Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610} (REHS9799-03)

26/2/24, 12:03 SIS 2.
Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP
4.2 {4490, 7610} (REHS9799-03)
SMCS - 4490, 7610 i10044757

Electric Power Generation
PIP
All
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202 1011
8
Revision History:
Table 1
15: 4 /0 791
0 2 / 2
RE :43- 6
3
Revision Summary of Changes
03 Added optional part information in Table 6.
02 H
© 2 S979 03:00
Removed ATB from the winding ratings section and added a note to the winding
ratings section.
Introduction 024 9
Cat
erp
This Special Instruction contains necessary information for upgrading Electric Power Generator Set
illa
Control mounted panels that use the Electronic Modular Control Panel (EMCP) Engine Status
Control (ECS), EMCP 1 (per 7C-1000 Control Panel Chart), EMCP 2, EMCP 2+, EMCP 3.1, EMCP
3.2, and EMCP 3.3 to EMCP 4.2. rI nc.
Reference Section
Reference: Systems Operations Troubleshooting/Testing and Adjusting, UENR1209 ,
"EMCP4.1/EMCP4.1 4.2"
Reference: Application and Installation Guide, LEBE0006, "EMCP 4.1, 4.2 Generator Set Control"
Safety Section
Do not perform any procedure in this Special Instruction until you have read this Special Instruction
and you understand this information. Use only proper tools and observe all precautions that pertain
to the use of those tools. Failure to follow these procedures can result in personal injury. The
following procedures should be observed.
Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person must also have the necessary training,
skills, and tools to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar
cannot anticipate every possible circumstance of a potential hazard.
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Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. Avoid using a tool, a procedure, a work method, or operating technique that is not
recommended by Caterpillar.
Ensure that the operation, lubrication, maintenance, or the repair procedures used will not create
an unsafe condition or damage the product.
Do not operate or work on this engine or generator set unless

you have read and understand the instructions and warnings in
the Operation and Maintenance Manuals.
Failure to follow the warnings and instructions could result in

injury or death. Contact any Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
Failure to follow all safety guidelines prescribed in this

document and by governing authorities and regulatory agencies
could result in severe injury or death of personnel or machine
damage.
Personal injury or death can result from improper maintenance

procedures. To avoid injury or death, follow the procedures
exactly as stated below.
Bodily contact with electrical potential can cause bodily injury

or death.
To avoid the possibility of injury or death, ensure that the main

power supply has been disconnected before performing any
maintenance or removing any modules.
Access to this service point may require climbing on the

equipment. Slipping or falling while climbing on the equipment
26/2/24, 12:03 SIS 2.0
could result in personal injury or death. Refer to the Operation

and Maintenance Manual, "Mounting and Dismounting" topic,
for safety information.
Never disconnect any charging unit circuit or battery circuit

cable from the battery when the charging unit is operated. A
spark can cause an explosion from the flammable vapor mixture
of hydrogen and oxygen that is released from the electrolyte
through the battery outlets. Injury to personnel can be the result.
Working with electrical circuits is hazardous. Bodily contact with

electrical potential will cause personal injury or death. Ensure
that personnel are trained in proper operating procedures in
order to ensure safe operation.
Lock Out/Tag Out
Accidental engine starting can cause injury or death to

personnel working on the equipment.
To avoid accidental engine starting and to bring the equipment

to a zero energy state, disconnect all positive (+) and negative
(−) battery cables. Install an appropriate battery cable lockout
device and protect the battery posts to prevent accidental
contact and shorting.
Place a Do Not Operate tag at the Start/Stop switch location to

inform personnel that the equipment is being serviced.
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Illustration 1 g06276183
Attach a "Do Not Operate" warning tag or a similar warning tag to the start switch or to the battery
disconnect location before you service the equipment. The warning tags are available from your
Caterpillar dealer.
Hazardous Voltage Information
ELECTROCUTION HAZARD - The electrical system contains

hazardous voltage levels.
DO NOT remove any covers that will expose energized

hazardous-voltage electrical components without shutting down
and discharging the electrical system.
DO NOT perform any maintenance on the electrical system until

after the electrical system has been shut down and the voltage
has been discharged by qualified personnel.
Read and understand the instructions and warnings found in the

Operation and Maintenance Manual to properly shut down the
electrical system and discharge hazardous-voltage electrical
components.
Failure to follow these instructions will result in personal injury

or death.
ELECTROCUTION HAZARD - Ensure proper grounding.
Avoid a buildup of hazardous live voltages on exposed surfaces

by ensuring that all grounding wires/straps are always properly
connected.
Disconnected grounding wires, including grounding wires/straps

for hazardous-voltage components and electrical enclosures,
must be properly reconnected before connecting equipment to
the power supply.
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Failure to follow these instructions will result in personal injury

or death.
When service or maintenance must be performed in a

hazardous-voltage component enclosure, always assume that a
hazardous voltage level could be present.
Qualified personnel should manually check for hazardous

voltage using electrical measuring tools that have the capacity
to measure the hazardous-voltage components being checked.
The voltage level present must be confirmed to be below 50

