Emcp 3 1

RENR7902
September 2004
Systems Operation
Troubleshooting
Testing and Adjusting
EMCP 3
CNB1-Up (Generator Set)
CMC1-Up (Generator Set)
BRK1-Up (Generator Set)
CAL1-Up (Generator Set)
FDN1-Up (Generator Set)
i01658146
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.
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. 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 be made unsafe by the operation, lubrication,
maintenance or repair procedures that you choose.
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 Caterpillar 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 premature failures, product damage, personal injury or
death.
RENR7902
Table of Contents
Systems Operation Section
General Information ................................................ 4
Component Location ............................................... 6
Electronic Control Module (Generator Set) ............. 8
Thermocouple Module .......................................... 10
Discrete Input/Output Module ............................... 14
Resistive Temperature Device Module ................. 17
Annunciator Module .............................................. 21
Data Link .............................................................. 26
Electronic Control Module (Engine) (EUI Engines
Only) ................................................................... 27
System Operation ................................................. 28
Password Entry ..................................................... 28
Event Viewing ....................................................... 30
Event Resetting .................................................... 31
Setpoint Programming .......................................... 32
Digital Input Programming .................................... 33
Digital Output Programming ................................. 34
Spare Analog Input Programming ........................ 35
Relay Output Programming .................................. 36
Voltage and Frequency Adjustment ...................... 38
Real Time Clock Programming ............................. 38
Troubleshooting Section
Introduction
General Information .............................................. 40
Service Tools ........................................................ 41
Diagnostic Capabilities ......................................... 42
Diagnostic Trouble Code List ................................ 43
Diagnostic System Procedures
Engine Cooldown Warning ................................... 54
Engine Overcrank Warning ................................... 54
Engine Speed Warning ......................................... 56
Engine Overspeed Warning .................................. 56
Engine Underspeed Warning ................................ 59
Generator Control Not in Automatic Warning ....... 61
Generator Output Sensing Circuit Fault ................ 61
Generator Overcurrent Warning ........................... 61
Generator Overfrequency Warning ....................... 62
Generator Overvoltage Warning ........................... 65
Generator Reverse Power Warning ...................... 66
Generator Underfrequency Warning ..................... 68
Generator Undervoltage Warning ......................... 71
Service Maintenance Interval Warning ................. 73
Analog Input Circuit Fault ..................................... 74
Charging System .................................................. 75
Data Link Circuit Fault .......................................... 77
Digital Input Circuit Fault ....................................... 78
Digital Output Circuit Fault .................................... 79
Engine Speed Circuit Fault ................................... 80
Unexpected Engine Shutdown ............................. 83
Testing and Adjusting Section

Electrical Connector - Inspect ............................... 85
3
Table of Contents
Wiring Harness (Open Circuit) - Test .................... 85

Wiring Harness (Short Circuit) - Test .................... 86
External Potential Transformer Connections ........ 86
Speed Sensor (Engine) - Adjust ........................... 88
Electronic Control Module (Generator Set) Replace ............................................................... 89
Electronic Control Module (Generator Set) - Flash
Program .............................................................. 89
Electronic Control Module (Generator Set) Configure ............................................................ 89
Typical Generator Abbreviations ......................... 140
ECM Connections ............................................... 142
Index Section
Index ................................................................... 146

i01985375
General Information
SMCS Code: 4490
Illustration 1
Block diagram of a generator set with EMCP 3 and EUI Engine
g01030625
RENR7902
Illustration 2
Block diagram of a generator set with EMCP 3 and MUI Engine
5
g01035964
i02155374
Component Location
SMCS Code: 4490
g01095847
Illustration 3
EMCP 3 Control Panel - Face Of Front Panel
(1) Electronic Control Module (ECM) for the
Generator Set
(2 ) Annunciator Module (ALM)
(3) Panel Light Switch (PLS)
(4)
(5)
(6)
(7)
Either Start Aid Switch (SAS) (optional)

Speed Potentiometer (SP) (optional)
Emergency Stop Push Button (ESPB)
Lamp Test Switch
(8) Alarm Acknowledge/Silence Switch

(9) Alarm Horn
(10) Panel Lights
g01095834
Illustration 4
EMCP 3 Control Panel -Subpanel
(1)
(2)
(3)
(4)
AC Terminal Strip
DC Terminal Strip
Switchgear Option Terminal Strip
Discrete Input Output (I/O) Terminal Strip
(5) Discrete Input Output (I/O) Module or

Resistive Temperature Device (RTD)
Module
i01990626
Electronic Control Module

(Generator Set)
SMCS Code: 4490
g01045431
Illustration 5
(1)
(2)
(3)
(4)
(5)
(6)
Display Screen
AC Overview Key
Engine Overview Key
Yellow Warning Lamp
Red Shutdown Lamp
Alarm Acknowledge/Silence Key
(7) Lamp Test Key

(8) Run Key
(9) Auto Key
(10) Stop Key
(11) Scroll Up Key
(12) Escape Key
Navigation Keys
AC Overview The AC Overview Key (2) will
navigate the display the first screen of AC
information. The AC Overview Key information
contains various AC parameters that summarize the
electrical operation of the generator set.
Engine Overview The Engine Overview Key (3)
will navigate the display to the first screen of engine
information. The Engine Overview information
contains various engine parameters that summarize
the operation of the generator set.
(13)
(14)
(15)
(16)
Scroll
Enter
Scroll
Scroll
Right Key
Key
Down Key
Left Key
Alarm Acknowledge/Silence Pressing the Alarm

Acknowledge/Silence Key (6) will cause the horn
relay output to turn off and silence the horn. Pressing
the key will also cause any yellow or red flashing
lights to turn off or to become solid depending
on the active status of the alarms. The Alarm
Acknowledge/Silence Key may also be configured to
send out a global alarm silence on the J1939 Data
Link which will silence horns on annunciators.
Lamp Test Pressing and holding the Lamp Test
Key (7) will cause all of the LEDs and the display
screen pixels to turn on solid until the Key is
released.
RUN Pressing the RUN Key (8) will cause the
engine to enter the RUN mode.
AUTO Pressing the AUTO Key (9) will cause the
engine to enter the AUTO mode.
STOP Pressing the STOP Key (10) will cause

the engine to enter the STOP mode.
Scroll Up The Scroll Up Key (11) is used to
navigate up through the various menus or monitoring
screens. The Scroll Up Key is also used during
setpoint entry. During numeric data entry the Scroll
Up Key is used in order to increment the digits (0-9).
If the setpoint requires selection from a list, the Scroll
Up Key is used to navigate through the list.
Escape The Escape Key (12) is used during
menu navigation in order to navigate up through the
menu/sub-menu structure. Each key press causes
the user to move backwards/upwards through the
navigation menus. The Escape Key is also used
to cancel out of data entry screens during setpoint
programming. If the Escape Key is pressed during
setpoint programming, none of the changes made on
screen will be saved to memory.
Scroll Right The Scroll Right Key (13) is used
during setpoint adjustment. During numeric data
entry, the Scroll Right Key is used to choose which
digit is being edited. The Scroll Right Key is also
used during certain setpoint adjustments to select
or deselect a check box. If a box has a check mark
inside the box, pressing the Scroll Right Key will
cause the check mark to disappear, disabling the
function. If the box does not have a check mark
inside the box, pressing the Scroll Right Key will
cause a check mark to appear, Enabling the function.
Enter The Enter Key (14) is used during menu
navigation to select menu items in order to navigate
forward/downward in the menu/sub-menu structure.
The Enter Key is also used during setpoint
programming in order to save setpoints changes.
Pressing the Enter Key during setpoint programming
causes setpoint changes to be saved to memory
Down The Down Key (15) is used to navigate
down through the various menus or monitoring
screens. The Down Key is also used during setpoint
entry. During numeric data entry the Down Key is
used in order to decrement the digits (0-9). If the
setpoint requires selection from a list, the Down Key
is used to navigate down through the list.
Scroll Left The Scroll Left Key (16) is used during
setpoint adjustment. During numeric data entry,
the Scroll Left Key is used to choose which digit is
being edited. The Scroll Left Key is also used during
certain setpoint adjustments to select or deselect
a check box. If a box has a check mark inside the
box, pressing the Scroll Left Key will cause the check
mark to disappear, disabling the function. If the box
does not have a check mark inside the box, pressing
the Scroll Left Key will cause a check mark to
appear,
enabling the function.
Alarm Indicators
Yellow Warning Light A flashing yellow light
indicates that there are unacknowledged active
warnings. A solid yellow light indicates that there
are acknowledged warnings active. If there are any
active warnings, the yellow light will change from
flashing yellow to solid yellow after the alarm Alarm
Acknowledge/Silence Key (6 )is pressed. If there are
no longer any active warnings, the yellow light will
turn off after the Alarm Acknowledge/Silence Key (6 )
is pressed.
Red Shutdown Light A flashing red light indicates
that there are unacknowledged active shutdown
events. A solid red light indicates that there are
acknowledged shutdown events active. If there
are any active shutdown events the red light will
change from flashing red to solid red after the Alarm
Acknowledge/Silence Key (6 ) is pressed. Any
condition that has caused a shutdown event must
be manually reset. If there are no longer any active
shutdown events, the red light will turn off.
Digital Inputs
Note: There are 8 digital inputs on EMCP 3.2 and
EMCP 3.3. There are 6 digital inputs on EMCP
3.1.
Digital Input #1 Digital Input #1 is used for the
emergency stop. This input should be wired to
GROUND 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 operate the
genset in the Reduced Power Mode, The Emergency
Stop must be configured for Active Low Refer to:
Testing and Adjusting , Electronic Control Module
generator Set) ConfigureActivating the emergency
stop input will cause the generator set to stop
immediately or prevent the generator set from
starting. Once Digital Input #1 goes active, the
engine will not start until the event is reset. Refer to:
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 GROUND 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 engine mode switch is in AUTO, the
engine will attempt to start and run. Once the input
becomes inactive the engine will enter into cooldown
(if programmed) and then stop.
The remainder of the inputs can be configured. The

main purpose for the other DIGITAL INPUTS is to
add additional monitoring capabilities of the
parameters for the engine or generator. The inputs
can be configured by going to the EVENT I/P
FUNCTIONS parameter under the SETPOINTS
menu. 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.
ATS in Emergency Position
The inputs can be programmed to monitor the

following parameters or components. Refer
to:System Operation Troubleshooting Testing and
Adjusting, Digital Input Programming
Custom Event
Battery Charger Failure

Generator Breaker Closed
Utility Breaker Closed
Fuel Leak Detected
i02014825
Pressures
Thermocouple Module
Air Filter Differential Pressure
SMCS Code: 7490
Engine Oil Pressure
General Information
Fire Extinguisher Pressure

Fuel Filter Differential Pressure
Oil Filter Differential Pressure
Starting Air Pressure
The Thermocouple Module (TC) is capable of

reading twenty inputs from Type-J or Type-K
thermocouples . The Thermocouple Module is also
capable of generating diagnostics. The diagnostics
that are generated by the Thermocouple Module
are maintained in non-volatile memory. Storing the
diagnostics in non-volatile memory will make the
diagnostics available following a power loss.
Engine Oil Temperature
The Termocouple Module will read the inputs and

then calculates the temperature in Celsius. The
Thermocouple Module will then broadcast the
information onto the J1939 data link. The EMCP
3 will read the information from the Thermocouple
Module and display the information on the display
screen. This eliminates the need for a pyrometer or
similar separate display unit.
Exhaust Temperature
Diagnostics
Rear Bearing Temperature
Table 2 shows the Thermocouple Module
Right Exhaust Temperature
diagnostics. The Thermocouple Module is capable of
Left Exhaust Temperature
storing
twenty diagnostics log entries. Each of the log entries
have a format as shown in Table 1. The log can be
viewed from the EMCP 3.
Temperatures
Ambient Air Temperature

Engine Coolant Temperature
Levels
Engine Coolant Level

Engine Oil Level
Fuel Level
External Tank Fuel Level
Other
Air Damper Closed

ATS in Normal Position
Each of the 20 inputs have sensor diagnostics in

order to detect open or short circuits that go to the
thermocouple sensors. Overtemperature warnings
and shutdowns, as well as undertemperature
warnings are detected by comparing the measured
temperature to the low warning and the high warning
and the high shutdown temperature setpoints stored
in the module. All of these diagnostic messages are
broadcast on the J1939 data link. The EMCP 3
controller reads these messages and annunciates
and/or performs engine shutdown appropriately. Any
of the inputs can be disabled to prevent unnecessary
diagnostic faults.
Table 1
Diagnostic Log Entry Format Table

Description
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)
(2)
Refer to Table 3 for possible code numbers.

Refer to Table 2 for possible code numbers.
Table 2
FMI Codes - Thermocouple Module Diagnostics

FMI
Description
Thermocouple Input #n High Temperature Shutdown
Thermocouple Input Sensor #n Short Circuit
Thermocouple Input Sensor #n Open Circuit
15
Thermocouple Input #n High Temperature Warning
17
Thermocouple Input #n Low Temperature Warning
Monitoring Features
The Thermocouple Module monitors twenty Type-J
or Type-K thermocouple inputs. All monitored
values are available on the communication link as
read-only information. Temperatures are configured
to indicate the SAE J1939 Suspect Parameter
Number (SPN) transmitted by each temperature
input.
Each input is fully configurable and can be set to any
one SPN that is listed in Table 3. The display units
are selectable at the EMCP 3 controller as either
Fahrenheit or Celcius.
Table 3 shows the SPNs that are available for
configuration of temperature inputs.
Table 3
SPNs Available for Configuration of Temperature Inputs

SPN
Description
52
Engine Intercooler Temperature
105
Intake Manifold 1 Temperature
110

(continued)
(Table 3, contd)
171
172
Air Inlet Temperature
173
Exhaust Gas Temperature
174
Fuel Temperature
175
Engine Oil Temperature 1
176
Turbo Oil Temperature
441
Auxiliary Temperature 1
442
1122
Alternator Bearing 1 Temperature
1123
1124
Alternator Winding 1 Temperature
1125
1126
1131
1132
1133
1135
1137
Exhaust Gas Port 1 Temperature
1138
1139
1140
1141
1142
1143
1144
1145
1146
1147
1148
1149
1150
1151
1152
1153
1154
1155
1156
1157
Main Bearing 1 Temperature (engine)
1158

(continued)
(Table 3, contd)
1159
1160
1161
1162
1163
1164
1165
1166
1167
1172
Turbocharger 1 Compressor Inlet Temperature
1173
1174
1175
1180
Turbocharger 1 Turbine Inlet Temperature
1181
1182
1183
1184
Turbocharger 1 Turbine Outlet Temperature
1185
1186
1187
1212
Engine Auxiliary Coolant Temperature
1800
Battery 1 Temperature
1801
1802
1803
2433
Right Manifold Exhaust Gas Temperature
2434
Left Manifold Exhaust Gas Temperature
Configurability
The Thermocouple Module will remain fully functional
during single setpoint configuration and while
communicating through the communication link. The
Thermocouple Module will also operate normally if
the communication link is terminated.
All configured values and error codes are stored
in non-volatile memory. When the Thermocouple
Module is de-energized, all parameter values and
error codes are retained.
The Thermocouple Module is configured by using

the Caterpillar service tool on the primary data link.
This service tool has the capability to configure any
programmable/configurable parameter. The input to
each thermocouple has the configuration parameters
that are shown in Table 4.
Table 4
Configuration Parameters for Each Input

Description
Default Value
Range
Input #n Suspect Parameter

Number (SPN)
Any SPN listed in Table 3
Input #n - Type
Not Installed
Not Installed
Type-J TypeK
Input #n High Temperature

Shutdown Threshold
95
0 to 1735 C

Warning Threshold
85
0 to 1735 C
Input #n Low Temperature

Warning Threshold
-200
-200 to 800 C

Shutdown Delay Time
0 to 120 seconds

Warning Delay Time
Range = 0 to 120 seconds

Warning Delay Time
Range = 0 to 120 seconds
Specifications
Only Type-J and Type-K thermocouples can be
used with the Thermocouple Module.
The operating voltage range is 9 VDC to 32
VDC. The nominal voltage is 12 - 24 VDC. The

overvoltage capability is 32 VDC for one hour at
85 C (185 F).
The ambient operating temperature range is
40 C (40 F) to 120 C (248 F). If the

ambient temperatures exceed 85 C (185 F), the
Thermocouple Module may deviate in accuracy +/1C. If the ambient temperature exceeds 120 C
(248 F), the Thermocouple Module may not return
to proper operation.
The ambient storage temperature is 50 C

(58 F) to 125 C (257 F).
i02015971
Discrete Input/Output Module

SMCS Code: 7490
General Information
The Discrete Input/Output (I/O) Module is a module
capable of reading twelve discrete inputs. The
Discrete I/O Module is capable of operating eight
relay outputs. The Discrete I/O Module can be
mounted on the genset package or can be remote
mounted away from the genset package.
Inputs
The Discrete I/O Module has twelve inputs with four
return channels.The inputs can be activated by either
switching to a return or to battery negative. Each of
the inputs can be configured to signal one of many
possible event IDs. The Caterpillar Service Tool is
used to configure the Discrete I/O Module inputs.
Inputs that generate a warning message will
auto-reset whenever the input returns to a non-active
state. Inputs that generate a shutdown message will
continue until the input returns to a non-active state
and a reset message is received on the J1939 Data
Link.
Table 5

