Upgrading the EMCP on the New Control Box Design for Asia Pacific, Africa, and Middle East Regions{4490} Caterpillar

Generator Set:

C32 GEN SET (S/N: NRC100-UP)

Introduction

This Special Instruction outlines the procedure for upgrading from an EMCP4.2 to an EMCP4.3 or EMCP4.4. After upgrade completion, the generator set will have the same wiring as if the unit was built that way from the factory. Only the original controller will need to be removed during this process. All wiring from the original build will remain.

There are two upgrade kits available. One kit is to go from the EMCP4.2 to EMCP4.4. The other kit is to go from the EMCP4.2 to EMCP4.3. The upgrade kits may be purchased from the price list as a shipped loose option, or as serviceable parts through the parts department. When the upgrade is complete, the controller will need to have the programming changed to match the original EMCP4.2 settings.

Important Safety Information

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 in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.

Caterpillar cannot anticipate every possible circumstance of a potential hazard. Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Avoid using a tool, a procedure, a work method, or an operating technique that is not recommended by Caterpillar. If used, ensure the safety of the operating personnel and others.

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

Show/hide table

Accidental engine starting can cause injury or death to personnel working on the equipment. To avoid accidental engine starting, disconnect the battery cable from the negative (−) battery terminal. Completely tape all metal surfaces of the disconnected battery cable end in order to prevent contact with other metal surfaces which could activate the engine electrical system. Turn the battery disconnect switch to the OFF position and lockout the battery disconnect switch with a safety lock. Place a Special Instruction, SEHS7332, "Do Not Operate" tag at the start switch and battery disconnect location to inform personnel that the machine is being worked on.

Show/hide table

Only persons with training in electrical installations must carry connections to the generator. The generator must be wired correctly. A fire or electrocution could result from wiring that is incorrect. The generator is capable of generating high voltages. Ensure that the generator is not on while the connections are being made. Follow these steps in order to prevent accidental starting: Isolate the machine from all external loads and sources. Shut off the Engine. Disconnect the battery supply lines and tape the leads.

Show/hide table

Do not operate or work on this engine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manual. Failure to follow the instructions or heed the warnings could result in injury or death. Contact any Caterpillar dealer for replacement manuals. Proper care is your responsibility.

Show/hide table

Do not connect generator to a utility electrical distribution system unless it is isolated from the system. Electrical feedback into the distribution system can occur and could cause personal injury or death. Open and secure main distribution system switch, or if the connection is permanent, install a double throw transfer switch to prevent electrical feedback. Some generators are specifically approved by a utility to run in parallel with the distribution system and isolation may not be required. Always check with your utility as to the applicable circumstances.

Required Tools

The required tools for upgrading EMCP on new control box design are listed below:

• EMCP Upgrade Kit ( 447-3803 Electronic Control Kit for EMCP4.2 to EMCP4.3, and 447-3804 Electronic Control Kit for EMCP4.2 to EMCP4.4)

• Engineering Prints ( 444-8218 Generator Wiring Gp for EMCP4.3 kit, 444-8218 Generator Wiring Gp , and 444-8219 Generator Wiring Gp for EMCP4.4 kit)

• Computer with Cat^® Electronic Technician (Cat ET) Service Tool installed on the computer

• 4 mm Allen wrench

• 8 mm socket wrench

• 10 mm socket wrench

• 18 mm open-end wrench

• 18 mm socket wrench

• 8 mm hex wrench

• Phillips head screwdriver

• Small flat head screwdriver

• Side cutters

• Cable tie tool

Upgrading Procedure

Procedure for Upgrading EMCP4.2 to EMCP4.4

Perform the following procedure to upgrade from an EMCP4.2 to an EMCP4.4:

1. Save the configuration file of the EMCP4.2 using Cat ET.

2. Disconnect the battery and lock-out/tag-out the generator set.

Show/hide table



Illustration 1	g03735202
Cap bolts to be removed on the left side cover

3. Remove the left side cover. Use an 8 mm socket wrench to remove the cap bolts, circled in red. Removal of the cover exposes the terminal block on the sub panel. Refer to Illustration 1.