Volts before any exposure to the hazardous-voltage components
can take place.
Failure to follow these instructions could result in personal

injury or death.
There may be government regulations, local regulations, or site-specific rules that govern the
operation, service, and maintenance of high-voltage components and machines. Comply with
applicable rules and regulations for the work place.
Appropriate high-voltage protective equipment should be worn as defined by local rules

and regulations.
Only qualified service personnel should perform service on high-voltage systems.
DO NOT remove covers, or open enclosures, that will expose energized high-voltage
electrical components.
DO NOT perform service or maintenance on energized high-voltage electrical components.
High voltage can cause electrocution resulting in personal injury or death.
High-voltage components and connections must be properly maintained.
Refer to the Maintenance Section in the Operation and Maintenance Manual for additional
information.
Residual energy can remain in high-voltage components even after operation has stopped. Always
assume that a hazardous level of voltage could be present.
Before performing any type of service, repair, or maintenance on high-voltage electrical

components, perform the following:
Disconnect the electrical power source
26/2/24, 12:03 SIS 2.0
Isolate electrical components
Discharge residual energy
Check components for voltage using electrical measuring tools.
Note: Use electrical measuring tools that have the capacity to measure the high-voltage
components being checked. The level of voltage present must be confirmed to be below 50 Volts
before any exposure to the high-voltage components can take place.
Read and understand the instructions and warnings found in Operation and Maintenance Manual,
"Electrical Shutdown and Voltage Discharge" , to shut down the electrical system and discharge
high-voltage electrical components.
Electrical Safety
Note: Do not operate or work on a generator set unless you have read and understand the
instructions and warnings in this manual and the EMCP 4.2 Application and Installation Guide.
Failure to follow the instructions or heed the warnings could result in injury or death. Contact any
Cat Dealer for replacement manuals. Proper care is your responsibility.
Electrostatic Discharge Awareness
NOTICE
The EMCP 4 control contains components that are sensitive to
electrostatic discharge (ESD). An electrostatic charge can
damage the control resulting in EMCP 4 breakdown or improper
operation. Take the following precautions while installing,
removing, and handling the control.
Handle equipment correctly. Use ESD protective packaging and material handling containers
that are anti-static and provide discharge protection and electric field suppression.
Use protective devices. ESD - protective workstations and/or work surfaces that include a
grounding mat anti-static wrist strap.
Keep all plastic items away from the devices. Any plastic item is a potential static generator.
The plastic includes candy wrappers, foam cups, synthetic carpet, and foam cushions.
The anti-static bag cannot function as a static dissipating mat.
DO NOT use an anti-static bag for any other purpose than to enclose a product.
The 120-pin connector and 70-pin connector for EMCP 4.2 on the back of the control is the most
vulnerable area to electrostatic discharge (ESD). While handling the EMCP 4, extra attention is
26/2/24, 12:03 SIS 2.0
required to the back of the control. The control may become damaged or inoperable if extra care is
not taken.
Consult the Electrostatic Discharge Association for proper procedure during particular situations at
http://www.esda.org.
Overview
Applicability
This kit is intended to replace EMCP controls by using the existing generator-mounted enclosure.
Features
As implemented, the EMCP 4.2 control offers more features and communication options than what
was available with the earlier EMCP models. Refer to Application and Installation Guide,
LEBE0006, "EMCP 4.1, 4.2 Generator Set Control" for a complete description.
Required Documents
Refer to the following documents for review prior to installation.
Table 2
Media
Systems Operations, Troubleshooting, Testing and Adjusting, UENR1209 ,
"EMCP4.1/EMCP4.2"
LEBE0006 EMCP 4.2 Application and Installation Guide
Power Requirements
This control is designed to operate on 24 VDC only. Current draw of the control package is less
than 2.0 amps. External solenoids, loads driven by the control's relays and connection of a Cat
Electronic Technician (ET) communications adapter will add to the current draw.
Removal of the Existing Control

Resolve Existing Issues
Resolve any existing issues with the control, the generator set, or the wiring between them. If
the existing installation has generator set or control issues, these issues should be repaired
prior to performing a control upgrade. Troubleshooting a failure will only become more difficult
after the new control is installed. If the control has failed, it may not be possible to perform
some of the following tasks.
Use the documentation appropriate for the control. The document should be available on Cat
Service Information System 2.0 (SIS 2.0) .
Check the control for stored diagnostic codes and repair the issues that are causing the codes
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As much as practical, insure that the control and generator set are working without issues.
Voltage and Continuity Check