Setpoint Parameter
Range
Default
Input #nn Active State Configuration
Active Low
Active High
Active
State
Low
Input #nn Time Delay
0 to 120 sec.
0 sec.
Input #nn Suspect parameter Number (SPN)
Any SPN Supported by EMCP 3
N/A
Input #nn Failure Mode Identifier (FMI)
Any FMI supported by EMCP 3
N/A
Table 6
(Table 6, contd)
Configuration Examples
SPN
SPN
Description
Input
Output
38
Fuel LevelSecondary Tank
82
Starting Air
Pressure
94
Fuel Press
95
Fuel Filter
Differential
Pressure
96
Fuel Level
(Primary Tank)
98
Engine Oil Level
99
Oil Filter
Differential
Pressure
100
Engine Oil
Pressure
101
Crankcase
Pressure
107
Air Filter
Differential
Pressure
110
Engine Coolant
Temperature
111
Engine Coolant
Level
137
Extinguisher
System Press
168
Battery Voltage
171
Ambient Air
Temperature
172
Inlet Air
Temperature
173
Exhaust
Temperature
174
Fuel Temp
X
(continued)
SPN
SPN
Description
175
Engine Oil
Temperature
190
Engine
Overspeed
628
Voltage
Regulator
Failure
970
Emergency
Stop Shutdown
1122
Generator
Bearing
Temperature #1
1124
Generator
Winding
Temperature #1
1125
Generator
Winding
Temperature #2
1126
Generator
Winding
Temperature #3
1237
Input
Output
Emergency
Shutdown
Override Mode
Active Warning
1239
Ruptured Fuel
Basin-Primary
Tank
1383
Unexpected
Engine
Shutdown
1664
Engine Failure
to Start
Shutdown
2436
Generator
Frequency
2440
Generator
Voltage
X
(continued)
(Table 6, contd)
(Table 6, contd)
SPN
SPN
Description
2448
2452
Input
Output
SPN
Generator AC
Current
SPN
Description
Generator
Reverse Power
(kW)
Range
701-716
User
Defined
Input #8
Generator
Reactive Power
(VAR)
Range
701-716
User
Defined
Input #9
2648
Service Interval
Warning
Range
701-716
User
Defined
Input #10
4000
Air Shutoff
Damper Close
User
Defined
Input #11
Range
701-716
4001
ATS in Normal
Position
Range
701-716
4002
Gen Supplying
Load
User
Defined
Input #12
4003
Battery Charger
Failure
4004
Gen Breaker
Closed
4005
Utility Breaker
Closed
4006
Engine in
Cooldown
4007
Generator
Control Not in
Auto
User
Defined
Input #1
Range
701-716
User
Defined
Input #2
Range
701-716
User
Defined
Input #3
Range
701-716
User
Defined
Input #4
Range
701-716
User
Defined
Input #5
Range
701-716
User
Defined
Input #6
Range
701-716
User
Defined
Input #7
Range
701-716
2456
Input
Output
Outputs
The Discrete I/O Module has eight " Form C" relay
outputs. Each output can be configured to signal
one of many possible Event IDs. The Caterpillar
Service Tool is used to configure the Discrete I/O
Module outputs. Each output can be configured for
either general or specific events. Each output has the
configuration parameters that are shown in table 7
For general events, each output activates whenever
any Alarm Condition, Shutdown Condition, or
Alarm and/or Shutdown Condition exists.
For specific events, each output activates when
the diagnostic message contains the SPN and
FMI combination that matches the SPN and FMI
combination that is programmed for that particular
output. This includes events such as High or Low
alarms, Shutdowns, or Condition Exists.
(continued)
Table 7
Configuration Parameters for Each Output

Setpoint Parameter
Range
Output #nn Suspect Parameter Number (SPN)
Any SPN supported by EMCP 3
Output #nn Triggger Condition
Disabled Condition Exists

- Specific Diagnostic General Diagnostic Specific
High Shutdown - Specific
High Warning - Specific
Low Shutdown - Specific
Low Warning - Specific
Shutdown - General
Warning - General
Warning or Shutdown - Specific
Warning, Shutdown or Diagnostic - General
Warning, Shutdown or Diagnostic - Specific
Configurability
The Discrete I/O Module maintains functionality (with
no loss in performance) during single setpoint
configuration and while communicating through the
communications link. The Discrete I/O Module
retains all configured values in non-volatile memory.
The Discrete I/O Module is configured by
using the Caterpillar service tool.This service
tool has the capability to configure any
configurable/programmable parameter.
The Resistive Temperature Device (RTD) Module will

read the inputs and then calculates the temperature
in Celsius. The RTD Module will then broadcast the
information onto the J1939 data link. The Engine
Control Module (ECM) for the generator set will read
the information from the RTD Module and display the
information on the display screen.
Diagnostics
The RTD Module is capable of storing the twenty
diagnostic log entries. Each of the log entries have a
format as shown in Table 8. The log can be viewed
from the ECM.
Specifications
The operating voltage range is 9 VDC to 32 VDC.
The nominal voltage is 12 VDC or 24 VDC (external
power supplies). The output relay contacts are rated
for 2A @ 277 VAC, 5A @120 VAC and 5A @ 30
VDC.
The ambient operating temperature is -40C to 70C.
i02014957
Resistive Temperature Device

Module
SMCS Code: 7490
General Information
The Resistive Temperature Device (RTD) Module is
a temperature scanner capable of reading eight
Platinum RTD inputs. The eight Platinum RTD inputs
can have two, three, or four-wire configurations.
The RTD Module is also capable of generating
diagnostics. The diagnostics that are generated
by the RTD Module are maintained in non-volatile
memory. Storing the diagnostics in non-volatile
memory will make the diagnostics available following
a power loss.
Each of the 8 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, the High Shutdown
temperatures stored in the module. All of these
diagnostic messages are broadcast on the J1939
data link. The ECM reads these messages and
annunciates and/or performs engine shutdown
appropriately. Any of the inputs can be disabled in
order to prevent unnecessary diagnostic faults.
Table 8
Diagnostic Log Entry Format Table

Description
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)
(2)
See Table 10 for possible code numbers.

See Table 9 for possible code numbers.
Table 9 shows the RTD Module diagnostics.

Table 9
RTD Module Diagnostics - FMI Codes

FMI
Description
RTD Input #n High Temperature Shutdown
RTD Input Sensor #n Short Circuit
RTD Input Sensor #n Open Circuit
15
RTD Input #n High Temperature Warning
17
RTD Input #n Low Temperature Warning
Monitoring Features
The RTD Module monitors eight Platinum RTD
inputs. All monitored values are available on the
communication link as read-only information.
Temperatures are configured to indicated the SAE
J1939 Suspect Parameter Number (SPN)
transmitted by each temperature input.
Each input is fully configurable and can be set to any
one SPN that is listed in Table 10. The display units
are selectable at the EMCP 3 controller as either
Fahrenheit or Celsius.
Table 10 shows the SPNs that are available for
configuration of temperature inputs.
Table 10

SPN
Description
52
Engine Intercooler Temperature

(continued)
(Table 10, contd)

SPN
Description
105
110
171
172
Air Inlet Temperature
173
Exhaust Gas Temperature
174
Fuel Temperature
175
176
Turbo Oil Temperature
441
442
1122
1123
1124
1125
1126
1131
1132
1133
1135
1137
1138
1139
1140
1141
1142
1143
1144
1145
1146
1147
1148
1149
1150
1151
1152
1153
1154
1155

(continued)
(Table 10, contd)

SPN
Description
1156
1157
1158
1159
1160
1161
1162
1163
1164
1165
1166
1167
1172
1173
1174
1175
1180
1181
1182
1183
1184
1185
1186
1187
1212
Engine Auxiliary Coolant Temperature
1800
1801
1802
1803
2433
Right Manifold Exhaust Gas Temperature
2434
Left Manifold Exhaust Gas Temperature
Configurability
The RTD Module will remain fully functional
during single setpoint configuration and while
communicating through the communication link.
The RTD Module will also operate normally if the
communication link is terminated.
All configured values and error codes are stored in

non-volatile memory. When the RTD Module is deenergized, all parameter values and error codes
are retained.
The RTD Module is configured by using the

Caterpillar service tool. This service tool has the
capability to configure any
configurable/programmable parameter. Each RTDs
input has the configuration parameters that are
shown in Table 11.
Table 11

Description
Default Value
Range
Input #n Suspect Parameter

Number (SPN)
Any SPN that is listed in Table 10
Input #n - RTD Temperature Coefficient

Configuration
IEC
IEC Platinum (0.00385)

JIS Platinum (0.003916)
US Platinum (0.003902)
Legacy US Platinum (0.003920)
SAMA Platinum (0.003923)
Input #n RTD Sensor Type
Not Installed
Not Installed
2-wire RTD
3-wire RTD
4-wire RTD

Shutdown Threshold
95
0 to 1735 C

Warning Threshold
85
0 to 1735 C

Warning Threshold
-200
-200 to 800 C

Shutdown Delay Time
0 to 120 seconds

Warning Delay Time
0 to 120 seconds
Input #n - Low Temperature Warning

Delay Time
0 to 120 seconds
Specifications
The operating voltage range is 9 VDC to 32
VDC. The nominal voltage is 12 - 24 VDC. The

overvoltage capability is 32 VDC for one hour at
85 C (185 F).
The ambient operating temperature range is
40 C (40 F) to 120 C (248 F). If the ambient

temperatures exceed 85 C (185 F), the RTD
Module may deviate in accuracy +/- 1C. If the
ambient temperature exceeds 120 C (248 F), the
RTD Module may not return to proper operation.
The ambient storage temperature is 50 C

(58 F) to 125 C (257 F).
i02014506
Annunciator Module
SMCS Code: 4490
General Information
The EMCP 3 Annunciator Module is used to indicate
various system events and status conditions. The
Annunciator Module uses indicator lights and an
audible horn to give the operator information about
the current status of the system. The Annunciator
Module can be used to announce faults and/or status
signals to the operator. The Annunciator Module
also allows the operator to silence the horn or
acknowledge faults to the system.
There are seventeen pair of LED indicators on the

annunciators front panel. Sixteen pair of LED
indicators are used to announce events, diagnostics,
and ready signals. The seventeenth pair of LED
indicators is used as a combined network/module
status LED. The seventeenth pair of LED indicators
can tell the operator if there is a problem with the
J1939 data link connection.
Basic Operation
Each pair of LED indicators on the annunciator
consists of two of the following three colors: green,
yellow, and red. For example, a pair of red and
yellow 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
Yellow 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.
To acknowledge the Shutdown and Alarm conditions
or silence the horn, press the Alarm Acknowledge
button that is located near the middle of the
Annunciator.
To test the LED indicators or test the horn when the
data link is connected or disconnected, hold in the
Lamp Test button that is located near the top of the
Annunciator.
Configuration
The Annunciator Module can be customized to signal
many different conditions related to the system. The
data link parameters that are supported are shown in
Table 12. The parameters that are shown in Table 12
are in the form of J1939 Suspect Parameter
Numbers (SPN).
Each LED pair must be configured by using the
appropriate service tool. Once the service tool has
been connected to the Annunciator, the user must
enter the Configuration screen. Each LED pair has
four settings: SPN, Trigger Type, Trigger Severity
Level, and Failure Mode Identifier (FMI).
Custom Event Annunciation

The annunciator can be configured for any event
(SPN and FMI combination) listed in tables 12 and
13. For custom events (that are not listed on the
standard film) the user has two options. A descriptive
label may be placed next to the appropriate LED pair
after the LEDs have been configured or the standard
film may be replaced with a label from the 260-6898
Custom Label Kit.
Custom events that originate from sensing devices

that do not communicate on the J1939 Data Link
need to have their dry contacts wired to EMCP3
spare digital inputs or wired to an unused input on
the optional Discrete I/O Module. For information
on programming EMCP3 spare digital inputs see
System Operation, Digital Input Programming. For
information on programming the Discrete I/O Module
see System Operation, Discrete Input/Output
Module.
Suspect Parameter Number (SPN)

Choose the SPN from Table 12.
Trigger Type
The Trigger Type may be set as Disabled, General
Event, or Specific Event.
Disabled Disabling the Trigger Type disables
the LED pair. When disabled, the LED pair will not
respond to any data link message.
General Event If General Event is chosen, the
SPN does not matter. General Event is used when
it is desired that the LED pair illuminate for any
Warning, Shutdown, High, or Low.
Specific Event Specific Event is used when
the LED pair is to be associated with a specific
system parameter such as oil pressure or coolant
temperature.
Trigger Severity Level

The Trigger Severity Level defines how the LED pair
will behave when a message associated with the
programmed SPN is received (or not received).
Table 12
Supported SPNs
SPN Description
SPN
Fuel Level (External Tank)
38
Aftercooler Temperature
52
82
95
Fuel Level (Local Tank)
96
Engine Oil Level
98
99
Engine Oil Pressure
100
Crankcase Pressure
101
107
(continued)
(Table 12, contd)
(Table 12, contd)
Supported SPNs
Supported SPNs
SPN Description
SPN
SPN Description
SPN
Altitude
108
1140
110
1141
111
1142
137
1143
Battery Voltage (switched)
158
1144
Battery Voltage
168
1145
171
1146
Inlet Air Temperature
172
1147
Exhaust Temperature
173
1148
175
1149
Engine Speed
190
1150
SCADA Data Link Fault
625
1151
Primary Data Link (J1939 #1)
639
1152
Event Input Function #1
701
1153
702
1154
703
1155
704
1156
705
Accessory Data Link Fault (J1939 #2)
1231
706
1237
707
Emergency Shutdown Override Mode

Active Warning
708
Ruptured Fuel Basin - Primary Tank
1239
709
Unexpected Engine Shutdown
1383
710
Engine Failure to Start Shutdown
1664
711
2433
712
2434
713
Generator Frequency
2436
714
Generator AC Voltage
2440
715
Generator AC Current
2448
716
Generator Reverse Power (kW)
2452
Emergency Stop Shutdown
970
Generator Reverse Power (kVAr)
2456
Generator Bearing Temperature #1
1122
Service Interval Warning
2648
Generator Bearing Temperature #2
1123
Air Damper Closed
4000
Generator Winding Temperature #1
1124
4001
1125
4002
1126
4003
1137
Generator Control Not in Automatic

Warning
4007
1138
Generator Breaker Failure to Open
4009
1139
Utility Breaker Failure to Open
4010
(continued)
(continued)
(Table 12, contd)
Supported SPNs
SPN Description
SPN
Generator Breaker Failure to Close
4011
Utility to Generator Transfer Failure

Warning
4015
Utility to Generator Transfer Failure

Shutdown
4015
Utility Breaker Failure to Close
4015
Generator to Utility Transfer Failure

Warning
4016
Loss of Utility
4017
Failure Mode Identifier (FMI)

Choose the FMI from Table 13
Table 13
FMI Number
Description
Failure Mode Identifier (FMI) Codes
Short Description
Data Valid but Above Normal Operational Range - Most Severe Level
High Shutdown
Data Valid but Below Normal Operational Range - Most Severe Level
Low Shutdown
Data Erratic, Intermittent or Incorrect
N/A
Voltage Above Normal or Shorted to High Source
N/A
Voltage Below Normal or Shorted to Low Source
N/A
Current Below Normal or Grounded Circuit
N/A
Current Above Normal or Grounded Circuit
N/A
Mechanical System Not Responding or Out of Adjustment
N/A
Abnormal Frequency, Pulse Width or Period
N/A
Abnormal Update Rate
N/A
10
Abnormal Rate of Change
N/A
11
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
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
19
Received Network Data In Error
N/A
31
Not Available or Condition Exists
Status
Adding Optional Remote

Annunciator
An additional annunciator may be added if desired.
In order to operate properly, the annunciator must
be located within 243.8 m (800 ft.) of the EMCP 3
control panel and the end of line terminating resistor
must be relocated. Refer to Illustration 6.
Illustration 6
Adding Optional Remote Annunciator.
An additional Discrete I/O Module may be added in

parallel to remote annunciators. In order to operate
properly, the device to be added in parallel to the
annunciator must be within 2.7 m (9 ft.) of the
annunciator. Refer to Illustration 7.
g01093231
g01093228
Illustration 7
Connection details for devices in parallel with remote annunciator.
i01996622
Data Link
SMCS Code: 4490
Data Links
The EMCP 3 has up to three different data links:
One Primary Data Link

One Accessory Data Link
One 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 two Primary
Data Links and a single 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), Thermocouple
Module and EUI Engine Sensor information. 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 Control 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.
System Control and Data

Acquisition (SCADA) Data Link Modbus RS-485
The SCADA Data Link is used for communication
with a System Control And Data Acquisition
(SCADA) system, and for support of a service tool
connection.
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 to allow access using
single request.
The SCADA Data Link is a Master/Slave Data Link.
The SCADA controller Service Tool 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 a RS485 to RS232
converter. Passwords levels are used 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 genset controls.
i02003335

(Engine)
(EUI Engines Only)
SMCS Code: 1901
The Electronic Control Module (ECM) for the engine
controls engine speed on EUI engines in electric
power generation applications. The desired engine
speed is based on the following information:
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
Feedback from the sensors that are mounted on

the engine
Note: There are primary and secondary speed inputs

for the EMCP 3 The speed inputs can be a pulse
width modulated signal or the speed inputs can be
transmitted over the Data Link. The speed inputs
are configurable as primary or secondary with the
Electronic Technician. If the primary speed input fails
the EMCP 3 will acknowledge and respond to the
secondary input. If the primary speed input fails and
the secondary input is disabled, the engine will go
to the idle speed setting.
The EMCP 3 receives the following information from
the engine ECM:
Engine Oil Pressure

Left Exhaust Manifold Temperature
Right Exhaust Manifold Temperature
Intake Manafold Temperature
Oil Temperature
Fuel Pressure
Boost Pressure
Fuel Filter Differential Pressur
Fuel Consumption
The above information is shown on the display
screen of the EMCP 3. The information is used by
the EMCP 3 in order to monitor the system for
events.
The EMCP 3 also displays diagnostic codes from

the ECM as a convenience to the operator. See
Troubleshooting, Diagnostic code Trouble Code
List for more information on the management of
diagnostic codes by the EMCP 3 and ECM.
The operator presses the STOP Key.