Show/hide table



Illustration 2	g03735914
Door latch bolt head is circled in red

4. Rotate the door latch to open the controls panel door. Use an 8 mm hex wrench. The door latch is circled in red. Refer to Illustration 2.

Show/hide table



Illustration 3	g03735920
(1) EMCP4.2 ground strap

5. Remove the ground wire (1) that is attached to the back of the EMCP4.2. Use a Phillips head screw driver. Refer to Illustration 3.

Show/hide table



Illustration 4	g03735923
(2) EMCP4.2 connector

6. Use a 4 mm T-handle Allen wrench to unscrew the bolt for the connector (2). The connector (2) is plugged into the back of the EMCP4.2. Refer to Illustration 4.

Show/hide table



Illustration 5	g03735927
(3) EMCP mounting nuts

7. Remove the EMCP4.2 from the door by removing the six nuts (3) that secure the EMCP4.2 to the door. Use a 10 mm socket wrench. Refer to Illustration 5.

Show/hide table



Illustration 6	g03735929
(4) Main harness

8. Cut the tie strap that holds the main harness (4) to the top weld link inside the control panel. Refer to Illustration 6.

9. Remove the nylon sleeve from the EMCP4.2 main harness (4) .

Show/hide table



Illustration 7	g03735935
(5) Access hole with 4D-3100 Grommet

10. Remove the plug from the access hole (5) that is located just above the main harness. Insert the 4D-3100 Grommet into the access hole (5). Refer to Illustration 7.

Show/hide table



Illustration 8	g03735938
(6) 440-4452 Panel Harness As in access hole

11. Route the 440-4452 Panel Harness As (EMCP4.3) through the 4D-3100 Grommet (6) .

Show/hide table



Illustration 9	g03735962
(10) 440-4452 Panel Harness As 70-pin connector

12. Connect the 70-pin connector (10) of the 440-4452 Panel Harness As to the 70-pin connector of the EMCP4.2 main harness with the 4 mm Allen wrench. Refer to Illustration 9.

Show/hide table



Illustration 10	g03735973
Securing the 440-4452 Panel Harness Assembly (10) Secured 70-pin connector

13. Use the 204-2281 Cable Strap to secure the 70-pin connector (10) to the top most weld link inside the control panel. Use the 7K-1181 Cable Strap to keep the individual wires bundled together as needed. Refer to Illustration 10.

Show/hide table



Illustration 11	g03735989
EMCP4.4 installed (12) Six nuts

14. Install the EMCP4.4 into the door using the six nuts (12) removed in Step 7. Refer to Illustration 11.

Show/hide table



Illustration 12	g03736505
Connecting the EMCP4.4 to the upgrade harness (13) 120-pin connector

15. Connect the 120-pin connector (13) of the 440-4452 Panel Harness As to the rear of the EMCP4.4 with the 4 mm Allen wrench while the door is fully open. Refer to Illustration 12.

Show/hide table



Illustration 13	g03736506
(14) Connecting the ground strap to the EMCP4.4

16. Attach the ground strap (14) to the EMCP4.4 using the Philips head screw driver. Refer to Illustration 13.

17. Secure the harness to the chain links using tie straps. Ensure that the harness will not rub against the bus bars when the door is closed.

18. Remove the wire duct covers on either side of the DIN rail.

Show/hide table



Illustration 14	g03736861
EMCP4.3 components and harness installation

19. Add the terminal blocks, relays, and other parts and wire the 440-4452 Panel Harness As as shown in 444-8218 Generator Wiring Gp . Refer to Illustration 14.

Show/hide table



Illustration 15	g03736865
(15) 374-5721 Terminal Clip

20. Keep the bottom most 374-5721 Terminal Clip (15) on the bottom of the DIN rail until Step 29. Refer to Illustration 15.

Show/hide table



Illustration 16	g03736935
Nylon sleeve installation (20) Nylon sleeve

21. Use the nylon sleeve that was removed earlier (20). Wrap the 440-4453 Panel Harness As (EMCP4.4) with the nylon sleeve at the location where the harness rubs the door opening. Refer to Illustration 16.

Show/hide table



Illustration 17	g03736981
(21) 440-4453 Panel Harness As installed

22. Connect the 70-pin connector (21) of the 440-4453 Panel Harness As to the rear of the EMCP4.4 with the 4 mm Allen wrench while the door is fully open. Refer to Illustration 17.