Perform a voltage and continuity check to determine that the schematic conforms to the old
control as it has been installed. An accurate schematic of the existing installation will be
required when installing the new control.
Using a voltmeter, connect the negative lead to ground
Measure the voltage at every point shown on the schematic that is connected to battery (+).
Check continuity for every point on the schematic. Mark up the schematic to reflect the control
as it is installed. Continuity should be < 10 ohms. Voltage is Vbat ± 0.5 V
Determine Idle and Rated Speed Parameters

Record the generator set parameters when the generator is at idle and rated speed.
The value of the generator set parameters will be needed to verify that there are no problems after
the installation of the new sensors.
Start the generator set and force the generator to remain at idle. The governor must be
disconnected or disabled. When the coolant temperature has stabilized, record the following values
listed in Table 3.
Table 3
Value Unit Recorded Value

Engine Idle Speed RPM
Engine Oil Pressure psi / kPa
Engine Coolant Temperature C/F
Enable the generator set to go to rated speed. When the coolant temperature has stabilized, record
the values listed in Table 4.
Table 4
Value Unit Recorded Value

Engine Rated Speed RPM
Engine Oil Pressure psi / kPa
Engine Coolant Temperature C/F
Baseline Generator Set Operating Parameters

Record the existing baseline operating parameters of the generator set.
Use documentation found in the service information system website to determine how to access
the generator set parameters. The parameters will be needed to program the new control. Record
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the data for the list of parameters that are shown in Illustration 2.
Removing Existing Control

1. Insure that the generator has been disconnected and isolated from the utility power and any
other power source. Ensure that proper lock out and tag out procedures are followed.
2. Disconnect Alternating Current (AC) power from the battery charger.
3. Disconnect the battery charger from the battery.
4. Disconnect the battery from the generator set.
5. Inspect the wiring coming out of the conduit that enters the bottom of the panel. All the wires
must be labeled with the number of the terminal blocks that the wires are connected to. Ensure
that the terminal block numbers match the wire numbers. The labeling is shown on the
schematic for the existing installation. When all the wires have been labeled, disconnect the
wires from the terminal blocks.
6. Disconnect the conduit and spiral wrap from the original EMCP panel. Ensure that none of the
wiring is damaged during removal of the conduit or spiral wrap.
Note: Do not remove any wiring from the conduit or spiral wrap.
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7. If the governor/speed control is going to be reused in the EMCP 4.2 panel, the governor/speed
control should be removed from the original EMCP panel.
8. Remove the original EMCP panel from the generator enclosure.
Installation of the EMCP 4.2 Control

Parts List
Table 5
Contents of the 467-4168 Electronic Panel Gp
Qty Part Number Part Name

1 457-1582 Panel Harness As
1 467-4169 Panel Harness As
1 459-1873 Terminal Marker As
15 3S-2093 Cable Strap
9 9X-8256 Washer
6 095-0827 Lockwasher
1 103-6272 Seal
9 208-8469 Locknut
1 442-0635 Bracket As
2 3E-2286 Contact Strip
2 5C-2890 Nut
2 8T-4205 Hard Washer
1 9Y-6027 Ceramic Fuse
1 105-7543 Fuse Block
8 115-1322 Terminal
1 115-2538 End Cover
22 116-5140 Terminal
1 125-9969 Rail
1 203-9007 Nut
2 225-3322 Screw
3 264-2957 Screw
2 314-9101 End Bracket
1 355-9019 Generator Set Electronics Gp
3 448-1934 Spacer
1 499-6725 Plate
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Table 6
Optional Part
1 465-6747 Electronic Panel Gp
Control Module Installation
(1) EMCP Control
(2) 499-6725 Plate
Mounting 499-6725 Plate is provided to give the installer an additional option for mounting the
EMCP. Refer to Illustration 3 for measurements.
Terminal Block Installation
26/2/24, 12:03 SIS 2.0
EMCP 4.2 Terminal Block-Rail mounting
Refer to Illustration 4 for layout of the terminal block assembly.
Control Harness Installation

Once the wire 467-4169 Panel Harness As has been installed , use Table 7 for wire to terminal
block assembly.
Table 7
Control Harnesses
467-4169 Panel Harness As Wire Number/Color Terminal Block Number