The control is in AUTO and the remote initiate
input (IC) becomes inactive.
The operator presses the AUTO Key and a

i02195508
System Operation
SMCS Code: 4490
Engine Starting Sequence
1. The EMCP 3 receives an engine start signal. The
signal will be one of three.
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.
stop command is sent via the RS-485 SCADA

Data Link.
2. After receiving the stop signal, the EMCP 3

checks that there are no present system faults.
3. The EMCP 3 begins the cooldown period. In
order to bypass the cooldown hold down the
STOP Key. PRESS ENTER TO BYPASS,
PRESS ESCAPE TO CONTINUE will be shown
on the display. Press the Enter Key to bypass the
cooldown sequence or press the Escape Key to
continue the cooldown sequence.
4. After the cooldown cycle, the EMCP 3 initiates a
engine shutdown by turning off the fuel supply.
a. On the MUI engines, the EMCP 3 deactivates
the fuel control relay (FCR) which shuts the
engine down.
2. The EMCP 3 checks the system before beginning

the cranking sequence. The EMCP 3 checks that
no system faults are present. The EMCP 3 checks
that all previous shutdown faults have been reset.
The EMCP 3 also checks that the engine is not
already running. If the engine is equipped with
prelube, the EMCP 3 checks the status of the
prelube. If the prelube is not complete, the EMCP
3 will not crank the engine.
Password Entry
3. The EMCP 3 begins the crank sequence.
SMCS Code: 4490
a. On MUI engines, the EMCP 3 activates the

starting motor relay (SMR) and the fuel control
relay (FCR).
b. On EUI engines, the EMCP 3 activates the
starting motor relay (SMR) and sends a start
signal to the Engine ECM via the J1939
Primary Data Link. The Engine ECM activates
the fuel control relay (FCR).
4. The EMCP 3 cycle cranks the engine until the
cycle crank time reaches the setpoint for total
crank time or until the engine starts.
5. The EMCP 3 deactivates the starting motor relay
(SMR) a when the engine speed reaches the
setpoint for crank terminate speed.
Engine Stopping Procedure
1. The EMCP 3 will receive an engine stop signal.
The signal will be one of three.
b. On EUI engines, the EMCP 3 sends a

shutdown signal to the Engine ECM. The
Engine ECM deactivates the Fuel Control
Relay (FCR) which shuts down the engine.
i02051829
There are 3 levels of password protection on

the EMCP 3 control panel. All of the adjustable
parameters are associated with a specific level
of security required 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. A 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
protection when viewing a parameter, the padlock
will not appear.
If a parameter is displayed with a padlock but no

security level identification number next to it, the
parameter cannot be changed from the EMCP 3
display.
Level 1 and Level 2 passwords are disabled when
shipped from the factory. On initial start up of the
EMCP 3, Level 1 and Level 2 passwords can be user
defined if desired.
Drop to Minimum Security Level

The first option on the security screen is DROP TO
MIN LEVEL. DROP TO MIN LEVEL refers to a
process of placing the EMCP 3 into the lowest level
of security authorized. This would be used when
leaving the control. If DROP TO MIN LEVEL is not
initiated manually, the control will automatically revert
to minimum level after 10 minutes.
1. From the MAIN MENU, press the UP key or
the DOWN key to highlight the CONFIGURE
menu.
a. Press the ENTER key in order to select
CONFIGURE. SECURITY will be
highlighted.
b. Press the ENTER key in order to select
SECURITY. DROP TO MIN LEVEL will be
displayed.
c. Press the ENTER key to select DROP TO
MIN LEVEL
d. The EMCP 3 will now be at the minimum
level of security
Note: The current level of security for the EMCP 3 is
displayed at the top of the display any time the
EMCP
3 is in the SECURITY screen.
Enter Level 1 or 2 Password

menu.
highlighted.
highlighted.
c. Press the DOWN key in order to highlight
ENTER LEVEL 1 OR 2
d. Press the ENTER key in order to select

ENTER LEVEL 1 or 2. ENTER PASSWORD
FOR DESIRED LEVEL is displayed. Also
shown is a 16 digit display with 0 highlighted at
the far right.
e. Press the UP or DOWN key in order to
increment or decrement the highlighted digit
to the desired number.
f. Press the RIGHT key in order to highlight
the next character to be entered. Press the
UP or DOWN key in order to increment or
decrement the highlighted digit to the desired
number.
g. Continue until the correct password has
been entered for the corresponding level.
When all digits of the password are correctly
entered press the ENTER key. The current
level of password protection is displayed and
parameters can be set.
Note: The EMCP 3 will go to the highest level of
security authorized by a correctly entered password.
Note: The password can be up to 16 digits, but does
not have to be 16 digits. The password can be as
few as 1 digit. The password is entirely determined
by the user.
Note: A password is not required if changing
parameters with Caterpillar Service Tool
Enter level 3 password

menu.
a. Press the ENTER key to select
highlighted.
displayed.
c. Press the DOWN key in order to highlight
ENTER LEVEL 3. Press ENTER to select
ENTER LEVEL 3 .
d. A 16 digit number is shown and ENTER
RESPONSE is highlighted. Copy this number
and call the factory to obtain a factory provided
response code to enter into the EMCP 3.
e. When the factory response is received from

the factory, press ENTER to select ENTER
RESPONSE. ENTER RESPONSE is
displayed. Also shown is a 16 digit entry field
where the factory provided password will be
entered.
f. Press the UP or DOWN key in order to
increment or decrement the highlighted digit to
the correct factory provided password.
g. Press the RIGHT key in order to highlight
decrement the highlighted digit to the correct
password.
h. Continue to set all 16 digits until the factory
provided password is displayed.
i. When all digits of the factory password are
correctly entered, press the ENTER key. The
current level (LEVEL 3) of security is displayed
and parameters can be set.
Note: A password is not required if changing
parameters with Caterpillar Service Tool
Change level 1 or level 2 password

menu.
highlighted.
highlighted
g. Continue until the desired password is

displayed.
h. Press the ENTER key. The password is now
set.
Note: To change level 2 password, substitute
CHANGE LEVEL 2 PSWD for CHANGE LEVEL 1
PSWD in step 1.d above.
Note: To disable a security level, set the password
to a single zero.
i02011357
Event Viewing
SMCS Code: 4490
Information from the EMCP 3 is displayed on the
display screen (1). The arrow keys on the keypad are
used in order to navigate through the main menu.
Press the UP key (11) or the DOWN key (15) in order
to highlight the main menu options.
Press the Enter key (14) in order to select one of
the main menu options. The arrow keys are used in
order to view one of the setpoints.
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 (12) in order to return to the
main menu.
The event system uses the following terms to
describe the status of an Event:
PRESENT The condition causing the event is
present and affecting system behavior.
c. Make sure that the current level of security is

at least as high as the level of the password to
be changed.
ACTIVE The event was previously present but it is

no longer. It has been latched by the event system
and needs to be reset before the engine can be
restarted.
d. Press the DOWN key to highlight CHANGE

LEVEL 1 PSWD. Press the ENTER key to
select CHANGE LEVEL 1 PSWD
INACTIVE The event was active at some time

but is no longer active and is not affecting system
behavior
e. CHANGE LEVEL 1 PSWD is displayed.

Press the UP or DOWN key in order to
increment or decrement the highlighted digit to
the desired new password.
Perform the following steps in order to view one of

the events.
f. Press the RIGHT key in order to highlight

number.
2. Press the ENTER key (14).
1. From the main menu, highlight Event Log.
3. Select an ECM and press the ENTER key (14).

4. In order to scroll through the Events, use the UP
and DOWN keys.
5. Press ENTER after highlighting an event to see

additional information such as SPN, FMI, time
and date of first occurrence, time and date of last
occurrence, engine hours at first occurrence, and
engine hours at last occurrence.
i02011347
Event Resetting
SMCS Code: 4490
A flashing red shutdown light indicates there is an
unacknowledged shutdown event. The red shutdown
light will change from flashing red to solid red when
the Alarm Acknowledged key is pressed. Use the
following procedure in order to reset the event.
1. Press the STOP Key (10). Enter the EVENT
LOG option from the main menu.
2. Select an ECM from the list.
3. Scroll through the event conditions in order to
highlight the active events.
4. Make sure the condition that caused the event is
no longer present
5. Press the Enter Key.
6. RESET will be highlighted if the condition is no
longer present and the control is in STOP.
7. Press the Enter Key again.
The fault will clear and the red shutdown light
will be turned off if there are no other active
shutdowns.
8. Press the Escape Key 3 times in order to get back
to the main menu.
i01990612
Setpoint Programming
SMCS Code: 4490
g01045431
Illustration 8
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
Display Screen
AC Overview Key
Engine Overview Key
Yellow Warning Lamp
Red Shutdown Lamp
Lamp Test Key
Run Key
(9) Auto Key

(10) Stop Key
(11) Scroll Up Key
(12) Escape Key
(13) Scroll Right Key
(14) Enter Key
(15) Scroll Down Key
(16) Scroll Left Key
Main Menu
Display Screen (1). The arrow keys on the keypad
are used in order to navigate through the main menu.
Press the Scroll Up Key (11) or the Scroll Down
Key (15) in order to highlight one of the main menu
options.
Press the Enter Key (14) in order to select one of
the main menu options. The arrow keys are used in
order view or to select one of the setpoints listed on
the main menu.
The engine/generator setpoints affect the proper
operation and serviceability of the engine, and the
accuracy of information shown on the display screen.
The setpoints are programmed in the EMCP 3 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 requirements of the installation. The
setpoints that are stored in the EMCP 3 must match
the specified setpoints of the particular generator set.
The setpoints are programmable. See the Testing
and Adjusting, Electronic Control Module (Generator
Set) - Configure.
i02155375
Digital Input Programming

SMCS Code: 4490
Programming the Event Input

Functions
1. To program the Active State of the Digital Input,
go through the following menu options:
There are two parts to programming the Digital

Inputs. The first part involves programming the
Active State of the Digital Input (Active High or Active
Low). The second part involves programming the
Event Input Functions.
Digital Input #1 is dedicated to Emergency Stop.
Digital Input #2 is dedicated to Remote Initiate
(Remote Start). The six remaining Digital Inputs on
the EMCP 3.3 and EMCP 3.2 (four remaining Digital
Inputs on EMCP 3.1) can be programmed for various
other applications.
Programming the Active State of

the Digital Input
The digital inputs of the EMCP 3 are tied to an
internal pull-up resistor. Therefore, if there is no
connection
to a digital input, the digital input will sit at a logical
high. A ground or -batt input should be wired to each
EMCP 3 Digital Input. If an Active High configuration
is desired, the ground or -batt input should be wired
through a normally-closed switch. If an Active Low
configuration is desired, the ground or -batt input
should be wired through a normally-open switch.
1. To program the Active State of the Digital Input,
Main Menu
>Configure
>Setpoints
>I/O
>Digital Inputs
2. Select the Digital Input that you want to program.
Press the Enter Key.
3. Press the Enter Key again. The current
configuration will be highlighted.
4. Use the Scroll Up Key and the Scroll Down Key
in order to change the current configuration to the
desired setting.
5. Press the Enter Key to save the setting.
Main Menu
>Configure
>Setpoints
>Events
>Event I/P Functions
2. Once in the Input Function menu, the first setting
is the Active State. The Active State should
always be set to Active High. The next setting is
the Time Delay. While on the Time Delay Setting,
press Enter and use the arrow keys to enter the
desired value.
Note: Event Input Function #1 corresponds to Digital
Input #3, Event Input Function #2 corresponds to
Digital Input #4, etc.
3.
The next setting is the Suspect Parameter

Number (SPN). Press the Enter Key in order to
choose the SPN. Refer to the list of available
SPNs below.
Pressures

Engine Oil Pressure
Temperatures

Exhaust Temperature
Levels
The digital outputs have diagnostics for a short to

battery when the driver is on and diagnostics for a
open circuit when the driver is off. If a short to battery
persists for 5 seconds, the driver will be disabled until
the condition goes away.
Engine Oil Level

Fuel Level

the Digital Output

Others
The outputs are internally controlled in the EMCP 3.

The active state is programmable but should always
be set to active high.
Air Damper Closed

1. To program the Active State of the Digital Output,


Main Menu
>Configure
>Setpoints
Fuel Leak Detected
>I/O
Custom Event
>Digital Outputs
4. After the SPN is chosen, the Failure Mode

Identifier (FMI) is the next setting. The following
FMIs are available:
2. Select the Digital Output that you want to program.

High Warning (example: High Temperature

Low Warning (example: Low Temperature

desired setting.
High Shutdown
Low Shutdown
Programming the Digital Selectors
Status
There are 8 digital selectors. The digital selectors

determine what conditions cause the Digital Outputs
to become active. Only two of the digital selectors
are associated with digital outputs.
Warning)
Warning)
i02184156
Digital Output Programming

SMCS Code: 4490
1. In order to program the Digital Selectors, go

through the following menu options
There are two parts to programming the Digital

Outputs. The first part involves programming the
Active State of the Digital Output (Active High or
Active Low). The second part involves programming
the Digital Selectors.
Main Menu
The EMCP 3.1 does not have any Digital Outputs.

The EMCP 3.2 has one Digital Output. The EMCP
3.3 has two (2) Digital Outputs.
>Digital Selectors
Each output is capable of sinking 300mA.
>Configure
>Other
2. Select the Digital Selector that you want to

program. Press the Enter Key.

desired setting
i02155393
Spare Analog Input

Programming
SMCS Code: 4490
The Spare Analog Input is intended to be connected
to a resistive sender such as the Coolant
Temperature Sensor or the Oil Pressure Sensor.
Available Digital Selectors

Digital Selector # 7
Digital Selector #7 controls Digital Output #1. The
available configuration options for Digital Selector
#7 are shown in table 14.
Programming the Spare Analog

Input
To program the Spare Analog Input, go through the
following menu options:
Table 14
Digital Selector # 7 Configuration Options

Display Text
Condition
Disabled
Disabled
Use Input #1
(1)
(1)
Disable Shore Power(1)
Use Input #2
Start Aid
Use Input #3
Breaker #1
Use Input #4
Breaker #2
Use Input #5
Low Oil Pressure Warning
Use Data Link Input
Use SCADA Data Link

Command
Default
Digital Selector #8 controls Digital Output #2 The
#8 are shown in table 15.
Main Menu
>Configure
>Setpoints
>I/O
>Spare Analog Input
The Spare Analog Input setpoints are shown below.
Enable/Disable
If you intend to use the Spare Analog Input, the
Enable/Disable setpoint must first be enabled. If you
do not intend to use the Spare Analog Input, the
Enable/Disable setpoint MUST be disabled. If the
Spare Analog Input is enabled and not being used,
diagnostic codes will be logged
Suspect Parameter Number (SPN)
Table 15

Display Text
Disabled
(1)
(1)
Condition
Disabled
(1)
Use Input #1
Breaker #1
Use Input #2
Breaker #2
Use Input #3
Common Alarm
Use Input #4
Auto Mode
Use Input #5
High Coolant Temperature

Warning
Use Data Link Input
Use SCADA Data Link

Command
Default
The following SPNs are available:

Pressures

Temperatures

Exhaust Temperature

i02183827
Relay Output Programming
SMCS Code: 4490
Levels
There are two parts to programming the Relay

Outputs. The first part involves programming the
Active State of the Relay Output (Active High or
Active Low). The second part involves programming
the Digital Selectors.

