Flash Procedure For The Software Update Of The EMCP II+ With Generator Set Control+{4490} Caterpillar

Engine:

3116 (S/N: 1NJ1-UP)

3208 (S/N: 29A1-UP)

3304 (S/N: 83Z1-UP)

3304B (S/N: 9HK1-UP)

3306 (S/N: 85Z1-UP)

3306B (S/N: 2AJ1-UP; 9DS1-UP; 8NS1-UP)

G3406 (S/N: 4FD1-UP)

G3408 (S/N: 6NB1-UP)

G3412 (S/N: 7DB1-UP)

G3412C (S/N: 6ZM1-UP)

3208 T DI (S/N: 30A1-UP)

3306B RENTL TA DI (S/N: 8JJ1-UP)

3208 STDBY T DI (S/N: 5YF1-UP)

3306B ATAAC (S/N: 9NR1-UP)

3412 (S/N: 2WJ1-UP; 4BZ1-UP; 1EZ1-UP; 3FZ1-UP; 38S1-UP; 81Z1-UP)

3508 (S/N: 1ZF1-UP; 5XM1-UP; 3LS1-UP; 5PW1-UP; 96Y1-UP; 23Z1-UP; 69Z1-UP; 70Z1-UP; 1JZ1-UP)

3508B (S/N: 4GM1-UP; 6PN1-UP; 2HW1-UP; 5KW1-UP; 1FZ1-UP)

3512 (S/N: 3YF1-UP; 6PM1-UP; 3MS1-UP; 6WW1-UP; 50Y1-UP; 24Z1-UP; 66Z1-UP; 67Z1-UP; 1KZ1-UP)

3512B (S/N: 8RM1-UP; 6WN1-UP; 4AW1-UP; 5AW1-UP; 6GW1-UP; 2EZ1-UP; 1GZ1-UP)

3516 (S/N: 4XF1-UP; 4MJ1-UP; 5SJ1-UP; 7KM1-UP; 3NS1-UP; 8TW1-UP; 29Z1-UP; 72Z1-UP; 73Z1-UP; 1LZ1-UP; 25Z1-UP)

3516B (S/N: 6HN1-UP; 7RN1-UP; 1NW1-UP; 2JW1-UP; 8NW1-UP; 1HZ1-UP)

3408 (S/N: 67U1-UP; 78Z1-UP)

3408B (S/N: 67U1-UP; 78Z1-UP)

3408C (S/N: 67U1-UP; 78Z1-UP)

Generator Set:

3406 GEN SET (S/N: 4ZR1-UP)

3406B GEN SET (S/N: 4JK1-UP; 2WB1-UP; 4RG1-UP)

3406E GEN SET (S/N: 9NN1-UP)

3406C GEN SET (S/N: C2G1-UP; C5G1-UP; 1LS1-UP; 8FS1-UP; 9ES1-UP)

Paving Compactor:

CS-553 (S/N: 8BD1-UP)

Introduction

This Special Instruction contains the procedures for updating the software for generator sets that have an Electronic Modular Control Panel II+ (EMCP II+) with Generator Set Control + (GSC+). There is a procedure for connecting the service tools to the Generator Set Control + (GSC+) and there is a procedure for flashing the software.

Connection Procedure

Illustration 1	g01726354
Connection Diagram (1) Relay module on the GSC+ control (2) AUX terminal strip (3) 152-7143 GSC Data Cable (4) Personal Computer (5) 275-5122 Adapter Cable As (DATALINK) (6) 139-4166 Data Link Cable (7) 171-4401 Communication Adapter As

Note: This procedure is for Generator Set Control + that is mounted in an EMCP II+ panel. 24 VDC must be available from the panel.

1. Verify that the generator set is not running. Turn OFF the power to the EMCP II+ panel by disconnecting the negative terminal of the battery.

2. Connect the communication adapter to the PC by using the 275-5122 Adapter Cable As (DATALINK). The metal Deutsch connector should be connected to the "SERVICE TOOL" port on the communication adapter.