7 196-E6 GY 404
9 185-E5 BR 403
11 183-E7 PU 402
13 180-E4 OR 401
16 P735-E35 E-CBL2 WH 306
18 101-E18 RD 104
26 R957-E42 BK 313
27 L925-E43 PU 314
31 A368-E13 BR 405
37 R952-E38 E-CBL3 BK 308
38 R951-E37 E-CBL3 RD 307
39 184-E8 BU 408
46 P734-E34 E-CBL2 BK 305
47 A367-E12 GN 406
48 R955-E41 BK 312
51 R954-E40 BK 311
52 101-E17 RD 103
55 A775-E15 BK 310
56 P733-E33 E-CBL2 RD 304
57 A364-E11 YL 407
58 101-E19 RD 105
60 200-E10 BK 201
61 101-E16 RD 104
65 200-E9 BK 201
66 G404-E30 E-CBL1 RD 303
67 G405-E31 E-CBL1 BK 302
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70 A774-E14 BK 309
457-1582 Panel Harness As Wire Number/Color Terminal Block Number

A 101-G1 RD 105
B 200-G2 BK 202
457-1582 Panel Harness As Splice together 467-4169 Panel Harness As

F711-G8 GN Splice together F711-E27 GN
F712-G5 YL Splice together F711-E22 YL
The schematic for the existing installation and the schematic for the EMCP 4.2 is required to install
the wiring to the EMCP 4.2 control. Since the EMCP 4.2 can replace many different controls, the
wire numbers on the existing wiring will likely not correspond with the EMCP 4.2 terminal blocks.
The wire numbers on the existing wiring along with the schematic for the existing control will help to
identify the function for each wire. Using the schematic for the EMCP 4.2, find the corresponding
function and the terminal block number. Connect each wire to the correct terminal block. In many
installations there will be wiring that is not used. If it is certain that a wire will not be used, it can be
pulled out of the conduit and discarded.
Note: All wiring connected to generator output must have an insulation rating of 600 V.
Wiring Diagrams
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Wiring Diagram 1
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Items shown as dashed lines are not included in the kit.
Note: Replacing the oil pressure sensor, engine speed sensor, and coolant temperature sensor
may be necessary if the existing sensors are not compatible with the EMCP 4.2 or have failed.
Install Existing Sensors

Note: PWM Sensors will not work with the EMCP 4.2 Control. For more information refer to the
section "Recommended Sensors".
Use wiring schematic Illustration 5 and 6 for help in the wiring of sensors. Use the reference
document (UENR1209) for sensor configuration.
Control Parameter Configuration

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Configuration Parameter Default Values

For information on configuration of various sensors, reference Application and Installation Guide,
LEBE0006, "EMCP 4.1, 4.2 Generator Set Control" which can be found on Power Net.
Winding Ratings
Note: The EMCP 4 family of controls supports direct sense capability to 600Vac RMS. Any
monitored Generator voltages above the rating should be transformed to a voltage that is
supported, in accordance with local regulatory requirements.
Potential Winding Rating
The EMCP 4.2 control can directly monitor generator voltages up to 600 V. Voltages more than 600
V must use potential transformers to scale the generator voltage to less than 600 V.
Secondary Winding Rating
Whether the generator is wired directly to the EMCP 4.2, or when potential transformers are used,
it is recommended that fuses at the appropriate voltage rating be installed. Fuses are connected to
the load bus generator tab as shown in Illustration 6. If there is a short on one of the connections to
the control (bus voltage L1, L2 and L3, neutral), a fuse will blow to protect the generator, control,
and personnel. If potential transformers are used, the voltage ratio is set in the potential
transformer secondary winding rating setting. The value of this rating depends on the turns ratio of
the potential transformer primary winding to secondary winding.
Primary Winding Rating
The EMCP 4.2 control must use current transformers to measure generator output current. The
current transformers must scale the generator output current from, 0 to 1 or 0 to 5 amps for use by
the EMCP 4.2. The current transformer ratio is set in the EMCP 4.2 parameter settings. Use
(configuration setup for "Generator AC Monitor") shown above, as a path to access the current
primary and secondary winding rating parameter using Cat ET.
The recommended transformers can be found in Table 8.
Table 8
Part Number Part Name Rating

122-6585 Current Transformer As 1000:5 Amps, 600 Volt, Stud terminals
365-1431 Link and Bearing As 3000:5 Amps, 600 Volt, Stud terminals
357-1219 Transformer 1500:5 Amps, 600 Volt, Stud terminals
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Configuration Setup for "Generator AC Monitor"

To change the following parameters, refer to the following instructions:
1. Navigate to the EMCP 4.2 screen in Cat ET, and click "Configuration Tool".
2. Navigate to desired parameter "Generator AC Monitor", and double-click the "desired

parameter line of choice" to change "VALUE".
3. In the (change parameter value) box, enter new value and click "OK".
4. Continue to the next parameter as needed.
5. Double-click Cat ET (configuration tool) icon

Analog Inputs
There are two analog inputs from the generator set:
Engine oil pressure
Engine coolant temperature