Engine Oil Level
Fuel Level
High Warning Threshold
This is a numerical value entry.
High Warning Time Delay

High Shutdown Threshold

High Shutdown Time Delay

Low Warning Threshold

Low Warning Time Delay

Low Shutdown Threshold

Low Shutdown Time Delay

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 (four remaining Relay Outputs on
EMCP 3.1) can be programmed for various other
applications.
The EMCP 3.1 will have six relays: All six will be
type-A. The EMCP 3.2 and EMCP 3.3 will have eight
relays: Six will be type-A and two will be type-C.
Type-A is defined as one normally-open contact
plus common. Type-C is defined as two contacts,
normally-open and normally-closed plus common.
Each relay is capable of handling 2A @ 30 VDC.
The relay contacts are not protected against shorts
to battery or ground.
The relay contacts are not protected against shorts
to battery or ground.

the Relay Output
The relay contacts are dry contacts. The relays are
internally controlled in the EMCP 3. The active state
is programmable but should always be set to active
high.
1. To program the Active State of the Relay Output,
Main Menu
>Configure
>Setpoints
>I/O
>Relay Outputs
2. Select the Relay Output that you want to program.

desired setting.
Programming the Digital Selectors
Digital Selector #2 controls Relay Output #4 The
#2 are shown in Table 17.
Table 17
There are 8 digital selectors. The digital selectors

determine what conditions cause the Relay Outputs
to become active. Only six of the digital selectors are
associated with Relay Outputs.
Display Text
Condition
Disabled
Disabled
Use Input #1
Horn Control
Use Input #2
Common Alarm
Use Input #3
Common Warning
Main Menu
Use Input #4(1)
Common Shutdown(1)
>Configure
Use Input #5
Control not In Automatic
Use Data Link Input
Use SCADA Data Link

Command
1. In order to program the Digital Selectors, go

through the following menu options
>Other
(1)
>Digital Selectors
2. Select the Digital Selector that you want to
program. Press the Enter Key.
Default
Digital Selector #3 controls Relay Output #5. The
Table 18

desired setting

Display Text
Condition
Disabled
Disabled
Use Input #1
Common Alarm
Available Digital Selectors
Use Input #2
Common Warning
Use Input #3
Overcrank Shutdown
Use Input #4(1)
Engine Started(1)
Use Input #5
Breaker #2
Use Data Link Input
Use SCADA Data Link

Command

Table 16
Digital Selector # 1 configuration Options
(1)
Display Text
Condition
Disabled
Disabled
Use Input #1(1)
Air Shutoff(1)
Use Input #2
Start Aid
Use Input #3
Common Warning
Use Input #4
Low Coolant Temperature

Warning
Use Input #5
Breaker #1
Use Data Link Input
Use SCADA Data Link

Command
Default
(1)
Default
Table 19
Table 21

Display Text
Disabled
(1)
(1)
Condition
Display Text
Condition
Disabled
Disabled
Use Input #1

Warning
Disabled
(1)
Use Input #1
Common Warning
Use Input #2
Overspeed Shutdown
Use Input #3
Engine Started
Use Input #2
Crank Alert
Use Input #4
Crank Alert
Use Input #3
ECU Fault Reset
Use Input #5
ECM Fault Reset
Use Input #4

Shutdown
Use Data Link Input
Use SCADA Data Link

Command
Use Input #5(1)
Start Aid(1)
Use Data Link Input
Use SCADA Data Link

Command
Default
(1)

#5 are shown in Table 20
Table 20
(1)
Display Text
Condition
Disabled
Disabled
Use Input #1
Low Oil Pressure Warning
Use Input #2
Engine Started
Use Input #3
Low Oil Pressure

Shutdown
Use Input #4
ECM Fault Reset
Use Input #5(1)
Rated Speed(1)
Use Data Link Input
Use SCADA Data Link

Command
Default
Digital Selector #6
#5 are shown in Table 21
Default
i02054560
Voltage and Frequency

Adjustment
SMCS Code: 4490
1. From the MAIN MENU, press the Scroll Up
Key (11) or the Scroll Down Key (15) in order to
highlight the CONTROL menu.
a. Press the Enter Key (14) in order to select
CONTROL. ADJUST SPEED and ADJUST
VOLTAGE will be displayed.
b. Press the Scroll Up Key (11) in order to
increase the voltage and the Scroll Down key
(15) in order to decrease the voltage.
c. Press the Scroll Left Key (16) in order to
decrease the engine speed and the Scroll
Right Key (13) in order to increase the engine
speed.
Note: The voltage can only be controlled from the
EMCP 3 if a CDVR is installed on the generator
and the EMCP is a version 3.3 Speed can only be
controlled if there is an A 3 or newer ECM on the
engine.
i01988040
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.
The EMCP 3 will keep track of the time and the date
with an internal real time clock with a 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 power
is disconnected, the real time clock must be
reprogrammed when the control is repowered.
Key (11) or the Scroll Down Key (15) in order to
highlight the CONFIGURE menu.
2. Press the Enter Key (14 ) in order to select
CONFIGURE. SECURITY is highlighted.
3. Press the Scroll Down Key (15) in order to
highlight TIME/DATE.
4. Press the Enter Key (14) in order to select
TIME/DATE. SET TIME/DATE is displayed.
Also shown is the current time and date
programmed into the EMCP 3. The currently
programmed time is shown highlighted inside a
box
5. With the currently programmed time shown inside
the box, press the Enter Key (14). SET TIME
and the currently programmed time is displayed.
6. Press Enter Key (14) and the 6 digit time will be
displayed with seconds highlighted at the far right.
7. Use the Scroll Right Key (13) or the Scroll Left
Key (16) in order to highlight the digit to be
programmed.
8. Press the Scroll Up Key (11) or the Scroll Down
Key (15) in order to increment or decrement the
highlighted digit to the desired number.
9. Continue until the correct time has been entered.
When all digits of the time are correctly entered,
press the Enter Key (14). SET TIME is shown
with the newly programmed time highlighted.
10. Press the Escape Key (12) once. SET
TIME/DATE is shown and the newly programmed
time will be displayed inside a box.
11. Press the Scroll Right Key (13) in order to
highlight the currently programmed date inside a
box. Press the Enter Key (14) in order to select
the date. SET DATE and the currently
programmed date is displayed.
12. Press the Enter Key (14) in order to select the
date. A 8 digit display is shown with the year
highlighted at the far right.
13. Use the Scroll Right Key (13) or Scroll Left

Key (16) in order to highlight the digit to be
programmed.
14. Press the Scroll Up Key (11) or Scroll Down
Key (15) in order to increment or decrement the
highlighted digit to the desired number.
15. Continue until the correct date has been entered.
When all digits of the date are correctly entered,
press the Enter Key (14). SET DATE is shown
with the newly programmed date highlighted.
16. Press the Escape Key (12) three times to return
to the MAIN MENU.
40
RENR7902
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.
Introduction
i02196307
General Information
SMCS Code: 4490
Personal injury or death can result from high

voltage.
When power generation equipment must be in
operation 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 current tests being made.
When servicing or repairing electric power generation equipment:
Do not short these terminal with line voltage to

ground with any part of the body or any conductive material. Loss of life or injury could result
from electrical shock or injury from molten metal.
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 circum- stances.
Make sure the unit is off-line (disconnected
from utility and/or other generators power

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.
Illustration 9
Danger Label for Electrical Shock (North America)
g00891948
i02174153
Service Tools
SMCS Code: 0785
Table 22
Genset Diagnostic Tools
Illustration 10
g00874165
Danger Label for Electrical Shock (Outside of North America)
190-8900
Deutsch HD Style Connector

Repair Kit.
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
175-3700
Deutsch DT Style Connector

Repair Kit.
4 mm Hex Wrench
The Cat VR6 presents an electrical shock/electrocution hazard. This hazard will cause serious injury or death.
237-5130
Digital Multimeter with infrared

thermometer
257-9140
Fluke 80 Series Digital Multimeter
Service by trained personnel only.
146-4080
Digital Multimeter with RS232

output
The terminals and heat sinks are live at

hazardous voltages when power is applied and
for up to 8 minutes after power is removed.
The Cat Digital Voltage Regulator presents an

electrical shock/electrocution hazard. This hazard will cause serious injury or death.
Service by trained personnel only.
The terminals and heat sinks are live at
hazardous voltages when power is applied and
for up to 8 minutes after power is removed.
The secondary wires of the current transformer

must be shorted together when they are disconnected from the equipment. Extremely high voltages will be generated at the lead ends if the secondary wires are not shorted together. Bodily
contact with high voltage will result in serious
injury or death.
7X-1710
Multimeter Connector Probe

Group
155-5175
1000 Amp AC Current Probe for

use with digital multimeters
155-5176
1000 Amp AC / 1400 Amp DC

Current Probe for use with digital
multimeters
243-3134
Insulation Tester
255-8266
1200 Amp AC/DC Clamp On

Ammeter
227-4324
2000 Amp AC/DC clamp On

Ammeter
i02173768
Program the ECM (Flash). This is done with the
WINflash program. See Testing and Adjusting,

Program.
Diagnostic Capabilities
SMCS Code: 1400
Print reports.
The Caterpillar Electronic

Technician (ET)
The following list contains some of the diagnostic

functions and programming functions that are
performed by the service tools.
The failures of the ECM system are displayed.

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.
Illustration 11
g00774942
Connections for the Communication Adapter II and the Electronic

Technician (ET)
The components that are needed in order to use the
Communication Adapter II and the CAT Electronic Technician in
order to determine diagnostic codes are listed:
(6)
(7)
(8)
(9)
Cable
171-4400 Communication Adapter ii
Service diagnostic cable.
Current version of Caterpillar Electronic Technician software
and an IBM-COMPATIBLE personal computer
The Caterpillar Electronic Technician (ET) is a

software program that is used to access data. The
service technician can use the ET 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
Load new FLASH software.

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
View the status of parameters.
The number of occurrences of the problem
Clear active diagnostic codes and clear logged
A time stamp will display the first occurrence of
diagnostic codes
the problem.
A time stamp will display the last occurrence of the

problem.
Status Groups For The Electronic

Technician
The Status Groups are lists of ECM parameters. The
status of the parameters are shown in real time.
i02015216
Diagnostic Trouble Code List

SMCS Code: 7569
The following table lists the diagnostic trouble codes
for the genset. The column titled "Display Text
String" is what will be displayed on the EMCP 3
control panel. In order to view the "Suspect
Parameter Number" and the "Failure Mode Identifier"
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 your particular engine and
perform the diagnostic procedure indicated by the
SPN/FMI.
If the diagnostic code is generated from the EMCP 3
Electronic Control Module for the generator set, refer
to the last column of the following table and
reference
the " Troubleshooting Topic", within this section.
Note: All of the following codes require a level 1
password in order to clear the code with the
exception of the Emergency Shutdown Override
Mode Active Warning that requires a level 3
password in order to clear the code
Table 23
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
Code Description
Display Text
String
Troubleshooting topic
38
External Tank High Fuel

Level Shutdown
EXT TANK HIGH

FUEL LEVEL S/D
Digital Input Circuit

Fault and Analog Input
Circuit Fault
38
External Tank Low Fuel

Level Shutdown
EXT TANK LOW

FUEL LEVEL S/D

Circuit Fault
38
External Tank Fuel Level EXT TANK FUEL

LEVEL SENSOR
Sensor Short High
SHORT HIGH
Analog Input Circuit

Fault
38
External Tank Fuel Level EXT TANK FUEL

LEVEL SENSOR
Sensor Short Low
SHORT LOW

Fault
38
15
External Tank High Fuel

Level Warning
EXT TANK
HIGH FUEL LVL
WARNING

Circuit Fault
38
17
External Tank Low Fuel

Level Warning
EXT TANK
LOW FUEL LVL
WARNING

Circuit Fault
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
82
High Starting Air

Pressure Shutdown
HIGH STARTING
AIR PRES
SHUTDOWN

Circuit Fault
82
Low Starting Air

Pressure Shutdown
LOW STARTING
AIR PRES
SHUTDOWN

Circuit Fault
82

Sensor Short High
STARTING AIR
PRES SENSOR
SHORT HIGH

Fault
82

Sensor Short Low
STARTING AIR
PRES SENSOR
SHORT LOW

Fault
82
15
High Starting Air

Pressure Warning
HIGH STARTING
AIR PRES
WARNING

Circuit Fault
82
17
Low Starting Air

Pressure Warning
LOW STARTING
AIR PRES
WARNING

Circuit Fault
95
High Fuel Filter

Differential Pressure
Shutdown
HIGH FUEL
FLTR DIFF PRES
SHUTDOWN

Circuit Fault
95
Low Fuel Filter

Shutdown
LOW FUEL FILTER Digital Input Circuit

DIFF PRES
SHUTDOWN
Circuit Fault
95
Fuel Filter Differential

Pressure Sensor Short
High
FUEL FLTER DIFF

PRES SENSOR
SHORT HIGH

Fault
95
Fuel Filter Differential

Low
FUEL FLTR DIFF

PRES SENSOR
SHORT LOW

Fault
95
15
High Fuel Filter

Warning
HIGH FUEL
FLTR DIFF PRES
WARNING

Circuit Fault
95
17
Low Fuel Filter

Warning
LOW FUEL FILTER Digital Input Circuit

DIFF PRES
WARNING
Circuit Fault
96
High Fuel Level

Shutdown
HIGH FUEL LEVEL

SHUTDOWN

Circuit Fault
96
Low Fuel Level

Shutdown
LOW FUEL LEVEL

SHUTDOWN

Circuit Fault
96
Fuel Level Sensor Short

High
FUEL LEVEL
SENSOR SHORT
HIGH

Fault
96
Fuel Level Sensor Short

Low
FUEL LEVEL
SENSOR SHORT
LOW

Fault
Code Description
Display Text
String
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
Code Description
Display Text
String
96
15
High Fuel Level Warning
HIGH FUEL LEVEL

WARNING

Circuit Fault
96
17
Low Fuel Level Warning
LOW FUEL LEVEL

WARNING

Circuit Fault
98
High Engine Oil Level

Shutdown
HIGH ENGINE OIL

LVL SHUTDOWN

Circuit Fault
98
Low Engine Oil Level

Shutdown
LOW ENGINE OIL

LVL SHUTDOWN

Circuit Fault
98
Engine Oil Level Sensor

Short High
ENGINE OIL
LEVEL SENSOR
SHORT HIGH

Fault
98
Engine Oil Level Sensor

Short Low
ENGINE OIL
LEVEL SENSOR
SHORT LOW

Fault
98
15
High Engine Oil Level

Warning
HIGH ENGINE OIL

LVL WARNING

Circuit Fault
98
17
Low Engine Oil Level

Warning
LOW ENGINE OIL

LVL WARNING

Circuit Fault
99
High Oil Filter Differential HIGH OIL FILTER

DIFF PRES
Pressure Shutdown
SHUTDOWN

Circuit Fault
99
Low Oil Filter Differential

Pressure Shutdown
LOW OIL FILTER

DIFF PRES
SHUTDOWN

Circuit Fault
99
Oil Filter Differential

High
OIL FILTER DIFF

PRES SENSOR
SHORT HIGH

Fault
99
Oil Filter Differential

Low
OIL FILTER DIFF

PRES SENSOR
SHORT LOW

Fault
99
15
High Oil Filter Differential HIGH OIL FILTER

DIFF PRES
Pressure Warning
WARNING

Circuit Fault
99
17
Low Oil Filter Differential

Pressure Warning
LOW OIL FILTER

DIFF PRES
WARNING

Circuit Fault
100
Low Engine Oil Pressure

Shutdown
LOW ENGINE
OIL PRESS
SHUTDOWN
Data Link circuit Fault

and Digital Input Circuit
Fault
100
17
Low Engine Oil Pressure

Warning
LOW ENGINE OIL

PRESS WARNING
Data Link circuit Fault

Fault
107
High Air Filter Differential HIGH AIR FILTER

Pressure Shutdown
DIFF PRES
SHUTDOWN

Circuit Fault
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
Code Description
Display Text
String
107
Low Air Filter Differential

Pressure Shutdown
LOW AIR FILTER

DIFF PRES
SHUTDOWN

Circuit Fault
107
Air Filter Differential

High
AIR FILTER DIFF

PRES SENSOR
SHORT HIGH

Fault
107
Air Filter Differential

Low
AIR FILTER DIFF

PRES SENSOR
SHORT LOW

Fault
107
15
High Air Filter Differential HIGH AIR FILTER

DIFF PRES
Pressure Warning
WARNING

Circuit Fault
107
17
Low Air Filter Differential

Pressure Warning
LOW AIR FILTER

DIFF PRES
WARNING

Circuit Fault
110
High Engine Coolant

Temperature Shutdown
HIGH ENGINE
COOLANT TEMP
SHUTDOWN
Data Link Circuit Fault

Fault
110
15
High Engine Coolant

Temperature Warning
HIGH ENGINE
COOLANT TEMP
WARNING

Fault
110
17
Low Engine Coolant

Temperature Warning
LOW COOLANT
TEMP WARNING

Fault
111
High Engine Coolant

Level Shutdown
HIGH ENG
COOL LEVEL
SHUTDOWN

Circuit Fault
111
Low Engine Coolant

Level Shutdown
LOW ENG
COOL LEVEL
SHUTDOWN

Circuit Fault
111

Sensor Short High
ENGINE
COOLANT LEVEL
SENSOR SHORT
HIGH

Fault
111

Sensor Short Low
ENGINE
COOLANT LEVEL
SENSOR SHORT
LOW

Fault
111
15
High Engine Coolant

Level Warning
HIGH ENG COOL

LEVEL WARNING

Circuit Fault
111
17
Low Engine Coolant

Level Warning
LOW ENG COOL

LEVEL WARNING

Circuit Fault
137
High Fire Extinguisher

Pressure Shutdown
HIGH FIRE
EXTNG PRES
SHUTDOWN

Circuit Fault
137
Low Fire Extinguisher

Pressure Shutdown
LOW FIRE
EXTNG PRES
SHUTDOWN

Circuit Fault
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
137
Fire Extinguisher
High
FIRE EXTING
PRES SENSOR
SHORT HIGH

Fault
137
Fire Extinguisher
Low
FIRE EXTNG
PRES SENSOR
SHORT LOW

Fault
137
15
High Fire Extinguisher

Pressure Warning
HIGH FIRE EXTNG

PRES WARNING

Circuit Fault
137
17
Low Fire Extinguisher

Pressure Warning
LOW FIRE EXTNG

PRES WARNING

Circuit Fault
167
17
Low Battery Charging

System Voltage Warning
LOW BATTERY
CHARGING SYS
VOLT WARN
Charging System
168
High Battery Voltage

Shutdown
HIGH BATTERY
VOLTAGE
SHUTDOWN
Charging System
168
15

Warning
HIGH BATTERY
VOLTAGE
WARNING
Charging System
168
17
Low Battery Voltage

Warning
LOW BATTERY
VOLTAGE
WARNING
Charging System
171
High Ambient Air

HIGH AMBIENT
AIR TEMP
SHUTDOWN

Circuit Fault
171
Low Ambient Air

LOW AMBIENT
AIR TEMP
SHUTDOWN

Circuit Fault
171
Ambient Air Temperature AMBIENT AIR

Sensor Short High
TEMP SENSOR
SHORT HIGH

Fault
171
Ambient Air Temperature AMBIENT AIR

TEMP SENSOR
Sensor Short Low
SHORT LOW

Fault
171
15
High Ambient Air

Temperature Warning
HIGH AMBIENT
AIR TEMP
WARNING

Circuit Fault
171
17
Low Ambient Air

Temperature Warning
LOW AMBIENT
AIR TEMP
WARNING

Circuit Fault
173
High Exhaust
HIGH EXHAUST
TEMP
SHUTDOWN

Circuit Fault
173
Low Exhaust
LOW EXHAUST
TEMP
SHUTDOWN

Circuit Fault
Code Description
Display Text
String
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
173
Exhaust Temperature
Sensor Short High
EXHAUST
TEMPERATURE
SENSOR SHORT
HIGH

Fault
173
Exhaust Temperature
Sensor Short Low
EXHAUST
TEMPERATURE
SENSOR SHORT
LOW