Show/hide table



Illustration 18	g03736982
(22) 440-4453 Panel Harness As routing

23. Push the other end of the 440-4453 Panel Harness As through the same hole as the 440-4452 Panel Harness As . Refer to Illustration 18.

24. Secure the harness to the chain links and ladder clips inside the control box using tie straps. Ensure that the harness will not rub against the bus bars when the door is closed.

Show/hide table



Illustration 19	g03736996
(23) Push-button plugs

25. Remove the circuit breaker push-button plugs (23) from the front of the door. Refer to Illustration 19.

Show/hide table



Illustration 20	g03736997
(24) Circuit breaker push buttons

26. Install the circuit breaker push buttons (24) as shown in 444-8219 Generator Wiring Gp . Refer to Illustration 20.

Show/hide table



Illustration 21	g03737001
Push-button wiring

27. Wire the circuit breaker push buttons (24) as per 444-8219 Generator Wiring Gp . Refer to Illustration 21.

Show/hide table



Illustration 22	g03737004
EMCP4.4 terminal block installation

28. Install the terminal blocks, relays, and other components. Wire the 440-4453 Panel Harness As as shown in 444-8219 Generator Wiring Gp . Refer to Illustration 22.

29. Install the bottom most 374-5721 Clip up to the bottom of the DIN rail mounted components.

30. Secure the harnessing with tie straps as necessary.

Show/hide table



Illustration 23	g03737008
440-4454 Wiring Harness routing (25) 440-4454 Wiring Harness

31. Route the 440-4454 Wiring Harness (25) through the same hole as the 440-4453 Panel Harness As . Refer to Illustration 23.

32. Wire the 440-4454 Wiring Harness (25) as per 444-8219 Generator Wiring Gp .

33. Secure the harness with tie straps as needed.

Show/hide table



Illustration 24	g03737010
(30) Interior 440-4454 Wiring Harness routing path

34. Remove the wire duct covers (30) inside of the control panel. Route the 440-4454 Wiring Harness (25) inside the duct. Refer to Illustration 24.

Show/hide table



Illustration 25	g03736983
(31) 440-4454 Wiring Harness connections

35. Attach the 440-4454 Wiring Harness (25) to the circuit breaker output as per 444-8219 Generator Wiring Gp . Refer to Illustration 25.

Show/hide table



Illustration 26	g03736993
(32) Securing 440-4454 Wiring Harness

36. Secure the 440-4454 Wiring Harness (25) to the interior weld link, ladder clips (if installed) or horseshoe cutouts (32) as necessary. Refer to Illustration 26.

37. Bundle the extra harness inside the wire duct.

38. Reattach all wire duct covers.

39. Reinstall the left side cover.

40. Close and latch the EMCP door.

41. Use Cat ET to update all required set points to match the set points of the EMCP4.2 with the output functions as shown in Table 1. Use Cat ET to update all required set points to match any addition paralleling set points.

Procedure for Upgrading EMCP4.2 to EMCP4.3

Perform the following procedure for upgrading the EMCP4.2 to the EMCP4.3:

1. Save the configuration file of the EMCP4.2 using Cat ET.

2. Disconnect the battery and lock-out/tag-out the generator set.

Show/hide table



Illustration 27	g03735202
Cap bolts circled in red to be removed on left side cover

3. Remove the left side cover with an 8 mm socket wrench. Refer to Illustration 27.

Show/hide table



Illustration 28	g03741687
(33) Door latch

4. Open the control panel door with the use of an 8 mm hex wrench. Rotate the door latch (33) to open the control panel door. Refer to Illustration 28.

Show/hide table



Illustration 29	g03742007
(34) EMCP4.2 ground strap

5. Use a Phillips head screw driver to remove the ground wire (34) that is attached to back of the EMCP4.2. Refer to Illustration 29.

Show/hide table



Illustration 30	g03742021
(35) EMCP4.2 connector

6. Use a 4 mm (0.16 inch) "T"-Allen wrench, to remove the mounting bolt for the connector (35). The connector is located on the back of the EMCP4.2. Refer to Illustration 30.

