuration” dialog in order to change the set
point to “Enabled”.
RENR7902-07
Illustration 38
The Cat ET configuration screen shows the desired
ECU instance and the actual hardware, “Aarm Module
2”, that is related to the specific ECU instance. In
Illustration 38, the annunciator will be programmed to
ECU instance 1. Perform the following steps in order
to program the desired instance.
1. Select the desired ECU instance row.
2. Double click on the current ECU instance. A dialog
box will open that allows entry of the new ECU
instance.
3. Type a numeric value such as 1, 2, 3, or 4. Click
“OK”.
When the “OK” button is clicked, the service
tool software will automatically restart and will
automatically reconnect to the data link. After the
service tool software has connected once again,
the summary screen will now show the new module
name, based on the ECU instance.
63
Systems Operation Section
g01510429
Configuring the Annunciator LED
Behavior
Each LED pair has four parameters that are required
in order to configure each LED pair. The best practice
is to configure the four columns in order from left to
right, that is, first configure “Trigger Condition”, next
configure “Severity Level”, then configure “Suspect
Parameter Number”, and finally configure “Failure
Mode Identifier” (FIM), if required. The reason for
the order is because the value that is set in one
column does affect the choices that are available in
the subsequent columns. If a field is grayed out, that
particular field is not available due to conditions set
in the previous columns.
Perform the following steps in order to configure the
behavior of the LED pairs.
1. Select “Service” in order to enter the “LED Pair
Configuration” dialog.
2. Select “LED Pair Configuration”.
Refer to Illustration 39.
64
Systems Operation Section
Illustration 39
Trigger Condition
There are three possible selections for the “Trigger
Condition”. The selections are “Specific Event”,
“General Event”, and “Disabled”.
Disabled – Disabling the trigger condition disables
the LED pair. If trigger condition is disabled, then the
LED pair will not respond to any data link message.
General Event – “General Event” is used in order to
assign an LED pair as a general alarm or shutdown
indicator. If the LED pair is configured as “General
Event”, then the LED will not be assigned to a
particular parameter. The LED will respond to any
event with a severity level that is chosen in the
“Severity Level” column, regardless of the SPN.
Specific Event – “Specific Event” is used is used
in order to assign an LED pair to a specific data
link parameter, such as oil pressure, engine speed,
coolant temperature, etc. The desired parameter
must be chosen in the SPN column.
RENR7902-07
g01510553
Severity Level Trigger
The severity level defines which types of events
that the LED pair will react to. Selections that begin
with “Condition Exists” will respond to J1939 event
messages for “FMI 31 Condition Exists”.
For example, LED pair 2 is configured for “Condition
Exists”, “Red On”, “Other Not Used”, and “Horn
On with SPN 190 (Emergency Stop Active)”. The
“Condition Exists” selection means that when the
annunciator receives a J1939 message indicating
“Emergency Stop with FMI 31”, the red LED will turn
on and the horn will also turn on. “Other Not Used”
indicates that the other LED color in the pair is never
used. “Green Off”, for example, indicates that the
green LED will illuminate when the condition chosen
for this LED pair is NOT active.
Most severity level selections imply one or more
J1939 “Failure Mode Identifier” (FMI) codes:
• Condition Exists is equivalent to FMI 31
• High Warning can be FMI 15 or FMI 16
RENR7902-07 65
Systems Operation Section

• Low Warning can be FMI 17 or FMI 18 (Table 30, contd)

Supported SPNs
• High Shutdown is equivalent to FMI 0
SPN Description SPN
• Low Shutdown is equivalent to FMI 1 Battery Voltage 168

• High or Low Shutdown is equivalent to FMI 0 or Ambient Air Temperature 171

FMI 1 Inlet Air Temperature 172

Since the FMI codes are implied by this column, the Exhaust Temperature 173
FMI column is grayed out for any of these selections. Engine Oil Temperature 175
Only the “Specific” option will allow an FMI to be
configured. Engine Speed 190
SCADA Data Link Fault 625
Suspect Parameter Number
Primary Data Link (J1939 #1) 639
The “Suspect Parameter Number” column is used Event Input Function #1 701
in order to select or in order to type in the SPN for
Event Input Function #2 702
the parameter that is assigned to the LED pair. Most
supported SPNs can be selected from the list. Refer Event Input Function #3 703
to the “SAE J1939” literature or Systems Operation
Testing and Adjusting Manual, RENR7902 for a Event Input Function #4 704
complete list of supported SPNs. Event Input Function #5 705

Note: Remember to click the “Submit” button that Event Input Function #6 706
is at the bottom of the LED “Pair Configuration” tool Event Input Function #7 707
after the selections for each LED pair has been
made. Only after the “Submit” button has been Event Input Function #8 708
pressed, will the new settings take effect. If selections Event Input Function #9 709
are made and an attempt is made to leave the LED
“Pair Configuration” tool before the “Submit” button Event Input Function #10 710
has been pressed, then a prompt will ask if the user Event Input Function #11 711
wishes to have the changes take effect. If the user
declines, then the changes will be lost. Event Input Function #12 712
Event Input Function #13 713
Table 30
Event Input Function #14 714
Supported SPNs
Event Input Function #15 715
SPN Description SPN
Event Input Function #16 716
Fuel Level (External Tank) 38
Emergency Stop Shutdown 970
Aftercooler Temperature 52
Generator Bearing Temperature #1 1122
Starting Air Pressure 82
Generator Bearing Temperature #2 1123
Fuel Filter Differential Pressure 95
Generator Winding Temperature #1 1124
Fuel Level (Local Tank) 96
Generator Winding Temperature #2 1125
Engine Oil Level 98
Generator Winding Temperature #3 1126
Oil Filter Differential Pressure 99
Exhaust Gas Port 1 Temperature 1137
Engine Oil Pressure 100
Exhaust Gas Port 2 Temperature 1138
Crankcase Pressure 101
Exhaust Gas Port 3 Temperature 1139
Air Filter Differential Pressure 107
Exhaust Gas Port 4 Temperature 1140
Atmospheric Pressure 108
Exhaust Gas Port 5 Temperature 1141
Engine Coolant Temperature 110
Exhaust Gas Port 6 Temperature 1142
Engine Coolant Level 111
Exhaust Gas Port 7 Temperature 1143
Fire Extinguisher Pressure 137
Exhaust Gas Port 8 Temperature 1144
Battery Voltage (switched) 158
(continued)
(continued)
66 RENR7902-07
Systems Operation Section

(Table 30, contd) Failure Mode Identifier (FMI)

Supported SPNs
Choose the FMI from Table 31.
SPN Description SPN
Exhaust Gas Port 9 Temperature 1145
Exhaust Gas Port 10 Temperature 1146
Exhaust Gas Port 11 Temperature 1147
Exhaust Gas Port 12 Temperature 1148
Exhaust Gas Port 13 Temperature 1149
Exhaust Gas Port 14 Temperature 1150
Exhaust Gas Port 15 Temperature 1151
Exhaust Gas Port 16 Temperature 1152
Exhaust Gas Port 17 Temperature 1153
Exhaust Gas Port 18 Temperature 1154
Exhaust Gas Port 19 Temperature 1155
Exhaust Gas Port 20 Temperature 1156
Accessory Data Link Fault (J1939 #2) 1231
Emergency Shutdown Override Mode 1237
Active Warning
Ruptured Fuel Basin - Primary Tank 1239
Unexpected Engine Shutdown 1383
Engine Failure to Start Shutdown 1664
Right Exhaust Temperature 2433
Left Exhaust Temperature 2434
Generator Frequency 2436
Generator AC Voltage 2440
Generator AC Current 2448
Generator Reverse Power (kW) 2452
Generator Reverse Power (kVAr) 2456
Service Interval Warning 2648
Air Damper Closed 4000
ATS in Normal Position 4001
ATS in Emergency Position 4002
Battery Charger Failure 4003
Generator Control Not in Automatic Warning 4007
Generator Breaker Failure to Open 4009
Utility Breaker Failure to Open 4010
Generator Breaker Failure to Close 4011
Utility Breaker Failure to Close 4012
Utility to Generator Transfer Failure Warning 4015
Generator to Utility Transfer Failure Warning 4016
Loss of Utility 4017
RENR7902-07 67
Systems Operation Section

Table 31
Failure Mode Identifier (FMI) Codes
FMI Description Short Description
0 Data Valid but Above Normal Operational Range - Most Severe Level High Shutdown
1 Data Valid but Below Normal Operational Range - Most Severe Level Low Shutdown
2 Data Erratic, Intermittent or Incorrect N/A
3 Voltage Above Normal or Shorted to High Source N/A
4 Voltage Below Normal or Shorted to Low Source N/A
5 Current Below Normal or Grounded Circuit N/A
6 Current Above Normal or Grounded Circuit N/A
7 Mechanical System Not Responding or Out of Adjustment N/A
8 Abnormal Frequency, Pulse Width or Period N/A
9 Abnormal Update Rate N/A
10 Abnormal Rate of Change N/A

11 Unexpected Engine Shutdown N/A

12 Bad Intelligent Device or Component N/A
13 Out of Calibration N/A
14 Special Instructions N/A
15 Data Valid But Above Normal Operating Range - Least Severe Level High Warning
16 Data Valid But Above Normal Operating Range - Moderately Severe Level High Warning
(Derate)
17 Data Valid But Below Normal Operating Range - Least Severe Level Low Warning
18 Data Valid But Below Normal Operating Range - Moderately Severe Level Low Warning
(Derate)
19 Received Network Data In Error N/A
31 Not Available or Condition Exists Status

Adding Additional Remote

Annunciator
An additional remote annunciator may be added if
desired. In order to operate properly, the annunciator
must be located within 244 m (800)of the EMCP
3 and the end of line terminating resistor must be
relocated. Refer to Illustration 40.
68 RENR7902-07
Systems Operation Section

g01093231
Illustration 40
Adding additional remote annunciator

Additional modules may be added in parallel to

remote annunciators. In order to operate properly,
the device to be added in parallel to the annunciator
must not have cable drop lengths greater than 2.7 m
(9 ft.). Refer to Illustration 41.
RENR7902-07 69
Systems Operation Section

g01093228
Illustration 41
Connection details for devices in parallel with remote annunciator

i02936516

Monitoring Software for

Computer
SMCS Code: 4490

The EMCP 3 Monitoring Software can be used in

order to control a generator set over the SCADA data
link. The EMCP 3 Monitoring Software can be used in
order to monitor a generator set over the SCADA data
link. The EMCP 3 Monitoring Software l functionality
is available on the EMCP 3.2 and the EMCP 3.3.

Illustration 42 shows the default control panel that

is provided with the EMCP 3 Monitoring Software.
The control panels can be edited or created. Refer
to the “Creating a Control Panel View” section of this
document.
70 RENR7902-07
Systems Operation Section

g01457718
Illustration 42
Default Control Panel that is Provided with the EMCP 3 Monitoring Software

Software Set Up
Connect a computer to the EMCP 3. The SCADA
data link must be used. Follow the instructions that
are located in the “EMCP 3 Monitoring Software
Quick Start Guide” section of this publication. After
the program launched, a login dialog will appear. A
user name and a password are required. Use the
default user name “administrator”. Enter “admin” for
the password. Refer to Illustration 43.

g01457841
Illustration 43
Log On Screen

Add Device
1. Click on “Network”.
RENR7902-07 71
Systems Operation Section

2. Select “Add Device” or right click on the cable 3. Click “Set Points”.
symbol that is located at the top left corner of the
dialog. The symbol is located near the “Offline” 4. Select “Network”
text that is on the dialog.
5. Select “Data Link – SCADA”.
3. Select “Add Device”. The “Add a Device” dialog
will appear. Refer to Illustration 44. Check the Online Configuration Settings
Use the following steps in order to check the online
configuration settings:

1. Select “Network”.

2. Click “Online Configuration” or right click the cable

symbol that is located at the top left corner of the
dialog. The symbol is located near the “Offline” text
that is on the dialog. Select “Online Configuration”.

3. Verify that the interface connection is correct.

Verify that the baud rate and the parity match the
settings that are programmed in the EMCP 3.
Refer to Illustration 45.

Note: The interface connection settings, the baud

rate settings, and the parity settings can be accessed
with the “EMCP 3”. In order to access the settings,
refer to procedure in the “Access the SCADA Data
Link Slave Address Set Point” section.
g01457842
Illustration 44

Device Name

1. Perform the following steps in order to designate

a “Device Name”:

2. Type a desired name for the device in the “Device

Name” field.

3. Click on the arrow that is for the “Device Type”.

Select the desired device type from the drop down
menu.

4. Click on the arrow that is for the “Node Address”.

Select the desired “Node Address” from the drop
down menu. Refer to Illustration 44.

Note: Ensure that the node address matches the

“SCADA Data Link Slave Address” set point that is
on the EMCP 3.
g01457843
Illustration 45
Note: The “SCADA Data Link Slave Address” set
point data can be accessed with the EMCP 3. 1. If desired, create a simple test. Select “Edit”.

Access the SCADA Data Link Slave Address Set 2. Select “Control Panel Configuration”.
Point
Add a Control
Perform the following steps in order to access the
SCADA data link slave address set point. 1. Select “Edit”.
1. Begin at the main menu. 2. Select “Add Control”.
2. Select “Configure”.
72
Systems Operation Section
3. Click “Digital Display” or click the “Digital Display”
button that is on the tool bar. In order to add the
control, double click on the desired location within
the control panel (77). The process will add the
digital display as shown in Illustration 46.
g01457844
Illustration 46
Digital Display Added to Control Panel
4. After adding the display, the display needs to
be programmed in order to display the battery
voltage.
a. Right click on the display.
b. Select “Set Parameter Association”. The
“Control Configuration” dialog will appear.
Refer to Illustration 47.
g01457845
Illustration 47
RENR7902-07
5. Click on a previously defined device name that is
listed in the “Device/Group” field of the dialog. For
this example, “ENG” has been selected.
All of the possible parameters for the digital
display will be shown in the “Parameter List”.
6. Double click on “Battery Voltage” in order to select
the battery voltage. Refer to Illustration 48.
Note: Be sure to double click the parameter. If the
parameter is not double clicked, then the parameter
will not be selected. If the parameter has been
selected, the parameter will appear in the “Selected
Parameter” field of the dialog.
In the control panel, a digital display will show
battery voltage. The battery voltage is shown in
order to verify that a connection between the
EMCP 3 and the software has been established.
Directing the software to go online does not verify
that a connection is present. The software will
appear to successfully make an online connection
whether or not a connection is present.
RENR7902-07 73
Systems Operation Section

g01457846
Illustration 48

7. Click “OK” in order to define the parameter

association.

8. After the parameter has been programmed, then

save the settings. Select “File”.

9. Click “OK” or click the “Save” button that is on the

tool bar.

10. Select a desired location for the file and select a

name for the file. Click “Save”. The control panel
should now look similar to Illustration 49.

g01457849
Illustration 49

Close the “Control Panel Edit” dialog. Click the “X”

that is in the top right corner of the dialog. Make sure
to close only the control panel window and not the
program.

Perform the following steps in order to access the

“Control Panel View” dialog:

1. Select “View”.
74 RENR7902-07
Systems Operation Section

2. Select “Control Panel Data”.

Refer to Illustration 50.

g01457851
Illustration 51

If the battery voltage is reading correctly, then the

g01457850 connection is working properly. After the connection
Illustration 50
has been confirmed, begin to design the “Control
Test the Connection Panel View”.

Perform the following steps in order to test the
connection:
1. Click “Network” or right click on the cable symbol
that is in the top left corner of the dialog where the
dialog displays “Offline”.
2. Click “Go Online”.
If the battery voltage is not reading correctly, then
insure that the dialog that is being displayed is the
“Control Panel View” dialog and not the “Control
Panel Edit” dialog.
Also, recheck all of the settings that are mentioned at
the beginning of this software setup section. Finally,
check the wiring for any possible problems.

The procedure instructs the computer to begin Click the “View Current Events” button that is located
the connection. The battery voltage should on the tool bar in order to perform another simple
be displayed within a few seconds. Refer to test. The dialog should display all of the events that
Illustration 51. are currently listed in the EMCP 3.

Quick Start Guide

The “EMCP 3 Monitoring Software Quick Start Guide”
is located on the SIS web site at “https://sis.cat.com”.

1. Log into the Caterpillar network with the correct

“Caterpillar Web Security” (CWS) ID and CWS
password. If needed, copy and paste the web
address, that is shown above, into the browser.
Under “Highlights”, that is displayed on the left
side of the screen, select “Downloads”. Refer to
Illustration 52.
RENR7902-07 75
Systems Operation Section

g01457873
Illustration 52

2. The next screen will display a list of available

downloads. Refer to Illustration 53.

g01457874
Illustration 53

3. Use the scroll bar that is on the right of the 4. Click on the “EMCP Monitoring Software –
screen in order to scroll down until “EMCP QUICKSTART ver1_ 0.doc” link in order to start
Monitoring Software” is found in the left column. the download. The “File Download” dialog will
The second column from the left contains the open.
“EMCP Monitoring Software.zip” file. The far right
column shows the “Additional Info” link. Click on
the “Additional Info” link in order to access the
“Quick Start Guide”. Refer to Illustration 53.
76 RENR7902-07
Systems Operation Section

g01457875
Illustration 54

5. Select “OPEN” in order to start a document editor.

The system will display the open to access the
“Quick Start Guide” or “SAVE” the quick start
guide to a folder. Refer to Illustration 55.

g01457876
Illustration 55
RENR7902-07
Creating a Control Panel View
In the “Software Set Up” section, a control panel view
was created in order to display the battery voltage. A
control panel view can be created in order to serve
other purposes. This section will provide an overview
of the steps that are necessary in order to design a
control panel view.
Add Controls
1. Access the control panel edit dialog. Refer to
Illustration 56.
Note: The entire control panel can be created from
within the control panel edit dialog.
g01457877
Illustration 56
a. Click “Edit”.
b. Click “Control Panel Configuration”.
Note: If the “Control Panel Edit” option is unavailable,
close out of the “Control Panel View” dialog. The
“Control Panel View” dialog and the “Control Panel
Edit” dialog cannot be open at the same time. Also, it
is recommended that the control be “offline” before
any attempt is made to edit the “Control Panel View”.
In order to place the control offline, click “Network”,
then click “Go Offline” or right click on the cable
symbol, then click “Go Offline”.
77
Systems Operation Section
Note: The monitoring software provides the
option to create new control panel views. A new
control panel view can be defined by selecting the
desired parameters and by selecting the desired
format for the parameters. The types of parameter
formats include, but are not limited to, circular
gauge and numeric display. After the parameter
and the parameter format has been selected, the
configuration should be saved to a file. A default
configuration file is supplied with the monitoring
software. The file name, “default.pvc”, contains the
basic screens that have the standard parameters
already configured. The user can modify the file. The
modified file can be save as a new file if desired.
2. New controls can be added by two different
methods.
a. Click the desired button that is shown on the
tool bar and then double click within the control
panel.
b. Click “Edit”, then click “Add Control”. Choose
a control from the list.
There are three types of controls that are
available.
• Displays
• Switches
• Indicators
The display controls consist of:
• Circular gauge
• Digital display
• Thermometer
• Linear gauge
The displays can be used in order to display
the information about the generator set. Some
examples include engine coolant temperature,
generator total real power, engine RPM, and
battery voltage. Refer to Illustration 57.
78 RENR7902-07
Systems Operation Section

g01457878
Illustration 57

3. The types of switches that are available include

the:

• Sliding switch
• Panel switch
• Lever switch
• Rocker switch
• Single button
• Rotary switch
The rotary knob and the multiple button switch
are included in this category. These switches
can be used in order to control something that
is either “off” or “on”. Some of the examples
include the emergency stop switch, the remote
initiate command, and the digital selectors. The
multiple button switch can also control the engine
operating mode command. Refer to Illustration 58.

g01457880
Illustration 58
RENR7902-07 79
Systems Operation Section

4. The LEDs consist of the:

• Single LED control

• Multiple LED control
The LEDs are used in order to display the outputs
from the generator set. Some examples include
the digital input active state and the engine
operating mode. Refer to Illustration 59.

g01457881
Illustration 59

5. After the controls are added to the control panel,

the controls can be moved and resized. In order to
move a control, click and drag the control to the
desired location. In order to resize the control,
select the control by clicking on it and then move
the mouse to the edge of the control until the
pointer becomes an arrow. Click and drag the
control to the desired size. Refer to Illustration 60.

g01457883
Illustration 60
80 RENR7902-07
Systems Operation Section

6. Other display properties can be changed for any

of the controls. In order to change other display
properties, right click on the control, then select
“Set Display Properties”. For example, the font
size or the color for the digital display can be
changed. Refer to Illustration 61. The digital
display (45) was changed to a larger font and
changed to a different color.

g01457885
Illustration 61

Note: Each control has different parameters that

are associated with the control. In order to change
parameters, refer to the parameter selection
information that is in the “Add a Control” section.
Select any desired parameter for this example. After
the parameter has selected, the list of parameters
can be viewed by the categories of block types,
control, engine, generator, I/O, and status.

7. The list of parameters that are associated with

each control can be viewed.

a. Navigate to the “Control Configuration” dialog.

b. Click the desired device name that is listed in

the “Device/Group” field.

c. Select the desired parameter from the

“Parameter List”. Refer to Illustration 62.

Note: Remember to double click the desired

parameter in order to select the parameter.
RENR7902-07 81
Systems Operation Section

g01457887
Illustration 62

8. Click “OK” in order to set the parameter. Refer to

Illustration 63.

g01457898
Illustration 63

9. The displayed text (51) can be changed after the a. Right click on the text box.
desired parameter has been selected.
82 RENR7902-07
Systems Operation Section

b. Select “Set Text” or double click the text. Refer

to Illustration 64.

g01457899
Illustration 64

10. The background of the control panel can be

changed.

a. Right click on an empty space within the control

panel or select “Edit”.

b. Click “Set Background Image”.

The background can be set to a color.

c. Open the “Paint” software.

d. Create a screen with the desired color.

e. Save the screen first, then open the screen as

the background image.

The controls and the text can be set to

“transparent”.

f. Right click on the desired item.

g. Select “Display Transparent”. Refer to

Illustration 65.
RENR7902-07 83
Systems Operation Section

g01457900
Illustration 65

Control Panel Tabs

Tabs can be configured for used on the control panel.

Perform the following two steps in order to rename

an existing tab.

1. Select “Edit”.

2. Select “Rename Selected Tab”.

Perform the following two steps in order to add

another tab.

3. Select “Edit”.

4. Select “Add Tab”.

Note: In order to edit the new tab, click the desired

tab. A new sheet will open.

Refer to Illustration 66. Illustration 66

g01457903

If a control must be moved or resized, after the

parameter has been set, move the control to the
desired location. Then “RESET” the parameter again.
This process will reset the standard position for the
control and will prevent the control from moving. Be
sure to reset the parameter for any control that has
been moved.
84 RENR7902-07
Systems Operation Section

Note: When multiple tabs are used, the parameters

for each control must be reset after the control
has been moved or resizing. If the parameters are
not reset, the control may revert to the original
configuration.

Logging Data to a File

The “EMCP 3 Monitoring Software” can view data
that is in a text format and can log the data to a file.

1. In order to access the data that is to be logged,

navigate to the “Data Log Configuration” dialog.

a. Click “Edit”.

b. Click “Data Log Configuration”.

2. Select the desired parameter that is to have the

data logged. or simply double click the desired
parameter.

a. After the “Data Log Configuration” dialog has

appeared, click the desired parameter that is
shown on the “Parameter List”.

b. Click the “Add” button.

c. The parameter will appear in the under the

“Parameter” tab information.

Note: If the desired parameter is double clicked, then

the parameter will appear under the “Parameter” tab
information without the use of the “Add” button.

Multiple parameters can be chosen if desired.

Refer to Illustration 67.
RENR7902-07 85
Systems Operation Section

g01457914
Illustration 67

3. The parameters can be viewed in the block type

group, control group, engine group, generator
group, I/O group, and the status group. Perform
the following steps in order to select a certain
group type.

a. Click on one of the choices that is shown in the

“Device/Group” field.

b. The “Parameter List” will change in order to

show only the parameters that are related to
the group that is selected.

c. Select the desired parameter(s) that are to

have the parameter data logged. Click “OK” in
order to close the configuration screen.

d. Click “OK” in order to confirm the changes

that have been made in the “Data Log
Configuration” dialog.

4. Perform the following steps in order to view the

data that has been selected.

a. Click “View” that is on the tool bar.

b. Click “Data Log Data”. A dialog will appear that

looks like Illustration 68.

Note: If the data value says that the control is “Off

Line”, be sure to go “On Line” as described in this
“Software Setup” section.
86 RENR7902-07
Systems Operation Section

g01457915
Illustration 68

c. Once the control is on line, click “Data

Configuration”.

d. Click either “Arm” or press the “Play” button

that is on the tool bar in order to begin receiving
the data.

5. If desired, the data can be logged to a file.

a. In order to log the data, navigate to the “Data

Log Configuration” dialog. Click “Edit”, then
click “Data Log Configuration”.

b. Select the “Data Storage” tab.

c. Write the desired name and the desired

location of the file into the “Log File” field (153)
or click “Browse” in order to select the name
and the location. Refer to Illustration 69.
RENR7902-07 87
Systems Operation Section

g01457916
Illustration 69

6. Select the “Triggering” tab in order to configure
when events should start and in order to configure
when events should stop.
a. In order to start an event, select “On Arm”,
“Manual Trigger” , or “Absolute Time”.
On Arm will start the data collection
immediately after “Arm” has been selected or
after clicking the “Play” button.
The text file can be opened after the data has been
collected. Locate the saved file. Open the saved
file with a text editor such as Notepad. The file will
contain a timestamp from the start of data logging.
The file will also contain data that was captured
according to the “Base Scan Rate” setting that is in
the “Data Log Configuration” dialog that is shown
in Illustration 69. The file should look similar to
Illustration 70.

Manual Trigger will begin the data collection

once the manual trigger button has been
pressed. Data collection will also begin if “Data
Configuration” and “Start Trigger” is selected.

Absolute Time will begin data collection at the

specific date and time that is specified.

b. The stop event can be configured for “Manual

Trigger”, “Duration”, or “Absolute Time”.

Manual Trigger will stop the data collection

once the manual trigger button is clicked.
Data collection will also stop if the “Data
Configuration” and “Stop Trigger” commands
are used.

Duration will stop collecting data as soon as

the specified amount of time has passed.

Absolute Time will stop the data collection

once the specified date and time has been met.
88 RENR7902-07
Systems Operation Section

g01457917
Illustration 70
RENR7902-07 89
Troubleshooting Section

Troubleshooting Section
Do not connect generator to a utility electrical dis-
Introduction tribution system unless it is isolated from the sys-
tem. Electrical feedback into the distribution sys-
tem can occur and could cause personal injury or
i02464576 death.

General Information Open and secure main distribution system switch,

or if the connection is permanent, install a double
SMCS Code: 4490 throw transfer switch to prevent electrical feed-
back. Some generators are specifically approved
by a utility to run in parallel with the distribution
system and isolation may not be required. Always
Personal injury or death can result from high volt- check with your utility as to the applicable circum-
age. stances.

When power generation equipment must be in op-

eration to make tests and/or adjustments, high
voltage and current are present.

Improper test equipment can fail and present a

high voltage shock hazard to its user.

Make sure the testing equipment is designed for

and correctly operated for high voltage and cur-
rent tests being made.

When servicing or repairing electric power gener-

ation equipment:
g00891948
• Make sure the unit is off-line (disconnected Illustration 71
from utility and/or other generators power Danger Label for Electrical Shock (North America)
service) , and either locked out or tagged DO
NOT OPERATE.

• Remove all fuses.

• Make sure the generator engine is stopped.
• Make sure all batteries are disconnected.
• Make sure all capacitors are discharged.
Failure to do so could result in personal injury or
death. Make sure residual voltage in the rotor, sta-
tor and the generator is discharged.
g00874165
Illustration 72
Danger Label for Electrical Shock (Outside of North America)

When the engine-generator, or any source to

which the engine-generator is synchronized to, is
operating, voltages up to 600V are present in the
control panel.

Do not short these terminal with line voltage to

ground with any part of the body or any conduc-
tive material. Loss of life or injury could result
from electrical shock or injury from molten met-
al.
90 RENR7902-07
Troubleshooting Section

i02464702

The Cat VR6 presents an electrical shock/electro-

Service Tools
cution hazard. This hazard will cause serious in- SMCS Code: 0785
jury or death.
Table 32
Service by trained personnel only.
Genset Diagnostic Tools
The terminals and heat sinks are live at hazardous 190-8900 Deutsch HD Style Connector
voltages when power is applied and for up to 8 Repair Kit.
minutes after power is removed. Replaces 4C-3406 Repair Kit
and does not contain 1U5804
Crimp Tool that can be ordered
separately if needed.
6V-3000 Sure Seal Repair Kit
The Cat Digital Voltage Regulator presents an
electrical shock/electrocution hazard. This hazard 175-3700 Deutsch DT Style Connector
will cause serious injury or death. Repair Kit.
4 mm Hex Wrench
Service by trained personnel only.
237-5130 Digital Multimeter with infrared
The terminals and heat sinks are live at hazardous thermometer
voltages when power is applied and for up to 8 257-9140 Fluke 80 Series Digital Multimeter
minutes after power is removed.
146-4080 Digital Multimeter with RS232
output
7X-1710 Multimeter Connector Probe
Group
The secondary wires of the current transformer
must be shorted together when they are discon- 155-5175 1000 Amp AC Current Probe for
nected from the equipment. Extremely high volt- use with digital multimeters
ages will be generated at the lead ends if the sec- 155-5176 1000 Amp AC / 1400 Amp DC
ondary wires are not shorted together. Bodily con- Current Probe for use with digital
tact with high voltage will result in serious injury multimeters
or death.
243-3134 Insulation Tester
255-8266 1200 Amp AC/DC Clamp On
Ammeter
227-4324 2000 Amp AC/DC clamp On
Ammeter
RENR7902-07 91
Troubleshooting Section

i02461489 • Print reports.