Fault
173
15
High Exhaust
Temperature Warning
HIGH EXHAUST
TEMP WARNING

Circuit Fault
173
17
Low Exhaust
Temperature Warning
LOW EXHAUST
TEMP WARNING

Circuit Fault
175
High Engine Oil

HIGH ENGINE
OIL TEMP
SHUTDOWN

Circuit Fault
175
Low Engine Oil

LOW ENGINE
OIL TEMP
SHUTDOWN

Circuit Fault
175

Sensor Short High
ENGINE OIL TEMP

SENSOR SHORT
HIGH

Fault
175

Sensor Short Low
ENGINE OIL TEMP

SENSOR SHORT
LOW

Fault
175
15
High Engine Oil

Temperature Warning
HIGH ENGINE OIL

TEMP WARNING

Circuit Fault
175
17
Low Engine Oil

Temperature Warning
LOW ENGINE OIL

TEMP WARNING

Circuit Fault
190
Engine Over Speed

Shutdown
ENGINE
OVER SPEED
SHUTDOWN
Engine Over Speed

Warning
190
Engine Under Speed

Shutdown
ENGINE
UNDER SPEED
SHUTDOWN
Engine Under Speed

Warning
190
Engine Speed Sensor

Erratic or Not Present
ENGINE SPEED
SENSOR
ERRATIC/LOST
Engine Speed Circuit

Fault
190
Engine Speed Sensor

Open
ENGINE SPEED
SENSOR OPEN
Engine Speed Circuit

Fault
190
17
Engine Under Speed

Warning
ENGINE UNDER
SPEED WARNING
Engine Under Speed

Warning
625
11
SCADA Data Link Fault
SCADA DATA LINK Data Link Circuit Fault

FAULT
639
11
Primary Data Link Fault
PRIMARY DATA
LINK FAULT
Code Description
Display Text
String

(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
701
Custom Event #1 High

Shutdown
CUSTOM
EVENT #1 HIGH
SHUTDOWN

Fault
701
Custom Event #1 Low

Shutdown
CUSTOM
EVENT #1 LOW
SHUTDOWN

Fault
701
15

Warning
CUSTOM
EVENT #1 HIGH
WARNING

Fault
701
17
Custom Event #1 Low

Warning
CUSTOM EVENT
#1 LOW WARNING

Fault
701
31
Custom Event #1 Status
CUSTOM EVENT
#1 STATUS
ACTIVE

Fault
702

Shutdown
CUSTOM
EVENT #2 HIGH
SHUTDOWN

Fault
702
Custom Event #2 Low

Shutdown
CUSTOM
EVENT #2 LOW
SHUTDOWN

Fault
702
15

Warning
CUSTOM
EVENT #2 HIGH
WARNING

Fault
702
17
Custom Event #2 Low

Warning
CUSTOM EVENT
#2 LOW WARNING

Fault
702
31
CUSTOM EVENT
#2 STATUS
ACTIVE

Fault
703

Shutdown
CUSTOM
EVENT #3 HIGH
SHUTDOWN

Fault
703
Custom Event #3 Low

Shutdown
CUSTOM
EVENT #3 LOW
SHUTDOWN

Fault
703
15

Warning
CUSTOM
EVENT #3 HIGH
WARNING

Fault
703
17
Custom Event #3 Low

Warning
CUSTOM EVENT
#3 LOW WARNING

Fault
703
31
CUSTOM EVENT
#3 STATUS
ACTIVE

Fault
704

Shutdown
CUSTOM
EVENT #4 HIGH
SHUTDOWN

Fault
704
Custom Event #4 Low

Shutdown
CUSTOM
EVENT #4 LOW
SHUTDOWN

Fault
704
15

Warning
CUSTOM
EVENT #4 HIGH
WARNING

Fault
Code Description
Display Text
String
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
704
17
Custom Event #4 Low

Warning
CUSTOM EVENT
#4 LOW WARNING

Fault
704
31
CUSTOM EVENT
#4 STATUS
ACTIVE

Fault
705

Shutdown
CUSTOM
EVENT #5 HIGH
SHUTDOWN

Fault
705
Custom Event #5 Low

Shutdown
CUSTOM
EVENT #5 LOW
SHUTDOWN

Fault
705
15

Warning
CUSTOM
EVENT #5 HIGH
WARNING

Fault
705
17
Custom Event #5 Low

Warning
CUSTOM EVENT
#5 LOW WARNING

Fault
705
31
CUSTOM EVENT
#5 STATUS
ACTIVE

Fault
706

Shutdown
CUSTOM
EVENT #6 HIGH
SHUTDOWN

Fault
706
Custom Event #6 Low

Shutdown
CUSTOM
EVENT #6 LOW
SHUTDOWN

Fault
706
15

Warning
CUSTOM
EVENT #6 HIGH
WARNING

Fault
706
17
Custom Event #6 Low

Warning
CUSTOM EVENT
#6 LOW WARNING

Fault
706
31
CUSTOM EVENT
#6 STATUS
ACTIVE

Fault
924
Digital Output #1 Short

High
DIGITAL OUTPUT
1 SHORT HIGH
Digital Output Circuit

Fault
925
Digital Output #2 Short

High
DIGITAL OUTPUT
2 SHORT HIGH
Digital Output Circuit

Fault
970
31
Emergency Stop
Shutdown
EMERGENCY
STOP
SHUTDOWN

Fault
1122
High Generator Bearing

#1 Temperature
Shutdown
HIGH GEN
BEARING
#1 TEMP
SHUTDOWN

Circuit Fault
1122
Low Generator Rear

Bearing Temperature
Shutdown
LOW GEN REAR

BEARING TEMP
SHUTDOWN

Circuit Fault
Code Description
Display Text
String
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
Code Description
Display Text
String
1122
Generator Rear Bearing

Temperature Sensor
Short High
GEN REAR
BEARING TEMP
SENSOR SHORT
HIGH

Fault
1122
Generator Rear Bearing

Temperature Sensor
Short Low
GEN REAR
BEARING TEMP
SENSOR SHORT
LOW

Fault
1122
15
High Rear Generator

Bearing Temperature
Warning
HIGH GEN REAR

BEARING TEMP
WARNING

Circuit Fault
1122
17
Low Generator Rear

Bearing Temperature
Warning
LOW GEN REAR

BEARING TEMP
WARNING

Circuit Fault
1231
11
Accessory Data Link

Fault
ACCESSORY
DATA LINK FAULT
1239
31
Fuel Tank Leak (Fuel

Rupture Basin)
FUEL TANK LEAK

Fault
1664
31
Engine Failure to Start

Shutdown
ENGINE FAILURE
TO START
SHUTDOWN
Engine Overcrank
Warning
2433
High Right Exhaust

HIGH RIGHT
EXHAUST TEMP
SHUTDOWN

Circuit Fault
2433
Low Right Exhaust

LOW RIGHT
EXHAUST TEMP
SHUTDOWN

Circuit Fault
2433
Right Exhaust
Temperature Sensor
Short High
RIGHT EXHAUST
TEMP SENSOR
SHORT HIGH

Fault
2433
Right Exhaust
Temperature Sensor
Short Low
RIGHT EXHAUST
TEMP SENSOR
SHORT LOW

Fault
2433
15
High Right Exhaust

Temperature Warning
HIGH RIGHT
EXHAUST TEMP
WARNING

Circuit Fault
2433
17
Low Right Exhaust

Temperature Warning
LOW RIGHT
EXHAUST TEMP
WARNING

Circuit Fault
2434
High Left Exhaust

HIGH LEFT
EXHAUST TEMP
SHUTDOWN

Circuit Fault
2434
Low Left Exhaust

LOW LEFT
EXHAUST TEMP
SHUTDOWN

Circuit Fault
2434
Left Exhaust
Temperature Sensor
Short High
LEFT EXHAUST
TEMP SENSOR
SHORT HIGH

Fault
2434
Left Exhaust
Temperature Sensor
Short Low
LEFT EXHAUST
TEMP SENSOR
SHORT LOW

Fault
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
2434
15
High Left Exhaust

Temperature Warning
HIGH LEFT
EXHAUST TEMP
WARNING

Fault
2434
17
Low Left Exhaust

Temperature Warning
LOW LEFT
EXHAUST TEMP
WARNING

Circuit Fault
2436
Generator Over
Frequency Shutdown
GEN OVER
FREQUENCY
SHUTDOWN
Generator Over
Frequency Warning
2436
Generator Under
Frequency Shutdown
GEN UNDER
FREQUENCY
SHUTDOWN
Generator Under
Frequency Warning
2436
Engine SpeedGenerator Output

Frequency Mismatch
Warning
ENG SPEED-GEN
FREQ MISMATCH
WARN
Engine Speed Warning
2436
12
Generator Output
Sensing System Failure
GEN AC
METERING SYS
FAILURE
Generator Output
Sensing Circuit Fault
2436
15
Generator Over
Frequency Warning
GEN OVER
FREQUENCY
WARNING
Generator Over
Frequency Warning
2436
17
Generator Under
Frequency Warning
GEN UNDER
FREQUENCY
WARNING
Generator Under
Frequency Warning
2440
Generator Over Voltage

Shutdown
GEN OVER
VOLTAGE
SHUTDOWN

Warning
2440
Generator Under Voltage GEN UNDER

Shutdown
VOLTAGE
SHUTDOWN
Generator Under
Voltage Warning
2440
15

Warning

Warning
2440
17
Generator Under Voltage GEN UNDER

VOLTAGE
Warning
WARNING
Generator Under
Voltage Warning
2448
Generator Over Current

Shutdown
GEN OVER
CURRENT
SHUTDOWN

Warning
2448
15

Warning
GEN OVER
CURRENT
WARNING

Warning
2452
Generator Reverse
Power Shutdown
GEN REVERSE
POWER
SHUTDOWN
Generator Reverse
Power Warning
2452
17
Generator Reverse
Power Warning
GEN REVERSE
POWER
WARNING
Generator Reverse
Power Warning
Code Description
Display Text
String
GEN OVER
VOLTAGE
WARNING
(continued)
(Table 23, contd)
Trouble Codes
Suspect Parameter
Number (SPN)
Failure Mode
Identifier (FMI)
2648
31
Service Maintenance
Interval Warning
SERV MAINT
INTERVAL
WARNING
Service Information
Interval Warning
4000
31
Air Damper Closed
AIR DAMPER
CLOSED

Fault
4001
31
ATS IN NORMAL
POSITION

Fault
4002
31
ATS in Emergency
Position
ATS IN
EMERGENCY
POSITION

Fault
4003
31
BATTERY
CHARGER
FAILURE

Fault
4004
31
Generator Circuit
Breaker Closed
GENERATOR
BREAKER
CLOSED

Fault
4005
31
Utility Circuit Breaker

Closed
UTILITY BREAKER
CLOSED

Fault
4006
31
Engine in Cooldown
ENGINE IN
COOLDOWN
Engine Cooldown
Warning
4007
31
Generator Control Not in

Automatic Warning
GEN CONTROL
NOT IN AUTO
WARNING
Generator Control Not

In Automatic Warning
4008
31
Unexpected Engine
Shutdown
UNEXPECTED
ENGINE
SHUTDOWN
Unexpected Engine
Shutdown
Code Description
Display Text
String
Diagnostic System
Procedures
i02174686
Engine Overcrank Warning

SMCS Code: 4490
i02174519
Engine Cooldown Warning
System Operation Description:
SMCS Code: 4490
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.

Loss of a remote initiate signal, activation of the stop
signal input or a data link message calling for a
engine shutdown causes the engine to enter the stop
mode. If 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. 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 a 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.
Note: Refer to the engine Troubleshooting

manual for more information on engine starting
and engine cranking for your particular genset.
The code for the engine overcrank is generated
when the EMCP 3 determines that a 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.
Expected Result:
The setpoints are correct.
Results:
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.
OK The setpoints are correct for your particular
Test Step 4. Check communications

between EMCP 3 and Engine ECM. (EUI
Engines Only)
NOT OK The setpoints are NOT correct.
A. Use the CAT ET to Verify the Fuel enable input on

the Engine ECM is configured for "CAN Input".
genset. Proceed to Test Step 3 for MUI engines.

Proceed to Test step 4 for EUI engines.
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.
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.

again. If the failure is not found, replace the EMCP
3.
STOP.
NOT OK The wiring is not correct.

STOP.
i02177056
Engine Speed Warning

SMCS Code: 4490
The EMCP 3 determines the engine speed, in
rpm, from the magnetic pickup. The input from the
magnetic pickup will be a frequency 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 in order to
inform the operator of a mismatch condition.
Note: Refer to the engine Troubleshooting
manual for more information regarding engine
speed for your particular genset.
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

CHECK.
Expected Result:
Results:



STOP.

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
Expected Result:
Results:

genset.
Repair: Reset the genset. Resume normal

operation and verify that the problem has been
corrected.
STOP.

STOP.
i02199208
Engine Overspeed Warning

SMCS Code: 4490
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.
The code for engine overspeed is generated when
the EMCP 3 determines that a engine overspeed
condition has occurred.
Test Step 1. TALK TO THE OPERATOR
Expected Result:

overspeed condition.
The engine speed can be viewed and adjusted from

the EMCP 3 Display Screen.
Expected Result:
Results:
A overspeed was caused by a occurrence known to

the operator and the operator would like to put the
genset back into service.
OK The engine speed can be viewed and
Results:
OK The operator can determine the cause for

the overspeed condition, the condition has been
repaired and the operator wants to put the
genenset back into service.
corrected.
STOP.
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.
NOT OK The overspeed condition was not
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.
caused by a occurrence known to the operator.

Proceed to Test Step 2
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.
Test Step 4. CHECK THE SYSTEM BY

USING THE SPEED POTENTIOMETER.
(MUI ENGINES ONLY)
Expected Result:
Expected Result:
The engine can be adjusted to the desired speed.
Results:
Results:
OK The engine speed can be adjusted.
genset. Proceed to test step 3 for EUI engines.

Proceed to test step 4 for MUI engines

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.
A. With the engine running, adjust the speed of the

engine by turning the speed potentiometer.

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.
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)
Test Step 6. CHECK THE SPEED

POTENTIOMETER HARNESS FOR A
OPEN CIRCUIT. (MUI ENGINES ONLY)

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 .
A. Disconnect the speed potentiometer harness from

the 2301A governor.
Results:
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
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.
Results:
OK The harness functions properly.
OK The J1939 Data Link wiring is correct.

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.
i02199252
Engine Underspeed Warning

SMCS Code: 4490
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.
The code for engine underspeed is generated when
the EMCP 3 determines that a engine underspeed
condition has occurred.

underspeed condition.
Expected Result:
A underspeed was caused by a occurrence known
to the operator and the operator would like to put the
Results:

the underspeed condition, the condition has
been repaired and the operator wants to put the
corrected.
STOP.
NOT OK The underspeed condition was not


A. View the Engine Speed Monitor and Generator
Expected Result:
Results:


STOP.
Test Step 3. VERIFY ENGINE SPEED CAN

Verify the engine speed can be viewed and adjusted
Expected Result:
The engine speed can be viewed and adjusted from
Results:
OK The engine speed can be viewed and


STOP.
NOT OK The engine speed cannot be adjusted.

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.

(MUI ENGINES ONLY)

POTENTIOMETER HARNESS FOR A
A. With the engine running, adjust the speed of the

engine by turning the speed potentiometer.

the 2301A governor.
Expected Result:

ohms or less.
The engine can be adjusted to the desired speed.

Results:
OK The engine speed can be adjusted.


ohms or less
STOP.
Expected Result:
NOT OK The engine speed cannot be adjusted
with the speed potentiometer. Proceed to test step

5

(MUI ENGINES ONLY)

Results:
OK The harness functions properly.

100 ohms.

Results:
STOP.
Expected Result:



STOP.

Test Step 7. CHECK THE J1939 DATA

LINK BETWEEN THE EMCP 3 AND THE
Troubleshooting, Data Link Circuit Fault .
Results:
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.
STOP.
i02183223

Generator Output Sensing

Circuit Fault
SMCS Code: 4490
STOP.
i02177111
Generator Control Not in

Automatic Warning
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.
SMCS Code: 4490
Perform the following procedure: Electronic Control

Module (Generator Set) - Replace
Results:
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, continuous activation of the
Remote Initiate input causes the engine to start and
run (after a programmed Start Aid Activation delay
and Crank Alert interval). When the Remote Initiate
signal is removed, 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.
OK STOP.
Note: The event can be disabled via the Generator

Control Not in Automatic Warning Event Response
Configuration setpoint).
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.
diagnostic code.
i02177245
Generator Overcurrent
Warning
SMCS Code: 4490
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 a overcurrent condition is detected, 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

The code for generator overcurrent is generated
when the EMCP 3 determines that a generator
overcurrent condition has occurred.

overcurrent condition.

corrected.
STOP.

STOP.
Expected Result:
i02178029
A overcurrent was caused by a occurrence known to

Generator Overfrequency
Warning
Results:
SMCS Code: 4490
the overcurrent condition, the condition has

corrected.
STOP.
NOT OK The overcurrent condition was not


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.
If the frequency rises above the Generator

Overfrequency Percentage Threshold setpoint value,
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, the Generator Overfrequency
event will be made inactive and the timer will be reset.
If a overfrequency condition is detected, 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.
The code for generator overfrequency is generated
overfrequency condition has occurred.
Expected Result:

overfrequency condition.
Results:

genset.
Expected Result:
A overfrequency condition was caused by a
occurrence known to the operator and the operator
would like to put the genset back into service.
Results:

the overfrequency condition, the condition has
corrected.
STOP.
Repair: Adjust the generator output frequency to

meet site requirements. Resume normal operation
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
NOT OK The overfrequency condition was not

(MUI ENGINES ONLY)
A. With the engine running, adjust the generator

output frequency by turning the speed
potentiometer.

A. View the Generator Overfrequency and Generator

Expected Result:
Results:


STOP.
Test Step 3. VERIFY FREQUENCY CAN

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
Results:
OK The generator output frequency can be

viewed and adjusted from the EMCP 3 Display
Screen.
Expected Result:
The generator output frequency can be adjusted to
the desired frequency.
Results:

adjusted.