High Coolant Temperature Shut-down
This can be found listed as analog input #2 high shutdown event threshold. The range of this
parameter is 95 °C (203 °F) to 120 °C (248 °F). The default value is set at 108 °C (226.4 °F).
Low Oil Pressure Shut-down Event Threshold
This can be found listed as analog input #1 low shutdown event threshold. The range of this
parameter is 13.4 kPa (1.943 psi) to 880 kPa (127.63 psi). The default value is set at 150 kPa
(21.76 psi).
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6. Select the value of the parameter that is being modified. Enter the new value and click "OK" to
change
7. Program the parameters into the EMCP 4.2 control using the parameter data that was
obtained in 3.4 baseline generator set operating parameters.
8. For information on how to set the time and date on the EMCP 4.2 control, refer to Systems
Operations Troubleshooting Testing and Adjusting, UENR1209 , "EMCP4.1/EMCP4.2".
9. This control has not allocated inputs for battery charger fault detection. If it is necessary to
monitor the battery charger status and the battery charger provides status outputs, refer to
Systems Operations Troubleshooting Testing and Adjusting, UENR1209 ,
"EMCP4.1/EMCP4.2" for instruction on how to implement digital inputs.
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Validation
Electrical Validation
Power Off Tests
The battery should not be connected.
Check for continuity between the following points (TB designates the terminal blocks in the EMCP
4.2 control):
Table 9
From PIN To PIN

Battery (+) lug TB 101
Battery (-) lug TB 201
Remote Initiate Contact 1 (IC) TB 310 (Optional Feature)
Remote Shutdown Contact 1 (PSS) TB 309 (Optional Feature)
Air Shut Off Relay coil 2 TB 312 (Optional Feature)
Fuel Solenoid coil 2 TB 312
Fuse T1 protected terminal TB 401
Generator Enclosure TB 50 TB 408
Note: To check the continuity of the wiring from the generator output to the EMCP 4.2, remove the
three fuses (F10, F11, F12 in Illustration 6) to isolate the wiring from the generator. Replace the
fuses after the continuity checks have been completed.
Note: This validation assumes that potential transformers are not being used.
Power On Test
Perform the following procedure for power-on test :
1. Connect the battery terminals to the battery. Connect the battery charger to the battery and
insure the battery charger is connected to an AC source.
2. Using terminal block 201 as (-) battery, check that there is (+) battery voltage on the following
points: (See Illustration 4 schematic for fuse terminal block identification)
3. Fuse 1 terminal 2.
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4. Verify that the EMCP 4.2 control is powered up
Operational Validation
Cranking Cycle, E-Stop Test
This test will verify that the generator set cranking cycle can be stopped with the E-Stop button. To
prevent the engine from starting, disconnect wire from TB312. Make sure to isolate wire, to prevent
short to ground.
1. Push the "RUN" button and allow the generator set to go through the first crank/rest cycle.
When the second crank cycle begins, press the E-Stop button to verify that the generator set
can be stopped
2. Acknowledge the cranking cycle faults and reset the EMCP 4.2 control.
3. Connect wire to TB312 to allow the Fuel Control Relay (FCR) to function.
Idle Speed Tests

Disconnect or disable any speed governor to prevent the generator set from running at rated
speed.
Idle Speed, E-Stop Test

This test will verify that the generator set can be stopped at idle speed with the E-Stop button.
1. Press the "RUN" button and allow the generator set to start and run at idle speed.
2. Press the E-Stop button to verify that the generator set will come to a controlled stop.
Idle Speed Parameter Validation

Perform the following procedure for idle speed parameter validation:
1. Push the "RUN" button on the EMCP 4.2 control panel. The generator set should start and run
at idle speed.
2. Check the coolant temperature as the generator set starts and verify that it is close to the
block temperature of the generator set. This check is done to determine if the coolant
temperature sensor and related wiring are functional.
3. Allow the coolant temperature to stabilize, then read the following parameters from the ECM
display:
Engine speed - RPM
Battery voltage - Volts
Engine oil pressure - kPa or psi (circle which)
Engine coolant temperature - °C / °F (circle which)
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4. Any parameter that is not the same as the original data value data will need to be investigated
and resolved before proceeding.
5. Press "Stop" button on the EMCP 4.2. The generator set should come to a controlled stop.
6. Correct any issues that prevented the generator set from starting, idling, or verification of the
idle speed parameters.
Engine Speed Sensor Loss Test

The engine speed sensor loss test will verify that the generator set will stop if the engine speed
sensor fails.
1. Push "RUN" button and allow the generator set to start and run at idle speed.
2. Jumper terminal 302 to terminal 303. The generator set should shut down immediately. Loss of
engine speed results in an "Unexpected Engine Shutdown" fault. To recover from this fault,
remove power from the EMCP 4.2 control by removing fuse 1 to remove power from the
control, and then reinstall the fuse.
3. Restart the generator set and allow it to run at idle speed.
4. Disconnect the engine speed sensor from either terminal 302 or 303. The generator set should
shut down immediately. Reconnect the engine speed sensor and cycle the power on the
EMCP 4.2 by removing fuse 1 to remove power from the control, and then reinstall the fuse.
5. Reconnect or enable the governor to allow the generator set to run at rated speed.
Engine Set point Verification