Diagnostic Capabilities The following list contains some of the diagnostic
functions and programming functions that are
SMCS Code: 1400 performed by the service tools.

The Caterpillar Electronic • The failures of the ECM system are displayed.
Technician • The status of most of the inputs and the outputs
are displayed.

• The settings for the ECM are displayed.

• Display the status of the input and output
parameters in real time.

• Display the clock hour of the internal diagnostic

clock.

• The number of occurrences and the clock hour

of the first occurrence and the last occurrence is
displayed for each logged diagnostic code.

• The definition for each logged diagnostic code and

each event is displayed.

• Load new FLASH software.

g00774942
Illustration 73
Connections for the Communication Adapter II and the Caterpillar
Electronic Technician
The components that are needed in order to use the
Communication Adapter II and the Caterpillar Electronic Technician
in order to determine diagnostic codes are listed:
(6) Cable
(7) 171-4400 Communication Adapter ii
(8) Service diagnostic cable.
(9) Current version of Caterpillar Electronic Technician software
and an IBM-COMPATIBLE personal computer
The Caterpillar Electronic Technician is a software
program that is used as a service tool in order to
access data. The service technician can use this
service tool in order to perform maintenance on the
machine. Some of the options that are available with
the Caterpillar Electronic Technician are listed below:
• View diagnostic codes.
• Viewing active event codes and logged event
codes
See Troubleshooting, “Diagnostic Trouble Code List”
for the list of diagnostic codes for the ECM.
• Active diagnostic codes
• Logged diagnostic codes
Event Codes
Logged Event Codes
An indicator for logged events is provided. The
indicator allows the service technician to keep track
of event codes that are intermittent. The data for the
logged event will include the following information:
• An event identifier
• A text description of the problem
• The number of occurrences of the problem
• A time stamp will display the first occurrence of the
problem.

• View the status of parameters.
• Clear active diagnostic codes and clear logged
diagnostic codes
• Program the ECM (Flash). This is done with the
“WINflash” program. See Testing and Adjusting,
“Electronic Control Module (Generator Set) - Flash
Program”.
• A time stamp will display the last occurrence of the
problem.
Status Groups For The Caterpillar
Electronic Technician
The Status Groups are lists of ECM parameters. The
status of the parameters are shown in real time.
92 RENR7902-07
Troubleshooting Section

i03206911

Diagnostic Trouble Code List

SMCS Code: 7569

Reference: For a full explanation of the use of the

enter function key that is referenced in this section,
refer to the Systems Operation, “Electronic Control
Module (Generator Set)” section of this publication.

Table 33 lists the diagnostic trouble codes for the

genset. The column titled “Display Text String” is the
information that is displayed on the EMCP 3 control
panel. In order to view the “Suspect Parameter
Number” (SPN) and the “Failure Mode Identifier”
(FMI), press the “Enter” key while viewing the
“Display Text String”.

If the diagnostic code was generated from the

“Electronic Control Module” (ECM) for the engine,
refer to the Systems Operation, Testing and Adjusting
manual for the particular engine. Perform the
diagnostic procedure as indicated by the SPN and
FMI information.

If the diagnostic code is generated from the EMCP 3

ECM for the generator set, then refer to Table 33 and
refer to the information that is in the “Troubleshooting
Topic” column.

Note: The “Emergency Shutdown Override Mode

Active Warning” requires a level 3 password in order
to clear the code. All remaining listed codes require a
level 1 password in order to clear the code.

Table 33

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
38 0 External Tank High Fuel EXT TANK HIGH Digital Input Circuit
Level Shutdown FUEL LEVEL Fault and Analog Input
SHUTDOWN Circuit Fault
38 1 External Tank Low Fuel EXT TANK LOW Digital Input Circuit
Level Shutdown FUEL LEVEL Fault and Analog Input
SHUTDOWN Circuit Fault
38 3 External Tank Fuel Level EXT TANK FUEL Analog Input Circuit
Sensor Short High LEVEL SENSOR Fault
SHORT HIGH
38 4 External Tank Fuel Level EXT TANK FUEL Analog Input Circuit
Sensor Short Low LEVEL SENSOR Fault
SHORT LOW
38 15 External Tank High Fuel EXT TANK Digital Input Circuit
Level Warning HIGH FUEL LVL Fault and Analog Input
WARNING Circuit Fault
38 17 External Tank Low Fuel EXT TANK Digital Input Circuit
Level Warning LOW FUEL LVL Fault and Analog Input
WARNING Circuit Fault
(continued)
RENR7902-07 93
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
82 0 High Starting Air HIGH STARTING Digital Input Circuit
Pressure Shutdown AIR PRES Fault and Analog Input
SHUTDOWN Circuit Fault
82 1 Low Starting Air LOW STARTING Digital Input Circuit
Pressure Shutdown AIR PRES Fault and Analog Input
SHUTDOWN Circuit Fault
82 3 Starting Air Pressure STARTING AIR Analog Input Circuit
Sensor Short High PRES SENSOR Fault
SHORT HIGH
82 4 Starting Air Pressure STARTING AIR Analog Input Circuit
Sensor Short Low PRES SENSOR Fault
SHORT LOW
82 15 High Starting Air HIGH STARTING Digital Input Circuit
Pressure Warning AIR PRES Fault and Analog Input
WARNING Circuit Fault
82 17 Low Starting Air LOW STARTING Digital Input Circuit
Pressure Warning AIR PRES Fault and Analog Input
WARNING Circuit Fault
95 0 High Fuel Filter HIGH FUEL Digital Input Circuit
Differential Pressure FLTR DIFF PRES Fault and Analog Input
Shutdown SHUTDOWN Circuit Fault
95 1 Low Fuel Filter LOW FUEL FILTER Digital Input Circuit
Differential Pressure DIFF PRES Fault and Analog Input
Shutdown SHUTDOWN Circuit Fault
95 3 Fuel Filter Differential FUEL FLTER DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
High SHORT HIGH
95 4 Fuel Filter Differential FUEL FLTR DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
Low SHORT LOW
95 15 High Fuel Filter HIGH FUEL Digital Input Circuit
Differential Pressure FLTR DIFF PRES Fault and Analog Input
Warning WARNING Circuit Fault
95 17 Low Fuel Filter LOW FUEL FILTER Digital Input Circuit
Differential Pressure DIFF PRES Fault and Analog Input
Warning WARNING Circuit Fault
96 0 High Fuel Level HIGH FUEL LEVEL Digital Input Circuit
Shutdown SHUTDOWN Fault and Analog Input
Circuit Fault
96 1 Low Fuel Level LOW FUEL LEVEL Digital Input Circuit
Shutdown SHUTDOWN Fault and Analog Input
Circuit Fault
96 3 Fuel Level Sensor Short FUEL LEVEL Analog Input Circuit
High SENSOR SHORT Fault
HIGH
96 4 Fuel Level Sensor Short FUEL LEVEL Analog Input Circuit
Low SENSOR SHORT Fault
LOW
96 15 High Fuel Level Warning HIGH FUEL LEVEL Digital Input Circuit
WARNING Fault and Analog Input
Circuit Fault
(continued)
94 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
96 17 Low Fuel Level Warning LOW FUEL LEVEL Digital Input Circuit
WARNING Fault and Analog Input
Circuit Fault
98 0 High Engine Oil Level HIGH ENGINE OIL Digital Input Circuit
Shutdown LVL SHUTDOWN Fault and Analog Input
Circuit Fault
98 1 Low Engine Oil Level LOW ENGINE OIL Digital Input Circuit
Shutdown LVL SHUTDOWN Fault and Analog Input
Circuit Fault
98 3 Engine Oil Level Sensor ENGINE OIL Analog Input Circuit
Short High LEVEL SENSOR Fault
SHORT HIGH
98 4 Engine Oil Level Sensor ENGINE OIL Analog Input Circuit
Short Low LEVEL SENSOR Fault
SHORT LOW
98 15 High Engine Oil Level HIGH ENGINE OIL Digital Input Circuit
Warning LVL WARNING Fault and Analog Input
Circuit Fault
98 17 Low Engine Oil Level LOW ENGINE OIL Digital Input Circuit
Warning LVL WARNING Fault and Analog Input
Circuit Fault
99 0 High Oil Filter Differential HIGH OIL FILTER Digital Input Circuit
Pressure Shutdown DIFF PRES Fault and Analog Input
SHUTDOWN Circuit Fault
99 1 Low Oil Filter Differential LOW OIL FILTER Digital Input Circuit
Pressure Shutdown DIFF PRES Fault and Analog Input
SHUTDOWN Circuit Fault
99 3 Oil Filter Differential OIL FILTER DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
High SHORT HIGH
99 4 Oil Filter Differential OIL FILTER DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
Low SHORT LOW
99 15 High Oil Filter Differential HIGH OIL FILTER Digital Input Circuit
Pressure Warning DIFF PRES Fault and Analog Input
WARNING Circuit Fault
99 17 Low Oil Filter Differential LOW OIL FILTER Digital Input Circuit
Pressure Warning DIFF PRES Fault and Analog Input
WARNING Circuit Fault
100 1 Low Engine Oil Pressure LOW ENGINE Data Link circuit Fault
Shutdown OIL PRESS and Digital Input Circuit
SHUTDOWN Fault
100 3 Engine Oil Pressure ENG OIL PRES
Sensor Short High SENSOR SHORT
HIGH
100 4 Engine Oil Pressure ENG OIL PRES
Sensor Short Low SENSOR SHORT
LOW
100 17 Low Engine Oil Pressure LOW ENGINE OIL Data Link circuit Fault
Warning PRESS WARNING and Digital Input Circuit
Fault
(continued)
RENR7902-07 95
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
107 0 High Air Filter Differential HIGH AIR FILTER Digital Input Circuit
Pressure Shutdown DIFF PRES Fault and Analog Input
SHUTDOWN Circuit Fault
107 1 Low Air Filter Differential LOW AIR FILTER Digital Input Circuit
Pressure Shutdown DIFF PRES Fault and Analog Input
SHUTDOWN Circuit Fault
107 3 Air Filter Differential AIR FILTER DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
High SHORT HIGH
107 4 Air Filter Differential AIR FILTER DIFF Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
Low SHORT LOW
107 15 High Air Filter Differential HIGH AIR FILTER Digital Input Circuit
Pressure Warning DIFF PRES Fault and Analog Input
WARNING Circuit Fault
107 17 Low Air Filter Differential LOW AIR FILTER Digital Input Circuit
Pressure Warning DIFF PRES Fault and Analog Input
WARNING Circuit Fault
110 0 High Engine Coolant HIGH ENGINE Data Link Circuit Fault
Temperature Shutdown COOLANT TEMP and Digital Input Circuit
SHUTDOWN Fault
110 3 Engine Coolant ENG COOLANT
Temperature Sensor TEMP SENSOR
Short High SHORT HI
110 4 Engine Coolant ENG COOLANT
Temperature Sensor TEMP SENSOR
Short Low SHORT LO
110 15 High Engine Coolant HIGH ENGINE Data Link Circuit Fault
Temperature Warning COOLANT TEMP and Digital Input Circuit
WARNING Fault
110 17 Low Engine Coolant LOW COOLANT Data Link Circuit Fault
Temperature Warning TEMP WARNING and Digital Input Circuit
Fault
111 0 High Engine Coolant HIGH ENG Digital Input Circuit
Level Shutdown COOL LEVEL Fault and Analog Input
SHUTDOWN Circuit Fault
111 1 Low Engine Coolant LOW ENG Digital Input Circuit
Level Shutdown COOL LEVEL Fault and Analog Input
SHUTDOWN Circuit Fault
111 3 Engine Coolant Level ENGINE Analog Input Circuit
Sensor Short High COOLANT LEVEL Fault
SENSOR SHORT
HIGH
111 4 Engine Coolant Level ENGINE Analog Input Circuit
Sensor Short Low COOLANT LEVEL Fault
SENSOR SHORT
LOW
111 15 High Engine Coolant HIGH ENG COOL Digital Input Circuit
Level Warning LEVEL WARNING Fault and Analog Input
Circuit Fault
(continued)
96 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
111 17 Low Engine Coolant LOW ENG COOL Digital Input Circuit
Level Warning LEVEL WARNING Fault and Analog Input
Circuit Fault
137 0 High Fire Extinguisher HIGH FIRE Digital Input Circuit
Pressure Shutdown EXTNG PRES Fault and Analog Input
SHUTDOWN Circuit Fault
137 1 Low Fire Extinguisher LOW FIRE Digital Input Circuit
Pressure Shutdown EXTNG PRES Fault and Analog Input
SHUTDOWN Circuit Fault
137 3 Fire Extinguisher FIRE EXTING Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
High SHORT HIGH
137 4 Fire Extinguisher FIRE EXTNG Analog Input Circuit
Pressure Sensor Short PRES SENSOR Fault
Low SHORT LOW
137 15 High Fire Extinguisher HIGH FIRE EXTNG Digital Input Circuit
Pressure Warning PRES WARNING Fault and Analog Input
Circuit Fault
137 17 Low Fire Extinguisher LOW FIRE EXTNG Digital Input Circuit
Pressure Warning PRES WARNING Fault and Analog Input
Circuit Fault
167 17 Low Battery Charging LOW BATTERY Charging System
System Voltage Warning CHARGING SYS
VOLT WARN
168 0 High Battery Voltage HIGH BATTERY Charging System
Shutdown VOLTAGE
SHUTDOWN
168 15 High Battery Voltage HIGH BATTERY Charging System
Warning VOLTAGE
WARNING
168 17 Low Battery Voltage LOW BATTERY Charging System
Warning VOLTAGE
WARNING
171 0 High Ambient Air HIGH AMBIENT Digital Input Circuit
Temperature Shutdown AIR TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
171 1 Low Ambient Air LOW AMBIENT Digital Input Circuit
Temperature Shutdown AIR TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
171 3 Ambient Air Temperature AMBIENT AIR Analog Input Circuit
Sensor Short High TEMP SENSOR Fault
SHORT HIGH
171 4 Ambient Air Temperature AMBIENT AIR Analog Input Circuit
Sensor Short Low TEMP SENSOR Fault
SHORT LOW
171 15 High Ambient Air HIGH AMBIENT Digital Input Circuit
Temperature Warning AIR TEMP Fault and Analog Input
WARNING Circuit Fault
171 17 Low Ambient Air LOW AMBIENT Digital Input Circuit
Temperature Warning AIR TEMP Fault and Analog Input
WARNING Circuit Fault
(continued)
RENR7902-07 97
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
173 0 High Exhaust HIGH EXHAUST Digital Input Circuit
Temperature Shutdown TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
173 1 Low Exhaust LOW EXHAUST Digital Input Circuit
Temperature Shutdown TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
173 3 Exhaust Temperature EXHAUST Analog Input Circuit
Sensor Short High TEMPERATURE Fault
SENSOR SHORT
HIGH
173 4 Exhaust Temperature EXHAUST Analog Input Circuit
Sensor Short Low TEMPERATURE Fault
SENSOR SHORT
LOW
173 8 Exhaust Temperature EXHAUST
Signal Abnormal TEMP SIGNAL
ABNORMAL
173 15 High Exhaust HIGH EXHAUST Digital Input Circuit
Temperature Warning TEMP WARNING Fault and Analog Input
Circuit Fault
173 17 Low Exhaust LOW EXHAUST Digital Input Circuit
Temperature Warning TEMP WARNING Fault and Analog Input
Circuit Fault
175 0 High Engine Oil HIGH ENGINE Digital Input Circuit
Temperature Shutdown OIL TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
175 1 Low Engine Oil LOW ENGINE Digital Input Circuit
Temperature Shutdown OIL TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
175 3 Engine Oil Temperature ENGINE OIL TEMP Analog Input Circuit
Sensor Short High SENSOR SHORT Fault
HIGH
175 4 Engine Oil Temperature ENGINE OIL TEMP Analog Input Circuit
Sensor Short Low SENSOR SHORT Fault
LOW
175 15 High Engine Oil HIGH ENGINE OIL Digital Input Circuit
Temperature Warning TEMP WARNING Fault and Analog Input
Circuit Fault
175 17 Low Engine Oil LOW ENGINE OIL Digital Input Circuit
Temperature Warning TEMP WARNING Fault and Analog Input
Circuit Fault
190 0 Engine Over Speed ENGINE Engine Over Speed
Shutdown OVER SPEED Warning
SHUTDOWN
190 1 Engine Under Speed ENGINE Engine Under Speed
Shutdown UNDER SPEED Warning
SHUTDOWN
190 2 Engine Speed Sensor ENGINE SPEED Engine Speed Circuit
Erratic or Not Present SENSOR Fault
ERRATIC/LOST
190 5 Engine Speed Sensor ENGINE SPEED Engine Speed Circuit
Open SENSOR OPEN Fault
(continued)
98 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
190 17 Engine Under Speed ENGINE UNDER Engine Under Speed
Warning SPEED WARNING Warning
234 31 Software Version SOFTWARE
Mismatch VERSION
MISMATCH
625 11 SCADA Data Link Fault SCADA DATA LINK Data Link Circuit Fault
FAULT
639 11 Primary Data Link Fault PRIMARY DATA Data Link Circuit Fault
LINK FAULT
701 0 Custom Event #1 High CUSTOM Digital Input Circuit
Shutdown EVENT #1 HIGH Fault
SHUTDOWN
701 1 Custom Event #1 Low CUSTOM Digital Input Circuit
Shutdown EVENT #1 LOW Fault
SHUTDOWN
701 15 Custom Event #1 High CUSTOM Digital Input Circuit
Warning EVENT #1 HIGH Fault
WARNING
701 17 Custom Event #1 Low CUSTOM EVENT Digital Input Circuit
Warning #1 LOW WARNING Fault
701 31 Custom Event #1 Status CUSTOM EVENT Digital Input Circuit
#1 STATUS Fault
ACTIVE
702 0 Custom Event #2 High CUSTOM Digital Input Circuit
Shutdown EVENT #2 HIGH Fault
SHUTDOWN
702 1 Custom Event #2 Low CUSTOM Digital Input Circuit
Shutdown EVENT #2 LOW Fault
SHUTDOWN
702 15 Custom Event #2 High CUSTOM Digital Input Circuit
Warning EVENT #2 HIGH Fault
WARNING
702 17 Custom Event #2 Low CUSTOM EVENT Digital Input Circuit
Warning #2 LOW WARNING Fault
702 31 Custom Event #2 Status CUSTOM EVENT Digital Input Circuit
#2 STATUS Fault
ACTIVE
703 0 Custom Event #3 High CUSTOM Digital Input Circuit
Shutdown EVENT #3 HIGH Fault
SHUTDOWN
703 1 Custom Event #3 Low CUSTOM Digital Input Circuit
Shutdown EVENT #3 LOW Fault
SHUTDOWN
703 15 Custom Event #3 High CUSTOM Digital Input Circuit
Warning EVENT #3 HIGH Fault
WARNING
703 17 Custom Event #3 Low CUSTOM EVENT Digital Input Circuit
Warning #3 LOW WARNING Fault
(continued)
RENR7902-07 99
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
703 31 Custom Event #3 Status CUSTOM EVENT Digital Input Circuit
#3 STATUS Fault
ACTIVE
704 0 Custom Event #4 High CUSTOM Digital Input Circuit
Shutdown EVENT #4 HIGH Fault
SHUTDOWN
704 1 Custom Event #4 Low CUSTOM Digital Input Circuit
Shutdown EVENT #4 LOW Fault
SHUTDOWN
704 15 Custom Event #4 High CUSTOM Digital Input Circuit
Warning EVENT #4 HIGH Fault
WARNING
704 17 Custom Event #4 Low CUSTOM EVENT Digital Input Circuit
Warning #4 LOW WARNING Fault
704 31 Custom Event #4 Status CUSTOM EVENT Digital Input Circuit
#4 STATUS Fault
ACTIVE
705 0 Custom Event #5 High CUSTOM Digital Input Circuit
Shutdown EVENT #5 HIGH Fault
SHUTDOWN
705 1 Custom Event #5 Low CUSTOM Digital Input Circuit
Shutdown EVENT #5 LOW Fault
SHUTDOWN
705 15 Custom Event #5 High CUSTOM Digital Input Circuit
Warning EVENT #5 HIGH Fault
WARNING
705 17 Custom Event #5 Low CUSTOM EVENT Digital Input Circuit
Warning #5 LOW WARNING Fault
705 31 Custom Event #5 Status CUSTOM EVENT Digital Input Circuit
#5 STATUS Fault
ACTIVE
706 0 Custom Event #6 High CUSTOM Digital Input Circuit
Shutdown EVENT #6 HIGH Fault
SHUTDOWN
706 1 Custom Event #6 Low CUSTOM Digital Input Circuit
Shutdown EVENT #6 LOW Fault
SHUTDOWN
706 15 Custom Event #6 High CUSTOM Digital Input Circuit
Warning EVENT #6 HIGH Fault
WARNING
706 17 Custom Event #6 Low CUSTOM EVENT Digital Input Circuit
Warning #6 LOW WARNING Fault
706 31 Custom Event #6 Status CUSTOM EVENT Digital Input Circuit
#6 STATUS Fault
ACTIVE
707 0 Custom Event #7 High CUSTOM
Shutdown EVENT #7 HIGH
SHUTDOWN
707 1 Custom Event #7 Low CUSTOM
Shutdown EVENT #7 LOW
SHUTDOWN
(continued)
100 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
707 15 Custom Event #7 High CUSTOM
Warning EVENT #7 HIGH
WARNING
707 17 Custom Event #7 Low CUSTOM EVENT
Warning #7 LOW WARNING
707 31 Custom Event #7 Status CUSTOM EVENT
#7 STATUS
708 0 Custom Event #8 High CUSTOM
Shutdown EVENT #8 HIGH
SHUTDOWN
708 1 Custom Event #8 Low CUSTOM
Shutdown EVENT #8 LOW
SHUTDOWN
708 15 Custom Event #8 High CUSTOM
Warning EVENT #8 HIGH
WARNING
708 17 Custom Event #8 Low CUSTOM EVENT
Warning #8 LOW WARNING
708 31 Custom Event #8 Status CUSTOM EVENT
#8 STATUS
709 31 Custom Event #9 Status CUSTOM EVENT
#9 STATUS
710 31 Custom Event #10 CUSTOM EVENT
Status #10 STATUS
711 31 Custom Event #11 CUSTOM EVENT
Status #11 STATUS
712 31 Custom Event #12 CUSTOM EVENT
Status #12 STATUS
713 31 Custom Event #13 CUSTOM EVENT
Status #13 STATUS
714 31 Custom Event #14 CUSTOM EVENT
Status #14 STATUS
715 31 Custom Event #15 CUSTOM EVENT
Status #15 STATUS
716 31 Custom Event #16 CUSTOM EVENT
Status #16 STATUS
924 3 Digital Output #1 Short DIGITAL OUTPUT Digital Output Circuit
High 1 SHORT HIGH Fault
925 3 Digital Output #2 Short DIGITAL OUTPUT Digital Output Circuit
High 2 SHORT HIGH Fault
970 31 Emergency Stop EMERGENCY Digital Input Circuit
Shutdown STOP Fault
SHUTDOWN
1122 0 High Generator Bearing HIGH GEN Digital Input Circuit
#1 Temperature BEARING Fault and Analog Input
Shutdown #1 TEMP Circuit Fault
SHUTDOWN
(continued)
RENR7902-07 101
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
1122 1 Low Generator Rear LOW GEN REAR Digital Input Circuit
Bearing Temperature BEARING TEMP Fault and Analog Input
Shutdown SHUTDOWN Circuit Fault
1122 3 Generator Rear Bearing GEN REAR Analog Input Circuit
Temperature Sensor BEARING TEMP Fault
Short High SENSOR SHORT
HIGH
1122 4 Generator Rear Bearing GEN REAR Analog Input Circuit
Temperature Sensor BEARING TEMP Fault
Short Low SENSOR SHORT
LOW
1122 15 High Rear Generator HIGH GEN REAR Digital Input Circuit
Bearing Temperature BEARING TEMP Fault and Analog Input
Warning WARNING Circuit Fault
1122 17 Low Generator Rear LOW GEN REAR Digital Input Circuit
Bearing Temperature BEARING TEMP Fault and Analog Input
Warning WARNING Circuit Fault
1124 0 High Generator Winding HIGH GEN
#1 Temperature WINDING
Shutdown #1 TEMP
SHUTDOWN
1124 15 High Generator Winding HIGH GEN
#1 Temperature Warning WINDING #1
TEMP WARNING
1125 0 High Generator Winding HIGH GEN
#2 Temperature WINDING
Shutdown #2 TEMP
SHUTDOWN
1125 15 High Generator Winding HIGH GEN
#2 Temperature Warning WINDING #2
TEMP WARNING
1126 0 High Generator Winding HIGH GEN
#3 Temperature WINDING
Shutdown #3 TEMP
SHUTDOWN
1126 15 High Generator Winding HIGH GEN
#3 Temperature Warning WINDING #3
TEMP WARNING
1231 11 Accessory Data Link ACCESSORY Data Link Circuit Fault
Fault DATA LINK FAULT
1239 31 Fuel Tank Leak (Fuel FUEL TANK LEAK Digital Input Circuit
Rupture Basin) Fault
1383 11 Unexpected Engine UNEXPECTED
Shutdown ENGINE
SHUTDOWN
1390 0 High Gas Pressure HIGH GAS
Shutdown PRESSURE
SHUTDOWN
1390 1 Low Gas Pressure LOW GAS
Shutdown PRESSURE
SHUTDOWN
(continued)
102 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
1390 15 High Gas Pressure HIGH GAS
Warning PRESSURE
WARNING
1390 17 Low Gas Pressure LOW GAS
Warning PRESSURE
WARNING
1664 31 Engine Failure to Start ENGINE FAILURE Engine Overcrank
Shutdown TO START Warning
SHUTDOWN
2433 0 High Right Exhaust HIGH RIGHT Digital Input Circuit
Temperature Shutdown EXHAUST TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
2433 1 Low Right Exhaust LOW RIGHT Digital Input Circuit
Temperature Shutdown EXHAUST TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
2433 3 Right Exhaust RIGHT EXHAUST Analog Input Circuit
Temperature Sensor TEMP SENSOR Fault
Short High SHORT HIGH
2433 4 Right Exhaust RIGHT EXHAUST Analog Input Circuit
Temperature Sensor TEMP SENSOR Fault
Short Low SHORT LOW
2433 8 Right Exhaust RIGHT EXHAUST
Temperature Signal TEMP SGNL
Abnormal ABNORMAL
2433 15 High Right Exhaust HIGH RIGHT Digital Input Circuit
Temperature Warning EXHAUST TEMP Fault and Analog Input
WARNING Circuit Fault
2434 8 Left Exhaust LEFT EXHAUST
Temperature Signal TEMP SGNL
Abnormal ABNORMAL
2433 17 Low Right Exhaust LOW RIGHT Digital Input Circuit
Temperature Warning EXHAUST TEMP Fault and Analog Input
WARNING Circuit Fault
2434 0 High Left Exhaust HIGH LEFT Digital Input Circuit
Temperature Shutdown EXHAUST TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
2434 1 Low Left Exhaust LOW LEFT Digital Input Circuit
Temperature Shutdown EXHAUST TEMP Fault and Analog Input
SHUTDOWN Circuit Fault
2434 3 Left Exhaust LEFT EXHAUST Analog Input Circuit
Temperature Sensor TEMP SENSOR Fault
Short High SHORT HIGH
2434 4 Left Exhaust LEFT EXHAUST Analog Input Circuit
Temperature Sensor TEMP SENSOR Fault
Short Low SHORT LOW
2434 15 High Left Exhaust HIGH LEFT Digital Input Circuit
Temperature Warning EXHAUST TEMP Fault and Analog Input
WARNING Circuit Fault
2434 17 Low Left Exhaust LOW LEFT Digital Input Circuit
Temperature Warning EXHAUST TEMP Fault and Analog Input
WARNING Circuit Fault
(continued)
RENR7902-07 103
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
2436 0 Generator Over GEN OVER Generator Over
Frequency Shutdown FREQUENCY Frequency Warning
SHUTDOWN
2436 1 Generator Under GEN UNDER Generator Under
Frequency Shutdown FREQUENCY Frequency Warning
SHUTDOWN
2436 2 Engine Speed- ENG SPEED-GEN Engine Speed Warning
Generator Output FREQ MISMATCH
Frequency Mismatch WARN
Warning
2436 12 Generator Output GEN AC Generator Output
Sensing System Failure METERING SYS Sensing Circuit Fault
FAILURE
2436 15 Generator Over GEN OVER Generator Over
Frequency Warning FREQUENCY Frequency Warning
WARNING
2436 17 Generator Under GEN UNDER Generator Under
Frequency Warning FREQUENCY Frequency Warning
WARNING
2440 0 Generator Over Voltage GEN OVER Generator Over Voltage
Shutdown VOLTAGE Warning
SHUTDOWN
2440 1 Generator Under Voltage GEN UNDER Generator Under
Shutdown VOLTAGE Voltage Warning
SHUTDOWN
2440 15 Generator Over Voltage GEN OVER Generator Over Voltage
Warning VOLTAGE Warning
WARNING
2440 17 Generator Under Voltage GEN UNDER Generator Under
Warning VOLTAGE Voltage Warning
WARNING
2448 0 Generator Over Current GEN OVER Generator Over Current
Shutdown CURRENT Warning
SHUTDOWN
2448 15 Generator Over Current GEN OVER Generator Over Current
Warning CURRENT Warning
WARNING
2452 1 Generator Reverse GEN REVERSE Generator Reverse
Power Shutdown POWER Power Warning
SHUTDOWN
2452 15 Generator High Power GENERATOR
Warning HIGH POWER
WARNING
2452 17 Generator Reverse GEN REVERSE Generator Reverse
Power Warning POWER Power Warning
WARNING
2648 31 Service Maintenance SERV MAINT Service Maintenance
Interval Warning INTERVAL Interval Warning
WARNING
(continued)
104 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
3543 9 Engine Controller Not ENG
Responding CONTROLLER
NOT
RESPONDING
3546 11 Utility Breaker System UTILITY BREAKER
Fault SYSTEM FAULT
3783 31 Engine Inlet Manifold ENGINE INLET
Charge Combustion MANIFOLD CHRG
COMBUSTION
3829 31 EPS Supplying Load EPS SUPPLYING
LOAD
3880 31 Custom Event #17 CUSTOM EVENT
Status #17 STATUS
3881 31 Custom Event #18 CUSTOM EVENT
Status #18 STATUS
3882 31 Custom Event #19 CUSTOM EVENT
Status #19 STATUS
3883 31 Custom Event #20 CUSTOM EVENT
Status #20 STATUS
3888 31 Custom Event #21 CUSTOM EVENT
Status #21 STATUS
3889 31 Custom Event #22 CUSTOM EVENT
Status #22 STATUS
3890 31 Custom Event #23 CUSTOM EVENT
Status #23 STATUS
3891 31 Custom Event #24 CUSTOM EVENT
Status #24 STATUS
3892 31 Custom Event #25 CUSTOM EVENT
Status #25 STATUS
3893 31 Custom Event #26 CUSTOM EVENT
Status #26 STATUS
3894 31 Custom Event #27 CUSTOM EVENT
Status #27 STATUS
3895 31 Custom Event #28 CUSTOM EVENT
Status #28 STATUS
3896 31 Custom Event #29 CUSTOM EVENT
Status #29 STATUS
3897 31 Custom Event #30 CUSTOM EVENT
Status #30 STATUS
3898 31 Custom Event #31 CUSTOM EVENT
Status #31 STATUS
3899 31 Custom Event #32 CUSTOM EVENT
Status #32 STATUS
3904 31 Custom Event #33 CUSTOM EVENT
Status #33 STATUS
3905 31 Custom Event #34 CUSTOM EVENT
Status #34 STATUS
(continued)
RENR7902-07 105
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
3906 31 Custom Event #35 CUSTOM EVENT
Status #35 STATUS
3907 31 Custom Event #36 CUSTOM EVENT
Status #36 STATUS
3908 31 Custom Event #37 CUSTOM EVENT
Status #37 STATUS
3909 31 Custom Event #38 CUSTOM EVENT
Status #38 STATUS
3910 31 Custom Event #39 CUSTOM EVENT
Status #39 STATUS
3911 31 Custom Event #40 CUSTOM EVENT
Status #40 STATUS
3912 31 Custom Event #41 CUSTOM EVENT
Status #41 STATUS
3913 31 Custom Event #42 CUSTOM EVENT
Status #42 STATUS
3914 31 Custom Event #43 CUSTOM EVENT
Status #43 STATUS
3915 31 Custom Event #44 CUSTOM EVENT
Status #44 STATUS
3920 31 Custom Event #45 CUSTOM EVENT
Status #45 STATUS
3921 31 Custom Event #46 CUSTOM EVENT
Status #46 STATUS
3922 31 Custom Event #47 CUSTOM EVENT
Status #47 STATUS
3923 31 Custom Event #48 CUSTOM EVENT
Status #48 STATUS
3924 31 Custom Event #49 CUSTOM EVENT
Status #49 STATUS
3925 31 Custom Event #50 CUSTOM EVENT
Status #50 STATUS
3926 31 Custom Event #51 CUSTOM EVENT
Status #51 STATUS
3927 31 Custom Event #52 CUSTOM EVENT
Status #52 STATUS
3928 31 Custom Event #53 CUSTOM EVENT
Status #53 STATUS
3929 31 Custom Event #54 CUSTOM EVENT
Status #54 STATUS
3930 31 Custom Event #55 CUSTOM EVENT
Status #55 STATUS
3931 31 Custom Event #56 CUSTOM EVENT
Status #56 STATUS
4000 31 Air Damper Closed AIR DAMPER Digital Input Circuit
CLOSED Fault
(continued)
106 RENR7902-07
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
4001 31 ATS in Normal Position ATS IN NORMAL Digital Input Circuit
POSITION Fault
4002 31 ATS in Emergency ATS IN Digital Input Circuit
Position EMERGENCY Fault
POSITION
4003 31 Battery Charger Failure BATTERY Digital Input Circuit
CHARGER Fault
FAILURE
4004 31 Generator Circuit GENERATOR Digital Input Circuit
Breaker Closed BREAKER Fault
CLOSED
4005 31 Utility Circuit Breaker UTILITY BREAKER Digital Input Circuit
Closed CLOSED Fault
4006 31 Engine in Cooldown ENGINE IN Engine Cooldown
COOLDOWN Warning
4007 31 Generator Control Not in GEN CONTROL Generator Control Not
Automatic Warning NOT IN AUTO In Automatic Warning
WARNING
4009 31 Generator Breaker GENERATOR
Failure to Open BREAKER
FAILURE TO
OPEN
4010 31 Utility Breaker Failure to UTILITY BREAKER
Open FAILURE TO
OPEN
4011 31 Generator Breaker GENERATOR
Failure to Close BREAKER
FAILURE TO
CLOSE
4012 31 Utility Breaker Failure to UTILITY BREAKER
Close FAILURE TO
CLOSE
4013 31 Generator Circuit GENERATOR
Breaker Open BREAKER OPEN
4014 31 Utility Breaker Open UTILITY BREAKER
OPEN
4015 0 Utility to Generator UTIL TO GEN
Transfer Failure TRANSFER
Shutdown FAILURE
SHUTDOWN
4015 15 Utility to Generator UTIL TO GEN
Transfer Failure Warning TRANSFER
FAILURE
WARNING
4016 15 Generator to Utility GEN TO UTIL
Transfer Failure Warning TRANSFER
FAILURE
WARNING
4017 31 Loss of Utility LOSS OF UTILITY
(continued)
RENR7902-07 107
Troubleshooting Section