3. Connect the 139-4166 Data Link Cable to the "CONTROL" port on the communication adapter.

4. Connect 152-7143 GSC Data Cable to the opposite end of the 139-4166 Data Link Cable .

5. Connect the "Data+" and "Data-" spade terminals of the cable to the appropriate terminals in the AUX terminal strip. The AUX terminal strip is located inside the EMCP II+ panel. Connect the "Power+" spade terminal to "RM1" of the relay module on the GSC+. Connect the "Power-" spade terminal to "RM28" of the relay module on the GSC+.

   Note: For a switchgear conversion that contains the GSC+ control, the connection point for the "Data+" wire is GSC-19 on the 40 connector pin of the GSC+. The connection point for the "Data-" wire is at GSC-20 on the 40 connector pin of the GSC+. The spade terminals that are on the harness for these wires need to be replaced with two 8T-8730 Connector Sockets . After the terminals have been replaced, the modified portion of the harness can be removed from the 40 connector pin by using the 121-9588 Wire Removal Tool .

6. Set the engine control switch (ECS) to OFF/RESET. Connect the battery to the electrical system again. Then, turn the ECS to the COOL/STOP position.

7. Verify that the GSC+ is receiving power and that the communication adapter is receiving power.

   Note: Power loss to the GSC+ is unacceptable once the process for the update of the software begins. The loss of power may render the GSC+ unusable.

8. Turn on the PC. The operating system on the computer must finish loading.

Procedure for Flash Update

1. Obtain a flash file on a floppy disk or a CD-ROM. See Special Instruction, REHS0494, "Accessing Flash Software For Machines".

2. Find the ET directory by using the "File Manager". Open ET.

3. Start "WinFlash" by double clicking on the "WinFlash" icon with the pointer of the mouse. "WinFlash" is part of the ET software package.

4. After the start-up is complete, ET will automatically try to connect to the GSC+ through the communication adapter.

5. The "WinFlash" program will display the serial numbers of any modules that are found on the data link.

6. Select the serial number of the unit that needs the software update. Click on "OK". The serial number of the GSC+ that is desired can be obtained by looking at the first value under OP2-2 in service mode. In order to obtain the value, press the "service mode" key on the GSC+ once. Then, press the "SCROLL UP" key once. The "SCROLL UP" key is also the "LAMP-TEST" key. All GSC+ units have a serial number suffix of "HA". This can be used for verification.

7. Insert the floppy disk or the CD-ROM that contains the flash file. Click on the "select file" button and open the contents of the appropriate drive. Select the appropriate ".fls" file. If the flash file is already on the hard drive, select the file from the appropriate drive.

8. If the generator set has an energize-to-run solenoid, proceed to 9. If the generator set has an energize-to-shutoff solenoid, wait for at least 70 seconds before proceeding to 9.

9. Click on the "Begin" button. The flash process should begin. A bar that shows the progress of the update will be displayed on the screen.

   Note: Power loss to the GSC+ is unacceptable once the process for the update of the software begins. The loss of power may render the GSC+ unusable. Ensure that the power that is supplied to the control is available for the entire process. If the process is aborted, do not remove the power from the GSC+. The process will start reprogramming. Wait until the process is finished.

10. The display of the GSC+ will be blank and the "Fault Shutdown" indicator will be blinking while the software update is in progress.

11. Do not disturb the process until the process is finished. Once the process is finished, the GSC+ will automatically start working again. Exit the "WinFlash" software.

12. The GSC+ should now have the new software. In order to verify the version of the software, go to the display at OP2-2. Scroll up one time. Read the part number that is displayed. This update will not affect the setpoints or the calibration.

13. Turn the engine control switch (ECS) back to the "OFF/RESET" position and disconnect the negative terminal of the battery from the electrical system again. Disconnect the cables for the service tool and close the panel.

14. Reconnect the battery to the electrical system and return the generator set back to service.