The engine set point verification procedure verifies that the EMCP 4.2 operates correctly when a
low oil pressure or high coolant temperature event occurs. The engine set point verification
procedure also verifies that the EMCP 4.2 operates correctly when an engine overspeed event
occurs.
Low oil pressure and high coolant temperature each have two events, warning and shutdown. The
EMCP 4.2 will issue a warning whenever the warning threshold is reached and a shutdown
whenever the shutdown threshold is reached. This verification procedure will modify configuration
set points used in normal operation. The steps below outline how to perform the low oil pressure
shutdown and high coolant temperature shut-down procedures. A similar process can be used for
low oil pressure warning and high coolant temperature warning, along with low idle low oil
pressure.
During this procedure, each configuration set point should be recorded prior to adjustment then
returned back to the original setting after the set point has been verified.
The following conditions are required before the engine set points are verified:
The set points must be correct for the generator set application.
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No shutdown events should be present. If necessary, troubleshoot, correct, and reset any
shutdown events
Low Oil Pressure Verification

Note: Low oil pressure shutdown is disabled during start-up and while the generator set is not
running by the Fault Protection Timer (FPT). The fault protection timer starts timing when crank
terminate RPM is reached during the starting sequence. The fault protection timer will then run for
a programmed time which is determined by the engine start fault protection activation delay time
set point. Make sure that the fault protection timer has elapsed before starting the low oil pressure
verification.
1. Start the generator set and run the generator set at rated speed.
2. Adjust the set point value for analog input #1 low shutdown event threshold to a value that is
above the oil pressure at which the generator set is operating. The shutdown event will occur
after the programmable time delay (analog input #1 low shut down event delay time set point).
3. View the event by going to the EMCP 4.2 event log.
4. Reset the event.
5. Return the set point value for analog input #1 low shutdown event threshold to the original
value.
Overspeed Verification
Perform the following procedure on overspeed verification:
2. Adjust the set point value for engine overspeed set point to a value that is below the speed
that the generator set is running at. An engine overspeed set point event will occur
immediately after the set point is changed, and the generator set will shut down.
3. View the event by going to the EMCP 4.2 control event log.
4. Reset the event.
5. Return the set point value for the engine overspeed set point to the original value.
Overspeed Verification
Perform the following procedure on overspeed verification:
2. Adjust the set point value for engine overspeed set point to a value that is below the speed
that the generator set is running at. An engine overspeed set point event will occur
immediately after the set point is changed, and the generator set will shut down.
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3. View the event by going to the EMCP 4.2 control event log.
4. Reset the event.
5. Return the set point value for the engine overspeed set point to the original value.
Analog Inputs
There are two analog inputs from the generator set:
Engine oil pressure
Engine coolant temperature
High Coolant Temperature Shutdown - This can be found listed as analog input #2 high
shutdown event threshold. The range of this parameter is 95 °C (203 °F) to 120 °C (248 °F). The
default value is set at 108 °C (226.4 °F).
Low Oil Pressure Shut down Event Threshold - This can be found listed as analog input #1 low
shutdown event threshold. The range of this parameter is 13.4 kPa (1.943 psi) to 880 kPa
(127.63 psi). The default value is set at 150 kPa (21.76 psi).
Automatic Start/Stop
Configuration of the automatic start/stop parameters is done in Cat ET via the parameters shown
below.
Cycle Crank Configuration
This can be found listed as crank duration. The range of this parameter is 1 - 60 seconds. The
default value is set at 10 sec.
Cycle Crank Rest Interval
The range of this parameter is 1 - 60 seconds. The default value is set at 5 sec.
Maximum Number of Crank Cycles
The range of this parameter is 1 - 99. The default is set to 1.
Cool down Configuration

This can be found listed as cool down duration.
The range of this parameter is 0 - 30 minutes. The default value is set at 5 minutes.
Crank Termination Speed Configuration

This can be found listed as crank terminate RPM.
The range of this parameter is 100 - 1000 RPM. The default value is set at 300 RPM battery
voltage monitor.
26/2/24, 12:03 SIS 2.0
Idle Speed Oil Pressure Shutdown

This is listed as low idle low engine oil pressure shutdown event threshold. The range of this
parameter is from 20 kPa (2.90 psi) to 420 kPa (60.92 psi). The default value is set at 200 kPa
(29.01 psi).
Low Idle Low Engine Speed Oil Pressure Warning Event Threshold
The range of this parameter is from 22 kPa (3.19 psi) to 462 kPa (67.01 psi). The default value is
set at 2. The value of this parameter should be set at least 110% of the value of the idle speed oil
pressure shutdown parameter.
Oil Step Speed