(Table 33, contd)

Trouble Codes
Suspect Parameter Failure Mode Code Description Display Text Troubleshooting
Number (SPN) Identifier (FMI) String Topic
4018 31 Generator Breaker GENERATOR
Locked Out BREAKER
LOCKED OUT
4019 31 Utility Breaker Locked UTILITY BREAKER
Out LOCKED OUT
4028 31 Earth Fault EARTH FAULT
4029 31 Earth Leakage EARTH LEAKAGE
4256 17 Low Battery Cranking LOW BATT
Voltage Warning CRANKING
VOLTAGE WARN
108
Troubleshooting Section
Diagnostic System
Procedures
i02461490
Engine Cooldown Warning
SMCS Code: 4490
System Operation Description:
The following conditions cause the engine to enter a
stop mode
• Loss of a remote initiate signal
• Activation of the stop signal input
• A data link message calling for a engine shutdown
If the engine is running, the engine will continue to run
in cooldown. When the cooldown interval is complete,
the engine will stop. An immediate shutdown due to
a critical fault will cause the engine to shutdown and
the Cooldown Timer to be bypassed.
Reference: For more information on setting the
cooldown duration setpoint, see Testing and
Adjusting, “Electronic Control Module (Generator
Set) - Configure”,
Conditions Which Generate This Code:
The code for the engine cooldown is generated when
the EMCP 3 determines that an engine cooldown is
in progress. The engine will continue to run until the
cooldown duration time has expired.
Talk to the Operator
Note: No repair to the engine is necessary.
A. Determine the conditions that caused the
diagnostic code.
Expected Result:
A shutdown was initiated by the operator or by the
software that caused the engine to enter into the
cooldown mode.
Results:
• OK – STOP.
RENR7902-07
i02461491
Engine Overcrank Warning
SMCS Code: 4490
System Operation Description:
The crank cycle and the number of crank cycles
are programmable. The crank cycle is the amount
of time for engagement of the starting motor. This
also includes the amount of time for cooling of the
starting motor between crank cycles. If the engine
does not start within the number of crank cycles that
are programmed, “ENGINE FAILURE TO START
SHUTDOWN ” will be displayed on the EMCP 3 in
order to inform the operator of an overcrank condition.
Note: Refer to the engine Troubleshooting
manual for more information on engine starting
and engine cranking for your particular genset.
Conditions Which Generate This Code:
The code for the engine overcrank is generated when
the EMCP 3 determines that an engine overcrank
condition has occurred.
Test Step 1. PERFORM THE INITIAL
CHECK.
A. Check for active diagnostic codes on the engine
ECM and the EMCP 3. If any codes are present,
correct the diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active.
Results:
• OK – No other diagnostic codes or indicators are
active. Proceed to Test Step 2
• NOT OK – Another diagnostic code is active or an
indicator is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Resume normal operation
and verify that the problem has been corrected.
STOP.
Test Step 2. CHECK THE SETPOINTS.
A. View the setpoints (Crank Duration, Crank
Cycle Rest Interval, and Maximum Number of
Crank Cycles). Make a note of the setpoints.
See Testing and Adjusting, “Electronic Control
Module (Generator Set) - Configure”. Compare
the setpoints against the default setpoints of the
particular generator set.
RENR7902-07
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to Test Step 3 for MUI engines.
Proceed to Test step 4 for EUI engines.
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. Inspect the 2301A Governor
Power Source and Wiring. (MUI Engines
Only)
Refer to the Genset Electrical System Schematic in
the Service Manual for an accurate representation of
the genset that is being serviced.
A. Verify the Emergency Stop Push Button is not
pressed
B. Verify pin 58 on the EMCP 3 is connected through
a normally open contact on the emergency stop
switch to battery positive.
C. Verify the Fuel Control Relay Output on pin 38
of the EMCP 3 is connected to terminal 2 on the
2301A Governor and verify the in line fuse is not
open.
D. Verify terminal 1 on the 2301A is connected to
battery negative.
Expected Result:
The 2301A Governor power Source and wiring are
correct.
Results:
• OK – The wiring is correct. The EMCP 3 may have
failed.
Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
again. If the failure is not found, replace the EMCP
3.
STOP.
• NOT OK – The wiring is not correct.
109
Troubleshooting Section
Repair: Repair the wiring or replace the wiring.
Reset the genset. Resume normal operation and
verify that the problem has been corrected.
STOP.
Test Step 4. Check communications
between EMCP 3 and Engine ECM. (EUI
Engines Only)
A. Use the Caterpillar Electronic Technician in order
to verify that the fuel enable input on the Engine
ECM is configured for “CAN Input”.
B. Refer to the Genset Electrical System Schematic
in the Service Manual and check the Data Link
wiring between the EMCP and the Engine ECM.
See Troubleshooting, “Data Link Circuit Fault”
Results:
• OK – The Data Link wiring is correct. The EMCP
3 may have failed.
Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
again. If the failure is not found, replace the EMCP
3.
STOP.
• NOT OK – The wiring is not correct.
Repair: Repair the wiring or replace the wiring.
Reset the genset. Resume normal operation and
verify that the problem has been corrected.
STOP.
i02463431
Engine Speed Warning
SMCS Code: 4490
System Operation Description:
The EMCP 3 determines the engine speed, in
rpm, from the magnetic pickup. The input from
the magnetic pickup will be a frequency that is
proportional to the engine speed and to the number
of flywheel teeth. The EMCP 3 will convert the
frequency of the engine speed sensor input into rpm
based on the flywheel teeth setpoint value.
The relationship between engine speed and
generator frequency can be computed based on
the number of generator poles. If the engine speed
does not correspond to the generator frequency,
ENG SPEED-GEN FREQ MISMATCH WARN will be
displayed on the EMCP 3. This message informs the
the operator of the mismatch condition.
110
Troubleshooting Section
Note: Refer to the engine Troubleshooting manual
for more information regarding engine speed for
your particular genset.
Conditions Which Generate This Code:
This code is generated when engine speed and
frequency values mismatch by more than 10% for
more than 10 seconds, If the setpoint for number of
generator poles is set to a value of 0 poles, then this
condition is not tested
Test Step 1. PERFORM THE INITIAL
CHECK.
A. Check for active diagnostic codes on the engine
ECM and the EMCP 3. If any codes are present,
correct the diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active.
Results:
• OK – No other diagnostic codes or indicators are
active. Proceed to Test Step 2
• NOT OK – Another diagnostic code is active or an
indicator is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Resume normal operation
and verify that the problem has been corrected.
STOP.
Test Step 2. CHECK THE SETPOINTS.
A. View the setpoints (number of generator poles)
and (flywheel teeth). Make a note of the setpoints.
See Testing and Adjusting, “Electronic Control
Module (Generator Set) - Configure”. Compare
the setpoints against the default setpoints of the
particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The setpoints are NOT correct.
RENR7902-07
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
i02461492
Engine Overspeed Warning
SMCS Code: 4490
System Operation Description:
If the engine speed rises above the Engine
Overspeed Threshold setpoint value, the Engine
Overspeed event is made active.
If a overspeed condition is detected, “ENGINE
OVERSPEED SHUTDOWN” will be displayed on
the EMCP 3 in order to inform the operator of
an overspeed condition. The Engine Overspeed
Shutdown will always be a hard shutdown and may
not be disabled.
Conditions Which Generate This Code:
The code for engine overspeed is generated when
the EMCP 3 determines that an engine overspeed
condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
overspeed condition.
Expected Result:
A overspeed was caused by a occurrence known to
the operator and the operator would like to put the
genset back into service.
Results:
• OK – The operator can determine the cause for
the overspeed condition, the condition has been
repaired and the operator wants to put the genset
back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The overspeed condition was not
caused by a occurrence known to the operator.
Proceed to Test Step 2
RENR7902-07
Test Step 2. CHECK THE SETPOINTS.
A. View the Engine Speed Monitor and Generator
Desired Engine Speed Request setpoints. Make a
note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3 for EUI engines.
Proceed to test step 4 for MUI engines
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. VERIFY ENGINE SPEED CAN
BE VIEWED AND ADJUSTED FROM THE
EMCP 3 (EUI ENGINES ONLY)
Verify the engine speed can be viewed and adjusted
from the EMCP 3 Display Screen.
Expected Result:
The engine speed can be viewed and adjusted from
the EMCP 3 Display Screen.
Results:
• OK – The engine speed can be viewed and
adjusted from the EMCP 3 Display Screen.
Repair: Adjust the engine speed to meet site
requirements. Resume normal operation and verify
that the problem has been corrected.
STOP.
• NOT OK – The engine speed cannot be adjusted.
Proceed to test step 7
• NOT OK – The engine speed reads zero on the
EMCP Display Screen.
Repair: The Engine Speed Sensor may have
failed or needs to be adjusted. See Testing And
Adjusting, “Speed Sensor (Engine) - Adjust”. If
the problem remains, replace the Engine Speed
Sensor.
STOP.
111
Troubleshooting Section
Test Step 4. CHECK THE SYSTEM BY
USING THE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. With the engine running, adjust the speed of the
engine by turning the speed potentiometer.
Expected Result:
The engine can be adjusted to the desired speed.
Results:
• OK – The engine speed can be adjusted.
Repair: Adjust the engine speed to meet site
requirements. Resume normal operation and verify
that the problem has been corrected.
STOP.
• NOT OK – The engine speed cannot be adjusted
with the speed potentiometer. Proceed to test step
5
Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. Shut down the engine.
B. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
C. At the speed potentiometer, measure the
resistance of the speed potentiometer.
Expected Result:
The resistance should be adjustable between 0 and
100 ohms.
Results:
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6.
• NOT OK – The resistance of the speed
potentiometer is not correct.
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has
been corrected.
STOP.
Test Step 6. CHECK THE SPEED
POTENTIOMETER HARNESS FOR A
OPEN CIRCUIT. (MUI ENGINES ONLY)
A. Disconnect the speed potentiometer harness from
the 2301A governor.
112
Troubleshooting Section
B. Check for an open circuit. Check the resistance
from the wire connected to terminal “11” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less.
C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less
Expected Result:
When the resistance is measured between the wire
connected to terminal “11” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
When the resistance is measured between the wire
connected to terminal “12” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
Results:
• OK – The harness functions properly.
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The harness wiring with the incorrect
resistance measurement has failed. Replace
the failed harness from the 2301A governor
to the speed potentiometer or repair the failed
harness from the 2301A governor to the speed
potentiometer. Resume normal operation and
verify that the problem has been corrected. STOP.
Test Step 7. CHECK J1939 DATA LINK
BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
information on troubleshooting the Data Link, see
Troubleshooting, “Data Link Circuit Fault ”.
Results:
• OK – The J1939 Data Link wiring is correct.
RENR7902-07
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify the problem has been corrected.
STOP.
i02461493
Engine Underspeed Warning
SMCS Code: 4490
System Operation Description:
If the engine speed drops below the Engine
Underspeed Threshold setpoint value, the
underspeed timer will begin timing. When the timer
expires, the Engine Underspeed event is made active
(if the engine speed has been below the threshold
level continuously while timing). If the engine speed
rises above the Engine Underspeed Threshold, the
Engine Underspeed event will be made inactive and
the timer will be reset.
If a underspeed condition is detected, “ENGINE
UNDERSPEED SHUTDOWN” or “ENGINE
UNDERSPEED WARNING” will be displayed on
the EMCP 3 in order to inform the operator of an
underspeed condition.
Note: The severity of the underspeed condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for engine underspeed is generated when
the EMCP 3 determines that an engine underspeed
condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
underspeed condition.
Expected Result:
A underspeed was caused by a occurrence known
to the operator and the operator would like to put the
genset back into service.
RENR7902-07
Results:
• OK – The operator can determine the cause for
the underspeed condition, the condition has been
repaired and the operator wants to put the genset
back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The underspeed condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the Engine Speed Monitor and Generator
Desired Engine Speed Request setpoints. Make a
note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3 for EUI engines.
Proceed to test step 4 for MUI engines
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. VERIFY ENGINE SPEED CAN
BE VIEWED AND ADJUSTED FROM THE
EMCP 3 (EUI ENGINES ONLY)
Verify the engine speed can be viewed and adjusted
from the EMCP 3 Display Screen.
Expected Result:
The engine speed can be viewed and adjusted from
the EMCP 3 Display Screen.
Results:
• OK – The engine speed can be viewed and
adjusted from the EMCP 3 Display Screen.
113
Troubleshooting Section
Repair: Adjust the engine speed to meet site
requirements. Resume normal operation and verify
that the problem has been corrected.
STOP.
• NOT OK – The engine speed cannot be adjusted.
Proceed to test step 7
• NOT OK – The engine speed reads zero on the
EMCP Display Screen.
Repair: The Engine Speed Sensor may have
failed or needs to be adjusted. See Testing And
Adjusting, “Speed Sensor (Engine) - Adjust”. If
the problem remains, replace the Engine Speed
Sensor.
STOP.
Test Step 4. CHECK THE SYSTEM BY
USING THE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. With the engine running, adjust the speed of the
engine by turning the speed potentiometer.
Expected Result:
The engine can be adjusted to the desired speed.
Results:
• OK – The engine speed can be adjusted.
Repair: Adjust the engine speed to meet site
requirements. Resume normal operation and verify
that the problem has been corrected.
STOP.
• NOT OK – The engine speed cannot be adjusted
with the speed potentiometer. Proceed to test step
5
Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. Shut down the engine.
B. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
C. At the speed potentiometer, measure the
resistance of the speed potentiometer.
Expected Result:
The resistance should be adjustable between 0 and
100 ohms.
114
Troubleshooting Section
Results:
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6.
• NOT OK – The resistance of the speed
potentiometer is not correct.
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has
been corrected.
STOP.
Test Step 6. CHECK THE SPEED
POTENTIOMETER HARNESS FOR A
OPEN CIRCUIT. (MUI ENGINES ONLY)
A. Disconnect the speed potentiometer harness from
the 2301A governor.
B. Check for an open circuit. Check the resistance
from the wire connected to terminal “11” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less.
C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less
Expected Result:
When the resistance is measured between the wire
connected to terminal “11” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
When the resistance is measured between the wire
connected to terminal “12” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
Results:
• OK – The harness functions properly.
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The harness wiring with the incorrect
resistance measurement has failed.
RENR7902-07
Repair: Replace the failed harness from the 2301A
governor to the speed potentiometer or repair the
failed harness from the 2301A governor to the
speed potentiometer. Resume normal operation
and verify that the problem has been corrected.
STOP.
Test Step 7. CHECK THE J1939 DATA
LINK BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
information on troubleshooting the Data Link, see
Troubleshooting, “Data Link Circuit Fault ”.
Results:
• OK – The J1939 Data Link wiring is correct.
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify the problem has been corrected.
STOP.
i02464700
Generator Control Not in
Automatic Warning
SMCS Code: 4490
System Operation Description:
Pressing the Auto Key or a Modbus RS-485 SCADA
Data Link message causes the engine to enter AUTO
mode. When the engine is in AUTO mode and no
shutdowns are active, then continuous activation of
the Remote Initiate input causes the engine to start
and to run (after a programmed Start Aid Activation
delay and Crank Alert interval). When the Remote
Initiate signal is removed, then the engine will cool
down and then stop. When the genset control is not
in AUTO mode, "GEN CONTROL NOT IN AUTO
WARNING" will be displayed on the EMCP 3 in order
to inform the operator of the not in auto condition.
RENR7902-07
Note: The event can be disabled via the Generator
Control Not in Automatic Warning Event Response
Configuration setpoint).
Conditions Which Generate This Code:
The code is generated when the genset control is
not in AUTO mode.
Talk to the Operator
Note: No repair to the engine is necessary.
A. Determine the conditions that caused the
diagnostic code.
Expected Result:
The generator was place into a mode other than
AUTO by the operator or by a Modbus RS-485
SCADA data link message .
Results:
• OK – STOP.
i02461494
Generator Output Sensing
Circuit Fault
SMCS Code: 4490
System Operation Description:
If the engine is running and the EMCP 3 is
receiving AC voltage and current information,
but not processing any AC measurements, then
the “GENERATOR OUTPUT SENSING CIRCUIT
FAULT” is made active. The EMCP 3 has failed.
Perform the following procedure: Electronic Control
Module (Generator Set) - Replace
Results:
• OK – STOP.
115
Troubleshooting Section
i02461495
Generator Overcurrent
Warning
SMCS Code: 4490
System Operation Description:
The EMCP 3 detects an overcurrent condition that
persists for a duration that is a function of the over
current level or a condition that exceeds a threshold
for a programmed duration. If the RMS current of any
phase goes above the Generator Definite Time Over
Current (Amp) Percentage Threshold, then a timer
is started and the Generator Over Current event is
made active.
The tripping time for generator overcurrent detection
is determined from the phase with the highest current,
and is the smaller of two values: the Curve Time and
the Generator Definite Time Over Current (Amp)
Shutdown Event Notification Delay Time (setpoint
value).
If an overcurrent condition is detected, then
“GEN OVER CURRENT SHUTDOWN” or “GEN
OVERCURRENT WARNING” will be displayed on
the EMCP 3 in order to inform the operator of an
overcurrent condition.
Note: The severity of the overcurrent condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for generator overcurrent is generated
when the EMCP 3 determines that a generator
overcurrent condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
overcurrent condition.
Expected Result:
An overcurrent was caused by a occurrence known
to the operator and the operator would like to put the
genset back into service.
Results:
• OK – The operator can determine the cause
for the overcurrent condition, the condition has
been repaired and the operator wants to put the
genenset back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
116
Troubleshooting Section
• NOT OK – The overcurrent condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the setpoints (Generator Current Transformer
Primary Winding Rating), (Generator Current
Transformer Secondary Winding Rating), and
all of the overcurrent setpoints. Make a note
of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
i02464697
Generator Overfrequency
Warning
SMCS Code: 4490
System Operation Description:
If the frequency rises above the Generator
Overfrequency Percentage Threshold setpoint value,
then the overfrequency timer will begin timing. When
the timer expires, the Generator Overfrequency
event is made active (if the frequency has been
above the threshold level continuously while
timing). If the frequency rises above the Generator
Overfrequency Percentage Threshold, then the
Generator Overfrequency event will be made inactive
and the timer will be reset.
RENR7902-07
If an overfrequency condition is detected, then
“GEN OVERFREQUENCY SHUTDOWN” or “GEN
OVERFREQUENCY WARNING” will be displayed
on the EMCP 3 in order to inform the operator of an
overfrequency condition.
Note: The severity of the overfrequency condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for generator overfrequency is generated
when the EMCP 3 determines that a generator
overfrequency condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
overfrequency condition.
Expected Result:
An overfrequency condition was caused by an
occurrence that is known to the operator and the
operator would like to put the genset back into
service.
Results:
• OK – The operator can determine the cause for
the overfrequency condition, the condition has
been repaired and the operator wants to put the
genset back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The overfrequency condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the Generator Overfrequency and Generator
Desired Engine Speed Request setpoints. Make a
note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3 for EUI engines.
Proceed to test step 4 for MUI engines
RENR7902-07
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. VERIFY FREQUENCY CAN
BE VIEWED AND ADJUSTED FROM THE
EMCP 3 (EUI ENGINES ONLY)
Verify the generator output frequency can be viewed
and adjusted from the EMCP 3 Display Screen.
Expected Result:
The generator output frequency can be viewed and
adjusted from the EMCP 3 Display Screen.
Results:
• OK – The generator output frequency can be
viewed and adjusted from the EMCP 3 Display
Screen.
Repair: Adjust the generator output frequency to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The generator output frequency cannot
be adjusted. Proceed to test step 7
• NOT OK – The generator frequency reads zero on
the EMCP Display Screen. Proceed to test step 8
Test Step 4. CHECK THE SYSTEM BY
USING THE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. With the engine running, adjust the generator
output frequency by turning the speed
potentiometer.
Expected Result:
The generator output frequency can be adjusted to
the desired frequency.
Results:
• OK – The generator output frequency can be
adjusted.
Repair: Adjust the generator output frequency to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
117
Troubleshooting Section
• NOT OK – The generator output frequency cannot
be adjusted with the speed potentiometer. Proceed
to test step 5
Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. Shut down the engine.
B. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
C. At the speed potentiometer, measure the
resistance of the speed potentiometer.
Expected Result:
The resistance should be adjustable between 0 and
100 ohms.
Results:
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6.
• NOT OK – The resistance of the speed
potentiometer is not correct.
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has
been corrected.
STOP.
Test Step 6. CHECK THE SPEED
POTENTIOMETER HARNESS FOR AN
OPEN CIRCUIT. (MUI ENGINES ONLY)
A. Disconnect the speed potentiometer harness from
the 2301A governor.
B. Check for an open circuit. Check the resistance
from the wire connected to terminal “11” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less.
C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less
Expected Result:
When the resistance is measured between the wire
connected to terminal “11” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
118
Troubleshooting Section
When the resistance is measured between the wire
connected to terminal “12” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
Results:
• OK – The harness functions properly. Proceed to
test step 8
• NOT OK – The harness wiring with the incorrect
resistance measurement has failed. Replace
the failed harness from the 2301A governor
to the speed potentiometer or repair the failed
harness from the 2301A governor to the speed
potentiometer. Resume normal operation and
verify that the problem has been corrected. STOP.
Test Step 7. CHECK J1939 DATA LINK
BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
information on troubleshooting the Data Link, see
Troubleshooting , “Data Link Circuit Fault ”.
Results:
• OK – The J1939 Data Link wiring is correct.
Proceed to test step 8
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify that the problem has been corrected.
STOP.
Test Step 8. CHECK THE VOLTAGE
INPUT FUSES.
A. Check the three fuses on the AC voltage inputs of
the EMCP 3.
Expected Result:
The fuses should not be open.
Results:
• OK – The fuses are not open. Proceed to test step
9 the EMCP 3 voltage inputs and the voltage input
• NOT OK – One or more of the fuses are open.
RENR7902-07
Repair: Check for a shorted component or
damaged wiring. Troubleshoot and repair the
problem. See the Generator Set Wiring Diagram
for your particular genset. After the problem has
been repaired, replace the fuses.
STOP.
Test Step 9. CHECK THE GENERATOR
VOLTAGE OUTPUT.
A. Open the circuit breaker or remove the load.
B. Start the engine and run the genset.
C. Measure the voltage between all three AC input
fuses.
Expected Result:
The line to line voltage should measure the rated
voltage of the genset.
Results:
• OK – The voltages are correct and the problem
remains. Proceed to Test Step 10.
• NOT OK – One or more of the voltages are NOT
correct.
Repair: The wiring or the connections the are
damaged. Check for damaged wiring between
the fuses and the generator output bus. See the
Generator Set Wiring Diagram for your particular
genset. Repair the wiring or replace the wiring.
Resume normal operation and verify the problem
has been corrected.
STOP.
Test Step 10. CHECK THE VOLTAGE
INPUT CONNECTIONS
A. Shut down the engine.
B. Remove the EMCP 3 harness connector from the
EMCP 3.
C. Check the EMCP 3 harness connector. See
Testing And Adjusting, “Electrical Connector -
Inspect”.
D. Check for one or more damaged wires between
fuses. See the Generator Set Wiring Diagram for
your particular genset.
Expected Result:
The wiring and the connectors should have been
good.
RENR7902-07
Results:
• OK – NO problem was found with the connectors
or with the wiring.
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The problem was with the connectors
or with the wiring.
Repair: Repair the connectors or replace the
wiring harness. Resume normal operation and
verify that the problem has been corrected.
STOP.
i02464693
Generator Overvoltage
Warning
SMCS Code: 4490
System Operation Description:
If the voltage rises above the Generator Overvoltage
Percentage Threshold setpoint value, then the
overvoltage timer will begin timing. When the timer
expires, the Generator Overvoltage event is made
active (if the voltage has been above the threshold
level continuously while timing). If the voltage
drops below the Generator Overvoltage Percentage
Threshold, then the Generator Overvoltage event will
be made inactive and the timer will be reset.
If an overvoltage condition is detected, then
“GEN OVERVOLTAGE SHUTDOWN” or “GEN
OVERVOLTAGE WARNING” will be displayed on
the EMCP 3 in order to inform the operator of an
overvoltage condition.
Note: The severity of the overvoltage condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for generator overvoltage is generated
when the EMCP 3 determines that a generator
overvoltage condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
overvoltage condition.
119
Troubleshooting Section
Expected Result:
An overvoltage was caused by an occurrence that is
known to the operator and the operator would like to
put the genset back into service.
Results:
• OK – The operator can determine the cause for
the overvoltage condition, the condition has been
repaired and the operator wants to put the genset
back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The overvoltage condition was not
caused by an occurrence that is known to the
operator. Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the Generator Overvoltage setpoints. Make
a note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. VERIFY VOLTAGE CAN BE
ADJUSTED
Verify the generator output voltage can be adjusted
from the EMCP 3 Display Screen.
120
Troubleshooting Section
Expected Result:
The generator output voltage can be adjusted from
the EMCP 3 Display Screen.
Results:
• OK – The generator output voltage can be
changed from the EMCP 3 Display Screen.
Repair: Adjust the generator output voltage to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The generator output voltage cannot
be adjusted. Proceed to test step 4
Test Step 4. CHECK CAT DATA LINK
BETWEEN THE EMCP 3 AND THE
VOLTAGE REGULATOR
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Voltage Regulator. For
more information on troubleshooting the Data Link,
see Troubleshooting , “Data Link Circuit Fault ”.
Results:
• OK – The Data Link wiring is correct.
Repair: Refer to the appropriate voltage regulator
service manual and perform an operational check
of the voltage regulator. Replace the voltage
regulator if necessary. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify that the problem has been corrected.
STOP.
RENR7902-07
i02464689
Generator Reverse Power
Warning
SMCS Code: 4490
System Operation Description:
If the current rises above the Generator Reverse
Power Percentage Threshold setpoint value, then the
reverse power timer will begin timing. When the timer
expires, the Generator Reverse Power event is made
active (if the current has been above the threshold
level continuously while timing). If the current drops
below the Generator Reverse Power Percentage
Threshold, then the Generator Reverse Power event
will be made inactive and the timer will be reset.
If a reverse power condition is detected, “GEN
REVERSE POWER SHUTDOWN” or “GEN
REVERSE POWER WARNING” will be displayed
on the EMCP 3 in order to inform the operator of a
reverse power condition.
Note: The severity of the reverse power condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for generator reverse power is generated
when the EMCP 3 determines that a generator
reverse power condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the reverse
power condition.
Expected Result:
A reverse power was caused by an occurrence
known to the operator and the operator would like to
put the genset back into service.
Results:
• OK – The operator can determine the cause for
the reverse power condition, the condition has
been repaired and the operator wants to put the
genset back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The reverse power condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
RENR7902-07
Test Step 2. CHECK THE SETPOINTS.
A. View the Generator Reverse Power setpoints.
Make a note of the setpoints. See Testing and
Adjusting, “Electronic Control Module (Generator
Set) - Configure”. Compare the setpoints against
the default setpoints of the particular generator
set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to Test Step 3.
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. CHECK THE POLARITY OF
THE CURRENT TRANSFORMERS
g00607036
Illustration 74
(A) Current Transformer Polarity Dot
A. Press the STOP key in order to shut down the
engine.
B. Check the polarity of the current transformers. The
polarity dots on all of the transformers should be
towards the genset. Refer to Illustration 74.
121
Troubleshooting Section
Expected Result:
The polarity of the current transformers should be
correct.
Results:
• OK – The polarity of the current transformers is
correct.
Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
again. If the diagnostic code is still present,
then replace the EMCP 3. Refer to Testing and
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The polarity of the current transformers
is NOT correct.
Repair: Install the current transformers as shown
on the wiring diagram for your particular genset.
Reset the genset. Resume normal operation and
verify that the problem has been corrected.
STOP.
i02464681
Generator Underfrequency
Warning
SMCS Code: 4490
System Operation Description:
If the frequency drops below the Generator
Underfrequency Percentage Threshold setpoint
value, then the underfrequency timer will begin
timing. When the timer expires, then the Generator
Underfrequency event is made active (if the
frequency has been below the threshold level
continuously while timing). If the frequency rises
above the Generator Underfrequency Percentage
Threshold, then the Generator Underfrequency event
will be made inactive and the timer will be reset.
If an underfrequency condition is detected, then
“GEN UNDERFREQUENCY SHUTDOWN” or “GEN
UNDERFREQUENCY WARNING” will be displayed
on the EMCP 3 in order to inform the operator of an
underfrequency condition.
Note: The severity of the underfrequency condition
will determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
122
Troubleshooting Section
The code for generator underfrequency is generated
when the EMCP 3 determines that a generator
underfrequency condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
underfrequency condition.
Expected Result:
An underfrequency condition was caused by an
occurrence that is known to the operator and the
operator would like to put the genset back into
service.
Results:
• OK – The operator can determine the cause for
the underfrequency condition, the condition has
been repaired and the operator wants to put the
genset back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The underfrequency condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the Generator Underfrequency and
Generator Desired Engine Speed Request
setpoints. Make a note of the setpoints. See
Testing and Adjusting, “Electronic Control Module
(Generator Set) - Configure”. Compare the
setpoints against the default setpoints of the
particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3 for EUI engines.
Proceed to test step 4 for MUI engines
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
RENR7902-07
Test Step 3. VERIFY FREQUENCY CAN
BE VIEWED AND ADJUSTED FROM THE
EMCP 3 (EUI ENGINES ONLY)
Verify the generator output frequency can be viewed
and adjusted from the EMCP 3 Display Screen.
Expected Result:
The generator output frequency can be viewed and
adjusted from the EMCP 3 Display Screen.
Results:
• OK – The generator output frequency can be
viewed and adjusted from the EMCP 3 Display
Screen.
Repair: Adjust the generator output frequency to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The generator output frequency cannot
be adjusted. Proceed to test step 7
• NOT OK – The generator frequency reads zero on
the EMCP Display Screen. Proceed to test step 8
Test Step 4. CHECK THE SYSTEM BY
USING THE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. With the engine running, adjust the generator
output frequency by turning the speed
potentiometer.
Expected Result:
The generator output can be adjusted to the desired
frequency.
Results:
• OK – The generator output frequency can be
adjusted.
Repair: Adjust the generator output frequency to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The generator output frequency cannot
be adjusted with the speed potentiometer. Proceed
to test step 5
RENR7902-07
Test Step 5. CHECK THE RESISTANCE OF
THE ENGINE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
A. Disconnect the speed potentiometer from the
terminals “11” and “12” on the 2301A Governor.
B. At the speed potentiometer, measure the
resistance of the speed potentiometer.
Expected Result:
The resistance should be adjustable between 0 and
100 ohms.
Results:
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6.
• NOT OK – The resistance of the speed
potentiometer is not correct.
Repair: Replace the speed potentiometer. Resume
normal operation and verify that the problem has
been corrected.
STOP.
Test Step 6. CHECK THE SPEED
POTENTIOMETER HARNESS FOR AN
OPEN CIRCUIT. (MUI ENGINES ONLY)
A. Disconnect the speed potentiometer harness from
the 2301A governor.
B. Check for an open circuit. Check the resistance
from the wire connected to terminal “11” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less.
C. Check for an open circuit. Check the resistance
from the wire connected to terminal “12” of the
2301A governor to the same wire number at the
speed potentiometer. The resistance should be 5
ohms or less
Expected Result:
When the resistance is measured between the wire
connected to terminal “11” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
When the resistance is measured between the wire
connected to terminal “12” of the 2301A governor to
the same wire number at the speed potentiometer
connector, the resistance should be 5 ohms or less.
123
Troubleshooting Section
Results:
• OK – The harness functions properly. Proceed to
test step 8
• NOT OK – The harness wiring with the incorrect
resistance measurement has failed. Replace
the failed harness from the 2301A governor
to the speed potentiometer or repair the failed
harness from the 2301A governor to the speed
potentiometer. Resume normal operation and
verify that the problem has been corrected. STOP.
Test Step 7. CHECK J1939 DATA LINK
BETWEEN THE EMCP 3 AND THE
ENGINE ECM (EUI ENGINES ONLY)
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Engine ECM. For more
information on troubleshooting the Data Link, see
Troubleshooting , “Data Link Circuit Fault ”.
Results:
• OK – The J1939 Data Link wiring is correct.
Proceed to test step 8
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify the problem has been corrected.
STOP.
Test Step 8. CHECK THE VOLTAGE
INPUT FUSES.
A. Check the three fuses on the AC voltage inputs of
the EMCP 3.
Expected Result:
The fuses should not be open.
Results:
• OK – The fuses are not open. Proceed to test step
9
• NOT OK – One or more of the fuses are open.
Repair: Check for a shorted component or
damaged wiring. Troubleshoot and repair the
problem. See the Generator Set Wiring Diagram
for your particular genset. After the problem has
been repaired, replace the fuses.
STOP.
124
Troubleshooting Section
Test Step 9. CHECK THE GENERATOR
VOLTAGE OUTPUT.
A. Open the circuit breaker or remove the load.
B. Start the engine and run the genset.
C. Measure the voltage between all three AC input
fuses.
Expected Result:
The line to line voltage should measure the rated
voltage of the genset.
Results:
• OK – The voltages are correct and the problem
remains. Proceed to Test Step 10.
• NOT OK – One or more of the voltages are NOT
correct.
Repair: The wiring or the connections the are
damaged. Check for damaged wiring between
the fuses and the generator output bus. See the
Generator Set Wiring Diagram for your particular
genset. Repair the wiring or replace the wiring.
Resume normal operation and verify the problem
has been corrected.
STOP.
Test Step 10. CHECK THE VOLTAGE
INPUT CONNECTIONS
A. Shut down the engine.
B. Remove the EMCP 3 harness connector from the
EMCP 3.
C. Check the EMCP 3 harness connector. See
Testing And Adjusting, “Electrical Connector -
Inspect”.
D. Check for one or more damaged wires between
the EMCP 3 voltage inputs and the voltage input
fuses. See the Generator Set Wiring Diagram for
your particular genset.
Expected Result:
The wiring and the connectors should have been