STOP.
be adjusted with the speed potentiometer. Proceed

to test step 5

(MUI ENGINES ONLY)
Expected Result:
100 ohms.
Results:



STOP.

POTENTIOMETER HARNESS FOR AN
the 2301A governor.
ohms or less.
ohms or less
Expected Result:
Results:
OK The harness functions properly. Proceed to

test step 8


Troubleshooting , Data Link Circuit Fault .
Results:


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.
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.

INPUT CONNECTIONS
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:
Repair: Repair the connectors or replace the

wiring harness. Resume normal operation and
STOP.
i02178102
Generator Overvoltage
Warning
SMCS Code: 4490
If the voltage rises above the Generator Overvoltage
Percentage
Threshold
setpoint
value,
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,
the Generator Overvoltage event will be made
inactive and the timer will be reset.
If a overvoltage condition is detected, GEN
OVERVOLTAGE SHUTDOWN or GEN
OVERVOLTAGE WARNING will be displayed on
overvoltage condition.
Note: The severity of the overvoltage condition will
The code for generator overvoltage is generated
overvoltage condition has occurred.
The wiring and the connectors should have been

good.
Results:

overvoltage condition.
OK NO problem was found with the connectors
Expected Result:
or with the wiring.

STOP.
NOT OK The problem was with the connectors

or with the wiring.
A overvoltage was caused by a occurrence known to

Results:

the overvoltage condition, the condition has

corrected.
Repair: Adjust the generator output voltage to

STOP.
STOP.
NOT OK The overvoltage condition was not
NOT OK The generator output voltage cannot
Test Step 4. CHECK CAT DATA LINK

VOLTAGE REGULATOR

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

between the EMCP 3 and the Voltage Regulator. For
more information on troubleshooting the Data Link,
see Troubleshooting , Data Link Circuit Fault .
Expected Result:
Results:
OK The Data Link wiring is correct.
Results:

genset.

corrected.
STOP.

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 the problem has been corrected.
STOP.

STOP.
STOP.
i02178170
Test Step 3. VERIFY VOLTAGE CAN BE

ADJUSTED
Verify the generator output voltage can be adjusted
Generator Reverse Power

Warning
SMCS Code: 4490
Expected Result:
The generator output voltage can be adjusted from

If the current rises above the Generator Reverse

Power Percentage Threshold setpoint value, 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, the Generator Reverse Power event will
be made inactive and the timer will be reset.
Results:
OK The generator output voltage can be

changed from the EMCP 3 Display Screen.
If a reverse power condition is detected, GEN

REVERSE POWER SHUTDOWN or GEN
REVERSE POWER WARNING will be displayed on
reverse power condition.

Note: The severity of the reverse power condition

Test Step 3. CHECK THE POLARITY OF

THE CURRENT TRANSFORMERS
STOP.

The code for generator reverse power is generated
reverse power condition has occurred.

A. Determine the conditions that caused the reverse
power condition.
Expected Result:
A reverse power was caused by a occurrence known
Results:

the reverse power condition, the condition has
corrected.
STOP.
Illustration 12
g00607036
(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 12.
NOT OK The reverse power condition was not
Expected Result:
The polarity of the current transformers should be

correct.

A. View the Generator Reverse Power setpoints.

Make a note of the setpoints. See Testing and
Set) - Configure. Compare the setpoints against
the default setpoints of the particular generator
set.
Expected Result:
Results:

genset. Proceed to Test Step 3.
Results:
OK The polarity of the current transformers are

correct.

again. If the diagnostic code is still present,
replace the EMCP 3. Refer to Testing and
Adjusting,
Electronic Control Module (Generator Set) Replace.
STOP.
NOT OK The polarity of the current transformers

are NOT correct.
Repair: Install the current transformers as shown

on the wiring diagram for your particulart genset.

corrected.
STOP.
STOP.
NOT OK The underfrequency condition was not

i02178486
Generator Underfrequency
Warning
SMCS Code: 4490
If the frequency drops below the Generator
Underfrequency Percentage Threshold setpoint
value, the underfrequency timer will begin
timing. When the timer expires, 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, the Generator Underfrequency event will
be made inactive and the timer will be reset.
If a underfrequency condition is detected, GEN
UNDERFREQUENCY SHUTDOWN or GEN
UNDERFREQUENCY WARNING will be displayed
underfrequency condition.


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
Expected Result:
Results:

Note: The severity of the underfrequency condition


STOP.
The code for generator underfrequency is generated

underfrequency condition has occurred.
Test Step 3. VERIFY FREQUENCY CAN

Verify the generator output frequency can be viewed

and adjusted from the EMCP 3 Display Screen.

underfrequency condition.
Expected Result:
Expected Result:
The generator output frequency can be viewed and

A underfrequency condition was caused by a

occurrence known to the operator and the operator
would like to put the genset back into service.
Results:
Results:
viewed and adjusted from the EMCP 3 Display

Screen.

the underfrequency condition, the condition has

STOP.

NOT OK The generator frequency reads zero on

the EMCP Display Screen. Proceed to test step 8

(MUI ENGINES ONLY)
A. With the engine running, adjust the generator
output frequency by turning the speed
potentiometer.

POTENTIOMETER HARNESS FOR AN
the 2301A governor.
ohms or less.
The generator output can be adjusted to the desired

frequency.

ohms or less
Results:
Expected Result:
Expected Result:

adjusted.

STOP.
be adjusted with the speed potentiometer. Proceed

to test step 5

(MUI ENGINES ONLY)
A. Disconnect the speed potentiometer from the
B. At the speed potentiometer, measure the
Expected Result:
100 ohms.
Results:



STOP.

Results:

test step 8


Troubleshooting , Data Link Circuit Fault .
Results:


STOP.

INPUT FUSES.
the EMCP 3.
Expected Result:
Results:

9

STOP.

VOLTAGE OUTPUT.
fuses.
Expected Result:
Results:


correct.

has been corrected.
STOP.

INPUT CONNECTIONS
EMCP 3.
Expected Result:
good.
Results:

or with the wiring.

STOP.

or with the wiring.

STOP.
i02178509
Generator Undervoltage
Warning
SMCS Code: 4490
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
If a undervoltage condition is detected, GEN
UNDERVOLTAGE SHUTDOWN or GEN
UNDERVOLTAGE WARNING will be displayed on
undervoltage condition.
Note: The severity of the undervoltage condition will

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
set.
Expected Result:
Results:

genset. Proceed to test step 3

STOP.
Test Step 3. VERIFY VOLTAGE CAN BE

ADJUSTED
The code for generator undervoltage is generated

undervoltage condition has occurred.
Verify the generator output voltage can be adjusted

Expected Result:

The generator output voltage can be adjusted from

Expected Result:
Results:
A undervoltage was caused by a occurrence known

OK The generator output voltage can be

changed from the EMCP 3 Display Screen.
Results:
Repair: Adjust the generator output voltage to

STOP.
the undervoltage condition, the condition has

corrected.
STOP.
NOT OK The undervoltage condition was not

NOT OK The generator output voltage cannot

Test Step 4. CHECK CAT DATA LINK

VOLTAGE REGULATOR
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

STOP.


VOLTAGE OUTPUT.
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
STOP.
NOT OK All phases of voltage are not shown on

display. Proceed to test step 6

INPUT FUSES.
the EMCP 3.
Expected Result:
Results:

7

fuses.
Expected Result:
Results:


correct.

has been corrected.
STOP.

INPUT CONNECTIONS
EMCP 3.
Expected Result:
Expected Result:

good.
Genset maintenance records indicate that the

maintenance interval has been exceeded and
maintenance is required
Results:

or with the wiring.
OK Records indicate service is required.

STOP.
or with the wiring.

STOP.
NOT OK Records indicate service is not

required. Proceed to Test Step 2
A. View the setpoints (Service Maintenance Interval

Hours), and (Service Maintenance Interval Days)
and make note of the setpoints. See Testing and
set.
Expected Result:
i02178535
Service Maintenance Interval

Warning
SMCS Code: 4490
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.
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.

diagnostic code.
Perform the required maintenance and reset the

Service Maintenance Interval in order to indicate
when the genset will need to be serviced again.
STOP.
Test Step 1. Talk to the Operator
Results:
The setpoints are correct for your particular genset

and application.
Results:

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.

STOP.
i02179040
Analog Input Circuit Fault

SMCS Code: 4490
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 high/low
thresholds 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.
This code is generated when the measured Spare
Analog Input value goes above or below the
programmed threshold for a configurable duration.

CHECK.
A. Use ET 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:

NOT OK Another engine ECM diagnostic code

is active.

active code or indicator. Refer to the engine
Troubleshooting manual for your particular genset.
STOP.

A. View the Spare Analog Input setpoints. Make a
Expected Result:
Results:


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.

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.
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.
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.
i02179474
Charging System
SMCS Code: 1401; 1405
If a battery undervoltage condition is detected, LOW

BATTERY CHARGING SYS VOLT WARN or LOW
BATTERY VOLTAGE WARNING will be displayed
Note: The severity of the battery over/under voltage
condition will determine if a warning or shutdown
event occurs.
This code is generated when the measured battery
voltage value goes above or below the programmed
thresholds for a configurable duration.

CHECK.
A. The battery and charging system are located on
the engine. Use ET to Check for active diagnostic
codes on the engine ECM. If any codes are
present, correct the engine diagnostic codes first.
Expected Result:
on the engine ECM.
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
Results:
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.

active. 2

is active.

STOP.
A. View the Battery Voltage Monitor setpoints. Make

a note of the setpoints. See Testing and
set.
Expected Result:
Results:


STOP.
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:
Test Step 3. COMPARE ACTUAL

BATTERY VOLTAGE TO THE
VOLTAGE DISPLAYED ON THE EMCP 3
DISPLAY
Results:
NOT OK The battery voltage supply wiring is
B. Disconnect the harness connector from the EMCP

3.
C. At the harness connector, measure the battery
voltage at 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.
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.
OK No problems can be found with the battery

voltage supply wiring. Proceed to test step 5
defective.


CODE REMAINS
contacts of the harness connectors.
Expected Result:
Results:


failed.

STOP.
i02180062

SMCS Code: 4490
Note: There are three data links associated with the
EMCP 3. The Data Links are the (J1939 Accessory
Data Link), (J1939 Primary Data Link), and the
(Modbus RS-485 SCADA Data Link). Refer to
Systems Operation, General Information for details.
This procedure checks for an open circuit or a short
circuit in one of the Data Links
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. 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.
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.

Test Step 3. Check the Resistance

through the Modbus RS-485 SCADA Data
Link Harness
data link.
B. Use a suitable piece of wire to short (Data Link +)
and ( Data Link ) at the EMCP 3.
Results:
C. Measure the resistance between (Data Link +)

and (Data Link ) at all other connectors in the
circuit for the data link.
OK In order to troubleshoot the Modbus RS-485
Expected Result:
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
STOP.
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.

Test Step 4. Check for Shorts in the J1939

Data Link Harness
data link.
B. Measure the resistance between (data link +) and
data link ).

STOP.
Expected Result:
i02180563
The resistance is approximately 60 Ohms.
Digital Input Circuit Fault
Results:
SMCS Code: 4490
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 a open
data link circuit. if the resistance is much less than
60 ohms, there is a short circuit

CODE REMAINS
A. Inspect the Data Link harness connectors and
clean the contacts of the harness connectors.
B. Reconnect all Data Link harness connectors.
Expected Result:
Results:


failed.

Digital inputs are used to bring on/off information
such as switch closures to the Genset Control. The
EMCP
3 associates the inputs with levels, temperatures,
pressures, and status conditions depending on how
the input is programmed. Two of the Digital Inputs
are
used by the EMCP 3 to control Emergency Stop and
Remote Initiate functions and are programmed at the
factory. The spare digital inputs must be
programmed
before use.
For additional information on programming digital
inputs, see System Operation, Digital Input
Programming
This code is generated when the digital input is
active. The code may a indicate a problem exists
with the genset or the code may also indicate a
status that does not need to be repaired.

CHECK.
A. Use ET to Check for active diagnostic codes on
the engine ECM. If any codes are present, correct
the diagnostic codes first.
Expected Result:
on the engine ECM.
Results:


is active.


CODE REMAINS
STOP.

contacts of the machine harness connectors.

A. View the Digital Input setpoints. Make a note of
the setpoints. See Testing and Adjusting,
Expected Result:
Results:

genset. Proceed to Test Step 3

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:
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.


Expected Result:
Results:


failed.
STOP.
i02180829
Digital Output Circuit Fault

SMCS Code: 4490
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+).
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.

3.
Repair: Repair the digital output device or replace

the digital output device.
C. Disconnect the digital output from the device it is

connected to.
STOP.
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.

CODE REMAINS
A. Inspect the EMCP 3 connector and clean the
contacts of the EMCP 3 connector.
Expected Result:
B. Reconnect the harness connector.
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. Press the Emergency Stop Push Button to
prevent the engine from running while performing
this procedure. 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:
Results:


failed.
STOP.
i02181532
Expected Result:
Engine Speed Circuit Fault
The voltage is at or near 0 volts DC and not shorted

to battery positive (B+).
SMCS Code: 4490
Results:
OK The digital output device is not shorted to
The EMCP 3 determines the engine speed, in rpm,

from the Magnetic Pickup (Engine Speed Sensor)
input pins, detects diagnostics on the sensor,
and annunciates an engine over/under speed
condition. The engine speed sensor used for these
determinations is an independent sensor to be used
by the EMCP 3 only.
battery positive (B+). Proceed to Test Step 3
NOT OK The digital output device is shorted to

battery positive (B+)
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.
This code is generated when the EMCP 3 has
determined that an incorrect signal from the
engine speed sensor has occurred or a
overspeed/underspeed condition has occurred.
Refer to the engine Troubleshooting manual to
for more information on engine over/under speed
conditions for your particular genset.

STOP.

A. View the Engine Speed Monitor Setpoints. Make
a note of all the setpoints. See Testing and
set.
Expected Result:
Results:

genset. Proceed to Test Step 3

STOP.
Test Step 3. CHECK THE HARNESS AND

THE SPEED SENSOR.
Illustration 13
g01103901
A. Press the Stop Key on the EMCP 3 control.
Note: The Engine Speed Sensor is commonly

referred to as magnetic pickup.

3.

CHECK.
C. At the EMCP 3 harness connector, measure the

resistance from contact 66 to contact 67.

Expected Result:
Expected Result:
Results:
OK There is probably an intermittent problem.
Results:


The resistance should be from 100 to 350 ohms.
NOT OK The harness wiring or the speed

sensor has failed. Proceed to Test Step 4.
Test Step 4. CHECK FOR AN

INTERMITTENT FAULT.
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.
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.
Results:
Expected Result:
OK A speed sensor diagnostic code does not
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.
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.
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.
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.
The resistance from contact 66 to contact 67 of
the EMCP 3 harness connector should be greater
than 5000 ohms.
Results:

Test Step 7.
Expected Result:
The resistance should be between 100 to 350 ohms.
Results:

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.
B. Disconnect the sensor from the engine harness.
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.
NOT OK The ciruit 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.
B. Disconnect the sensor from the engine harness.
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.
Expected Result:
No damage should be present.
Results:
OK No damage is present. Reinstall the engine

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.
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.
speed sensor. Adjust the sensor.
C. Start and run the engine at rated speed.
Repair: For more information, refer to Testing And

Adjusting, Speed Sensor (Engine) - Adjust.
D. Measure the AC signal voltage of the engine

speed sensor.
Expected Result:
NOT OK Damage is present. Replace the

engine speed sensor.
Repair: Refer to Testing And Adjusting, Speed

Sensor (Engine) - Adjust.
STOP.
The voltage should be equal to 2 ACV or greater.

Results:
OK The voltage is equal to 2 ACV or greater.

The speed sensor circuit is correct. STOP.
NOT OK The voltage is not equal to 2 ACV or
Test Step 9. CHECK THE STATUS OF THE

FAULT.
greater. The most likely cause is improper air gap

of the pickup.
A. Reconnect the harness connector to the EMCP

3 and the sensor.
Repair: For more information, refer to Testing And

Adjusting, Speed Sensor (Engine) - Adjust.
B. Press the Stop Key on the EMCP 3 control.
STOP.
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.
i02182892

SMCS Code: 4490
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 determines the engine speed, in rpm,

from the Magnetic Pickup (Engine Speed Sensor)
input pins, detects diagnostics on the sensor,
and annunciates an engine over/under speed
condition. The engine speed sensor used for these
determinations is an independent sensor to be used
by the EMCP 3 only.
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.

unexpected shutdown.
Expected Result:
A unexpected shutdown was caused by a occurrence
known to the operator and the operator would like to
put the genset back into service.
Results:
the UNEXPECTED ENGINE SHUTDOWN, the

condition has been repaired and the operator
wants to put the genenset back into service.
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.
Expected Result:
Results:

active.
Repair: Refer to the engine Troubleshooting

manual to for more information on engine
unexpected engine shutdowns for your particular
genset.
STOP.