This is listed as low engine oil pressure step speed. The range of this parameter is from 400 to
1800 RPM. The default value is set at 400 RPM.
Overspeed
This can be found listed as engine overspeed set point. The default value is set at 1540 RPM. This
value is generator set specific.
Software Requirements
Flashing the EMCP 4.2 requires the following hardware and software:
The Caterpillar service tool software installed and licensed on a Personal Computer (PC).
A Caterpillar communication adapter.
A 9-pin round Deutsch connector service connection to the primary data link (CAN 1).
Use the following files when flashing or configuring:
EMCP 4.2 Electronic Control Module (ECM) Flash File: Can be found on SIS 2.0, ELEK GP-A6001
PN: 355-9019 Generator Set Electronics Gp.
Recommended Sensors
The recommended sensors for the EMCP 4.2 upgrade are listed below:
Coolant temperature sensor
Oil pressure (gauge) sensor
Oil temperature sensor
Coolant Temperature Sensor

The physical and electrical connections of 7X-1043 Temperature Sensor Gp are listed below:
Physical Connection - #6 STOR (9/16-18) male thread and use 214-7568 O-Ring Seal.
26/2/24, 12:03 SIS 2.0
Electrical Connection - Use mating connector 8T-8731 Connector Plug.
The configuration parameters of coolant temperature sensor (analog input #2) for the EMCP 4.2
are listed below:
Signal type is voltage output.
Supply voltage given is 5 V.
Signal range is between 0.5 4.5 V.
Data identification through engine coolant temperature.
Minimum data range is −3.442° C (25.80440° F).
Maximum data range is 238.982° C (462.16760° F).
Note: All configuration parameter values are in metric (SI) units (degree centigrade, kPa) even
though the user display may be in English units.
The connections of sensor wire for EMCP 4.2 are listed below:
Signal (white) wire is connected to terminal block 307.
Ground (black) wire is connected to terminal block 308.
Supply (orange) wire is connected to terminal block 306.
Note: Terminal block 308 (sensor ground) must be tied to battery ground (terminal block 204) in
order for the EMCP 4.2 to properly read the sensor.
Oil Pressure (Gauge) sensor

The physical and electrical connections of 246-8150 Pressure Sensor are listed below:
Physical Connection - Use 1/8-27 NPT (National Pipe Thread) male thread
Electrical Connection - Use M4 studs and 2L-8065 Ring Terminal (12-10 AWG), 2L-8075 Ring
Terminal (16 -14 AWG), 7N-9194 Terminal Ring (22 - 18 AWG)
The configuration parameters of oil pressure sensor (analog input #1) for the EMCP 4.2 are listed
below:
Signal type is resistive sender.
Configuration code is map #2.
Data identification through engine oil pressure.
The electrical connection for a resistive sensor on analog input #1 is given as follows:
26/2/24, 12:03 SIS 2.0
Terminal block 304 is connected to either terminal of temperature sensor (resistance sensors
do not have a polarity).
Terminal block 305 is connected to remaining terminal.
Note: Terminal block 305 (sensor ground) must be tied to battery ground (terminal block 204) in
order for the EMCP 4.2 to properly read the temperature sensor.
Oil Temperature Sensor

The physical and electrical connections of 106-0735 Temperature Sensor Gp are listed below:
Physical Connection - #8 STOR (3/4-16) male thread and use 3K-0360 O-Ring Seal.
Electrical Connection - Use 155-2260 Connecting Plug Kit (deutsch connector 3 pin).
The configuration parameters of oil temperature sensor (analog input #3) for EMCP 4.2 are listed
below:
Signal type is voltage output
Supply voltage given is 5 V.
Signal range is between 0.5 4.5 V.
Data identification through engine oil temperature.
Minimum data range is −23.671° C (−10.60780° F).
Maximum data range is 118.926° C (246.06680° F).
Note: All configuration parameter values are in metric (SI) units (degree centigrade, kPa) even
though the user display may be in English units.
On the EMCP 4.2 kit, analog input #3 has not been brought out to terminal blocks. The pins on the
70-pin connector are given as below:
Analog input #3 (+) - 30
Analog input #3 (-) - 29
Note: Analog input #3 (-) must be tied to battery ground (terminal block 204) in order for the EMCP
4.2 to properly read the sensor.
Available Hardware Add-ons

Annunciator
26/2/24, 12:03 SIS 2.0
Front EMCP 4.2 Panel
(1) Annunciator
(2) Potentiometer
(3) E-Stop
The EMCP annunciator serves to display generator set system alarm conditions and status
indications. The annunciator can be mounted with the generator control or in a desired remote
location.
Table 10
Annunciator Parts List