good.
Results:
• OK – NO problem was found with the connectors
or with the wiring.
RENR7902-07
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The problem was with the connectors
or with the wiring.
Repair: Repair the connectors or replace the
wiring harness. Resume normal operation and
verify that the problem has been corrected.
STOP.
i02464667
Generator Undervoltage
Warning
SMCS Code: 4490
System Operation Description:
If the voltage drops below the Generator
Undervoltage Percentage Threshold and Automatic
Voltage Regulator (AVR) Request setpoint value, the
undervoltage timer will begin timing. When the timer
expires, the Generator Undervoltage event is made
active (if the frequency has been below the threshold
level continuously while timing). If the voltage rises
above the Generator Undervoltage Percentage
Threshold, the Generator Undervoltage event will be
made inactive and the timer will be reset.
If an undervoltage condition is detected, “GEN
UNDERVOLTAGE SHUTDOWN” or “GEN
UNDERVOLTAGE WARNING” will be displayed on
the EMCP 3 in order to inform the operator of an
undervoltage condition.
Note: The severity of the undervoltage condition will
determine if a warning or shutdown event occurs.
Conditions Which Generate This Code:
The code for generator undervoltage is generated
when the EMCP 3 determines that a generator
undervoltage condition has occurred.
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
undervoltage condition.
RENR7902-07
Expected Result:
An undervoltage was caused by an occurrence
known to the operator and the operator would like to
put the genset back into service.
Results:
• OK – The operator can determine the cause for
the undervoltage condition, the condition has been
repaired and the operator wants to put the genset
back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The undervoltage condition was not
caused by an occurrence known to the operator.
Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the Generator Undervoltage, Automatic
Voltage Regulator (AVR) Desired Voltage
Request, and Generator AC Monitor setpoints.
Make a note of the setpoints. See Testing and
Adjusting, “Electronic Control Module (Generator
Set) - Configure”. Compare the setpoints against
the default setpoints of the particular generator
set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. VERIFY VOLTAGE CAN BE
ADJUSTED
Verify the generator output voltage can be adjusted
from the EMCP 3 Display Screen.
Expected Result:
The generator output voltage can be adjusted from
the EMCP 3 Display Screen.
125
Troubleshooting Section
Results:
• OK – The generator output voltage can be
changed from the EMCP 3 Display Screen.
Repair: Adjust the generator output voltage to
meet site requirements. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – The generator output voltage cannot
be adjusted. Proceed to test step 4
Test Step 4. CHECK CAT DATA LINK
BETWEEN THE EMCP 3 AND THE
VOLTAGE REGULATOR
Refer to the Genset Electrical System Schematic in
the Service Manual and check the Data Link wiring
between the EMCP 3 and the Voltage Regulator. For
more information on troubleshooting the Data Link,
see Troubleshooting , “Data Link Circuit Fault ”.
Results:
• OK – The Data Link wiring is correct. Proceed to
test step 5
• NOT OK – The wiring is not correct
Repair: Repair the Data Link wiring or Replace the
Data Link wiring. Resume normal operation and
verify the problem has been corrected.
STOP.
Test Step 5. VERIFY VOLTAGE SENSING
CIRCUITS
Verify all three phases of generator output voltage
are shown on the EMCP 3 Display Screen.
Expected Result:
All three phases of generator output voltage are
shown on the EMCP 3 Display Screen
Results:
• OK – All three phases of generator output voltage
are shown on the EMCP 3 Display Screen
Repair: Refer to appropriate voltage regulator
service manual and perform an operational check
of the voltage regulator. Resume normal operation
and verify that the problem has been corrected.
STOP.
• NOT OK – All phases of voltage are not shown on
display. Proceed to test step 6
126
Troubleshooting Section
Test Step 6. CHECK THE VOLTAGE
INPUT FUSES.
A. Check the three fuses on the AC voltage inputs of
the EMCP 3.
Expected Result:
The fuses should not be open.
Results:
• OK – The fuses are not open. Proceed to test step
7
• NOT OK – One or more of the fuses are open.
Repair: Check for a shorted component or
damaged wiring. Troubleshoot and repair the
problem. See the Generator Set Wiring Diagram
for your particular genset. After the problem has
been repaired, replace the fuses.
STOP.
Test Step 7. CHECK THE GENERATOR
VOLTAGE OUTPUT.
A. Open the circuit breaker or remove the load.
B. Start the engine and run the genset.
C. Measure the voltage between all three AC input
fuses.
Expected Result:
The line to line voltage should measure the rated
voltage of the genset.
Results:
• OK – The voltages are correct and the problem
remains. Proceed to Test Step 8.
• NOT OK – One or more of the voltages are NOT
correct.
Repair: The wiring or the connections the are
damaged. Check for damaged wiring between
the fuses and the generator output bus. See the
Generator Set Wiring Diagram for your particular
genset. Repair the wiring or replace the wiring.
Resume normal operation and verify that the
problem has been corrected.
STOP.
Test Step 8. CHECK THE VOLTAGE
INPUT CONNECTIONS
A. Shut down the engine.
RENR7902-07
B. Remove the EMCP 3 harness connector from the
EMCP 3.
C. Check the EMCP 3 harness connector. See
Testing And Adjusting, “Electrical Connector -
Inspect”.
D. Check for one or more damaged wires between
the EMCP 3 voltage inputs and the voltage input
fuses. See the Generator Set Wiring Diagram for
your particular genset.
Expected Result:
The wiring and the connectors should have been
good.
Results:
• OK – NO problem was found with the connectors
or with the wiring.
Repair: The EMCP 3 may have failed. It is unlikely
that the EMCP 3 has failed. Exit this procedure and
perform this entire procedure again. If the problem
remains, replace the EMCP 3. See Testing And
Adjusting, “ Electronic Control Module (Generator
Set) - Replace”.
STOP.
• NOT OK – The problem was with the connectors
or with the wiring.
Repair: Repair the connectors or replace the
wiring harness. Resume normal operation and
verify that the problem has been corrected.
STOP.
i02464635
Service Maintenance Interval
Warning
SMCS Code: 4490
System Operation Description:
A Service Maintenance Interval Warning event is
detected when the number of engine hours or the
number of days since the previous alarm occurrence
was reset exceeds the number of hours or days
specified by the Service Interval Setpoints. Once the
event is active, it will not become inactive until a
Reset Service Interval Counter Command is received
over the data link or from the display.
Conditions Which Generate This Code:
RENR7902-07
The Service Maintenance Interval code is generated
when the EMCP 3 determines a need for engine
service based on engine hours or the number of days
since last service, whichever occurs first.
Test Step 1. Talk to the Operator
A. Determine the conditions that caused the
diagnostic code.
Expected Result:
Genset maintenance records indicate that the
maintenance interval has been exceeded and
maintenance is required
Results:
• OK – Records indicate service is required. Perform
the required maintenance and reset the Service
Maintenance Interval in order to indicate when the
genset will need to be serviced again. STOP.
• NOT OK – Records indicate service is not
required. Proceed to Test Step 2
Test Step 2. CHECK THE SETPOINTS.
A. View the setpoints (Service Maintenance Interval
Hours), and (Service Maintenance Interval Days)
and make note of the setpoints. See Testing and
Adjusting, “Electronic Control Module (Generator
Set) - Configure”. Compare the setpoints against
the default setpoints of the particular generator
set.
Expected Result:
The setpoints are correct for your particular genset
and application.
Results:
• OK – The setpoints are correct for your particular
genset and application.
Repair: It is possible the Service Maintenance
Interval was not reset when the genset was last
serviced. Reset the Service Maintenance Interval
in order to indicate when the genset will need to be
serviced again. Resume normal operation.
STOP.
• NOT OK – The setpoints are NOT correct for your
particular genset and application.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
127
Troubleshooting Section
i02463493
Analog Input Circuit Fault
SMCS Code: 4490
System Operation Description:
Spare Analog Inputs are connected to resistive
type sensors either on the engine, generator, or
supporting systems. The EMCP 3 converts the
resistive sensor values into levels, temperatures, and
pressures depending on how the input is configured.
Six programmable thresholds are provided. These
thresholds include both high and low for each of
the three supported data types. The appropriate
thresholds are selected based on the Spare Analog
Input Type Configuration setpoints. The EMCP 3 will
also detect sensor diagnostics for shorted high and
shorted low conditions.
An active spare analog input can be programmed
to cause an alarm or a shutdown. For programming
of the spare inputs, see System Operation, “Spare
Analog Input Programming”.
Conditions Which Generate This Code:
This code is generated when the measured Spare
Analog Input value goes above or below the
programmed threshold for a configurable duration.
Test Step 1. PERFORM THE INITIAL
CHECK.
A. Use the Caterpillar Electronic Technician in order
to check for active diagnostic codes on the Engine
ECM. If any codes are present, then correct the
diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active
on the engine ECM.
Results:
• OK – No other diagnostic codes or indicators are
active. Proceed to Test Step 2
• NOT OK – Another Engine ECM diagnostic code
is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Refer to the engine
Troubleshooting manual for your particular genset.
STOP.
128
Troubleshooting Section
Test Step 2. CHECK THE SETPOINTS.
A. View the Spare Analog Input setpoints. Make a
note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. CHECK THE ANALOG INPUT
DEVICE WIRING
A. Check the wiring to the corresponding spare
analog input for an unwanted short circuit. The
short can be to the battery negative (“B-”). The
short can be to the battery positive terminal (“B+”).
Carefully check ALL wires that are connected to
the appropriate analog input for abrasion or worn
spots in the insulation that could be causing the
short. Check the wires in the generator control
panel. Check the wires in the engine harness.
Refer to the appropriate wiring diagrams for the
circuit that is being checked.
Expected Result:
The wiring is correct.
Results:
• OK – No problems can be found with the analog
input wiring. Proceed to test step 4
• NOT OK – The analog input wiring is defective.
Repair: Repair the wiring or replace the wiring.
Proceed to test step 4
Test Step 4. CHECK IF THE DIAGNOSTIC
CODE REMAINS
A. Inspect the harness connectors and clean the
contacts of the harness connectors.
B. Reconnect all harness connectors.
RENR7902-07
C. Reset the genset.
D. Operate the genset.
E. Check the status of the diagnostic code.
Expected Result:
The diagnostic code is not active.
Results:
• OK – The diagnostic code is not active. The
diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
normal operation. STOP.
• NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”.
STOP.
i02463497
Charging System
SMCS Code: 1401; 1405
System Operation Description:
The EMCP 3 monitors its battery supply voltage
based on the +BATT and –BATT voltage inputs to the
EMCP 3 control. If the battery voltage rises above
the High Battery Voltage Event Threshold setpoint
value, the high battery voltage event timer will begin
timing. When the high battery voltage timer expires,
the High Battery Voltage event is made active (if the
battery voltage has been above the event threshold
level continuously while timing). If the battery voltage
drops below the High Battery Voltage Warning
Threshold, the High Battery Voltage event will be
made inactive and the timer will be reset.
If a battery overvoltage condition is detected, “HIGH
BATTERY VOLTAGE SHUTDOWN” or “HIGH
BATTERY VOLTAGE WARNING” will be displayed
on the EMCP 3 in order to inform the operator of a
high battery voltage condition.
RENR7902-07
If the battery voltage drops below the Low Battery
Voltage Warning Threshold setpoint value, the low
battery voltage event timer will begin timing. When
the low battery voltage event timer expires, the Low
Battery Voltage event is made active (if the battery
voltage has been below the event threshold level
continuously while timing). If the battery voltage rises
above the Low Battery Voltage Event Threshold, the
Low Battery Voltage event will be made inactive and
the timer will be reset.
If a battery undervoltage condition is detected, “LOW
BATTERY CHARGING SYS VOLT WARN” or “LOW
BATTERY VOLTAGE WARNING” will be displayed
on the EMCP 3 in order to inform the operator of an
undervoltage condition.
Note: The severity of the battery over/under voltage
condition will determine if a warning or shutdown
event occurs.
Conditions Which Generate This Code:
This code is generated when the measured battery
voltage value goes above or below the programmed
thresholds for a configurable duration.
Test Step 1. PERFORM THE INITIAL
CHECK.
A. The battery and charging system are located
on the engine. Use the Caterpillar Electronic
Technician in order to check for active diagnostic
codes on the Engine ECM. If any codes are
present, correct the engine diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active
on the Engine ECM.
Results:
• OK – No other diagnostic codes or indicators are
active. 2
• NOT OK – Another Engine ECM diagnostic code
is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Refer to the engine
Troubleshooting manual for your particular genset.
STOP.
Test Step 2. CHECK THE SETPOINTS.
A. View the Battery Voltage Monitor setpoints. Make
a note of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
129
Troubleshooting Section
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to test step 3
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. COMPARE ACTUAL
BATTERY VOLTAGE TO THE VOLTAGE
DISPLAYED ON THE EMCP 3 DISPLAY
A. Shut down the engine.
B. Disconnect the harness connector from the EMCP
3.
C. At the harness connector, measure the battery
voltage between pin number 52 and pin number
65.
Expected Result:
The measured battery voltage should be the same as
the battery voltage displayed on the EMCP 3 display
screen.
Results:
• OK – The measured battery voltage is the same
as the battery voltage displayed on the EMCP 3
Display Screen. Proceed to test step 4
• NOT OK – The measured battery voltage is not
the same as the battery voltage displayed on the
EMCP 3 Display Screen. The EMCP 3 may have
failed.
Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
again. If the cause of the failure is not found,
replace the EMCP 3. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Replace”.
STOP.
130
Troubleshooting Section
Test Step 4. CHECK THE BATTERY
VOLTAGE WIRING BETWEEN THE EMCP
3 AND THE BATTERY SOURCE
A. Check the battery negative (“B-”) wiring to the
battery negative input for a short circuit or open
circuit. Check the battery positive (“B+”) wiring to
the battery positive input for a short circuit or open
circuit. Check the wires in the generator control
panel. Check the wires in the engine harness.
Refer to the appropriate wiring diagrams for the
circuit that is being checked.
Expected Result:
The wiring is correct.
Results:
• OK – No problems can be found with the battery
voltage supply wiring. Proceed to test step 5
• NOT OK – The battery voltage supply wiring is
defective.
Repair: Repair the wiring or replace the wiring.
Proceed to test step 5
Test Step 5. CHECK IF THE DIAGNOSTIC
CODE REMAINS
A. Inspect the harness connectors and clean the
contacts of the harness connectors.
B. Reconnect all harness connectors.
C. Reset the genset.
D. Operate the genset.
E. Check the status of the diagnostic code.
Expected Result:
The diagnostic code is not active.
Results:
• OK – The diagnostic code is not active. The
diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
normal operation. STOP.
• NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
RENR7902-07
Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”.
STOP.
i02463551
Data Link Circuit Fault
SMCS Code: 4490
System Operation Description:
This procedure checks for an open circuit or a short
circuit in a Data Link. There are three data links
associated with the EMCP 3.
• J1939 Accessory Data Link
• J1939 Primary Data Link
• Modbus RS-485 SCADA Data Link
Refer to Systems Operation, “General Information”
for details on each data link.
Note: Use the wiring diagram for your particular
genset in order to troubleshoot the Data Links.
Test Step 1. Inspect the Electrical
Connectors and the Wiring
A. Turn the keyswitch to the OFF position.
B. Thoroughly inspect the EMCP 3 connector, the
service tool connector, and all other connectors in
the circuit for the data link.
Reference: Refer to Troubleshooting, “Electrical
Connectors - Inspect” for details.
Expected Result:
All connectors, pins, and sockets are completely
inserted and coupled. The harness and wiring are
free of corrosion, of abrasion, and of pinch points.
Results:
• OK – In order to troubleshoot the Modbus RS-485
SCADA Data Link, proceed to Test Step 2
• OK – In order to troubleshoot the J1939 Primary
or the J1939 Accessory Data Link, proceed to Test
Step 4
• Not OK
RENR7902-07
Repair: Repair the wiring or replace the wiring.
STOP.
Test Step 2. Check for Shorts in the
Modbus RS-485 SCADA Data Link
Harness
A. Disconnect all connectors from the suspected
data link.
B. Measure the resistance between (data link +) and
data link −).
C. Measure the resistance between ( data link +) and
chassis ground.
D. Measure the resistance between ( data link −) and
chassis ground.
Expected Result:
The resistance is greater than 20,000 Ohms for each
measurement.
Results:
• OK – Proceed to Test Step 5
• Not OK – There is a short circuit in the harness
or connectors.
Repair: Repair the wiring or replace the wiring.
Proceed to Test Step 5
Test Step 3. Check the Resistance
through the Modbus RS-485 SCADA Data
Link Harness
A. Disconnect all connectors from the suspected
data link.
B. Use a suitable piece of wire to short (Data Link +)
and ( Data Link −) at the EMCP 3.
C. Measure the resistance between (Data Link +)
and (Data Link −) at all other connectors in the
circuit for the data link.
Expected Result:
The resistance is less than 10 Ohms.
Results:
• OK – The Data Link is OK. Proceed to test step 5
• Not OK – There is an open circuit or excessive
resistance in the harness or connectors.
131
Troubleshooting Section
Repair: Repair the wiring or replace the wiring.
Proceed to Test Step 5
Test Step 4. Check for Shorts in the J1939
Data Link Harness
A. Disconnect all connectors from the suspected
data link.
B. Measure the resistance between (data link +) and
data link −).
Expected Result:
The resistance is approximately 60 Ohms.
Results:
• OK – Proceed to Test Step 5.
• Not OK – If the resistance is approximately 120
ohms, a termination resistor is missing. If the
resistance is much greater than 120 ohms, both
termination resistors are missing or there is an
open data link circuit. if the resistance is much less
than 60 ohms, there is a short circuit
Repair: Repair the wiring or replace the wiring.
Proceed to Test Step 5
Test Step 5. CHECK IF THE DIAGNOSTIC
CODE REMAINS
A. Inspect the Data Link harness connectors and
clean the contacts of the harness connectors.
B. Reconnect all Data Link harness connectors.
C. Reset the genset.
D. Operate the genset.
E. Check the status of the diagnostic code.
Expected Result:
The diagnostic code is not active.
Results:
• OK – The diagnostic code is not active. The
diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
normal operation. STOP.
• NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
132
Troubleshooting Section
Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”.
STOP.
i02463502
Digital Input Circuit Fault
SMCS Code: 4490
System Operation Description:
Digital inputs are used to bring on/off information,
such as switch closures, to the Genset Control.
Depending on how the input is programmed,
the EMCP 3 associates the inputs with levels,
temperatures, pressures, and status conditions .
Two of the Digital Inputs, which are programmed
at the factory, are used by the EMCP 3 to control
Emergency Stop and Remote Initiate functions. The
spare digital inputs must be programmed before use.
For additional information on programming digital
inputs, see System Operation, “Digital Input
Programming”
Conditions Which Generate This Code:
This code is generated when the digital input is
active. The code may indicate that a problem exists
with the genset, or the code may indicate a status
that does not need to be repaired.
Test Step 1. PERFORM THE INITIAL
CHECK.
A. Use the Caterpillar Electronic Technician in
order to check for active diagnostic codes on the
Engine ECM. If any codes are present, correct the
diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active
on the Engine ECM.
Results:
• OK – No other diagnostic codes or indicators are
active. Proceed to Test Step 2
• NOT OK – Another Engine ECM diagnostic code
is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Refer to the engine
Troubleshooting manual for your particular genset.
STOP.
RENR7902-07
Test Step 2. CHECK THE SETPOINTS.
A. View the Digital Input setpoints. Make a note
of the setpoints. See Testing and Adjusting,
“Electronic Control Module (Generator Set) -
Configure”. Compare the setpoints against the
default setpoints of the particular generator set.
Expected Result:
The setpoints are correct.
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to Test Step 3
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. CHECK THE DIGITAL INPUT
WIRING
A. Check the wiring to the corresponding digital
inputs for an unwanted short circuit. The short can
be to the battery negative (“B-”). Carefully check
ALL wires that are connected to the appropriate
digital input for abrasion or worn spots in the
insulation that could be causing the short. Check
the wires in the generator control panel. Check
the wires in the engine harness. Refer to the
appropriate wiring diagrams for the circuit that is
being checked.
Expected Result:
The wiring is correct.
Results:
• OK – No problems can be found with the digital
input wiring. Proceed to test step 4
• NOT OK – The digital input wiring is defective.
Repair: Repair the wiring or replace the wiring.
Proceed to test step 4
Test Step 4. CHECK IF THE DIAGNOSTIC
CODE REMAINS
A. Inspect the harness connectors and clean the
contacts of the machine harness connectors.
B. Reconnect all harness connectors.
C. Reset the genset.
RENR7902-07
D. Operate the genset.
E. Check the status of the diagnostic code.
Expected Result:
The diagnostic code is not active.
Results:
• OK – The diagnostic code is not active. The
diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
normal operation. STOP.
• NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again. If
the cause of the failure is not found, then replace
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”.
STOP.
i02464600
Digital Output Circuit Fault
SMCS Code: 4490
System Operation Description:
Digital Outputs are used to convey on/off information
from the Genset Control for energizing loads such as
relays, solenoids, and indicator lamps. The digital
output must not be connected directly to battery
positive (B+).
Conditions Which Generate This Code:
This code is occurs when the digital output wiring is
shorted to battery positive (B+).
Test Step 1. CHECK FOR A SHORTED
HARNESS
A. Turn the key start switch and the disconnect
switch to the OFF position.
B. Disconnect the harness connector from the EMCP
3.
C. Disconnect the digital output from the device it is
connected to.
D. At the harness connector for the EMCP 3,
measure the resistance from the failed digital
output contact to all other EMCP 3 harness
contacts.
133
Troubleshooting Section
Expected Result:
Each resistance measurement is greater than 5000
ohms.
Results:
• OK – Each resistance measurement is greater
than 5000 ohms. The harness is correct. Proceed
to Test Step 2
• NOT OK – Each resistance measurement is
not greater than 5000 ohms. There is a short in
the harness on the wire that has that has a low
resistance measurement.
Repair: Repair the harness or replace the harness.
STOP.
Test Step 2. CHECK THE DEVICE
CONNECTED TO THE DIGITAL OUTPUT
CIRCUIT WIRING FOR SHORT TO THE
+BATTERY CIRCUIT.
A. In order to prevent the engine from running while
performing this procedure, press the Emergency
Stop Push Button and turn the battery disconnect
switch to the ON position.
B. At the digital output device, measure the DC
voltage on the wire connected to the failed digital
output.
Expected Result:
The voltage is at or near 0 volts DC and not shorted
to battery positive (B+).
Results:
• OK – The digital output device is not shorted to
battery positive (B+). Proceed to Test Step 3
• NOT OK – The digital output device is shorted to
battery positive (B+)
Repair: Repair the digital output device or replace
the digital output device.
STOP.
Test Step 3. CHECK IF THE DIAGNOSTIC
CODE REMAINS
A. Inspect the EMCP 3 connector and clean the
contacts of the EMCP 3 connector.
B. Reconnect the harness connector.
C. Reset the genset.
D. Operate the genset.
134
Troubleshooting Section
E. Check the status of the diagnostic code.
Expected Result:
The diagnostic code is not active.
Results:
• OK – The diagnostic code is not active. The
diagnostic code does not exist at this time. The
initial diagnostic code was probably caused by a
poor connection or a short at one of the connectors
that was disconnected and reconnected. Resume
normal operation. STOP.
• NOT OK – The code is active. The diagnostic code
has not been corrected. The ECM may have failed.
Repair: It is unlikely that the ECM has failed. Exit
this procedure and perform this procedure again.
If the cause of the failure is not found, replace
the ECM. See Testing and Adjusting, “Electronic
Control Module (Generator Set) - Replace”.
STOP.
i02464543
Engine Speed Circuit Fault
SMCS Code: 4490
System Operation Description:
The EMCP 3 performs the following using an
independent engine speed sensor that is dedicated
to EMCP 3 use only
• Determines the engine speed, in rpm, from the
Magnetic Pickup (Engine Speed Sensor) input pins
• Detects diagnostics on the sensor
• Annunciates an engine over/under speed condition
The engine speed sensor is mounted on the flywheel
housing of the engine.
The sensor creates a sine wave signal. The signal
is created from passing ring gear teeth. The rate of
the signal is one pulse per tooth. The sensor sends
the sine wave signal to the EMCP 3. The frequency
of the signal is directly proportional to the speed of
the engine.
Conditions Which Generate This Code:
This code is generated when the EMCP 3
has determined that an incorrect signal from
the engine speed sensor has occurred or an
overspeed/underspeed condition has occurred.
RENR7902-07
Refer to the engine Troubleshooting manual to
for more information on engine over/under speed
conditions for your particular genset.
g01103901
Illustration 75
Note: The Engine Speed Sensor is commonly
referred to as magnetic pickup.
Test Step 1. PERFORM THE INITIAL
CHECK.
A. Check for active diagnostic codes on the engine
ECM and the EMCP 3. If any codes are present,
correct the diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active.
Results:
• OK – No other diagnostic codes or indicators are
active. Proceed to Test Step 2
• NOT OK – Another diagnostic code is active or an
indicator is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Resume normal operation
and verify that the problem has been corrected.
STOP.
Test Step 2. CHECK THE SETPOINTS.
A. View the Engine Speed Monitor Setpoints. Make
a note of all the setpoints. See Testing and
Adjusting, “Electronic Control Module (Generator
Set) - Configure”. Compare the setpoints against
the default setpoints of the particular generator
set.
Expected Result:
The setpoints are correct.
RENR7902-07
Results:
• OK – The setpoints are correct for your particular
genset. Proceed to Test Step 3
• NOT OK – The setpoints are NOT correct.
Repair: Reprogram the setpoints. Reset the
genset. Resume normal operation and verify that
the problem has been corrected.
STOP.
Test Step 3. CHECK THE HARNESS AND
THE SPEED SENSOR.
A. Press the Stop key on the EMCP 3 control.
B. Disconnect the harness connector from the EMCP
3.
C. At the EMCP 3 harness connector, measure the
resistance from contact “66” to contact “67”.
Expected Result:
The resistance should be from 100 to 350 ohms.
Results:
• OK – There is probably an intermittent problem.
Proceed to Test Step 4.
• NOT OK – The harness wiring or the speed sensor
has failed. Proceed to Test Step 4.
Test Step 4. CHECK FOR AN
INTERMITTENT FAULT.
A. Press the Stop key on the EMCP 3 control.
B. Check the EMCP 3 display for a speed sensor
diagnostic code.
Expected Result:
A speed sensor diagnostic code should not appear
on the upper display.
Results:
• OK – A speed sensor diagnostic code does not
appear on the EMCP 3 display. This step has
corrected the problem. STOP.
• NOT OK – A speed sensor diagnostic code
appears on the EMCP 3 display. Proceed to Test
Step 5.
135
Troubleshooting Section
Test Step 5. CHECK THE RESISTANCE
OF THE ENGINE SPEED SENSOR.
A. Disconnect the sensor from the engine harness.
The sensor remains fastened to the engine.
B. At the connector of the sensor, measure the
resistance between contact “1” and contact “2”.
Expected Result:
The resistance should be between 100 to 350 ohms.
Results:
• OK – The resistance of the sensor is correct.
Proceed to Test Step 6.
• NOT OK – Replace the sensor.
Repair: Refer to Testing And Adjusting, “Speed
Sensor (Engine) - Adjust”.
STOP.
Test Step 6. CHECK THE HARNESS FOR
AN OPEN OR A SHORT.
A. Press the Stop key on the EMCP 3 control.
B. Disconnect the sensor from the engine harness.
The sensor remains fastened to the engine.
C. Disconnect the harness connector from the EMCP
3.
D. Check for an open circuit. Check the resistance
from contact “1” of the sensor harness connector
to contact “66” of the EMCP 3 harness connector.
The resistance should be 5 ohms or less.
E. Check for an open circuit. Check the resistance
from contact “2” of the sensor harness connector
to contact “67” of the EMCP 3 harness connector.
The resistance should be 5 ohms or less.
F. Check for a short circuit. Check the resistance
from contact “66” to contact “67” of the EMCP
3 harness connector. The resistance should be
greater than 5000 ohms.
Expected Result:
When the resistance is measured between contact
“1” of the sensor harness connector and contact “66”
of the EMCP 3 harness connector, there should be
5 ohms or less.
The resistance from contact “2” of the sensor harness
connector to contact “67” of the EMCP 3 harness
connector should be 5 ohms or less.
136
Troubleshooting Section
The resistance from contact “66” to contact “67” of
the EMCP 3 harness connector should be greater
than 5000 ohms.
Results:
• OK – The harness functions properly. Proceed to
Test Step 7.
• NOT OK – The circuit with the incorrect resistance
measurement has failed. Replace the failed
harness from the sensor to the EMCP 3 connector
or repair the failed harness from the sensor to the
EMCP 3 connector. STOP.
Test Step 7. CHECK THE SHIELD AND
THE CONNECTORS.
A. Press the Stop key on the EMCP 3 control.
B. Disconnect the sensor from the engine harness.
The sensor remains fastened to the engine.
C. Disconnect the harness connector from the EMCP
3.
D. The harness has a shield (bare wire) which
protects the sensor signal wire from electrical
interference. This shield must be securely
fastened and the shield must make a good
electrical connection to ground.
E. Check that the shield is securely fastened to
ground.
F. Check the connection between the sensor and the
mating harness connector. Refer to Testing and
Adjusting, “Electrical Connector - Inspect”.
Expected Result:
The shield should be securely fastened. The
connection between the sensor and the mating
harness connector should be secure.
Results:
• OK – The shield is securely fastened. The
connection between the sensor and the mating
harness connector is secure. Proceed to Test Step
8.
• NOT OK – One of the items is not correct. Repair
the harness or replace the harness. STOP.
Test Step 8. INSPECT THE SENSOR AND
ADJUST THE SENSOR.
A. Remove the sensor from the engine flywheel
housing.
B. Inspect the sensor for damage and remove any
debris from the tip.
RENR7902-07
Expected Result:
No damage should be present.
Results:
• OK – No damage is present. Reinstall the engine
speed sensor. Adjust the sensor.
Repair: For more information, refer to Testing And
Adjusting, “Speed Sensor (Engine) - Adjust”.
Proceed to Test Step 9.
• NOT OK – Damage is present. Replace the engine
speed sensor.
Repair: Refer to Testing And Adjusting, “Speed
Sensor (Engine) - Adjust”.
STOP.
Test Step 9. CHECK THE STATUS OF THE
FAULT.
A. Reconnect the harness connector to the EMCP
3 and the sensor.
B. Press the Stop key on the EMCP 3 control.
C. Check the EMCP 3 display for a sensor diagnostic
code.
Expected Result:
A speed sensor diagnostic code should still be active.
Results:
• OK – A speed sensor diagnostic code is showing
on the EMCP 3 display. The diagnostic code is still
active and the engine will not start.
Repair: It is unlikely that the EMCP 3 has failed.
Exit this procedure and perform this procedure
again. If the diagnostic code is still present, replace
the EMCP 3. Refer to Testing and Adjusting,
“Electronic Control (Generator Set) - Replace”.
STOP.
• NOT OK – A speed sensor diagnostic code is not
showing on the upper display. These procedures
have corrected the problem. The operator may
continue with this procedure. Proceed to Test Step
10.
Test Step 10. CHECK THE SIGNAL
VOLTAGE.
A. This is an additional check of the circuit. Make sure
that all of the harness connectors are connected.
RENR7902-07
B. Use a multimeter and 7x-1710 Multimeter
Probes in order to measure the AC signal voltage.
Measure the AC signal voltage between contact
“66” and contact “67” of the EMCP 3 connector.
C. Start the engine and run the engine at the rated
speed.
D. Measure the AC signal voltage of the engine
speed sensor.
Expected Result:
The voltage should be equal to 2 VAC or greater.
Results:
• OK – The voltage is equal to 2 VAC or greater.
The speed sensor circuit is correct. STOP.
• NOT OK – The voltage is not equal to 2 VAC or
greater. The most likely cause is improper air gap
of the pickup.
Repair: For more information, refer to Testing And
Adjusting, “Speed Sensor (Engine) - Adjust”.
STOP.
i02464587
Unexpected Engine Shutdown
SMCS Code: 4490
System Operation Description:
While the engine is running, if engine speed suddenly
becomes zero and the Auto Start/Stop function block
has not initiated a shutdown, an “UNEXPECTED
ENGINE SHUTDOWN” event will be activated.
The EMCP 3 performs the following using an
independent engine speed sensor that is dedicated
to EMCP 3 use only
• Determines the engine speed, in rpm, from the
Magnetic Pickup (Engine Speed Sensor) input pins
• Detects diagnostics on the sensor
• Annunciates an engine over/under speed condition
Conditions Which Generate This Code:
While the engine is running, if engine speed suddenly
becomes zero and the Auto Start/Stop function block
has not initiated a shutdown, an “UNEXPECTED
ENGINE SHUTDOWN” event will be activated.
137
Troubleshooting Section
Test Step 1. TALK TO THE OPERATOR
A. Determine the conditions that caused the
unexpected shutdown.
Expected Result:
A unexpected shutdown was caused by an
occurrence known to the operator and the operator
would like to put the genset back into service.
Results:
• OK – The operator can determine the cause for
the “UNEXPECTED ENGINE SHUTDOWN”, the
condition has been repaired and the operator
wants to put the genset back into service.
Repair: Reset the genset. Resume normal
operation and verify that the problem has been
corrected.
STOP.
• NOT OK – The “UNEXPECTED ENGINE
SHUTDOWN” was not caused by a occurrence
known to the operator. Proceed to Test Step 2
Test Step 2. CHECK FOR OTHER
DIAGNOSTIC CODES.
A. Check for active diagnostic codes on the engine
ECM and the EMCP 3. If any codes are present,
correct the diagnostic codes first.
Expected Result:
No other diagnostic codes or indicators are active.
Results:
• OK – No other diagnostic codes or indicators are
active.
Repair: Refer to the engine Troubleshooting
manual for more information on engine unexpected
engine shutdowns for your particular genset.
STOP.
• NOT OK – Another diagnostic code is active or an
indicator is active.
Repair: Exit this procedure. Troubleshoot the
active code or indicator. Resume normal operation
and verify that the problem has been corrected.
STOP.
138
Testing and Adjusting Section
Testing and Adjusting
Section
Testing and Adjusting
i02464725
Electrical Connector - Inspect
SMCS Code: 7553-040
Intermittent electrical problems are often caused by
poor connections. Use the following checks as a
reference for inspecting connectors.
1. Check the connection of the connectors.
• Ensure that the locking rings are properly
locked.
• Ensure that locking clips are used on Sure Seal
connectors.
• Ensure that the center of the connector is tight.
• Ensure that the connector pins and sockets
align properly.
2. Check the wires at the connector.
• Ensure that the wires are straight as they enter
the back of the connector.
• Ensure that each wire is properly crimped into
the proper connector contact.
• Ensure that each connector contact is properly
locked into the connector contact. When the
connector contact is locked properly, the contact
(wire) cannot be pulled out of the connector
body without excessive force.
3. Check each wire for nicks or signs of abrasion
in the insulation.
4. Check for moisture at the connector.
• Check for damaged connector seals or lost
connector seals.
• Check for missing or loose wire hole plugs.
• Check for wires that do not enter the connector
properly.
• If the wires enter the connector at an angle,
there may not be a good seal between the
connector and the wire insulation.
RENR7902-07
• Moisture can enter the connector through the
wire insulation.
5. Check for dirty contacts or corroded contacts.
• Clean contacts with a cotton swab or a soft
brush and denatured alcohol ONLY.
6. Check each pin and each socket.
• Check each contact of the connector for a snug
fit by using a new pin and socket. The new
contact should stay connected if the connector
is held with the contacts that are facing down.
i02985222
Wiring Harness (Open Circuit)
- Test
SMCS Code: 1408-081
An open is a failure of an electrical circuit that results
in no flow of electrical current. An open circuit is
usually caused by failed electrical wires or a poor
connection of electrical connectors. If an electrical
wire or a connection is broken, then the flow of
electrical current through the circuit is interrupted. A
normally closed circuit will have less than 5 ohms of
resistance. The following procedure explains the test
for an open circuit:
Reference: For a complete electrical schematic,
refer to Electrical System Schematic for the genset
that is being serviced.
TEST FOR AN OPEN CIRCUIT.
1. Identify the connectors and the wire numbers of
the suspect circuits. Use the Electrical System
Schematic of the genset to identify the circuits.
2. Turn the disconnect switch to the OFF position.
3. Disconnect the components and the ECM from
the wiring harness.
4. At one of the disconnected harness connections,
place a jumper wire from the contact of the
suspect wire to frame ground.
5. At the other connector of the genset harness, use
the multimeter probes to measure the resistance
from the contact of the suspect wire to frame
ground.
Expected Result: The resistance is less than 5
ohms.
OK – The resistance is less than 5 ohms. The
harness circuit is correct.
RENR7902-07 139
Testing and Adjusting Section