Show/hide table



Illustration 31	g03742039
(36) EMCP mounting nuts to be removed

7. Remove the EMCP4.2 from the door by removing the six nuts (36) that secure the EMCP4.2 to the door. Use a 10 mm socket wrench. Refer to Illustration 31.

Show/hide table



Illustration 32	g03742046
(37) Main harness after tie strap has been removed

8. Cut the tie strap holding the main harness (37) to the top weld link inside the control panel. Refer to Illustration 32.

Show/hide table



Illustration 33	g03742059
(38) Access hole with grommet

9. Remove the plug from the access hole (38) that is just above the main harness. Insert the 4D-3100 Grommet into the hole (38). Refer to Illustration 33.

Show/hide table



Illustration 34	g03742068
(39) 440-4452 Panel Harness Assembly in access hole

10. Route the 440-4452 Panel Harness As (EMCP4.3) through the access hole (39) and the 4D-3100 Grommet . Refer to Illustration 34.

Show/hide table



Illustration 35	g03742069
(40) 440-4452 Panel Harness As 70-pin connector

11. Connect the 70-pin connector (40) of the 440-4452 Panel Harness As to the 70-pin connector of the EMCP4.2 main harness. Use a 4 mm Allen wrench. Refer to Illustration 35.

Show/hide table



Illustration 36	g03742073
(40) Secure the 440-4452 Panel Harness As to the panel

12. Use the 204-2281 Cable Strap to secure the 70-pin connector (10) to the top most weld link inside the control panel. Use the 7K-1181 Cable Strap to keep the individual wires bundled together as needed. Refer to Illustration 36.

Show/hide table



Illustration 37	g03740520
(41) Installing the EMCP4.3

13. Install the EMCP4.3 into the door using the six nuts (41) removed in Step 7. Use a 10 mm socket wrench. Refer to Illustration 37.

Show/hide table



Illustration 38	g03740594
(42) 440-4452 Panel Harness As connector

14. Connect the 120-pin connector (42) of the 440-4452 Panel Harness As to the back of the EMCP4.3. Use a 4 mm Allen wrench. The door must be fully open. Refer to Illustration 38.

Show/hide table



Illustration 39	g03740595
(43) Connecting the ground screw to the EMCP4.3

15. Attach the ground strap (43) to the EMCP4.3 using the Philips head screw driver. Refer to Illustration 39.

16. Secure the harness to the chain links using tie straps. Ensure that the harness will not rub against the bus bars when the door is closed.

17. Remove the wire duct covers on either side of the DIN rail.

Show/hide table



Illustration 40	g03736861
EMCP4.3 components and harness installation

18. Add the terminal blocks, relays, and other parts and wire the 440-4452 Panel Harness As as shown in 444-8218 Generator Wiring Gp . Refer to Illustration 40.

19. Slide the bottom most 374-5721 Terminal Clip up to the bottom of the DIN rail mounted components.

20. Secure the harnessing with tie straps as necessary.

21. Reattach the wire duct covers.

22. Reinstall the left side cover.

23. Close and latch the EMCP door.

24. Use Cat ET to update all required set points to match the set points of the EMCP4.2 with the output functions as shown in Table 2.

Procedure for Upgrading EMCP4.3 to EMCP4.4

Perform the following procedure for upgrading EMCP4.3 to EMCP4.4:

Note: There is not a separate kit to upgrade the EMCP4.3 to EMCP4.4. In order to do this upgrade, the parts in 444-8218 Generator Wiring Gp must be used.

1. Follow Steps 1 through 7 above from "EMCP4.2 to EMCP4.4 Upgrade", replacing "EMCP4.2" with "EMCP4.3".

2. Remove the nylon sleeve from the EMCP4.2 main harness.

3. Remove and save the bottom most 374-5721 Terminal Clip on the bottom of the DIN rail.

4. Follow Steps 14 through 16 from ""Procedure for Upgrading EMCP4.2 to EMCP4.4" ".

5. Follow Steps 21 through 40 from ""Procedure for Upgrading EMCP4.2 to EMCP4.4" ".

6. Use Cat ET to update all required set points to match the set points of the EMCP4.3 and any additional paralleling set points.