1 422-1193 Film
1 303-5893 Alarm Module Gp
4 9x-8256 Washer
26/2/24, 12:03 SIS 2.0
4 5C-2890 Nut
1 244-9613 Gasket
1 265-4123 Connector Receptacle As
1 203-9007 Nut
2 155-2267 Connector Plug As
2 134-2540 Resistor As
Optional 130-4676 Electrical Wire
Optional 130-4673 Electrical Wire
Optional 206-3985 Wire
Optional 206-3986 Wire
4 9X-3401 Connector Pin
2 9X-3401 Connector Pin
1 8T-8737 Seal Plug
E-STOP
E-Stop Connection
The E-Stop is used to perform a hard shutdown of the engine in the event of an emergency. Use
the recommended parts listed in Table 11, for replacement.
Table 11
E-Stop Parts List

1 442-6212 Stop Switch
1 442-6215 Contact Block
1 442-6217 Holder
1 442-6219 Shroud
26/2/24, 12:03 SIS 2.0
1 443-2546 Adapter
Starter Motor Magnetic Solenoid (SMMS)
SMMS mounting location
SMMS Connection
SMMS acts as a switch control from the EMCP, to allow the engine to crank. The recommend
replacement is listed in Table 12.
Table 12
SMMS Parts List
26/2/24, 12:03 SIS 2.0
1 125-1302 Magnetic Switch Gp

1 5C-2890 Nut
1 8T-4205 Hard Washer
Potentiometer
Wiring diagram for connecting the potentiometer
The potentiometer can be used to adjust the engine speed manually. Use the recommended parts
list in Table 13.
Table 13
Potentiometer Parts List

1 122-9458 Potentiometer
1 4W-5972 Knob
1 7C-4550 Seal
PIP-10118791
2024/02/26
15:02:33-03:00
i06178015
© 2024 Caterpillar Inc.

Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610} (REHS9799-03)

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Procedure to Upgrade EMCP 1, EMCP 2, EMCP 2+, EMCP 3.1, EMCP 3.2, and EMCP 3.3 to EMCP 4.2 {4490, 7610} (REHS9799-03)

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26/2/24, 12:03 SIS 2.

SMCS - 4490, 7610 i10044757

Do not operate or work on this engine or generator set unless

Failure to follow the warnings and instructions could result in

Failure to follow all safety guidelines prescribed in this

Personal injury or death can result from improper maintenance

Bodily contact with electrical potential can cause bodily injury

To avoid the possibility of injury or death, ensure that the main

Access to this service point may require climbing on the

could result in personal injury or death. Refer to the Operation

Never disconnect any charging unit circuit or battery circuit

Working with electrical circuits is hazardous. Bodily contact with

Lock Out/Tag Out

Accidental engine starting can cause injury or death to

To avoid accidental engine starting and to bring the equipment

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

Hazardous Voltage Information

ELECTROCUTION HAZARD - The electrical system contains

DO NOT remove any covers that will expose energized

DO NOT perform any maintenance on the electrical system until

Read and understand the instructions and warnings found in the

Failure to follow these instructions will result in personal injury

ELECTROCUTION HAZARD - Ensure proper grounding.

Avoid a buildup of hazardous live voltages on exposed surfaces

Disconnected grounding wires, including grounding wires/straps

Failure to follow these instructions will result in personal injury

When service or maintenance must be performed in a

Qualified personnel should manually check for hazardous

The voltage level present must be confirmed to be below 50

Failure to follow these instructions could result in personal

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

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

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

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

High-voltage components and connections must be properly maintained.

Before performing any type of service, repair, or maintenance on high-voltage electrical

Disconnect the electrical power source

Isolate electrical components

Discharge residual energy

Check components for voltage using electrical measuring tools.

Electrostatic Discharge Awareness

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

Removal of the Existing Control

Voltage and Continuity Check

Using a voltmeter, connect the negative lead to ground

Determine Idle and Rated Speed Parameters

Value Unit Recorded Value

Value Unit Recorded Value

Baseline Generator Set Operating Parameters

Removing Existing Control

2. Disconnect Alternating Current (AC) power from the battery charger.

3. Disconnect the battery charger from the battery.

4. Disconnect the battery from the generator set.

8. Remove the original EMCP panel from the generator enclosure.

Installation of the EMCP 4.2 Control

Contents of the 467-4168 Electronic Panel Gp

Qty Part Number Part Name

Control Module Installation

Terminal Block Installation

Control Harness Installation

467-4169 Panel Harness As Wire Number/Color Terminal Block Number

457-1582 Panel Harness As Wire Number/Color Terminal Block Number

457-1582 Panel Harness As Splice together 467-4169 Panel Harness As

Install Existing Sensors