Stop. NOT OK – The resistance is less than 5000

ohms. There is a short in the genset harness. The
NOT OK – The resistance is greater than 5000 short is between the suspect wire and the wire
ohms. There is an open in the genset harness. with the lowest resistance measurement.

Repair: Repair the genset harness or replace the Repair: Repair the genset harness or replace the
genset harness. genset harness.

Stop. Stop.

i02464705 i02985320

Wiring Harness (Short Circuit) External Potential Transformer

- Test Connections
SMCS Code: 1408-081 SMCS Code: 1409-077

A short circuit is a failure of an electrical circuit that

results in undesired electrical current. Usually, a
Winding Connections
short circuit is a bypass of the circuit across a load.
The wiring connections that are used between the
For example, a short across the wires in a circuit for
generator and the EMCP 3 depend upon the winding
a lamp produces too much current in the wires but configurations of the generator. Refer to the following
no current is felt at the lamp. The lamp is shorted
connection diagrams.
out. The resistance in a normal circuit can vary, but
the resistance between a particular circuit and other
unrelated circuits is always greater than 5000 ohms.
The following procedure explains the test for a short
circuit:

Reference: For a complete electrical schematic,

refer to Electrical System Schematic for the genset
that is being serviced.

TEST FOR A SHORT CIRCUIT.

1. Identify the connectors and the wire numbers of

the suspect circuits. Use the Electrical System
Schematic of the genset to identify the circuits.

2. Turn the key start switch and the disconnect

switch to the OFF position.

3. Disconnect the component and the ECM from the

wiring harness.

4. At the genset harness connector for the ECM,

place one of the multimeter probes on the contact
of the suspect wire.

5. Use the other multimeter probe to check the

resistance across all other contacts in the
connector(s) of the ECM and frame ground.

Expected Result: The resistance is greater than

5000 ohms for all the measurements.

OK – The resistance is greater than 5000 ohms

for all the measurements. The harness circuits are
correct.

Stop.
140 RENR7902-07
Testing and Adjusting Section

g01512173
Illustration 76
Three Phase Four Wire (Series or Parallel) Wye (Star)

g01512193
Illustration 77
Three Phase Four Wire Delta
RENR7902-07 141
Testing and Adjusting Section

g01512213
Illustration 78
Three Phase Three Wire Delta

g01512215
Illustration 79
Single Phase Three Wire (Double Delta)
142 RENR7902-07
Testing and Adjusting Section

g01512236
Illustration 80
Single Phase Two Wire (Double Delta)

Transformer Connections
In order to monitor the generator output voltages
greater than 600 Volts, potential transformers (PTs)
must be used.

Note: The EMCP 3 must be programmed when

connecting external PTs.

Reference: Systems Operation, “Setpoint

Programming” and Testing and Adjusting, “Electronic
Control Module (Generator Set) - Configure”.

Note: The wye configuration of external PTs is

preferred for 4-wire wye generators because of the
greater accuracy when loads are unbalanced. With
the open delta configuration, some power parameters
cannot be determined. These parameters are real
power phase A, B, C and power factor phase A, B, C.
For maximum accuracy, the open delta configuration
of external PTs should be used only for 3-wire delta
generators.
RENR7902-07 143
Testing and Adjusting Section

g01228369
Illustration 81
Wye configuration of external potential transformers on the 4-wire Wye Generator
This configuration allows the accurate measurement of all power parameters by the EMCP 3 including when the loads are unbalanced and
neutral current is present. All power parameters are shown on the display of the EMCP 3. The EMCP 3 configuration parameter“ Generator
Connection Configuration” should be set to WYE (or STAR).

g01228370
Illustration 82
Open Delta Configuration of external potential transformers on the 3-wire Delta Generator
This configuration allows the accurate measurement of power parameters by the EMCP 3 including when the loads are unbalanced and
circulating current is present. The real power phase A, B and C cannot be determined. The power factor phase A, B and C cannot be
determined. The phases are not shown on the EMCP 3 display. The EMCP 3 configuration parameter “Generator Connection Configuration”
should be set to DELTA (3 WIRE).

g01228371
Illustration 83
Open Delta configuration of external potential transformers on the 4-wire Wye Generator
This configuration results in less accurate measurement of all power parameters by the “EMCP 3” when the loads are unbalanced and neutral
current is present. Real power phase A, B, C and power factor phase A, B, C cannot be determined and are not shown on the “EMCP 3”
display. The EMCP 3 configuration parameter “Generator Connection Configuration” should be set to DELTA (3 WIRE).
144 RENR7902-07
Testing and Adjusting Section

On 4-wire wye generators, three separate PTs are

required for accurate power metering unless the
loads are completely and continually balanced. Even
if the loads are balanced, some power parameters
cannot be determined. Real power phase A, B, C
and power factor phase A, B, C are not shown on
the EMCP 3 display.

On 3-wire delta generators, two PTs allow maximum

accuracy for all load conditions. Real power phase
A, B, C and power factor phase A, B, C cannot
be determined and are not shown on the EMCP 3
display.

Table 34
Transformer Connections
Parameter Star 3-WIRE DELTA 4-WIRE DELTA 2-WIRE 1-PHASE 3-WIRE 1-PHASE
Gen Freq OK OK OK OK OK
VL-L AVG OK OK OK OK OK
VA-B OK OK OK OK OK
VB-C OK OK OK Invalid Invalid
VC-A OK OK OK Invalid Invalid
VL-N AVG OK Invalid OK Invalid OK
VA OK Invalid OK Invalid OK
VB OK Invalid OK Invalid OK
VC OK Invalid OK Invalid Invalid
IAVG OK OK OK OK OK
IA OK OK OK OK OK
IB OK OK OK OK OK
IC OK OK OK Invalid Invalid

i02986620 2. If a device such as a load share module is

supplying the PWM signal in order to bias the
Engine Speed Timing engine speed, then disconnect the wires from the
Calibration - Setup device. Go to Step 4

SMCS Code: 1912-587
The following procedure describes the adjustments
that are required if an “Engine Speed Timing
Calibration” is performed. After this procedure has
been completed, the engine can be started and the
engine can be run at rated speed.
Note: This procedure does not include the
instructions for performing the actual calibration.
Note: Before changing any value per this procedure,
record the original value.
1. Stop the engine.
If there is not a device that is supplying the PWM
signal and the engine speed bias is controlled
from the EMCP 3, then go to Step 3.
3. Use the EMCP 3 control screen in order to go to
idle. Refer to the “Idle Speed and Rated Speed”
information that is in the “Voltage and Frequency
Adjustment” section of this publication. Go to Step
5.
4. Set the “Engine Start Fault Protection Activation
Delay Time” setpoint in the EMCP 3 to 90 seconds.
Use the Cat ET in order to set the “Secondary
Desired Speed Input Configuration” set point in
the engine ECM to “DISABLED”.

5. Start the engine and run the engine at idle speed.

6. Perform the “Engine Speed Timing Calibration” .

RENR7902-07
7. Stop the engine.
8. Use Cat ET in order to return the set points that
were modified in Step 2 through Step 4 to the
original values. Navigate to the “Control” screen,
then go to the “Rated” screen.
9. Reconnect any wires that were disconnected in
Step 2.
i02464712
Speed Sensor (Engine) - Adjust
SMCS Code: 1907-025
g00289497
Illustration 84
Speed Sensor
(1) Speed sensor
(2) Locknut
(A) Air gap
Note: The engine speed sensor is commonly referred
as a magnetic pickup sensor.
This adjustment procedure is for the engine speed
sensor.
1. Remove the speed sensor (1) from the flywheel
housing. Remove all debris from the tip of the
speed sensor. Align a ring gear tooth directly in
the center of the threaded sensor opening.
2. By hand, screw the speed sensor (1) into the hole
until the end of the sensor contacts the gear tooth.
3. Turn the sensor (1) in the counterclockwise
direction through 270 degrees (three-fourths turn).
4. Tighten locknut (2) to 25 ± 5 N·m (18 ± 4 lb ft).
Note: Do not allow speed sensor (1) to turn as
locknut (2) is tightened.
145
Testing and Adjusting Section
i02459627
Engine Setpoint Verification -
Test
SMCS Code: 4490-081
The Engine setpoint verification procedure verifies
that the EMCP 3 operates correctly when one of the
following faults occurs:
Engine overspeed – Causes the EMCP 3 to shut
the engine down
High coolant temperature – Causes the EMCP 3
to either shut the engine down or to issue a warning
based on the event response configuration setpoints
Low oil pressure – Causes the EMCP 3 to either
shut the engine down or to issue a warning based on
the event response configuration setpoints
Relevant Engine Parameter Group
Setpoints
The engine setpoint verification procedure is used in
order to adjust the relevant configuration setpoints
in the configuration parameter groups that are used
during normal operation.
The following conditions are required before the
engine setpoints are verified:
• The relevant setpoints listed in each configuration
parameter group must be correct for the engine
application
• No shutdown events should be present at the initial
start up. If necessary, troubleshoot, correct, and
reset any and all shutdown events.
During the procedure, each configuration setpoint
that is to be adjusted should be recorded, and then
returned to the original setting after the setpoint has
been verified.
Note: Prior to performing this procedure, a service
replacement file can be saved using the Caterpillar
service tool. The replacement file is used in order to
record the configuration to allow reprogramming the
control with the original setpoints after the procedure
has been completed.
Engine Protection Events Configuration
• High Engine Coolant Temperature Shutdown
Event Response Configuration (Hard Shutdown
Enable/Disable)
146 RENR7902-07
Testing and Adjusting Section

• Low Engine Oil Pressure Shutdown Event Reference: For details on changing the EMCP 3
Response Configuration (Hard Shutdown security level, see Systems Operation, “Password
Enable/Disable) Entry”.

Engine Speed Monitor 1. Start the engine and run the engine at its rated
speed.
Table 35
2. Adjust the setpoint value to a value that is below
Engine Over Speed Shutdown Threshold
(adjust value)
the speed that the engine is running, and then
press the ENTER key. An Engine Overspeed
Adjustment 400 to 4330 RPM in 1 RPM increments Shutdown event will immediately occur.
Range
Default 2120 RPM (or 1.18 times the rated speed) 3. View the event in the Genset Control event log.
value
Reference: Systems Operation, “Event Viewing”

Engine Coolant Temperature Monitor 4. Reset the event.

Table 36 Reference: Systems Operation, “Event Resetting”
High Engine Coolant Temperature Shutdown
Event Threshold (adjust value) (1) 5. Return the setpoint value to its original value.
Adjustment 49 °C (120 °F) to 120 °C (248 °F) in 1
Range degree increments Low Oil Pressure
Default 107 °C (225 °F) Setpoint: Low Engine Oil Pressure Shutdown
value Event Threshold
Warning Occurs at 102 °C (216 °F)
Indication 1. Start the engine and run the engine at its rated
speed.
Default 10 seconds
Time Delay
2. Adjust the setpoint value to a value that is above
(1) Requires engine to be running at rated speed for verification the oil pressure that is being displayed, and then
press the ENTER key. A shutdown event will occur
Engine Oil Pressure Monitor after the programmable time delay has expired.
The default for this delay is ten seconds..
Table 37
Low Engine Oil Pressure Shutdown Event 3. View the event in the Genset Control event log.
Threshold (adjust value) (1)
Reference: Systems Operation, “Event Viewing”
Adjustment 34 kPa (5 psi) to 690 kPa (100 psi) in one
Range unit increments 4. Reset the event.
Default 205 kPa (30 psi)
value Reference: Systems Operation, “Event Resetting”
Warning Occurs at 239 kPa (35 psi) 5. Return the setpoint value to its original value.
Indication
Default 10 seconds High Coolant Temperature
Time Delay
(1) Requires engine to be running at rated speed for verification Setpoint: High Engine Coolant Temperature
Shutdown Event Threshold
Verification Procedures 1. Start the engine and run the engine at its rated
speed.
Overspeed
2. Adjust setpoint value to a value that is below
Setpoint: Engine Over Speed Shutdown the engine coolant temperature that is being
Threshold displayed, and then press the ENTER key. A
shutdown event will occur after the programmable
Note: This is a password protected Level 3 setpoint. time delay has expired. The default for this delay
The passwords only affect changing parameters is ten seconds.
from the EMCP 3 control panel display. Changing
parameters with the Caterpillar Service Tool does not 3. View the event in the Genset Control event log.
require passwords.
RENR7902-07
Reference: Systems Operation, “Event Viewing”
4. Reset the event.
Reference: Systems Operation, “Event Resetting”
5. Return the setpoint value to its original value.
i02459197
Electronic Control Module
(Generator Set) - Replace
SMCS Code: 4490-510
Replacement Procedure
Note: The configuration from the old ECM can be
saved in the Caterpillar service tool. The configuration
can then be uploaded to the new ECM.
1. The new ECM must be reprogrammed after
installation. If the ECM that is being replaced is
functional, then make a note of the following items:
hour meter value, all engine setpoints, and any
spare inputs or outputs that are programmed. See
System OperationSystem Operation, “Setpoint
Programming”.
2. Shut down the engine. Remove the positive lead
wire from the battery.
3. Remove the harness connector from the ECM. A
4 mm hex wrench is required in order to turn the
fastening screw.
4. Remove the six nuts that fasten the ECM to the
front panel. Remove the ECM.
5. Place the new ECM in the front panel and then
install and tighten the six nuts that were previously
removed in order to secure the new ECM to the
front panel.
6. Reconnect the harness connector to the ECMand
reconnect the positive lead wire to the battery.
Reference: Generator Set Wiring Diagram Testing
And Adjusting, “Electronic Control Module Wiring
Diagrams”
7. Using the values from the original ECM, reprogram
the setpoints, the spare inputs/outputs, and the
hour meter. Refer to Step 1.
147
Testing and Adjusting Section
i02463503
Electronic Control Module
(Generator Set) - Flash
Program
SMCS Code: 4490-591
Perform the following procedure in order to flash
program the Electronic Control Module (ECM) for
the Generator Set. The ECM is flashed in order
to upgrade the software. Flash programming of
the ECM must also be done if the ECM has been
replaced. The Caterpillar Electronic Technician
contains the program WinFlash. WinFlash is used
in order to load(flash) the software into the ECM.
The following procedure is used in order to flash the
software into the ECM.
Procedure
1. Connect the Data Link Cable between the
Communication Adapter and the Caterpillar
Electronic Technician.
2. Connect the Data Link Cable between the
Communication Adapter and the Service
Connector of the genset.
3. Turn the disconnect switch to the ON position.
4. Use WinFlash in order to flash the software.
i02986821
Electronic Control Module
(Generator Set) - Configure
SMCS Code: 4490-025
Function Keys and Navigation Keys
Reference: For a full explanation of the use of the
Function keys (Enter, Escape) and the Navigation
keys (Scroll Left, Scroll Right, Scroll Up, Scroll Down)
that are referenced in this section, see Systems
Operation, “Electronic Control Module (Generator
Set)”
148 RENR7902-07
Testing and Adjusting Section

g01211086
Illustration 85
(1) Display Screen (7) Auto key (13) Scroll Up key
(2) Yellow Warning Lamp (8) Run key (14) Scroll Left key
(3) Red Shutdown Lamp (9) Escape key (15) Engine Overview key
(4) Alarm Acknowledge/Silence key (10) Enter key (16) AC Overview key
(5) Lamp Test key (11) Scroll Right key
(6) Stop key (12) Scroll Down key

(9) Escape – Navigate up (backward) through the Initial Setup

menu structure and also used to cancel out of data
entry screens during setpoint programming.
(10) Enter – Select a highlighted menu item
(11) Scroll Right – During numeric data entry,
choose the digit to edit. During certain setpoint
adjustments, select or deselect a checkbox.
Information from the EMCP 3 is displayed on the
Display Screen (1). Press the Scroll Up key or the
Scroll Down key in order to highlight the MAIN
MENU options.
Press the Enter key in order to select one of the main
menu options.