STOP.
RENR7902
85

Section
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.
i01988161
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.
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.
i02148670
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, 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:
Ensure that the wires enter the back of the
Reference: For a complete electrical schematic,

refer to Electrical System Schematic for the genset
that is being serviced.
Ensure that each wire is properly crimped into
TEST FOR AN OPEN CIRCUIT.
Ensure that each connector contact is properly
1. Identify the connectors and the wire numbers of

the suspect circuits. Use the Electrical System
Schematic of the genset to identify the circuits.
connector straight.
the proper connector contact.
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.
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.
Stop.
Stop.
NOT OK The resistance is greater than 5000

ohms. There is an open in the genset harness.
NOT OK The resistance is less than 5000

ohms. There is a short in the genset harness. The
short is between the suspected wire and the wire
with the lowest resistance measurement.
Repair: Repair the genset harness or replace the

genset harness.
Stop.
i02148682
Wiring Harness (Short Circuit)

- Test
SMCS Code: 1408-081
Repair: Repair the genset harness or replace the

genset harness.
Stop.
i01988211
External Potential Transformer

Connections
A short circuit is a failure of an electrical circuit that

results in undesired electrical current. Usually, a
short circuit is a bypass of the circuit across a load.
For example, a short across the wires in a circuit for
a lamp produces too much current in the wires but
no current is felt at the lamp. The lamp is shorted
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:
SMCS Code: 1409-077
Reference: For a complete electrical schematic,

refer to Electrical System Schematic for the genset
that is being serviced.
Note: The wye configuration of external potential

transformers (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 can not 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.
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.
In order to monitor generator output voltages greater

than 600 Volts, potential transformers will have to
be used.
Note: The EMCP 3 must be programmed when
connecting external PTs. See the Systems
Operation, Setpoint Viewing and Testing and
Set) - Configure.
Illustration 14
g01047743
Wye Configuration Of External Potential Transformers (PT) On 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.
Illustration 15
g01047744
Open Delta Configuration Of External Potential Transformers (PT) 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 can not be determined. The power factor phase A, B and C can not be
determined. The phases are not shown on the EMCP 3 display.
g01047747
Illustration 16
Open Delta Configuration Of External Potential Transformers (PT) 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 can not be determined and are not shown on the EMCP 3 display.
On 4-wire wye generators, three separate potential

transformers (PTs) are required for accurate power
metering unless the loads are completely and
continually balanced. Even if the loads are balanced,
some power parameters can not be determined.
These parameters are not shown on the EMCP 3
display: real power phase A, B, C and power factor
phase A, B, C.
i01988213
Speed Sensor (Engine) - Adjust

SMCS Code: 1907-025
On 3-wire delta generators, two potential

transformers allow maximum accuracy for all load
conditions. However, again real power phase A, B, C
and power factor phase A, B, C can not be
determined and are not shown on the EMCP 3
display.
Illustration 17
g00289497
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 Nm (18 4 lb ft).
Note: Do not allow speed sensor (1) to turn as
locknut (2) is tightened.
i01988326

(Generator Set) - Replace
SMCS Code: 4490-510
Replacement Procedure
Note: The configuration from the old ECM can be
saved in the ET Service Tool. The configuration can
then be uploaded to the new ECM.
i02148734

(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 (ET) contains
the program WinFlash. WinFlash is used in order to
load software into the ECM. The following procedure
is used in order to FLASH software into the ECM.
Procedure
1. Connect the Data Link Cable between the
Communication Adapter and the 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.
1. The new ECM must be reprogrammed after the

new ECM is installed. 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 Operation, Setpoint
Viewing and System Operation, Setpoint
Programming.
4. Use WinFlash in order to load the software.
2. Shut down the engine. Remove the positive lead

wire from the battery.
SMCS Code: 4490-025
3. Remove the harness connector from the ECM. A

4 mm hex wrench is required 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. Install the
six nuts. Tighten the nuts.
i02010071

(Generator Set) - Configure
Initial Setup
Display Screen (1). Press the Scroll Up Key (11) or
the Scroll Down Key (15) in order to highlight the
main menu options.
Press the Enter Key (14) in order to select one of the
main menu options.
6. Reconnect the harness connector to the ECM.

Reconnect the positive lead wire to the battery. If
necessary, see the Generator Set Wiring Diagram
Testing And Adjusting, Schematics And Wiring
Diagrams.
The keypad is also used in order to change the

setpoints. Press the Enter Key (14) in order to
change a setpoint. Press the Scroll Up Key (11) or
the Scroll Down Key (15) in order to increase or
decrease the value. Press the Scroll Left Key (16) or
the Scroll Right Key (13) in order to change the digit
that is to be adjusted.
7. Reprogram the setpoints, the spare

inputs/outputs, the hour meter, the
voltmeter/ammeter programming and the AC
offset adjustment. Use the values from the original
ECM. Refer to Step 1.
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 (12) in order to
return to the main menu.
g01045431
Illustration 18
(1)
(2)
(3)
(4)
(5)
(6)
Display Screen
AC Overview Key
Engine Overview Key
Yellow Warning Lamp
Red Shutdown Lamp
(7) Lamp Test Key

(8) Run Key
(9) Auto Key
(10) Stop Key
(11) Scroll Up Key
(12) Escape Key
(13)
(14)
(15)
(16)
Scroll
Enter
Scroll
Scroll
Right Key
Key
Down Key
Left Key
Setpoints
Engine Monitor/Protect
Within each setpoint category there are one or more

function blocks. Each of those function blocks may
contain one or more setpoints. Each of these setpoint
categories and its corresponding function blocks are
shown below.
Battery Voltage Monitor
Control
Automatic Start/Stop
Automatic Voltage Regulator (AVR) Desired
Voltage Request
Crank Attempt/Successful start Counter

Engine Coolant Temperature Monitor
Engine Oil Pressure Monitor
Engine Speed Monitor
Enhanced Engine Monitor
Generator Breaker Control
Events
Transfer Switch
Diagnostics Configuration
Utility Breaker Control
Engine protection Events Configuration

Generator Protection Events Configuration
Other System Events Configuration
Event Input Function

Event Output Function
Event System
Generator Monitor/Protect
Enhanced Generator Monitor
Generator AC Monitor
Generator AC Power Monitor
Generator Over/Under Frequency
Generator Over/Under Voltage
Discrete Input Output (I/O)
Digital Inputs
Digital Outputs
Relay Outputs
Spare Analog Input
Network
Data Link - SCADA
Other
Digital Selectors
Reduced Power Mode
Programming the Display

Preferences
The preferences affect the way data is viewed on the
display screen. The configuration may need to be
changed to meet local requirements.
1. In order program the display preferences, go
through the following menu options.
2. Press the ESCAPE key (12) in order to go back
to the main menu.
3. From the main menu, press the Scroll Up Key (11)
or the Scroll Down Key (15) in order to highlight
the PREFERENCES option.
a. Press the Enter Key (14) in order to select

PREFERENCES. CONTRAST will be
highlighted.
b. Press the Enter Key (14) in order to select
CONTRAST. Adjust the contrast as needed.
Use the right/left arrows to adjust the Contrast.
Press the Enter Key to save.
c. Press the Scroll Down Key (15) in order to
highlight BACKLIGHT.
d. Press the Enter Key (14) in order to select
BACKLIGHT. Adjust the backlight as needed.
Use the Scroll Left Key (16) or the Scroll Right
Key (13) in order to adjust the backlight. Press
the Enter Key (14)to save.
e. Press the Scroll Down Key (15) in order to
highlight PRESSURE.
f. Press the Enter Key (14) in order to select
PRESSURE. Use the Scroll Left Key (16) or
the Scroll Right Key (13) in order to highlight
kPa, PSI, or BAR.
g. Press the Enter Key (14) in order to save the
selection.
h. Press the Scroll Down Key (15) in order to
highlight TEMPERATURE.
i. Press the Enter Key key (14) in order to select
TEMPERATURE. Use the Scroll Left Key
(16) or the Scroll Right Key (13) in order to
highlight C, or F.
j. Press the Enter Key (14) in order to save the
selection.
k. Press the Scroll Down Key (15) in order to
highlight VOLUME.
l. Press the Enter Key (14) in order to select
VOLUME. Use the Scroll Left Key (16) or
LITERS, US GAL, or IMP GAL.
m. Press the Enter Key (14) in order to save the
selection.
n. Press the Scroll Down Key (15) in order to
highlight LANGUAGE.
o. Press the Enter Key (14) in order to select
LANGUAGE. Use the Scroll Left Key (16) or
ENGLISH, or the other language that is
available.
p. Press the Enter Key (14) in order to save the
selection.
q. Press the Escape Key in order to go back 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.
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.
11. Use the Scroll Up Key (11) and the Scroll

Down Key (15) in order to change the current
configuration to the desired setting.
12. Press the Enter Key (14) in order to save the
setting.
13. Repeat steps 9 through step 12 in order to
program all of the Automatic Start/Stop setpoints.
14. After all of the Automatic Start/Stop Setpoints are
programmed correctly, press the Escape Key (12)
in order to go back to the CONTROL menu.
15. The next block of setpoints to program is the
Automatic Voltage Regulator (AVR) Request
block. Press the DOWN Key (15) in order to
scroll through the setpoint options until AVR
DESIRED VOLTAGE is highlighted.
16. Press the Enter Key (14) in order to select AVR
DESIRED VOLTAGE
The first setpoint block to program is the Automatic

Start/Stop Block. The Automatic Start/Stop Block is
part of the Control Category.
17. Repeat step 9 through step 12 in order to

program all of the Automatic Voltage Regulator
(AVR) Request Setpoints.
1. In order program the Automatic Start/Stop

Setpoints, go through the following menu options.
18. Continue to program all of the function blocks in

the CONTROL menu.
2. Press the Escape Key (12) in order to go to the

main menu.
19. Press the Escape Key (12) twice in order to go

back to the SETPOINTS MENU menu.
3. From the main menu, Press the Scroll Down Key

(11) until CONFIGURE is highlighted.
20. Press the Scroll Down Key (15) in order to

scroll through the setpoint options until ENGINE
MONITOR/PROTECT is highlighted.

CONFIGURE.
5. Press the Scroll Down Key (15) until
SETPOINTS
is highlighted. Press the Enter Key (14) in order
to select SETPOINTS.
6. Press the Scroll Down Key (15) in order to scroll
through the setpoint options until CONTROL is
highlighted.
CONTROL. AUTOMATIC START / STOP is
highlighted.
AUTOMATIC START / STOP
9. Use the Scroll Up Key (11) and the Scroll Down
Key (15) in order to select the next setpoint that
you want to program. Press the Enter Key.
10. Press the Enter Key (14) again. The current
21. Press the Enter Key in order to select the

ENGINE MONITOR/PROTECT menu.
22. Continue to program all of the function blocks in
the ENGINE MONITOR/PROTECT menu.
23. Continue to program the rest of the setpoints until
each setpoint in every setpoint category have
been checked and programmed as required.
SETPOINT TABLES
All of the available setpoints on the EMCP3 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.
Table 24
Setpoints - Automatic Start/Stop(1)

Setpoint
Name
Min Value
Max
Value
Units
Factory
Default
Description
Engine start fault protection

activation delay time
300
sec.
30
Fault protection time delay prevents

shut down during start up fro low oil
pressure etc.
Crank Duration
300
sec.
Amount of time the EMCP 3 energizes

(cranks) the starting motor
Crank Cycle Rest Interval
300
sec.
Amount of time the EMCP 3

deenergizes the starting motor
between crank cycles
Engine Purge Cycle Time
20
sec.
Maximum Number of Crank

Cycles
20
n/a
Number of crank/rest cycles that

the EMCP 3 uses to declare that
a overcrank fault exists
Cooldown Duration
30
min.
Amount of time the EMCP 3 allows

the engine to run after a normal
shutdown is initiated
Start Aid Activation Time
240
sec.
Amount of time the EMCP 3 activates

start aid control output
Crank Alert Activation Time
60
sec.
Amount of time the EMCP activates

crank alert output
Crank Terminate RPM
100
1000
rpm
400
Engine speed setting used in order

to disengage the starting motor
during engine cranking.
Engine Fuel Type Configuration
n/a
n/a
n/a
Diesel
Setpoint allows for selection of

Diesel or Natural Gas.
Type of fuel system solenoid used
on the generator set Select
energized to run (ETR) or energized
to shut off (ETS)
(1)
Fuel Shutoff Solenoid Type

Configuration
n/a
n/a
n/a
Energize to
Run
Engine Type Configuration
n/a
n/a
n/a
Mechanical
Select mechanical or electronic
Engine Controller J1939 Data

Link Support Configuration
n/a
n/a
n/a
No Data Link
Setpoint allows for selection of No

Data Link, Basic Data Link, or
Enhanced Data Link.
Engine Cool Down Speed

Configuration
n/a
Rated
Setpoint allows for selection of

engine speed during cooldown.
Select rated or idle.
The setpoints that are stored or the setpoints that are being programmed must match the specified setpoints of the particular generator set.
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. The AVR Desired Voltage Request block is
used in synchronization load control and reactive
import/export control.
Table 25
Setpoints - AVR Desired Voltage Request(2)

Setpoint
Name
(2)
Min Value
Max Value
Units
Factory Default
Description
Maximum Generator
Voltage Output Bias
Percentage
100
The Maximum Generator Output

voltage Bias Percent is the
maximum value above and below
the Nominal Voltage that the
EMCP 3 will send a request for
when adjusting the voltage from
the control screen.
Generator Nominal
Output Voltage
100
50000
100
The Generator Nominal Output

Voltage is the desired output
voltage of the generator set.
Maximum Generator Output Voltage Bias Percent

The following settings will only apply if there is a
CDVR installed on the generator.
e. Press the Enter Key to select MAXIMUM

GEN OUTPUT VOLTAGE BIAS PERCENT.
MAXIMUM GEN OUTPUT VOLTAGE BIAS
PERCENT is displayed with the current
voltage bias percent.
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%.
f. Press the Scroll Up Key or the Scroll Down

Key in order to increment or decrement the
highlighted digit to the desired value.

Key or the Scroll Down Key to highlight the
CONFIGURE menu.
a. Press the Enter Key in order to select
highlighted.
b. Press the Scroll Down Key in order to highlight
SETPOINTS. Press the Enter Key in order to
select SETPOINTS.
c. AUTOMATIC START/STOP will be
highlighted. Press the Scroll Down Key in order
to highlight AVR DESIRED VOLTAGE
d. Press the Enter key in order to select AVR
DESIRED VOLTAGE. MAXIMUM GEN
OUTPUT VOLTAGE BIAS PERCENT will be
displayed.
g. Press the Scroll Right Key or the Scroll Left

Key in order to highlight the next character to
be entered. Press the Scroll Up Key or the
Scroll Down Key in order to increment or
value.
h. Continue until the desired MAXIMUM GEN
OUTPUT VOLTAGE BIAS PERCENT is
entered. When the MAXIMUM GEN OUTPUT
VOLTAGE BIAS PERCENT is correctly
entered, press the Enter key.
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.
Generator Breaker Control
The purpose of Generator Breaker Control block is
to open and close the generator breaker and to
generate alarms on failure of the generator breaker
to open or close.
Table 26
Setpoints - Generator Breaker Control(22)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Generator Breaker
Closing Pulse Active
Time
0.1
10
sec.
1.0
Generator Breaker
Closing Pulse Rest
Interval
60
sec.
1.0
Generator Breaker
Maximum Closing
Time
120
sec.
60
Generator Breaker
Maximum Opening
Time
20
sec.
Generator Breaker
Lockout Status
N/A
N/A
N/A
(22)
Description

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.
Table 27
Setpoints - Generator Desired Engine Speed Request(27)

Setpoint
Name
Min
Value
Max
Value
Units
Factory
Default
Description
The Maximum Engine Speed Range is
the maximum value above and below the
Nominal Engine Speed that the EMCP 3
will send a request for when adjusting the
speed from the control screen.
Maximum Engine Speed

Range
2000
rpm
100
Generator Nominal Output

Frequency
40
500
Hz
50
(27)
Transfer Switch
The purpose of the Transfer Switch block is to
automatically transition from utility power to standby
genset power in the case of a Loss of Utility event
or an internal request and then to automatically
transition back to utility power after the utility returns
or the external request is removed.
Table 28
Setpoints - Transfer Switch(33)

Setpoint
Name
Min Value
Max
Value
Units
Factory
Default
Generator/Utility Automatic
Transfer Enable Status
N/A
N/A
N/A
Loss of Utility Event Notification

Delay Time
30
sec.
10
Utility to Generator Transfer

Delay Time
60
sec.
Generator to Utility Transfer

Delay Time
60
min.
180
Generator to Utility Fast

Transfer Delay Time
60
sec.
10

Failure Warning Event
Threshold
240
sec.
60

Failure Shutdown Event
Threshold
240
sec.
90
Generator to Utility Transfer

Failure Warning Event
Threshold
240
sec.
60
(33)
Description
Utility Breaker Control

The purpose of Utility Breaker Control block is to
open and close the utility breaker and to generate
alarms on failure of the utility breaker to open or
close.
Table 29
Setpoints - Utility Breaker Control(34)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Utility Breaker Closing

Pulse Active Time
0.1
10.0
sec.
1.0
Utility Breaker Closing

Pulse Rest Interval
60
sec.
15
Utility Breaker Maximum

Closing Time
20
sec.
60
Utility Breaker Maximum

Opening Time
20
sec.
Utility Breaker Lockout

Status
N/A
N/A
N/A
(34)
Description
ENGINE MONITOR / PROTECT

Battery Voltage Monitor
The Battery Voltage Monitor block is used to
measure the battery supply voltage to the EMCP 3.
The EMCP3 will have the ability to monitor the
battery supply voltage based on the +BATT and
BATT.
Table 30
Setpoints - Battery Voltage Monitor(3)

Setpoint
Name
Min
Value
Max Value
Units
Factory Default

Warning Event Threshold
12
50
VDC
29.4

Warning Event Notification
Delay Time
240
sec.
30

Shutdown Event Threshold
12
50
VDC
30.0

Shutdown Event Notification
Delay Time
240
sec.
30
Low Battery Voltage

0.0
25.0
VDC
23.4
Low Battery Voltage

Delay Time
240
sec.
30

Event Threshold
30
VDC
26

Event Notification Delay
Time
240
sec.
30
(3)
Description
Crank Attempt/Successful Start Counter

The Crank Attempt/Successful Start Counter block
is used to track the number of times the engine has
been cranked and the number of times the engine
the engine has been successfully started
Table 31
Setpoints - Crank Attempt / Successful Start Counter(31)
(31)
Setpoint
Name
Min Value
Max
Value
Units
Factory Default
Description
Customer Security Password