(12) Scroll Down – Move down through the main
menu or navigate within a list in order to highlight one
of the items. Also used to decrement digits (0-9).
(13) Scroll Up – Move up through the main menu or
navigate within a list in order to highlight one of the
items. Also used to increment digits (0-9)
The keypad is also used in order to change the
setpoints. Press the Enter key in order to change a
setpoint. Press the Scroll Up key or the Scroll Down
key in order to increase or decrease the value. Press
the Scroll Left key or the Scroll Right key in order
to change the digit that is to be adjusted.

(14) Scroll Left – During numeric data entry, choose

the digit to edit. During certain setpoint adjustments,
select or deselect a checkbox.
RENR7902-07 149
Testing and Adjusting Section

Note: The EMCP 3 panel will power up to the MAIN
MENU screen. If the EMCP 3 panel is already
powered up, press the Escape key in order to return
to the main menu. Each press of the Escape key
moves you back one level in the menu structure,
• Generator AC Power Monitor
• Generator Over Current
• Generator Over/Under Frequency

Setpoints • Generator Over/Under Voltage

Within each setpoint category there are one or more • Generator Reverse Power
function blocks. Each of those function blocks may
contain one or more setpoints. Each of these setpoint Input/Output (I/O)
categories and its corresponding function blocks are
shown below. • Digital Inputs

Control • Digital Outputs

• Automatic Start/Stop • Relay Outputs

• Automatic Voltage Regulator (AVR) Desired • Spare Analog Input

Voltage Request
Network
• Generator Desired Engine Speed Request
• Data Link - SCADA
Engine Monitor/Protect
Other
• Battery Voltage Monitor
• Digital Selectors
• Crank Attempt/Successful start Counter
• Reduced Power Mode
• Engine Coolant Temperature Monitor
Menu Maps
• Engine Oil Pressure Monitor
The maps in this section are to be used as a guide
• Engine Speed Monitor when programming the EMCP 3. Maps are provided
for all versions of the controller.
• Enhanced Engine Monitor
• Service Maintenance Interval

Events
• Diagnostics Conguration
• Engine protection Events Conguration
• Generator Protection Events Conguration
• Other System Events Conguration
• Custom Events
• Event Output Function
• Event System

Generator Monitor/Protect
• Enhanced Generator Monitor
• Generator AC Monitor
 EMCP 3.1 Generator Set Control Menu Structure

sample screen

ENG SPEED SENSOR

ERRATIC/LOST 3/17 *2 or *3
sample screen ACTIVE OCC 1 ENTER
MAIN MENU ESCAPE
ACTIVE EVENTS 1 sample screen KEY KEY
EVENT LOG GENSET CONTROL 0
ENGINE CONTROL 1 GEN OVER CURRENT
WARNING 1/3 *2 *1. To adjust settings perform the following:
ENGINE OVERVIEW INACTIVE OCC 1
1. Use the Scroll Up and Scroll Down keys to select the submenu.
sample screen
2. Use the Scroll Up, Scroll Down, Scroll Left and the Scroll Right keys
AC OVERVIEW
0kPa 23 C 24.8V
OR to select and adjust the settings, and then select the Enter key for the new
0 rpm 2.1Hrs
CONFIGURE STOPPED settings to take effect.
I/O STATUS sample screen USE *2. Scroll down to see all events. Events are listed in the following order: Present,
OR AVG: 481 V L-L 324A Active, Inactive. Only SHUTDOWN events can be reset; some events can
PREFERENCES 60.2Hz 0.82 LAGGING
TOTAL kW 216 48% be set as a SHUTDOWN. To reset an event, the control must be in STOP.
All other events will become INACTIVE once the condition goes away.
*3. To RESET : press the ENTER key to get to the details of the event, and
CONFIGURE CURRENT LEVEL = 2 then press the ENTER key again.
DROP TO MIN LEVEL
SECURITY
ENTER LEVEL 1 OR 2
SETPOINTS ENTER LEVEL 3
*4. To get back to the MAIN MENU at any time, press or and
ENG OPERATE HRS CHANGE LEVEL 1
CHANGE LEVEL 2 5. When unsure about your location on the screen, press the ESCAPE key and
then refer to this menu map to navigate to the correct location.

SETPOINTS
CONTROL CONTROL
ENGINE MON/PROTECT AUTOMATIC START/STOP
GOV DESIRED ENG SPD *1
EVENTS
GEN MON/PROTECT
I/O
OTHER
ENG MONITOR/PROTECT
BATTERY VOLT MON
ENG COOL TEMP MON
ENG OIL PRES MON *1
ENG SPEED MON

EVENTS EVENT I/P FUNCTIONS

EVENT I/P FUNCTIONS EVENT INPUT #1
EVENT O/P FUNCTIONS EVENT INPUT #2
EVENT RESPONSE CFG EVENT INPUT #3 *1
EVENT SYSTEM EVENT INPUT #4

EVENT 0/P FUNCTIONS

EVENT OUTPUT #1 *1
150

EVENT RESPONSE CFG DIAGNOSTICS CONFIG

DIAGNOSTIC CONFIG PRESSURES

Illustration 86
ENG PROTECT CONFIG TEMPERATURES *1
GEN PROTECT CONFIG LEVELS
OTHER SYSTEM CONFIG OTHERS

*1 ENG PROTECT CONFIG

PRESSURES
*1
TEMPERATURES
LEVELS
OTHERS
Testing and Adjusting Section

WARNING AUTO RESET

ENABLED STATUS *1
ENABLED

GEN MON/PROTECT
GEN AC MONITOR *1

I/O DIGITAL INPUTS

DIGITAL INPUTS INPUT #1
RELAY OUTPUTS INPUT #2
INPUT #3
INPUT #4
INPUT #5 *1
INPUT #6

RELAY OUTPUTS
OUTPUT #1
OUTPUT #2
OUTPUT #3
OUTPUT #4 *1
OUTPUT #5
OUTPUT #6

sample screen
OTHER DIGITAL SELECTORS
DIGITAL SELECTORS DIGITAL SELECTORS #1
Digital I/P - 2 - 4 - -
REDUCED PWR MODE DIGITAL SELECTORS #2
Relay O/P 1 - - - 5 6
DIGITAL SELECTORS #3
DIGITAL SELECTORS #4 *1
*1
PREFERENCES
CONTRAST
BACKLIGHT
PRESSURE *1
TEMPERATURE
LANGUAGE
g01231819
RENR7902-07
RENR7902-07 151
Testing and Adjusting Section
 EMCP 3.2 Generator Set Control Menu Structure

sample screen

ENG SPEED SENSOR

ERRATIC/LOST 3/17 *2 or *3
sample screen ACTIVE OCC 1 ENTER
MAIN MENU
ESCAPE
ACTIVE EVENTS 1 KEY KEY
GENSET CONTROL 1 GEN OVER CURRENT
EVENT LOG
ENGINE CONTROL 0 WARNING 1/3 *2 *1. To adjust settings perform the following:
INACTIVE OCC 1
ENGINE OVERVIEW
1. Use the Scroll Up and Scroll Down keys to select the submenu.
AC OVERVIEW sample screen 2. Use the Scroll Up, Scroll Down, Scroll Left and the Scroll Right keys
0kPa 23 C 24.8V to select and adjust the settings, and then select the Enter key for the new
OR
CONFIGURE 0 rpm 2.1Hrs settings to take effect.
STOPPED
I/O STATUS USE
*2. Scroll down to see all events. Events are listed in the following order: Present,
sample screen
Active, Inactive. Only SHUTDOWN events can be reset; some events can
OR AVG: 481 V L-L 324A
PREFERENCES 60.2Hz 0.82 LAGGING be set as a SHUTDOWN. To reset an event, the control must be in STOP.
TOTAL kW 216 48% All other events will become INACTIVE once the condition goes away.
*3. To RESET : press the ENTER key to get to the details of the event, and
CONFIGURE CURRENT LEVEL = 2 then press the ENTER key again.
SECURITY DROP TO MIN LEVEL
ENTER LEVEL 3
*4. To get back to the MAIN MENU at any time, press or and
SETPOINTS
TIME DATE CHANGE LEVEL 1
ENG OPERATE HRS CHANGE LEVEL 2 5. When unsure about your location on the screen, press the ESCAPE key and
CHANGE SCADA PWD
then refer to this menu map to navigate to the correct location.

SETPOINTS
CONTROL
CONTROL
AUTOMATIC START/STOP
ENGINE MON/PROTECT GOV DESIRED ENG SPD *1
EVENTS
GEN MON/PROTECT
I/O
NETWORK ENG MONITOR/PROTECT
BATTERY VOLT MON
OTHER
ENG COOL TEMP MON
CRANK/START CTRS *1
ENG OIL PRES MON
ENG SPEED MON
SERVICE MAINT INTERVAL

EVENTS EVENT I/P FUNCTIONS

EVENT I/P FUNCTIONS EVENT INPUT #1
EVENT O/P FUNCTIONS EVENT INPUT #2
EVENT RESPONSE CFG EVENT INPUT #3 *1
EVENT SYSTEM EVENT INPUT #4

EVENT 0/P FUNCTIONS

EVENT OUTPUT #1 *1

EVENT RESPONSE CFG DIAGNOSTICS CONFIG

152

DIAGNOSTIC CONFIG PRESSURES

ENG PROTECT CONFIG TEMPERATURES
GEN PROTECT CONFIG
*1
LEVELS
OTHER SYSTEM CONFIG
OTHERS

Illustration 87
*1
ENG PROTECT CONFIG
PRESSURES
TEMPERATURES *1
LEVELS
OTHERS

WARNING AUTO RESET

ENABLED STATUS *1
ENABLED
Testing and Adjusting Section

GEN MON/PROTECT
GEN AC MONITOR
GEN AC PWR MONITOR *1
GEN OVER CURRENT
GEN OVER/UNDER FREQ
GEN OVER/UNDER VOLT

I/O DIGITAL INPUTS

DIGITAL INPUTS INPUT #1
DIGITAL OUTPUTS INPUT #2
RELAY OUTPUTS INPUT #3
SPARE ANALOG INPUT INPUT #4
INPUT #5 *1
INPUT #6
INPUT #7
INPUT #8

DIGITAL OUTPUTS
NETWORK *1
DATALINK- SCADA OUTPUT #1

RELAY OUTPUTS
OUTPUT #1
OUTPUT #2
sample screen OUTPUT #3
OUTPUT #4 *1
Digital I/P - 2 - 4 - - - 8 OUTPUT #5
Relay O/P 1 - - - 5 6 7- OUTPUT #6
OUTPUT #7
OUTPUT #8

OTHER DIGITAL SELECTORS

DIGITAL SELECTORS DIGITAL SELECTORS #1
REDUCED PWR MODE DIGITAL SELECTORS #2
DIGITAL SELECTORS #3
PREFERENCES
DIGITAL SELECTORS #4 *1
CONTRAST
*1 DIGITAL SELECTORS #5
BACKLIGHT
*1 DIGITAL SELECTORS #6
PRESSURE
DIGITAL SELECTORS #7
TEMPERATURE
LANGUAGE
g01233949
RENR7902-07
RENR7902-07 153
Testing and Adjusting Section
 EMCP 3.1 Generator Set Control Menu Structure

sample screen

ENG SPEED SENSOR

sample screen ERRATIC/LOST 3/17 *2 or *3
ACTIVE OCC 1
ACTIVE EVENTS 1 ESCAPE ENTER
MAIN MENU GENSET CONTROL 1
ENGINE CONTROL 0 KEY KEY
EVENT LOG GEN OVER CURRENT
WARNING 1/3 *2
INACTIVE OCC 1 *1. To adjust settings perform the following:
ENGINE OVERVIEW
1. Use the Scroll Up and Scroll Down keys to select the submenu.
AC OVERVIEW sample screen 2. Use the Scroll Up, Scroll Down, Scroll Left and the Scroll Right keys
0kPa 23 C 24.8V to select and adjust the settings, and then select the Enter key for the new
CONFIGURE OR
0 rpm 2.1Hrs
STOPPED settings to take effect.
I/O STATUS USE *2. Scroll down to see all events. Events are listed in the following order: Present,
sample screen

CONTROL OR AVG: 481 V L-L 324A Active, Inactive. Only SHUTDOWN events can be reset; some events can
60.2Hz 0.82 LAGGING be set as a SHUTDOWN. To reset an event, the control must be in STOP.
TOTAL kW 216 48%
PREFERENCES
All other events will become INACTIVE once the condition goes away.
*3. To RESET : press the ENTER key to get to the details of the event, and
CONFIGURE CURRENT LEVEL = 2 then press the ENTER key again.
SECURITY DROP TO MIN LEVEL *4. To get back to the MAIN MENU at any time, press or and
SETPOINTS ENTER LEVEL 1 OR 2
ENTER LEVEL 3
TIME DATE CHANGE LVL 1 PSWD 5. When unsure about your location on the screen, press the ESCAPE key and
ENG OPERATE HRS CHANGE LVL 2 PSWD
CHANGE SCADA PSWD then refer to this menu map to navigate to the correct location.

SETPOINTS CONTROL
CONTROL AUTOMATIC START/STOP
ENG MONITOR/PROTECT AVR DESIRED VOLTAGE
EVENTS GOV DESIRED ENG SPD
*1
GEN MONITOR/PROTECT
I/O
NETWORK ENG MONITOR/PROTECT
OTHER BATTERY VOLT MONITOR
CRANK/START CNTRS
ENG COOLANT TEMP MON *1
ENG OIL PRES MONITOR
ENG SPEED MON
ENHANCED ENG MONITOR
SERVICE MAINT INTERVAL

EVENT I/P FUNCTIONS

EVENTS EVENT INSTANCE #1
EVENT I/P FUNCTIONS EVENT INSTANCE #2
EVENT O/P FUNCTIONS EVENT INSTANCE #3
EVENT RESP CONFIG EVENT INSTANCE #4
EVENT SYSTEM EVENT INSTANCE #5 *1
EVENT INSTANCE #6

EVENT 0/P FUNCTIONS

EVENT INSTANCE #1 *1
154

EVENT RESPONSE CFG

DIAGNOSTICS CONFIG
DIAGNOSTIC CONFIG
PRESSURES
ENG PROTECT CONFIG
GEN PROTECT CONFIG
TEMPERATURES *1
LEVEL

Illustration 88
OTHER SYSTEM CONFIG OTHERS

*1 ENG PROTECT CONFIG

PRESSURES
TEMPERATURES *1
LEVELS
OTHERS

WARNING AUTO RESET

GEN MON/PROTECT ENABLED STATUS *1
Testing and Adjusting Section

GEN AC MONITOR ENABLED

GEN AC PWR MONITOR *1
GEN OVER CURRENT
GEN OVER/UNDER FREQ
GEN OVER/UNDER VOLT

I/O DIGITAL INPUTS

DIGITAL INPUTS INPUT #1
DIGITAL OUTPUTS INPUT #2
RELAY OUTPUTS INPUT #3
SPARE ANALOG INPUT INPUT #4
INPUT #5 *1
INPUT #6
INPUT #7
INPUT #8
*1
sample screen DIGITAL OUTPUTS
NETWORK OUTPUT #1 *1
Digital I/P - 2 - 4 - - - 8 DATALINK- SCADA OUTPUT #2
Relay O/P 1 - - - 5 6 7-

RELAY OUTPUTS
OUTPUT #1
OUTPUT #2
OUTPUT #3
OUTPUT #4 *1
OUTPUT #5
OUTPUT #6
OUTPUT #7
OUTPUT #8

OTHER DIGITAL SELECTORS

DIGITAL SELECTORS DIGITAL SELECTORS #1
PREFERENCES REDUCED PWR MODE DIGITAL SELECTORS #2
CONTRAST DIGITAL SELECTORS #3
DIGITAL SELECTORS #4
BACKLIGHT DIGITAL SELECTORS #5
*1
PRESSURE *1 *1 DIGITAL SELECTORS #6
TEMPERATURE DIGITAL SELECTORS #7
LANGUAGE DIGITAL SELECTORS #8
g01233950
RENR7902-07
RENR7902-07
Programming the Display
Preferences
The preferences affect the way data is viewed on the
display screen. The configuration may need to be
changed in order to meet local requirements.
In order to program the display preferences, perform
the following menu options.
1. Press the Escape key as many times as
necessary in order to go back to the “MAIN
MENU” display.
2. From the “MAIN MENU”, press the Scroll Down
key or the Scroll Up key in order to highlight
the “PREFERENCES” option. The following
parameters can be changed or viewed:
• CONTRAST
• PRESSURE
• TEMPERATURE
• VOLUME
• LANGUAGE
a. Press the Enter key in order to select
PREFERENCES. CONTRAST will be
highlighted.
b. Press the Enter key in order to select the
contrast level. The contrast can be adjusted
between 1 and 100, with 1 being the least
contrast and 100 being the greatest contrast.
The display will show a status bar and a
number representing the current contrast level.
c. Use the Scroll Right key or the Scroll Left key
in order to adjust the contrast to the desired
level, and then press the Enter key in order to
save the new contrast setting.
d. Press the Scroll Down key in order to highlight
PRESSURE, and then press the Enter key
in order to select the pressure function. The
available options for pressure measurement
are “kPa”, “PSI”, and “BAR”. The display will
list all three options, with the current option
highlighted.
e. Adjust the pressure to the desired
measurement unit using the Scroll Right
key or the Scroll Left key , and then press
the Enter key in order to save the pressure
measurement unit.
155
Testing and Adjusting Section
f. Press the Scroll Down key in order to highlight
TEMPERATURE and then press the Enter key
in order to select the temperature function. The
available options for temperature measurement
are “°C” or “°F”. The display will list both
options, with the current option highlighted.
g. Adjust the temperature to the desired
measurement scale using the Scroll Right
key or the Scroll Left key , and then press the
Enter key in order to save the temperature
measurement unit.
h. Press the Scroll Down key in order to highlight
VOLUME and then press the Enter key in order
to select the volume function. The available
options for volume measurement are “LITERS”,
“US GAL”, or “IMP GAL”. The display will
list all three options, with the current option
highlighted.
i. Highlight the desired volume measurement unit
using the Scroll Right key or the Scroll Left
key , and then press the Enter key in order to
save the volume measurement unit.
j. Press the Scroll Down key in order to highlight
LANGUAGE and then press the Enter key
in order to select the language function.
Language does not display a value to the
right. The display will show one or two options.
TECHNICIAN ENGLISH will always be shown
and, if another language is available on the
flash file, that language will also be shown as
an options.
k. Highlight the desired language that is to be
used for display on the EMCP 3 using the
Scroll Right key or the Scroll Left key , and
then press the Enter key (10) in order to save
the desired language selection
l. Press the Escape key as required in order to
step back up to the MAIN MENU.
Programming the Setpoints
The engine/generator setpoints affect the proper
operation and serviceability of the engine, and the
accuracy of information shown on the display screen.
The EMCP 3 setpoints are programmed at the
factory.
The setpoints may require changing when the EMCP
3 is moved from one engine to another engine.
The setpoints may also require changing in order
to satisfy the site requirements. The setpoints that
are stored in the EMCP 3 must match the specified
setpoints of the particular generator set.
156 RENR7902-07
Testing and Adjusting Section

See the Setpoint tables following these procedures
for a complete list of all the setpoint blocks. All of the
setpoints listed in the tables should be verified and
reprogrammed if required.
The first setpoint block to program is the Automatic
Start/Stop Block. The Automatic Start/Stop Block is
part of the Control Category. In order program the
Automatic Start/Stop Setpoints, perform the following:
1. Press the Escape key as required in order to step
back to the MAIN MENU.
2. From the MAIN MENU, press the Scroll Down
key until CONFIGURE is highlighted and then
press the Enter key in order to select the menu.
3. Press the Scroll Down key until SETPOINTS is
highlighted, and then press the Enter key in order
to select the menu.
4. Press the Scroll Down key in order to scroll
through the setpoint options until CONTROL is
highlighted, and then press the Enter key in order
to select the menu. The AUTOMATIC START /
STOP menu is highlighted.
5. Press the Enter Key in order to select the
AUTOMATIC START / STOP menu and then use
the Scroll Down key and the Scroll Up key in
order to highlight the next setpoint that is to be
programmed.
13. Press the Escape key twice in order to back up to
the SETPOINTS menu.
14. Press the Scroll Down key in order to scroll
through the setpoint options until ENGINE
MONITOR/PROTECT is highlighted.
15. Press the Enter key in order to select the ENGINE
MONITOR/PROTECT menu and then program all
of the function blocks in this menu.
16. Continue to program the remaining setpoints until
each setpoint in every setpoint category has been
checked and programmed as required.
Setpoint Tables
All of the available setpoints on the EMCP 3 are
listed in the following tables. Refer to these tables
while programming the setpoints.
Control
Automatic Start/Stop
The Automatic Start/Stop block receives starting
and stopping requests from various sources (local,
remote, internal), arbitrates between them and then
cranks or shuts down the engine in an orderly fashion.

6. Press the Enter key in order to select the setpoint

and then press the Enter key a second time in
order to highlight the current configuration of the
selected setpoint.

7. Use the Scroll Down key and the Scroll Up key

in order to change the current configuration to the
desired setting, and then use the Enter key in
order to the save the new setting.

8. Repeat steps 5 through 7 in order to program all

of the Automatic Start/Stop setpoints.

9. After all of the Automatic Start/Stop Setpoints are

programmed as required, then press the Escape
key in order to back up to the CONTROL menu.

10. The next block of setpoints that is to be

programmed is the Automatic Voltage Regulator
(AVR) Request block. Press the Scroll Down key
in order to scroll through the setpoint options until
AVR DESIRED VOLTAGE is highlighted, and then
press the Enter key in order to select the menu.

11. Repeat steps 5 through 7 in order to program all

of the AVR Request setpoints.

12. Continue programming the remaining function

blocks in the “CONTROL” menu.
RENR7902-07 157
Testing and Adjusting Section

Table 38
Setpoints - Automatic Start/Stop(1)
Setpoint Min Max Factory
Units Description
Name Value Value Default
Fault protection time delay prevents shut
Engine start fault protection sec
0 300 30 down during start up from low oil pressure
activation delay time
etc.

sec Amount of time the EMCP 3 energizes

Crank Duration 5 300 7
(cranks) the starting motor

sec Amount of time the EMCP 3 deenergizes

Crank Cycle Rest Interval 5 300 7
the starting motor between crank cycles
Engine Purge Cycle Time 0 20 sec 0
Number of crank/rest cycles that the
Maximum Number of Crank
1 20 n/a 3 EMCP 3 uses to declare that a overcrank
Cycles
fault exists
Amount of time the EMCP 3 allows the
Cooldown Duration 0 30 min. 180 sec engine to run after a normal shutdown is
initiated
Amount of time the EMCP 3 activates
Start Aid Activation Time 0 240 sec. 0 start aid control output. Set to 10 seconds
if the EUI with prelube option is installed.

sec. Amount of time the EMCP activates crank

Crank Alert Activation Time 0 60 0
alert output.
Engine speed setting used in order to
Crank Terminate RPM 100 1000 rpm 400 disengage the starting motor during
engine cranking
Setpoint allows for selection of “Diesel” or
Engine Fuel Type Configuration Setpoint Value List 0
“Natural Gas”
Type of fuel system solenoid used on the
Fuel Shutoff Solenoid Type
Setpoint Value List 0 generator set. Select “Energized to run”
Configuration
(ETR) or “Energized to Shut Off” (ETS).
Engine Type Configuration Setpoint Value List 0 Select mechanical or electronic
Setpoint allows for selection of “No Data
Engine Controller J1939 Data
Setpoint Value List 1 Link”, “Basic Data Link”, or “Enhanced
Link Support Configuration
Data” Link.
Setpoint allows for selection of engine
Engine Cool Down Speed
Setpoint Value List 0 speed during cooldown. Select rated or
Configuration
idle.
Setpoint configures whether the EMCP3
determines its operating state on its own,
or whether it receives it over the data link
Engine Operating State Input from the engine ECM. Set to “CAN Input”
Setpoint Value List 0
Configuration for common engine interface engines
and set to “Hard Wired ”for non-common
engine interface EUI engines and non-EUI
engines.
Engine Idle Operation Enable
Setpoint Value List 0
Status Engine
Fuel Priming Feature Enable
Setpoint Value List 0
Status
(1) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
158 RENR7902-07
Testing and Adjusting Section

AVR Desired Voltage Request

The AVR Desired Voltage Request block generates a

data link request over the J1939 data link in order to
request a desired output voltage from the CDVR.

Table 39

Setpoints - AVR Desired Voltage Request(2)

Setpoint Min Max Factory

Units Description
Name Value Value Default

The Maximum Generator Output voltage Bias Percent

Maximum Generator
is the maximum value above and below the Nominal
Voltage Output Bias 0 100 % 5
Voltage that the EMCP 3 will send a request for when
Percentage
adjusting the voltage from the control screen
The Generator Nominal Output Voltage is the desired
Generator Nominal
100 50000 V 100 output voltage of the generator set. This value is set to
Output Voltage
match the generator rated voltage.
(2) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Maximum Generator Output Voltage Bias Percent
The following settings will only apply if there is a
CDVR installed on the generator.
Note: It is possible to set the “MAXIMUM GEN
OUTPUT VOLTAGE BIAS PERCENT” from 0 to
100% but the CDVR will only allow the voltage to
change by a maximum of 15%.
1. From the MAIN MENU, press the Scroll Down
key or the Scroll Up key in order to highlight the
CONFIGURE menu, and then press the Enter
key in order to select the menu. “SECURITY” will
be highlighted.
2. Press the Scroll Down key in order to highlight
the SETPOINTS menu, and then press the Enter
key in order to select the menu. AUTOMATIC
START/STOP will be highlighted.
5. Press the Scroll Down key or the Scroll Up key
in order to decrement or increment the highlighted
digit to the desired value and then press the
Scroll Right key or the Scroll Left key in order to
highlight the next character that is to be entered.
6. Continue this process until the desired current
voltage bias percent has been entered and then
press the Enter key in order to save the new
value.
Generator Desired Engine Speed Request
The Generator Desired Engine Speed Request block
generates a data link request over the J1939 data
link in order to request a desired generator frequency
from a generator.

3. Press the Scroll Down key in order to highlight

the AVR DESIRED VOLTAGE menu, and then
press the Enter key in order to select the menu.
MAXIMUM GEN OUTPUT VOLTAGE BIAS
PERCENT will be displayed.

4. Press the Enter key in order to select the AVR

DESIRED VOLTAGE menu and then press
the Enter key a second time in order to select
the MAXIMUM GEN OUTPUT VOLTAGE BIAS
PERCENT function and in order to display the
current voltage bias percent.

Note: The voltage bias percent setpoint will

determine the amount of voltage change for each
key press on the voltage control screen. A higher
value will result in a larger change in voltage per key
press. A lower value will result in a smaller change
in voltage per key press.
RENR7902-07 159
Testing and Adjusting Section

Table 40
Setpoints - Generator Desired Engine Speed Request(27)
Setpoint Min Max Factory
Units Description
Name Value Value Default
The Maximum Engine Speed Range is the maximum
Maximum Engine rpm value above and below the Nominal Engine Speed
0 2000 100
Speed Range that the EMCP 3 will send a request for when
adjusting the speed from the control screen
Generator Nominal This value is set to match the generator rated
40 500 Hz 50
Output Frequency frequency
(27) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Engine Monitor/Protect
Battery Voltage Monitor

The Battery Voltage Monitor block measures the

battery supply voltage to the EMCP 3. The EMCP
3 will have the ability to monitor the battery supply
voltage based on the “+BATT” and “−BATT”.

Table 41

Setpoints - Battery Voltage Monitor(3)

Setpoint Factory
Min Value Max Value Units Description
Name Default
High Battery Voltage Warning Event Threshold 12 50 VDC 29.4
High Battery Voltage Warning Event Notification sec
0 240 30
Delay Time
High Battery Voltage Shutdown Event Threshold 12 50 VDC 30.0
High Battery Voltage Shutdown Event Notification sec
0 240 30
Delay Time
Low Battery Voltage Warning Event Threshold 0.0 25.0 VDC 23.4
Low Battery Voltage Warning Event Notification sec
0 240 30
Delay Time
Low Battery Charging System Voltage Warning
0 30 VDC 26
Event Threshold
Low Battery Charging System Voltage Warning sec
0 240 30
Event Notification Delay Time
Low Cranking Voltage Warning Event Threshold 0.0 30.0 VDC 0.0
Low Cranking Voltage Warning Event Notification sec
0 240 2
Delay Time
(3) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Crank Attempt/Successful Start Counter

The Crank Attempt/Successful Start Counter block

tracks the number of times the engine has been
cranked and the number of times the engine has
been successfully started.
160 RENR7902-07
Testing and Adjusting Section

Table 42
Setpoints - Crank Attempt / Successful Start Counter(31)
Setpoint Min Max Factory
Units Description
Name Value Value Default
Customer Security Password
Password level required in order to reset
Level to Reset Crank/Start 0 4 n/a 3
the Crank/Start Counters
Counters
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Engine Coolant Temperature Monitor

The Engine Coolant Temperature Monitor block

converts a raw sensor value into coolant temperature
and, when configured as a sensor, detects sensor
diagnostics.

Table 43

Setpoints - Engine Coolant Temperature Monitor(10)

Setpoint Min
Max Value Units Factory Default Description
Name Value
Select “Sensor” or “Data
Link”. Set to Sensor
Engine Coolant Temperature Sensor
Setpoint Value List 0 for MUI Engines or set
Configuration
to Data Link for EUI
engines.
High Engine Coolant Temperature 49 °C 120 °C
deg. 100 °C (212 °F)
Warning Event Threshold (120 °F) (248 °F)
High Engine Coolant Temperature sec.
0 30 15
Warning Event Notification Delay Time
High Engine Coolant Temperature 49 °C 120 °C
deg. 120 °C (248 °F)
Shutdown Event Threshold (120 °F) (248 °F)
High Engine Coolant Temperature
Shutdown Event Notification Delay 0 30 sec. 15
Time
Low Engine Coolant Temperature 0 °C
36 °C (99 °F) 21 °C (70 °F)
Warning Event Threshold ( 32°F)
Low Engine Coolant Temperature sec.
0 30 10
Warning Event Notification Delay Time
Coolant Temperature Sensor Map
1 5 N/A 1
Selection Number
(10) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Engine Oil Pressure Monitor

The Engine Oil Pressure Monitor block converts

a raw sensor value into oil pressure and, when
configured as a sensor, detects sensor diagnostics.
RENR7902-07 161
Testing and Adjusting Section

Table 44
Setpoints - Engine Oil Pressure Monitor(11)
Setpoint Min Factory
Max Value Units Description
Name Value Default
Select “Sensor” or “Data Link”. Set
Engine Oil Pressure Sensor
Setpoint Value List 0 to Sensor for MUI Engines or set
Configuration
to Data Link for EUI engines.
Low Engine Oil Pressure 34 kPa 690 kPa 160 kPa
kPa
Warning Event Threshold (5 psi) (100 psi) (23 psi)
Low Idle Low Engine Oil Pressure 34 kPa 690 kPa 160 kPa
kPa
Warning Event Threshold (5 psi) (100 psi) (23 psi)
Low Engine Oil Pressure
Warning Event Notification Delay 0 30 sec. 10
Time
Low Engine Oil Pressure 34 kPa 690 kPa 34 kPa
kPa
Shutdown Event Threshold (5 psi) (100 psi) (5 psi)

Low Idle Low Engine Oil Pressure 34 kPa 690 kPa 160 kPa
kPa
Shutdown Event Threshold (5 psi) (100 psi) (23 psi)

Low Engine Oil Pressure

Shutdown Event Notification 0 30 sec. 10
Delay Time
When the engine speed is below
this setpoint, the Low Idle setpoint
is used. Set to 800 RPM for
Low Engine Oil Pressure Step
400 1800 RPM 1350 engines rated at 1000 or 1200
Speed
RPM. Set to 1200 RPM for
engines rated at 1500 or 1800
RPM.
Oil Pressure Sensor Map
1 5 N/A 1
Selection Number
(11) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Engine Speed Monitor

The Engine Speed Monitor block determines the

engine speed, in rpm, from the Magnetic Pickup
(MPU) input pins and detects diagnostics on the
MPU. The MPU used for these determinations will be
an independent MPU to be used by the EMCP 3 only.

Note: All Engine Speed Monitor setpoints require

a “LEVEL 3” password. Engine Speed Monitor
setpoints may also be changed with Caterpillar
Electronic Technician software without a password.
162 RENR7902-07
Testing and Adjusting Section

Table 45
Setpoints - Engine Speed Monitor(12)
Setpoint Min
Max Value Units Factory Default Description
Name Value
Flywheel Teeth 95 350 N/A 95

rpm Set to 118% of

Engine Over Speed Shutdown Threshold 400 4330 400
rated speed

rpm Set to 86% of

Engine Under Speed Warning Event Threshold 400 4330 4330
rated speed
Engine Under Speed Warning Event Notification sec.
0.0 20.0 2.0
Delay Time

rpm Set to 82% of

Engine Under Speed Shutdown Event Threshold 400 4330 4330
rated speed
Engine Under Speed Shutdown Event Notification sec.
0.0 20.0 2.0
Delay Time
Engine Speed Sensor Configuration Setpoint Value List 0
(12) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Enhanced Engine Monitor

The “Enhanced Engine Monitor” block provides a

method to access the engine cylinder temperature
parameters from the primary data link for use in
configuration logic.

Note: Standard Caterpillar product does not utilize

this group of setpoints.

Table 46
Setpoints - Enhanced Engine Monitor (31)

Setpoint Min Max Factory

Units Description
Name Value Value Default
Engine Cylinder Temperature Sensor
Setpoint Value List 0 Select “Installed” or “Not installed”
Installation Status
Number of Engine Cylinders 1 20 n/a 1
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Service Maintenance Interval

The Service Maintenance Interval block annunciates

a need for engine service based on engine hours or
duration since the last service, whichever occurs first.

Table 47

Setpoints - Service Maintenance Interval(31)

Setpoint Min Max
Units Factory Default Description
Name Value Value
Service Maintenance Interval Hours 0 2000 hours 500 hours
Service Maintenance Interval Days 0 365 days 180
Customer Password Security Level to Reset
0 4 N/A 3
Service Maintenance Interval
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902-07 163
Testing and Adjusting Section

EVENTS
Table 48
Description of Event Response Selections
Active Only Only displays event in the event log (no history on the event)
Warning Event logged, amber warning status LED
Audible Alert Activates relay output configured as “horn control”
Soft Shutdown Shutdown event allows cooldown cycle
Hard Shutdown Shutdown event skips cooldown cycle for fast engine shutdown
Breaker 1 Trip Activates relay output configured as “breaker 1 trip”
Breaker 2 Trip Activates relay output configured as “breaker 2 trip”
FTP Suppress the event until the engine is running and the fault protection timer has expired

Diagnostics Configuration

Warning and/or shutdown events should not be

disabled. If warning or shutdown events are dis-
abled, the user may not be aware of conditions
that could cause damage to the engine, generator,
or electrical loads. If warning or shutdown events
are disabled, make sure that there is another con-
trol that is set up that can diagnose the event, and
if necessary, will shut the engine down.

The “Diagnostics Configuration” block is used in

order to configure the desired response for any
diagnostic that is generated by the genset control.

The Diagnostics Configuration block is subdivided

into four subcategories as follows: Pressures,
Temperatures, Levels, and Others. Each of the
Diagnostics Configuration subcategories is shown in
it's own table.

Note: Table 49 lists the available options for each

setpoint in the “PRESSURES” category. The options
that are available for each setpoint are designated by
an “X” in the option column.
164 RENR7902-07
Testing and Adjusting Section

Table 49
“PRESSURE” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Air Filter
Differential
Pressure Sensor
X X X X X X
Diagnostic
Response
Configuration
Engine Oil
Pressure Sensor
Diagnostic X X X X X X
Response
Configuration
Fire Extinguisher
Pressure Sensor
Diagnostic X X X X X X
Response
Configuration
Fuel Filter
Differential
Pressure Sensor
X X X X X X
Diagnostic
Response
Configuration
Engine Oil
Filter Differential
Pressure Sensor
X X X X X X
Diagnostic
Response
Configuration
Starting Air
Pressure Sensor
Diagnostic X X X X X X
Response
Configuration
(15)Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Note: Table 50 lists the available options for each

setpoint in the “TEMPERATURE” category. The
options that are available for each setpoint are
designated by an “X” in the option column.
RENR7902-07 165
Testing and Adjusting Section

Table 50
“TEMPERATURE” Setpoints - Diagnostics Configuration(15)
Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility
Ambient Air
Temperature
Sensor
X X X X X X
Diagnostic
Response
Configuration
Engine
Coolant
Temperature
Sensor X X X X X X
Diagnostic
Response
Configuration
Engine Oil
Temperature
Sensor
X X X X X X
Diagnostic
Response
Configuration
Exhaust
Temperature
Sensor
X X X X X X
Diagnostic
Response
Configuration
Right Exhaust
Temperature
Sensor
X X X X X X
Diagnostic
Response
Configuration
Left Exhaust
Temperature
Sensor
X X X X X X
Diagnostic
Response
Configuration
Generator
Bearing #1
Temperature
Sensor X X X X X X
Diagnostic
Response
Configuration
(15)Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Note: Table 51 lists the available options for each

setpoint in the “LEVEL” category. The options that
are available for each setpoint are designated by an
“X” in the option column.
166 RENR7902-07
Testing and Adjusting Section

Table 51
“LEVEL” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Engine
Coolant
Level Sensor
X X X X X X
Diagnostic
Response
Configuration
Engine Oil
Level Sensor
Diagnostic X X X X X X
Response
Configuration
Fuel Level
Sensor
Diagnostic X X X X X X
Response
Configuration
External
Tank Fuel
Level Sensor
X X X X X X
Diagnostic
Response
Configuration
(15)Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Note: Table 52 lists the available options for each

setpoint in the “OTHER” setpoints category. The
options that are available for each setpoint are
designated by an “X” in the option column.
RENR7902-07 167
Testing and Adjusting Section

Table 52
“OTHER” Setpoints - Diagnostics Configuration(15)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Accessory
Data Link
Diagnostic X X X X X X
Response
Configuration
Digital Output
#1 Diagnostic
X X X X X X
Response
Configuration
Digital Output
#2 Diagnostic
X X X X X X
Response
Configuration
Engine Speed
Sensor
Diagnostic X X(16) X X
Response
Configuration
Generator
Output
Sensing
System X X X X X X
Diagnostic
Response
Configuration
Primary
Data Link
Diagnostic X X X X X X
Response
Configuration
SCADA
Data Link
Diagnostic X X X X X X X
Response
Configuration
(15) Each setpoint in the Diagnostics Configuration block is used in order to program a system response to the associated Suspect Parameter
Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is not adjustable

Engine Protection Events Configuration
Warning and/or shutdown events should not be
disabled. If warning or shutdown events are dis-
abled, the user may not be aware of conditions
that could cause damage to the engine, generator,
or electrical loads. If warning or shutdown events
are disabled, make sure that there is another con-
trol that is set up that can diagnose the event, and
if necessary, will shut the engine down.
The Engine Protection events Configuration block is
subdivided into 4 categories as follows: Pressures,
Temperatures, Levels, and Others. Each of the
Diagnostics Configuration subcategories is shown in
it's own table.
Note: Table 53 lists the available options for each
“PRESSURE” setpoint. The options that are available
for each setpoint are designated by an “X” in the
option column.

The Engine Protection Events Configuration block is

used in order to configure the desired response for
any engine protection event generated by the genset
control.
168 RENR7902-07
Testing and Adjusting Section

Table 53
“PRESSURE” Setpoints - Engine Protection Events Configuration(17)
Loss
Setpoint Audible Soft Hard Breaker Breaker Trip Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 #2 Only
Utility
High Air Filter
Differential
Pressure
X X X X
Warning Event
Response
Configuration
High Air Filter
Differential
Pressure
Shutdown X X X X X
Event
Response
Configuration

Low Air Filter

Differential
Pressure
X X X X X
Warning Event
Response
Configuration

Low Air Filter

Differential
Pressure
Shutdown X X X X X X
Event
Response
Configuration
High Gas
Pressure
Warning Event X X X X
Response
Configuration
High Gas
Pressure
Shutdown
X X X X X
Event
Response
Configuration
Low Gas
Pressure
Warning Event X X X X
Response
Configuration
Low Gas
Pressure
Shutdown
X X X X X
Event
Response
Configuration
(continued)
RENR7902-07 169
Testing and Adjusting Section

(Table 53, contd)

“PRESSURE” Setpoints - Engine Protection Events Configuration(17)
Loss
Setpoint Audible Soft Hard Breaker Breaker Trip Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 #2 Only
Utility
Low Engine
Oil Pressure
Warning Event X X X X X
Response
Configuration
Low Engine
Oil Pressure
Shutdown
X X X X X X
Event
Response
Configuration
High Fuel Filter
Differential
Pressure x x x X
Warning Event
Response
Configuration
High Fuel Filter
Differential
Pressure
Shutdown X X X X X
Event
Response
Configuration
Low Fuel Filter
Differential
Pressure
X X X X X
Warning Event
Response
Configuration
Low Fuel Filter
Differential
Pressure
Shutdown X X X X X X
Event
Response
Configuration
High Engine
Oil Filter
Differential
Pressure X X X X
Warning Event
Response
Configuration
High Engine
Oil Filter
Differential
Pressure
X X X X X
Shutdown
Event
Response
Configuration
(continued)
170 RENR7902-07
Testing and Adjusting Section

(Table 53, contd)

“PRESSURE” Setpoints - Engine Protection Events Configuration(17)
Loss
Setpoint Audible Soft Hard Breaker Breaker Trip Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 #2 Only
Utility
Low Engine
Oil Filter
Differential
Pressure X X X X X
Warning Event
Response
Configuration
Low Engine
Oil Filter
Differential
Pressure
X X X X X X
Shutdown
Event
Response
Configuration
High Starting
Air Pressure
Warning Event X X X X
Response
Configuration
High Starting
Air Pressure
Shutdown
X X X X X
Event
Response
Configuration
Low Starting
Air Pressure
Warning Event X X X X X
Response
Configuration
Low Starting
Air Pressure
Shutdown
X X X X X X
Event
Response
Configuration
(17)Each setpoint in the Engine Protection Events Configuration block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Table 54 lists the available options for each

“TEMPERATURE” setpoint. The options that are
available for each setpoint are designated by an “X”
in the option column.

Table 54

“TEMPERATURE” Setpoints - Engine Protection Events Configuration(17)

Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
High Engine
Coolant
Temperature
X X X X X
Warning Event
Response
Configuration
(continued)
RENR7902-07 171
Testing and Adjusting Section

(Table 54, contd)

“TEMPERATURE” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
High Engine
Coolant
Temperature
Shutdown X X X X X X
Event
Response
Configuration
Low Engine
Coolant
Temperature
X X X X X
Warning Event
Response
Configuration
High
Engine Oil
Temperature
X X X X X
Warning Event
Response
Configuration
High
Engine Oil
Temperature
Shutdown X X X X X X
Event
Response
Configuration
Low Engine Oil
Temperature
Warning Event X X X X X
Response
Configuration
Low Engine Oil
Temperature
Shutdown
X X X X X X
Event
Response
Configuration
High Exhaust
Temperature
Warning Event X X X X X
Response
Configuration
High Exhaust
Temperature
Shutdown
X X X X X X
Event
Response
Configuration
Low Exhaust
Temperature
Warning Event X X X X X
Response
Configuration
(continued)
172 RENR7902-07
Testing and Adjusting Section

(Table 54, contd)

“TEMPERATURE” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Low Exhaust
Temperature
Shutdown
X X X X X X
Event
Response
Configuration
High Right
Exhaust
Temperature
X X X X X
Warning Event
Response
Configuration
High Right
Exhaust
Temperature
Shutdown X X X X X X
Event
Response
Configuration
Low Right
Exhaust
Temperature
X X X X X
Warning Event
Response
Configuration
Low Right
Exhaust
Temperature
Shutdown X X X X X X
Event
Response
Configuration
High Left
Exhaust
Temperature
X X X X X
Warning Event
Response
Configuration
High Left
Exhaust
Temperature
Shutdown X X X X X X
Event
Response
Configuration
Low Left
Exhaust
Temperature
X X X X X
Warning Event
Response
Configuration
(continued)
RENR7902-07 173
Testing and Adjusting Section

(Table 54, contd)

“TEMPERATURE” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Low Left
Exhaust
Temperature
Shutdown X X X X X X
Event
Response
Configuration
(17)Each setpoint in the Engine Protection Events Configuration block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Table 55 lists the available options for each “LEVEL”

setpoint. The options that are available for each
setpoint are designated by an “X” in the option
column.

Table 55

“LEVEL” Setpoints - Engine Protection Events Configuration(17)

Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
High Engine
Coolant Level
Warning Event X X X X
Response
Configuration
High Engine
Coolant Level
Shutdown
X X X X X
Event
Response
Configuration
Low Engine
Coolant Level
Warning Event X X X X
Response
Configuration
Low Engine
Coolant Level
Shutdown
X X X X X
Event
Response
Configuration
High Engine
Oil Level
Warning Event X X X X
Response
Configuration
High Engine
Oil Level
Shutdown
X X X X X
Event
Response
Configuration
(continued)
174 RENR7902-07
Testing and Adjusting Section

(Table 55, contd)

“LEVEL” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Low Engine
Oil Level
Warning Event X X X X
Response
Configuration
Low Engine
Oil Level
Shutdown
X X X X X
Event
Response
Configuration
High Fuel
Level Warning
Event X X X X
Response
Configuration
High Fuel
Level
Shutdown
X X X X X
Event
Response
Configuration
Low Fuel Level
Warning Event
X X X X
Response
Configuration
Low Fuel Level
Shutdown
Event X X X X X
Response
Configuration
External
Tank High
Fuel Level
X X X X
Warning Event
Response
Configuration
External
Tank High
Fuel Level
Shutdown X X X X X
Event
Response
Configuration
External Tank
Low Fuel Level
Warning Event X X X X
Response
Configuration
External Tank
Low Fuel Level
Shutdown
X X X X X
Event
Response
Configuration
(17)Each setpoint in the Engine Protection Events Configuration block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.
RENR7902-07 175
Testing and Adjusting Section

Table 56 lists the available options for each of the

“OTHER” setpoints. The options that are available for
each setpoint are designated by an “X” in the option
column.

Table 56
“OTHER” Setpoints - Engine Protection Events Configuration(17)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Air Damper
Closed Event
X X X
Response
Configuration
Emergency
Stop
Shutdown
X X(16) X X
Event
Response
Configuration
Engine Failure
to Start
Shutdown
X X(16) X X
Event
Response
Configuration
Unexpected
Engine
Shutdown
X X(16) X X
Event
Response
Configuration
Engine
Over Speed
Shutdown
X X(16) X X
Event
Response
Configuration
Engine
Under Speed
Warning Event X X X X X
Response
Configuration
Engine
Under Speed
Shutdown
X X X X X X
Event
Response
Configuration
Fuel Tank
Leak Event
X X X X X X
Response
Configuration
Service
Maintenance
Interval
X X
Warning Event
Response
Configuration
(17) Each setpoint in the Engine Protection Events Configuration block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is not adjustable
176 RENR7902-07
Testing and Adjusting Section

Generator Protection Events Configuration

Warning and/or shutdown events should not be

disabled. If warning or shutdown events are dis-
abled, the user may not be aware of conditions
that could cause damage to the engine, generator,
or electrical loads. If warning or shutdown events
are disabled, make sure that there is another con-
trol that is set up that can diagnose the event, and
if necessary, will shut the engine down.

The Generator Protection Events Configuration block

is used in order to configure the desired response
for any engine protection event generated by the
genset control.

Note: Table 57 lists the available options for each

setpoint number. The options that are available for
each setpoint are designated by an “X” in the option
column.

Table 57
Setpoints - Generator Protection Events Configuration(18)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Earth Fault
Event
X X X X X X
Response
Configuration
High
Generator
Winding #1
Temperature X X X X X
Warning Event
Response
Configuration
High
Generator
Winding #1
Temperature
X X X X X X
Shutdown
Event
Response
Configuration
High
Generator
Winding #2
Temperature X X X X X
Warning Event
Response
Configuration
(continued)
RENR7902-07 177
Testing and Adjusting Section

(Table 57, contd)

Setpoints - Generator Protection Events Configuration(18)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
High
Generator
Winding #2
Temperature
X X X X X X
Shutdown
Event
Response
Configuration
High
Generator
Winding #3
Temperature X X X X X
Warning Event
Response
Configuration
High
Generator
Winding #3
Temperature
X X X X X X
Shutdown
Event
Response
Configuration
High
Generator
Bearing #1
Temperature X X X X X
Warning Event
Response
Configuration
High
Generator
Bearing #1
Temperature
X X X X X X
Shutdown
Event
Response
Configuration
Low
Generator
Bearing #1
Temperature X X X X X
Warning Event
Response
Configuration
Low
Generator
Bearing #1
Temperature
X X X X X X
Shutdown
Event
Response
Configuration
(continued)
178 RENR7902-07
Testing and Adjusting Section

(Table 57, contd)

Setpoints - Generator Protection Events Configuration(18)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Generator
Over Current
(Amp)
X X X X
Warning Event
Response
Configuration
Generator
Over Current
(Amp)
Shutdown X X X X X
Event
Response
Configuration
Generator
Over
Frequency
X X X X
Warning Event
Response
Configuration
Generator
Over
Frequency
Shutdown X X X X X
Event
Response
Configuration
Generator
Under
Frequency
X X X X X
Warning Event
Response
Configuration
Generator
Under
Frequency
Shutdown X X X X X X
Event
Response
Configuration
Generator
Reverse
Power
X X X X
Warning Event
Response
Configuration
Generator
Reverse
Power
Shutdown X X X X X
Event
Response
Configuration
Generator
Over Voltage
Warning Event X X X X
Response
Configuration
(continued)
RENR7902-07 179
Testing and Adjusting Section

(Table 57, contd)

Setpoints - Generator Protection Events Configuration(18)
Setpoint Audible Soft Hard Loss of Breaker Breaker Active
Warning FPT
Name Alert Shutdown Shutdown Utility Trip #1 Trip #2 Only
Generator
Over Voltage
Shutdown
X X X X X
Event
Response
Configuration
Generator
Under Voltage
Warning Event X X X X X
Response
Configuration
Generator
Under Voltage
Shutdown
X X X X X X
Event
Response
Configuration
(18)Each setpoint in the “Generator Protection Events Configuration” block is used in order to program a system response to the associated
Suspect Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.

Other System Events Configuration

Warning and/or shutdown events should not be

disabled. If warning or shutdown events are dis-
abled, the user may not be aware of conditions
that could cause damage to the engine, generator,
or electrical loads. If warning or shutdown events
are disabled, make sure that there is another con-
trol that is set up that can diagnose the event, and
if necessary, will shut the engine down.

The “Other System Events Configuration” block is

used in order to configure the desired response for
any engine protection event generated by the genset
control.

Note: Table 58 lists the available options for each

setpoint number. The options that are available for
each setpoint are designated by an “X” in the option
column.

Table 58
Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

(continued)
180 RENR7902-07
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

High
Ambient Air
Temperature
X X X X X
Warning Event
Response
Configuration
High
Ambient Air
Temperature
Shutdown X X X X X X
Event
Response
Configuration
Low
Ambient Air
Temperature
X X X X
Warning Event
Response
Configuration
Low
Ambient Air
Temperature
Shutdown X X X X X
Event
Response
Configuration
Automatic
Transfer
Switch in
Normal X X X
Position Event
Response
Configuration
Automatic
Transfer
Switch in
Emergency X X X
Position Event
Response
Configuration
Battery
Charger
Failure
X X X
Diagnostic
Response
Configuration
High Battery
Voltage
Warning Event X X X X
Response
Configuration
(continued)
RENR7902-07 181
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

High Battery
Voltage
Shutdown
X X X X X
Event
Response
Configuration
Low Battery
Voltage
Warning Event X X X X X
Response
Configuration
Low Battery
Charging
System
Voltage X X X X X
Warning Event
Response
Configuration
Generator
Breaker
Failure to
X X X X X
Open Event
Response
Configuration
Generator
Breaker
Failure to x
X X X X
Close Event
Response
Configuration
Generator
Breaker
Open Event X X X
Response
Configuration
Generator
Breaker
Closed Event X X X
Response
Configuration
Utility Breaker
Failure to
Open Event X X X X X
Response
Configuration
Utility Breaker
Failure to
Close Event X X X X X
Response
Configuration
(continued)
182 RENR7902-07
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Utility Breaker
Open Event
X X X
Response
Configuration
Utility Breaker
Closed Event
X X X
Response
Configuration
Emergency
Shutdown
Override
Mode Active X(16) X
Warning Event
Response
Configuration
Engine in
Cooldown
Event X X X
Response
Configuration
Engine Speed-
Generator
Output
Frequency
X X X X
Mismatch
Warning Event
Response
Configuration
Custom Event
#1 High
Warning Event X X X X X
Response
Configuration
Custom Event
#1 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#1 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#1 Low
Shutdown
X X X X X X
Event
Response
Configuration
(continued)
RENR7902-07 183
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Custom Event
#1 Event
X X X X X X X X X
Response
Configuration
Custom Event
#2 High
Warning Event X X X X x
Response
Configuration
Custom Event
#2 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#2 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#2 Low
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#2 Event
X X X X X X X X X
Response
Configuration
Custom Event
#3 High
Warning Event X X X X X
Response
Configuration
Custom Event
#3 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#3 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#3 Low
Shutdown
X X X X X X
Event
Response
Configuration
(continued)
184 RENR7902-07
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Custom Event
#3 Event
X X X X X X X X X
Response
Configuration
Custom Event
#4 High
Warning Event X X X X X
Response
Configuration
Custom Event
#4 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#4 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#4 Low
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#4 Event
X X X X X X X X X
Response
Configuration
Custom Event
#5 High
Warning Event X X X X X
Response
Configuration
Custom Event
#5 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#5 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#5 Low
Shutdown
X X X X X X
Event
Response
Configuration
(continued)
RENR7902-07 185
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Custom Event
#5 Event
X X X X X X X X X
Response
Configuration
Custom Event
#6 High
Warning Event X X X X X
Response
Configuration
Custom Event
#6 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#6 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#6 Low
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#6 Event
X X X X X X X X X
Response
Configuration
Custom Event
#7 High
Warning Event X X X X X
Response
Configuration
Custom Event
#7 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#7 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#7 Low
Shutdown
X X X X X X
Event
Response
Configuration
(continued)
186 RENR7902-07
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Custom Event
#7 Event
X X X X X X X X X
Response
Configuration
Custom Event
#8 High
Warning Event X X X X X
Response
Configuration
Custom Event
#8 High
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#8 Low
Warning Event X X X X X
Response
Configuration
Custom Event
#8 Low
Shutdown
X X X X X X
Event
Response
Configuration
Custom Event
#8 Event
X X X X X X X X X
Response
Configuration
High Fire
Extinguisher
Pressure
X X X X
Warning Event
Response
Configuration
High Fire
Extinguisher
Pressure
Shutdown X X X X X
Event
Response
Configuration
Low Fire
Extinguisher
Pressure
X X X X X
Warning Event
Response
Configuration
(continued)
RENR7902-07 187
Testing and Adjusting Section

(Table 58, contd)

Setpoints - Other System Events Configuration(19)

Loss
Setpoint Audible Soft Hard Breaker Breaker Active
Warning of FPT
Name Alert Shutdown Shutdown Trip #1 Trip #2 Only
Utility

Low Fire
Extinguisher
Pressure
Shutdown X X X X X X
Event
Response
Configuration
Generator
Control Not
in Automatic
X X X
Warning Event
Response
Configuration
Loss of
Utility Event
X X X
Response
Configuration
Utility to
Generator
Transfer
Failure X X X X
Warning Event
Response
Configuration
Utility to
Generator
Transfer
Failure
X X X X
Shutdown
Event
Response
Configuration
Generator to
Utility Transfer
Failure
X X X X
Warning Event
Response
Configuration
(19) Each setpoint in the “Other System Events Configuration” block is used in order to program a system response to the associated Suspect
Parameter Number/Failure Mode Identifier (SPN/FMI) for any internal source.
(16) Setpoint Is not adjustable

Event Input Functions

The Event Input Function block allows the user

of the genset to define selected inputs to cause
user-defined events to become active.
188 RENR7902-07
Testing and Adjusting Section

Table 59
Setpoints - Event Input Functions (13)

Setpoint Min Max Factory

Units Description
Name Value Value Default
Custom Event #NN Active State
N/A N/A N/A High Settings for custom events #1- #8
Configuration
Custom Event #NN Event sec.
0 250 0 Settings for custom events #1- #8
Notification Delay Time
Custom Event #NN Suspect
N/A N/A N/A 107 Settings for custom events #1- #8
Parameter Number
Custom Event #NN Failure Mode
0 20 N/A 15 Settings for custom events #1- #8
Identifier
(13) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Event Output Functions

The Event Output function block provides a method

to access the active status of an event for use in
configuration logic

Table 60
Setpoints - Event Output Functions(14)
Setpoint Min Factory
Max Value Units Description
Name Value Default
Event Output Function #NN Trigger Settings for event output functions
N/A N/A N/A Disabled
Condition #1- #30
Event Output Function #NN Suspect Settings for event output functions
N/A N/A N/A 100
Parameter Number #1- #30
(14) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Event System

Event System block provides a method to log system

events to non-volatile memory. The Event System
block also manages the status of the events in order
to provide overall status outputs to the system.

Table 61
Setpoints - Event System(20)
Setpoint Max Factory
Min Value Units Description
Name Value Default
Event Warning Condition Response Auto
Setpoint Value List 1
Reset Enable Status
Event Audible Alert Response Auto Reset
Setpoint Value List 1
Enable Status
Event Loss of Utility Response Auto Reset
Setpoint Value List 1
Enable Status
Event Breaker #1 Trip Response Auto Reset
Setpoint Value List 1
Enable Status
Event Breaker #2 Trip Response Auto Reset
Setpoint Value List 1
Enable Status
(20) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902-07 189
Testing and Adjusting Section

Generator Monitor/Protect
Enhanced Generator Monitor

The Enhanced Generator Monitor block provides

a method to access the generator monitored
parameters from the Accessory Data Link for use in
configuration logic. The following generator values
will be monitored:

• Front bearing temperature

• Rear bearing temperature
• Winding #1 temperature
• Winding #2 temperature
• Winding #3 temperature
Table 62
Setpoints - Enhanced Generator Monitor(31)
Setpoint Min Max
Units Factory Default Description
Name Value Value
Set to “Installed” when
Generator Winding Temperature Sensor a temperature module
Setpoint Value List
Installation Status is installed on the
accessory data link
Number of Generator Bearing Temperature
Setpoint Value List
Sensors
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Generator AC Monitor

The Generator AC Monitor block measures the AC

voltage and current output by the generator. The
following generator values will be monitored:

• True RMS line - line voltages

• Average line - line voltage
• True RMS line - neutral voltages (for star/wye
configurations)

• Average line-neutral voltage (for star/wye

configurations)

• True RMS phase currents

• Average phase current
• Generator output frequency
190 RENR7902-07
Testing and Adjusting Section

Table 63
Setpoints - Generator AC Monitor(21)
Setpoint Min Max Factory
Units Description
Name Value Value Default
Configurations can be:
“Star/Wye”,
Generator Connection “Delta/3 Wire”
Setpoint Value List 0
Configuration “Delta/4 Wire”
“Single Phase 2 Wire”
“Single Phase 3 Wire”
Generator Potential For direct sensing, leave at default value. For an
Transformer Primary 1 50000 V 1 application requiring a potential transformer, set to
Winding Rating transformer primary winding value.
Generator Potential For direct sensing, leave at default value. For an
Transformer Secondary 1 240 V 1 application requiring a potential transformer, set to
Winding Rating transformer secondary winding value
Generator Current
Transformer Primary 1 7000 A 75 Set to current transformer primary winding value
Winding Rating
Generator Current
Transformer Secondary 1 5 A 5 Can only be set to 1 or 5
Winding Rating
Number of Generator
0 200 N/A 4
Poles
Generator Rated
Setpoint Value List 0
Frequency
Generator Rated Voltage 100 50000 V 100
Generator Rated Power 1 50000 kW 1
Generator Rated Apparent
1 50000 kVA 1
Power
(21) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Generator AC Power Monitor • Per phase kVA (for star/wye confutations)

The Generator AC Power Monitor Block measures • Total kVA
all generator power quantities following generator
values will be monitored: • Percent kVA output
• Per phase kW (for star/wye configurations) • Per phase genset output Power Factor with
lead/lag indication (for star/wye confutations)
• Total kW
• Average output Power Factor with lead/lag
• Total kW hours imported indication

• Total kW hours exported Note: Per phase quantities (kW, kVAr, KVA, and
Power Factor) will be monitored for 3-phase, 4-wire
• Percent kW output star-connected configurations)

• Per phase kVAr (for star/wye confutations)

• Total kVAr
• Total kVAr hours imported
• Total kVAr hours imported
• Percent kVAr output
RENR7902-07 191
Testing and Adjusting Section

Table 64
Setpoints - Generator AC Power Monitor(31)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Customer Password Security Level to
0 3 N/A 3
Reset Generator Energy Meters
(31) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Generator Over Current

The generator overcurrent block detects an

overcurrent condition that persists for a duration that
is a function of the overcurrent level or a condition
that exceeds a threshold for a programmed duration.

Table 65

Setpoints - Generator Over Current(23)

Setpoint Min Max Factory
Units Description
Name Value Value Default
Generator Definite Time Over
Current (Amp) Warning Event 80 130 % 100 Threshold for the Over Current Warning
Percentage Threshold
Generator Inverse Time Over
Time multiplier setpoint (TM) used in equation
Current (Amp) Shutdown Event 0.05 10.00 N/A 0.27
shown in Illustration 89
Time Multiplier
Generator Definite Time Over If current is above this setpoint value for the
Current (Amp) Shutdown Event 100 300 % 125 specified time (setpoint #4) there will be an
Percentage Threshold overcurrent shutdown.
Generator Definite Time Over
Current (Amp) Shutdown Event 0.1 20.0 sec. 10 Time delay for setpoint #3
Notification Delay Time
(23) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Generator Over / Under Frequency

The Generator Over/Under Frequency block detects

bus frequency above or below programmable
thresholds for a programmable duration and activates
an alarm.

g01239796
Illustration 89
192 RENR7902-07
Testing and Adjusting Section

Table 66
Setpoints - Generator Over / Under Frequency(24)
Setpoint Min Max Factory
Units Description
Name Value Value Default
Generator Over Frequency Warning Event
80 120 % 105
Percentage Threshold
Generator Over Frequency Warning Event sec.
0 120 10
Notification Delay Time
Generator Over Frequency Shutdown Event
80.0 120 % 110
Percentage Threshold
Generator Over Frequency Shutdown Event sec.
0 120 2
Notification Delay Time
Generator Under Frequency Warning Event
80.0 120.0 % 95.0
Percentage Threshold
Generator Under Frequency Warning Event sec.
0 120 10
Notification Delay Time
Generator Under Frequency Shutdown Event
80.0 120.0 % 90.0
Percentage Threshold
Generator Under Frequency Shutdown Event sec.
0 120 4
Notification Delay Time
(24) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Generator Over / Under voltage

The Generator Over/Under Voltage block

detects generator output voltage above or below
programmable thresholds for a programmable
duration and activates an alarm.

Table 67
Setpoints - Generator Over / Under Voltage(25)
Setpoint Min Max
Units Factory Default Description
Name Value Value
Generator Over Voltage Warning
100 125 % 105
Event Percentage Threshold
Generator Over Voltage Warning sec.
0 120 10
Event Notification Delay Time
Generator Over Voltage Shutdown
100 125 % 110
Event Percentage Threshold
Generator Over Voltage Shutdown sec.
0 120 2
Event Notification Delay Time
Generator Under Voltage Warning
60 100 % 95
Event Percentage Threshold
Generator Under Voltage Warning sec.
0 120 10
Event Notification Delay Time
Generator Under Voltage
60 100 % 90
Shutdown Event Threshold
Generator Under Voltage
Shutdown Event Notification 0 120 sec. 4
Delay Time
(25) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902-07 193
Testing and Adjusting Section

Generator Reverse Power

The Generator Reverse Power block detects a

reverse power condition that persists for a duration
above a programmed level.

Table 68

Setpoints - Generator Reverse Power(26)

Setpoint Min Max Factory
Units Description
Name Value Value Default
Generator Reverse Power Warning Event Percentage
1 20 % 5
Threshold
Generator Reverse Power Warning Event Notification Delay sec.
0 30 10
Time
Generator Reverse Power Shutdown Event Percentage
1 20 % 10
Threshold
Generator Reverse Power Shutdown Event Notification sec.
0 30 10
Delay Time
(26) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Discrete Input/Output (I/O)

Digital Inputs

The Digital Input block is used in order to relay on/off

information such as switch closures to the EMCP 3.

Note: There are eight digital inputs on “EMCP 3.2”

and “EMCP 3.3”. There are six digital inputs on
“EMCP 3.1.”
194 RENR7902-07
Testing and Adjusting Section

Table 69
Setpoints - Digital Inputs(5)
Setpoint Min Max
Units Factory Default Description
Name Value Value
Active Active Activating the E-STOP input will cause the
E-STOP N/A Active High
Low High generator set to stop immediately.
Setpoint allows for starting and stopping the
genset from a remote location.
If input is active and the engine mode switch
Active Active
REMOTE INITIATE N/A Active Low is in “AUTO”, the engine will attempt to start
Low High
and run. Once the input becomes inactive, the
engine will enter into cooldown (if programmed)
and then STOP.

Active Active
Digital #3(6) N/A Active Low
Low High

The inputs can be set to any of the values listed

in Table 70

Active Active
Digital #4(6) N/A Active Low
Low High
Active Active
Digital #5(6) N/A Active Low
Low High
Active Active
Digital #6(6) N/A Active Low
Low High
Active Active
Digital #7(6) N/A Active Low
Low High

Active Active
Digital #8(6) N/A Active Low
Low High

(5) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
(6) The “Digital Inputs” parameter can only be set to “Active High” or “Active Low” in order to initiate a High Warning, Low Warning, High
Shutdown. Low Shutdown, or Status.
RENR7902-07 195
Testing and Adjusting Section

Table 70
Available Digital Inputs
Pressures Other
Air Filter Differential Pressure Air Damper Closed
Engine Oil Pressure ATS in Normal Position
Fire Extinguisher Pressure ATS in Emergency Position
Fuel Filter Differential Pressure Battery Charger Failure
Engine Oil Filter Differential Pressure Battery Charging System Voltage
Starting Air Pressure Battery Voltage
Gas Pressure Fuel Leak
Custom Event
Temperatures Earth Fault
Ambient Air Temperature Earth Leakage
Engine Coolant Temperature Engine Inlet Manifold Charge Combustion
Engine Oil Temperature EPS Supplying Load
Exhaust Temperature Generator Circuit Breaker Closed
Generator Rear Bearing Temperature Generator Circuit Breaker Open
Right Exhaust Temperature Generator Frequency
Left Exhaust Temperature Generator Voltage
Generator Winding #1 Temperature Generator Current
Generator Winding #2 Temperature Generator Power
Generator Winding #3 Temperature Loss of Utility
Levels Utility Breaker Closed
Engine Coolant Level Utility Breaker Open
Engine Oil Level Utility to Generator Transfer Failure
Fuel Level Generator to Utility Transfer Failure
External Tank Fuel Level

Table 71
Custom Event Setpoint Value for Event Input
Functions cVue Block
Block Setpoint Description
Instance# Value
1 701 Custom Event (Instance
#1 only)
2 702 Custom Event (Instance
#2 only)
3 703 Custom Event (Instance
#3 only)
4 704 Custom Event (Instance
#4 only)
5 705 Custom Event (Instance
#5 only)
6 706 Custom Event (Instance
#6 only)
7 707 Custom Event (Instance
#7 only)
8 708 Custom Event (Instance
#8 only)

Digital Outputs

The Digital Output block is used in order to relay

on/off information from the EMCP 3 for purposes such
as operating relays, solenoids and indicator lamps.

There are two digital outputs on “EMCP 3.3”. There

is one digital output on “EMCP 3.2”. There are no
digital outputs on “EMCP 3.1”
196 RENR7902-07
Testing and Adjusting Section

Table 72
Setpoints - Digital Outputs(7)
Setpoint Max Factory
Min Value Units Description
Name Value Default
Digital Output #1 Active State Configuration Low High N/A Low
Digital Output #2 Active State Configuration Low High N/A Low
(7) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Relay Outputs

The Relay Output block is used in order to relay on/off

information from the EMCP 3 for purposes such as
operating relays, solenoids and indicator lamps.

There are eight relay outputs on the EMCP 3.2 and

EMCP 3.3. Six of the outputs have normally open
contacts and two of the outputs have normally open
and normally closed contacts.

There are six normally open relay outputs on the

EMCP 3.1. There are no normally closed outputs on
the EMCP 3.1

Note: The “active” state for relay outputs is not

configurable.

Table 73

Setpoints - Relay Outputs(29)

Setpoint Min Max Factory
Units Description
Name Value Value Default
Relay Output #1 Active State Relay Output #1 is always configured as
N/A N/A N/A High
Configuration the “Starter Motor Relay”
Relay Output #2 Active State Relay #2 is always configured as the “Fuel
N/A N/A N/A High
Configuration Control Relay”
Relay Output #3 Active State Relay Output #3 is controlled by Digital
N/A N/A N/A High
Configuration Selector #1
Relay Output #4 Active State Relay Output #4 is controlled by Digital
N/A N/A N/A High
Configuration Selector #2
Relay Output #5 Active State Relay Output #5 is controlled by Digital
N/A N/A N/A High
Configuration Selector #3
Relay Output #6 is controlled by Digital
Relay Output #6 Active State Selector #4
N/A N/A N/A High
Configuration The output can be set to “Active High” or“
Active Low”
Relay Output #7 Active State Relay Output #7 is controlled by Digital
N/A N/A N/A High
Configuration Selector #5
Relay Output #8 Active State Relay Output #8 is controlled by Digital
N/A N/A N/A High
Configuration Selector #6
(29) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Spare Analog Input

The Spare Analog Input block converts a resistive

sender value to engineering units, detects sender
diagnostics, and detects a high or low condition on
the spare sender input.
RENR7902-07 197
Testing and Adjusting Section

Note: If you have selected a spare input to be a

temperature, setpoints 6, 7, 10, and 11 will not appear
since they are associated with pressures and levels.
If you have selected a spare input to be a pressure,
setpoints 5, 7, 9, and 11 will not appear since they
are associated with temperatures and levels. If you
have selected a spare input to be a level, setpoints 5,
6, 9, and 10 will not appear since they are associated
with temperatures and pressures.
198 RENR7902-07
Testing and Adjusting Section

Table 74
Setpoints - Spare Analog Input(29)
Setpoint Min Factory
Max Value Units Description
Name Value Default
Set to “Enabled” for
MUI engines and set
Spare Analog Input Enable Status N/A N/A N/A Enabled
to “Disabled” for EUI
engines
Select
“Temperature”,
Spare Analog Input Type Configuration N/A N/A N/A Temperature
“Pressure”, or “Level”
.
Spare Analog Input Suspect Parameter
N/A N/A N/A 175 Oil temperature
Number (SPN)
Spare Analog Input High Percentage Warning
0 100 % 0
Event Threshold
Spare Analog Input High Temperature Deg.
-273 1,735 102 °C (216 °F)
Warning Event Threshold C
Spare Analog Input High Pressure Warning
-250 10,000 kPa -250
Event Threshold
Spare Analog Input High Warning Event sec.
0 60 2
Notification Delay Time
Spare Analog Input High Percentage
0 100 % 0
Shutdown Event Threshold
Spare Analog Input High Temperature Deg.
-273 1,735 107 °C (225 °F)
Shutdown Event Threshold C
Spare Analog Input High Pressure Shutdown
-250 10,000 kPa -250
Event Threshold
Spare Analog Input High Shutdown Event sec.
0 60 10
Notification Delay Time
Spare Analog Input Low Percentage Warning
0 100 % 100
Event Threshold
Spare Analog Input Low Temperature Deg.
-273 1735 1735
Warning Event Threshold C
Spare Analog Input Low Warning Event
-250 10000 kPa 10000
Threshold
Spare Analog Input Low Warning Event sec.
0 60 0
Notification Delay Time
Spare Analog Input Low Percentage
0 100 % 100
Shutdown Event Threshold
Spare Analog Input Low Temperature Deg.
-273 1735 1735
Shutdown Event Threshold C
Spare Analog Input Low Pressure Shutdown
-250 10000 kPa 10000
Event Threshold
Spare Analog Input Low Shutdown Event sec.
0 60 0
Notification Delay Time
(29) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
RENR7902-07 199
Testing and Adjusting Section

NETWORK
Data Link - SCADA

The SCADA Data Link block is used in order to

()communicate with a System Control and Data
Acquisition (SCADA) and is used for support of a
service tool connection. SCADA Data Link will use
the Modbus protocol with an RS-485 half duplex
hardware layer operation at a minimum 2400 bps.

Table 75
Setpoints - Data Link - SCADA(4)
Setpoint Factory
Min Value Max Value Units Description
Name Default
SCADA Data Link Baud Rate 2400 57600 N/A 19200
Select “None”,
SCADA Data Link Parity N/A N/A N/A None
“Odd”, or “Even”
SCADA Data Link Slave Address 1 247 N/A 1
SCADA Data Link Access Password 0 0xfffff N/A 0
SCADA Data Link Connection Timeout sec.
0.1 3600.0 30
Interval
RS-485 Bias Resistor Enable Status Disabled Enabled N/A Enabled
(4) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

OTHER
Digital Selectors

The Digital Selector block determines what

“EVENTS” or “STATUS” will cause each of the relays
to activate.

Table 76
Setpoints - Digital Selectors(8)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Digital Selector #1 controls Relay
Output #3
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#1 Source Input #1
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #2 controls Relay
Output #4
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#2 Source Input #4
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(continued)
200 RENR7902-07
Testing and Adjusting Section

(Table 76, contd)

Setpoints - Digital Selectors(8)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Digital Selector #3 controls Relay
Output #5
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#3 Source Input #6
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #4 controls Relay
Output #6
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#4 Source Input #6
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #5 controls Relay
Output #7
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#5 Source Disabled
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #6 controls Relay
Output #8
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#6 Source Disabled
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Digital Selector #7 controls Digital
Output #1
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#7 Source Input #1
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(continued)
RENR7902-07 201
Testing and Adjusting Section

(Table 76, contd)

Setpoints - Digital Selectors(8)
Setpoint
Min Value Max Value Units Factory Default Description
Name
Digital Selector #8 controls Digital
Output #2
Configuration Options are:
Disabled
Digital Selector
Use Input #1
#8 Source Disabled
Use Input #2
Configuration
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(8) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

Electronic Control Module Reduced Power Mode

The Electronic Control Module block Reduced Power

Mode block minimizes drain on the battery when the
engine is stopped and the control is operating in a
standby mode.

Note: Standard Caterpillar product does not utilize

this group of setpoints.

Table 77

Setpoints - Electronic Control Module Reduced Power Mode(9)

Setpoint Min Factory
Max Value Units Description
Name Value Default
Electronic Control Module Reduced Power Allows control to go into
Disabled Enabled N/A Disabled
Mode Enable Status reduced power mode
Electronic Control Module Reduced Power
0 120 min. 30
Mode Delay Time
(9) The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.

i02464721 ASOS – Air Shutoff Solenoid

Typical Generator ASR – Air Shutoff Relay
Abbreviations
ASSV – Air Start Solenoid Valve
SMCS Code: 4490
ATB – AC Transformer Box
A – Ammeter
AUX – Auxiliary Terminal Strip
ACT – Actuator
AUXREL – Auxiliary Relay (Crank Termination)
ADS – Engine Combustion Air Damper Position
Switch AWG – American Wire Gauge

AFCR – Auxiliary Fuel Control Valve BATT – Battery

ALM – Alarm Module BCF – Battery Charger Failure Switch

ALS – Alarm Silence Push Button BTB – Bus Transformer Box

ALT – Alternator C – Common

AR – Arming Relay CAM – Custom Alarm Module

202 RENR7902-07
Testing and Adjusting Section

CAR – Custom Alarm Relay FCTM – Fuel Control Timer Module

CB – Circuit Breaker FRB – Fuel Rupture Basin

CCM – Customer Communication Module FS – Fuel Solenoid

CDM – Engine Cooldown Timer Module FSOS – Fuel Shutoff Solenoid

CIM – Customer Interface Module GFR – Generator Fault Relay

CT – Current Transformer GOL – Generator On Load

CTR – Crank Termination Relay GOV – Governor

D – Diode GPHI – Ground Post (High Voltage)

DCV – DC Voltmeter GPLO – Ground Post (Low Voltage)

DS – Disconnect Switch GS – Governor Switch

ECLC – Engine Coolant Loss Sensor Connector GSC – Generator Set Control

ECLS – Engine Coolant Loss Sensor GSM – Governor Synchronizing Motor

ECS – Engine Control Switch GSOV – Gas Shutoff Valve

ECTS – Engine Coolant Temperature Sensor HZ – Frequency Meter

EFCR – Emergency Fuel Control Relay KWR – Kilowatt Level Relay

EFL – Emergency Fuel Light IC – Remote Start/Stop Initiate Contact

EG – Electronic Governor (Speed Sensing) L – Load Leads

EGA – Electronic Governor Actuator LFL – Low Fuel Level Light

EGR – Electronic Governor Relay LFLAS – Low Fuel Level Alarm Switch

EHC – Ether Hold-In Coil LFS – Latching Fuel Control Solenoid

EHS – Ether Hold-In Switch LOLAS – Low Oil Level Alarm Switch

ENFR – Engine Failure Relay LWLAS – Low Water Level Alarm Switch

EOTC – Engine Oil Temperature Sensor Connector LWTL – Low Water Temperature Light

EOTS – Engine Oil Temperature Sensor MAN – Manual

EOPS – Engine Oil Pressure Sensor MPU – Magnetic Speed Pickup

EPC – Ether Pull-In Coil NC – Normally Closed

EPS – Ether Pull-In Switch NO – Normally Open

ES – Ether Solenoid OCL – Overcrank Light

ESPB – Emergency Stop Push Button OCR – Overcurrent Relay

ESL – Emergency Stop Light OCT – Overcrank Timer

F – Fuse OP – Oil Pressure

FCR – Fuel Control Relay OPG – Oil Pressure Gauge

RENR7902-07 203
Testing and Adjusting Section

OPL – Oil Pressure Light SMR – Starting Motor Relay

OSL – Overspeed Light SP – Speed Adjust Potentiometer

OSR – Oil Step Relay SPM – Synchronizing Parallel Module

OVR – Overvoltage Relay SR – Slave Relay

PEEC – Programmable Electronic Engine Control SS – Synchronizing Switch

PL – Panel Illumination Light T – Generator Line Leads

PLS – Panel Light Switch TD – Time Delay Relay

POS – Positive TSC – Transfer Switch Position Indicating Contact

POT – Potentiometer V – AC Voltmeter

PP – Prelube Pump VAR – Voltage Adjust Rheostat

PPMS – Prelube Pump Magnetic Switch VR – Voltage Regulator

PPPS – Prelube Pump Oil Pressure Switch WT – Water Temperature

PR – Preregulator WTG – Water Temperature Gauge

PS – Pinion Solenoid WTL – Water Temperature Light

PWM – Electrical Converter (Pulse Width Modulated) XDUCER – Transducer

RAN – Remote Annunciator Z – Zener Diode

RDM – Relay Driver Module

i03140584

RPL – Reverse Power Light ECM Connections

RPR – Reverse Power Relay SMCS Code: 4490; 7566
RPSR – Reverse Power Slave Relay The following illustrations are simplified electrical
schematics of the “Electronic Control Module” (ECM)
RR – Run Relay for the generator set. The schematics do not show all
possible harness connectors.
SASV – Start Aid Solenoid Valve
The EMCP 3 control has one 70-pin connector on the
SATS – Start Aid Temperature Switch back of the control. Not all of the 70 pins are used.
The illustrations indicate the pins that are used for
SAS – Starting Aid Switch each version of the control. The illustrations also
provide the wiring connections for each pin that is
SEC – Second used for each version of the control.
SHTC – Circuit Breaker Shunt Trip Coil The passive analog input number 1, that is for oil
pressure, and the passive analog input number 2,
SIG – Signal that is for coolant temperature, will not be used with
“Electronic Unit Injection” (EUI) engines. The coolant
SL – Synchronizing Light temperature sensor and the oil pressure sensor will
be wired to the engine ECM for EUI engines that
SLM – Synchronizing Light Module use a “Common Engine Interface”. The EMCP 3 will
obtain the sensor data from the engine ECM via the
SLR – Synchronizing Light Resistor J1939 data link.
SM – Starting Motor

SMMS – Starting Motor Magnetic Switch

204 RENR7902-07
Testing and Adjusting Section

The illustrations show two different methods in order

to connect the analog inputs. The method that is
shown with all of the other connections is for sensors
with 2 wires. The connections for the sensors, that
have only 1 wire, are shown at the bottom right hand
side of the illustrations.

The connections that are for the discrete inputs are

shown with normally open contacts that are wired to
the battery negative. The discrete inputs can also be
connected to the battery negative through normally
closed contacts. In order to perform the connections,
the active state of the input will need to be set to
“active high”.

Reference: For information on programming the

digital inputs, refer to the Systems Operation, “Digital
Input Programming” section.

Reference: For additional information about the

electrical system, refer to the Electrical System
Schematic section of the service manual for the
generator set that is being serviced.
RENR7902-07 205
Testing and Adjusting Section

g01309357
Illustration 90
206 RENR7902-07
Testing and Adjusting Section

g01514111
Illustration 91
RENR7902-07 207
Testing and Adjusting Section

g01514113
Illustration 92
208
Index Section
Index
A Electronic Control Module (Generator Set) -
Analog Input Circuit Fault .................................... 127
Annunciator Module............................................... 60
[ OPTIONAL USE] ............................................. 60
Adding Additional Remote Annunciator ............. 67
Basic Operation ................................................. 61
Configuration...................................................... 61
General Information ........................................... 60
C Electronic Control Module (Generator Set) -
Charging System ................................................. 128
Component Location ............................................... 6
Cycle Timer Programming..................................... 38
Outputs .............................................................. 39
D Verification Procedures .................................... 146
Data Link ............................................................... 13
Data Links .......................................................... 13
Data Link Circuit Fault ......................................... 130
Diagnostic Capabilities .......................................... 91
The Caterpillar Electronic Technician................. 91
Diagnostic System Procedures ........................... 108
Diagnostic Trouble Code List ................................ 92
Digital Input Circuit Fault ..................................... 132
Digital Input Programming ..................................... 25
Digital Inputs ...................................................... 25
Function and Navigation Keys ........................... 26
Programming the Active State of the Digital
Input ................................................................. 27
Programming the Event Input Functions............ 27
Digital Output Circuit Fault................................... 133
Digital Output Programming .................................. 28
Function and Navigation Keys ........................... 29
Programming the Active State of the Digital
Output .............................................................. 29
Programming the Digital Selectors .................... 29
Discrete Input/Output Module................................ 55
[ OPTIONAL USE ] ............................................ 55
Configuration Behaviors..................................... 57
General Information ........................................... 55
Inputs ................................................................. 55
Outputs .............................................................. 56
Specifications..................................................... 57
E I
ECM Connections................................................ 203
Electrical Connector - Inspect.............................. 138
Electronic Control Module (Engine) (EUI Engines
Only) .................................................................... 14
Electronic Control Module (Generator Set) ............ 11
ECM Front Panel Components .......................... 12
General Information ............................................ 11
RENR7902-07
Configure ........................................................... 147
Function Keys and Navigation Keys ................ 147
Initial Setup ...................................................... 148
Menu Maps ...................................................... 149
Programming the Display Preferences ............ 155
Programming the Setpoints ............................. 155
Setpoint Tables ................................................ 156
Setpoints .......................................................... 149
Electronic Control Module (Generator Set) - Flash
Program ............................................................. 147
Replace.............................................................. 147
Replacement Procedure .................................. 147
Engine Cooldown Warning .................................. 108
Engine Overcrank Warning ................................. 108
Engine Overspeed Warning ................................. 110
Engine Setpoint Verification - Test....................... 145
Relevant Engine Parameter Group Setpoints.. 145
Engine Speed Circuit Fault.................................. 134
Engine Speed Timing Calibration - Setup ........... 144
Engine Speed Warning........................................ 109
Engine Underspeed Warning ............................... 112
Event Resetting ..................................................... 20
Reset Individual Events from the Generator Set
Control.............................................................. 21
Resetting All Events for a Single Module........... 20
Resetting All Events for All Modules .................. 22
Resetting Events for Engines Without J1939
Support............................................................. 22
Event Viewing........................................................ 19
External Potential Transformer Connections ....... 139
Transformer Connections ................................ 142
Winding Connections ....................................... 139
G
General Information........................................... 4, 89
Generator Control Not in Automatic Warning ....... 114
Generator Output Sensing Circuit Fault ............... 115
Generator Overcurrent Warning ........................... 115
Generator Overfrequency Warning ...................... 116
Generator Overvoltage Warning........................... 119
Generator Reverse Power Warning .................... 120
Generator Underfrequency Warning ................... 121
Generator Undervoltage Warning........................ 124
Important Safety Information ................................... 2
Introduction............................................................ 89
RENR7902-07 209
Index Section

M Thermocouple Module........................................... 52
Monitoring Software for Computer.........................
Creating a Control Panel View...........................
Logging Data to a File........................................
Quick Start Guide...............................................
Software Set Up.................................................
MUI Engine Monitoring and Control ......................
P
[ OPTIONAL USE] ............................................. 52
69 Configuration...................................................... 54
77 Diagnostics ........................................................ 52
84 General Information ........................................... 52
74 Monitoring Features ........................................... 53
70 Specifications..................................................... 54
15 Trip Point Programming......................................... 40
Troubleshooting Section........................................ 89
Typical Generator Abbreviations ......................... 201

Password Entry ..................................................... 17 U

Change Level 1 or Level 2 Password ................ 18
Drop to Minimum Security Level ........................ 17 Unexpected Engine Shutdown ............................ 137
Enter Level 1 or 2 Password.............................. 18
Enter Level 3 Password ..................................... 18
Function and Navigation Keys ........................... 17 V

Voltage and Frequency Adjustment....................... 49

R Adjustment ......................................................... 49
Function and Navigation Keys ........................... 49
Real Time Clock Programming.............................. 50 Idle Speed and Rated Speed............................. 49
Changing the Date Format................................. 51
Function and Navigation Keys ........................... 50
Programming the Time and Date ....................... 50 W
Relay Output Programming ................................... 32
Digital Selector Programming ............................ 32 Wiring Harness (Open Circuit) - Test................... 138
Function and Navigation Keys ........................... 32 Wiring Harness (Short Circuit) - Test ................... 139
Resistive Temperature Device Module .................. 57
[ OPTIONAL USE ] ............................................ 57
Configuration Behaviors..................................... 59
Diagnostics ........................................................ 58
General Information ........................................... 57
Module Overview ............................................... 57
Monitoring Features ........................................... 58
Specifications..................................................... 60

Service Maintenance Interval Warning ................ 126

Service Tools ......................................................... 90
Setpoint Programming........................................... 23
EMCP 3.x Programming Example ..................... 24
Function and Navigation Keys ........................... 23
Spare Analog Input Programming ......................... 37
Menu Navigation ................................................ 37
Parameters that can be Configured ................... 37
Speed Sensor (Engine) - Adjust .......................... 145
System Operation.................................................. 15
Systems Operation Section ..................................... 4

Table of Contents..................................................... 3
Testing and Adjusting .......................................... 138
Testing and Adjusting Section ............................. 138
Text String Programming ....................................... 41
Text String Programming ................................... 41
210 RENR7902-07
Index Section
RENR7902-07 211
Index Section
©2009 Caterpillar Cat, Caterpillar, their respective logos, “Caterpillar Yellow” and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.