Level to Reset Crank/Start
Counters
n/a
Password level required in order to

reset the Crank/Start Counters
Engine Coolant Temperature Monitor

The Engine Coolant Temperature Monitor block is
used to convert a raw sensor value into coolant
temperature and to detect sensor diagnostics.
Table 32
Setpoints - Engine Coolant Temperature Monitor(10)

Setpoint
Name
Min Value
Max Value
Units
Factory
Default
Description
Engine Coolant Temp

Sensor Configuration
N/A
N/A
N/A
Select Sensor or Data Link
High Engine Coolant

Temp Warning Event
Threshold
85 C (185 F)
120 C
(248 F)
deg.
100 C (215 F)
High Engine Coolant

Temp Warning Event
Notification Delay Time
30
sec.
15
High Engine Coolant

Temp Shutdown Event
Threshold
85 C (185 F)
120 C
(248 F)
deg.
120 C (225 F)
High Engine Coolant

Temp Shutdown Event
30
sec.
15
Low Engine Coolant

Temp Warning Event
Threshold
0 C ( 32F)
36 C (99 F)
Low Engine Coolant

Temp Warning Event
30
(10)
21 C (70 F)
sec.
10
Engine Oil Pressure Monitor

The Engine Oil Pressure Monitor block is used to
convert a raw sensor value into oil pressure and to
detect sensor diagnostics.
Table 33
Setpoints - Engine Oil Pressure Monitor(11)

Setpoint
Name
Min Value
Max Value
Units
Factory
Default
Description
Engine Oil
Pressure Sensor
Configuration
N/A
N/A
N/A
Select Sensor or Data Link
Low Engine Oil

Pressure Warning
Event Threshold
34 kPa (5 psi)
420 kPa (61 psi)
kPa
160 kPa (40 psi)
Low Idle Low

Engine Oil Pressure
Warning Event
Threshold
34 kPa (5 psi)
420 kPa (61 psi)
kPa
160 kPa (20 psi)
Low Engine Oil

Pressure Warning
Event Notification
Delay Time
30
sec.
10
Low Engine Oil

Pressure Shutdown
Event Threshold
34 kPa (5 psi)
420 kPa (61 psi)
kPa
34 kPa (30 psi)
Low Idle Low

Engine Oil Pressure
Shutdown Event
Threshold
34 kPa (5 psi)
420 kPa (61 psi)
kPa
160 kPa (10 psi)
Low Engine Oil

Pressure Shutdown
Event Notification
Delay Time
30
sec.
10
Low Engine Oil

Pressure Step
Speed
400
1800
rpm
1350
(11)
When the engine speed is

below this setpoint, the Low
Idle setpoint is used.
Engine Speed Monitor

The purpose of the Engine Speed Monitor block is
to determine the engine speed, in rpm, from the
Magnetic Pickup (MPU) input pins and to detect
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 all require
a LEVEL 3 password. Engine Speed Monitor
setpoints may also be changed with Electronic
Technician (ET) software without a password.
100
RENR7902
Table 34
Setpoints - Engine Speed Monitor(12)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Flywheel Teeth
95
350
N/A
350
Engine Over Speed

Shutdown Threshold
400
4330
rpm
400
Engine Under Speed

400
4330
rpm
4330
Engine Under Speed

Delay Time
0.0
20.0
sec.
2.0
Engine Under Speed

Shutdown Event Threshold
400
4330
rpm
4330
Engine Under Speed

Shutdown Event
0.0
20.0
sec.
2.0
(12)
Description
Enhanced Engine Monitor

The Enhanced Engine Monitor block provides a
method to access the engine mounted parameters
from the Primary Data Link for use in configuration
logic
Table 35
Setpoints - Enhanced Engine Monitor
(31)
(31)
Setpoint
Name
Min Value
Max
Value
Units
Factory
Default
Description
Engine Cylinder Temp Sensor

Installation Status
n/a
Choose Installed or Not installed
Number of Engine Cylinders
223
n/a

The purpose of the Service Maintenance Interval
block is to annunciate a need for engine service
based on engine hours or duration since last service,
whichever occurs first.
Table 36
Setpoints - Service Maintenance Interval(31)
(31)
Setpoint Name
Min
Value
Max Value
Units
Factory Default
Service Maintenance
Interval Hours
2000
hours
500 hours
Service Maintenance
Interval Days
365
days
180 days
Description
RENR7902
101
EVENTS
Diagnostics Configuration
The Diagnostics Configuration block is used to
configure the desired response for any diagnostic
generated by the genset control.
The Diagnostics Configuration block is subdivided
into 4 subcategories as follows: Pressures,
Temperatures, Levels, and Others. Each of the
Diagnostics Configuration subcategories is shown in
its own table.
Note: Table 37 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.
Table 37
PRESSURE Setpoints - Diagnostics Configuration(15)

Setpoint
Name
Warning
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Breaker
Trip #1
Breaker
Trip #2
Air Filter
Differential
Pressure Sensor
Diagnostic
Response Config
Engine Oil
Pressure Sensor
Diagnostic
Response Config
Fire Extinguisher
Pressure Sensor
Diagnostic
Response Config
Fuel Filter
Differential
Pressure Sensor
Diagnostic
Response Config
Engine Oil Filter

Differential
Pressure Sensor
Diagnostic
Response Config
Starting Air
Pressure Sensor
Diagnostic
Response Config
(15)
Loss of
Utility
FPT
Active
Only
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.

setpoint in the TEMPERATURE category. The
options that are available for each setpoint are
designated by an X in the option column.
102
RENR7902
Table 38
TEMPERATURE Setpoints - Diagnostics Configuration(15)

Setpoint
Name
Warning
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Ambient Air
Temp Sensor
Diagnostic
Response
Config
Engine
Coolant
Temp Sensor
Diagnostic
Response
Config
Engine Oil
Temp Sensor
Diagnostic
Response
Config
Exhaust
Temp Sensor
Diagnostic
Response
Config
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
Right Exhaust
Temp Sensor
Diagnostic
Response
Config
Left Exhaust
Temp Sensor
Diagnostic
Response
Config
Generator
Bearing #1
Temp Sensor
Diagnostic
Response
Config
(15)
FPT
Active
Only

setpoint in the LEVEL category. The options that
are available for each setpoint are designated by an
X in the option column.
RENR7902
103
Table 39
LEVEL Setpoints - Diagnostics Configuration(15)

Setpoint
Name
Warning
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Engine
Coolant
Level Sensor
Diagnostic
Response
Config
Engine Oil
Level Sensor
Diagnostic
Response
Config
Fuel Level
Sensor
Diagnostic
Response
Config
External Tank
Fuel Level
Sensor
Diagnostic
Response
Config
(15)
Breaker
Trip #1
Breaker
Trip #2
Loss of
Utility
FPT
Active
Only

setpoint in the OTHER setpoints category. The
options that are available for each setpoint are
designated by an X in the option column.
104
RENR7902
Table 40
OTHER Setpoints - Diagnostics Configuration(15)

Setpoint
Name
Warning
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Accessory
Data Link
Diagnostic
Response
Config
Digital Output
#1 Diagnostic
Response
Config
Digital Output
#2 Diagnostic
Response
Config
Engine Speed
Sensor
Diagnostic
Response
Config
Breaker
Trip #1
Breaker
Trip #2
X(16)
Loss of
Utility
Generator
Output
Sensing
System
Diagnostic
Response
Config
Primary
Data Link
Diagnostic
Response
Config
SCADA
Data Link
Diagnostic
Response
Config
FPT
Active
Only
(15)
(16) Setpoint Is Not Adjustable
Engine Protection Events Configuration

The Engine Protection Events Configuration block
is used to configure the desired response for any
engine protection event generated by the genset
control.
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
its own table.

PRESSURE setpoint. The options that are
available for each setpoint are designated by an X
in the option column.
Table 41
PRESSURE Setpoints - Engine Protection Events Configuration(17)

Setpoint
Name
Warning
Audible
Alert
High Air Filter

Differential
Pressure
Warning Event
Response
Config
High Air Filter

Differential
Pressure
Shutdown
Event
Response
Config
Low Air Filter
Differential
Pressure
Warning Event
Response
Config
Low Air Filter

Differential
Pressure
Shutdown
Event
Response
Config
Low Engine
Oil Pressure
Warning Event
Response
Config
Low Engine
Oil Pressure
Shutdown
Event
Response
Config
High Fuel Filter
Differential
Pressure
Warning Event
Response
Config
High Fuel Filter
Differential
Pressure
Shutdown
Event
Response
Config
Low Fuel Filter
Differential
Pressure
Warning Event
Response
Config
Hard
Shutdown
Soft
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker Trip
#2
FPT
Active
Only
(continued)
(Table 41, contd)

Setpoint
Name
Warning
Low Fuel Filter

Differential
Pressure
Shutdown
Event
Response
Config
High Engine
Oil Filter
Differential
Pressure
Warning Event
Response
Config
High Engine
Oil Filter
Differential
Pressure
Shutdown
Event
Response
Config
Low Engine
Oil Filter
Differential
Pressure
Warning Event
Response
Config
High Starting
Air Pressure
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Low Engine
Oil Filter
Differential
Pressure
Shutdown
Event
Response
Config
High Starting
Air Pressure
Warning Event
Response
Config
Audible
Alert
Loss
of
Utility
Breaker
Trip #1
Breaker Trip
#2
FPT
Active
Only
(continued)
(Table 41, contd)

Setpoint
Name
Warning
Audible
Alert
Low Starting
Air Pressure
Warning Event
Response
Config
Low Starting
Air Pressure
Shutdown
Event
Response
Config
(17)
Soft
Shutdown
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker Trip
#2
FPT
Active
Only
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 42 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 42
TEMPERATURE Setpoints - Engine Protection Events Configuration(17)

Setpoint
Name
Warning
Audible
Alert
High Engine
Coolant Temp
Warning Event
Response
Config
High Engine
Coolant Temp
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Low Engine
Coolant Temp
Warning Event
Response
Config
High Engine
Oil Temp
Warning Event
Response
Config
High Engine
Oil Temp
Shutdown
Event
Response
Config
Active
Only
(continued)
(Table 42, contd)

Setpoint
Name
Warning
Audible
Alert
Low Engine
Oil Temp
Warning Event
Response
Config
Low Engine
Oil Temp
Shutdown
Event
Response
Config
High Exhaust
Temp Warning
Event
Response
Config
High Exhaust
Temp
Shutdown
Event
Response
Config
Low Exhaust
Temp Warning
Event
Response
Config
Low Exhaust
Temp
Shutdown
Event
Response
Config
High Right
Exhaust Temp
Warning Event
Response
Config
High Right
Exhaust Temp
Shutdown
Event
Response
Config
Low Right
Exhaust Temp
Warning Event
Response
Config
Hard
Shutdown
Soft
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
(Table 42, contd)

Setpoint
Name
Warning
Low Right
Exhaust Temp
Shutdown
Event
Response
Config
High Left
Exhaust Temp
Warning Event
Response
Config
High Left
Exhaust Temp
Shutdown
Event
Response
Config
Low Left
Exhaust Temp
Warning Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss of
Utility
Low Left
Exhaust Temp
Shutdown
Event
Response
Config
(17)
Audible
Alert
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
Table 43 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 43
LEVEL Setpoints - Engine Protection Events Configuration(17)

Setpoint
Name
Warning
Audible
Alert
High Engine
Coolant Level
Warning Event
Response
Config
High Engine
Coolant Level
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
110
RENR7902
(Table 43, contd)

Setpoint
Name
Warning
Audible
Alert
Low Engine
Coolant Level
Warning Event
Response
Config
Low Engine
Coolant Level
Shutdown
Event
Response
Config
High Engine
Oil Level
Warning Event
Response
Config
High Engine
Oil Level
Shutdown
Event
Response
Config
Low Engine
Oil Level
Warning Event
Response
Config
Low Engine
Oil Level
Shutdown
Event
Response
Config
High Fuel
Level Warning
Event
Response
Config
High Fuel
Level
Shutdown
Event
Response
Config
Low Fuel
Level Warning
Event
Response
Config
Hard
Shutdown
Soft
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
RENR7902
111
(Table 43, contd)

Setpoint
Name
Warning
Low Fuel
Level
Shutdown
Event
Response
Config
External
Tank High
Fuel Level
Warning Event
Response
Config
External
Tank High
Fuel Level
Shutdown
Event
Response
Config
External
Tank Low
Fuel Level
Warning Event
Response
Config
External
Tank Low
Fuel Level
Shutdown
Event
Response
Config
(17)
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
Table 44 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.
112
RENR7902
Table 44
OTHER Setpoints - Engine Protection Events Configuration(17)

Setpoint
Name
Warning
Audible
Alert
Air Damper
Closed Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Emergency
Stop
Shutdown
Event
Response
Config
X(16)
Engine Failure
to Start
Shutdown
Event
Response
Config
X(16)
Unexpected
Engine
Shutdown
Event
Response
Config
X(16)
Engine Over
Speed
Shutdown
Event
Response
Config
X(16)
Engine Under
Speed
Warning Event
Response
Config
Engine Under
Speed
Shutdown
Event
Response
Config
Fuel Tank
Leak Event
Response
Config
Service
Maintenance
Interval
Warning Event
Response
Config
(17)
Active
Only
RENR7902
113
Generator Protection Events Configuration

The Generator Protection Events Configuration block
is used to configure the desired response for any
control.
setpoint number. The options that are available for
column.
Table 45
Setpoints - Generator Protection Events Configuration(18)

Setpoint
Name
Warning
Audible
Alert
High
Generator
Bearing #1
Temp Warning
Event
Response
Config
High
Generator
Bearing
#1 Temp
Shutdown
Event
Response
Config
Low
Generator
Bearing #1
Temp Warning
Event
Response
Config
Low
Generator
Bearing
#1 Temp
Shutdown
Event
Response
Config
Generator
Over Current
(Amp)
Warning
Event
Response
Config
Generator
Over Current
(Amp)
Shutdown
Event
Response
Config
Hard
Loss of
Shutdown Utility
Soft
Shutdown
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
114
RENR7902
(Table 45, contd)

Setpoint
Name
Warning
Audible
Alert
Generator
Over
Frequency
Warning
Event
Response
Config
Generator
Over
Frequency
Shutdown
Event
Response
Config
Generator
Under
Frequency
Warning
Event
Response
Config
Generator
Under
Frequency
Shutdown
Event
Response
Config
Generator
Reverse
Power
Warning
Event
Response
Config
Generator
Reverse
Power
Shutdown
Event
Response
Config
Generator
Over Voltage
Warning
Event
Response
Config
Generator
Over Voltage
Shutdown
Event
Response
Config
Hard
Loss of
Shutdown Utility
Soft
Shutdown
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
RENR7902
115
(Table 45, contd)

Setpoint
Name
Warning
Audible
Alert
Generator
Under Voltage
Warning
Event
Response
Config
Generator
Under Voltage
Shutdown
Event
Response
Config
(18)
Soft
Shutdown
Hard
Loss of
Shutdown Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
Each setpoint in the Generator Protection Events Configuration block is used in order to program a system response to the associated
Other System Events Configuration

The Other System Events Configuration block is
used to configure the desired response for any
control.
setpoint number. The options that are available for
column.
Table 46
Setpoints - Other System Events Configuration(19)
Setpoint
Name
Warning
Audible
Alert
High Ambient
Air Temp
Warning Event
Response
Config
High Ambient
Air Temp
Shutdown
Event
Response
Config
Low Ambient
Air Temp
Warning Event
Response
Config
Low Ambient
Air Temp
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
116
RENR7902
(Table 46, contd)
Warning
Audible
Alert
Automatic
Transfer
Switch in
Normal
Position Event
Response
Config
Automatic
Transfer
Switch in
Emergency
Position Event
Response
Config
Battery
Charger
Failure
Diagnostic
Response
Config
High Battery
Voltage
Warning Event
Response
Config
High Battery
Voltage
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss
of
Utility
Setpoint
Name
Breaker
Trip #1
Breaker
Trip #2
FPT
Low Battery
Voltage
Warning Event
Response
Config
Low Battery
Charging
System
Voltage
Warning Event
Response
Config
Generator
Breaker
Failure to
Open Event
Response
Config
Active
Only
(continued)
RENR7902
117
(Table 46, contd)
Soft
Shutdown
Hard
Shutdown
Loss
of
Utility
Setpoint
Name
Warning
Audible
Alert
Generator
Breaker
Failure to
Close Event
Response
Config
Generator
Breaker
Open Event
Response
Config
Generator
Breaker
Closed Event
Response
Config
Utility Breaker
Failure to
Open Event
Response
Config
Utility Breaker
Failure to
Close Event
Response
Config
Utility Breaker
Open Event
Response
Config
Utility Breaker
Closed Event
Response
Config
Emergency
Shutdown
Override
Mode Active
Warning Event
Response
Config
X(16)
Engine in
Cooldown
Event
Response
Config
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
118
RENR7902
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
Engine SpeedGenerator
Output
Frequency
Mismatch
Warning Event
Response
Config
Event Input
Function
#1 High
Warning Event
Response
Config
Event Input
Function
#1 High
Shutdown
Event
Response
Config
Event Input
Function
#1 Low
Warning Event
Response
Config
Breaker
Trip #2
Event Input
Function #1
Low Shutdown
Event
Response
Config
Event Input
Function
#1 Event
Response
Config
Event Input
Function
#2 High
Warning Event
Response
Config
Event Input
Function
#2 High
Shutdown
Event
Response
Config
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Soft
Shutdown
FPT
Active
Only
(continued)
RENR7902
119
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
Event Input
Function
#2 Low
Warning Event
Response
Config
Event Input
Function #2
Low Shutdown
Event
Response
Config
Event Input
Function
#2 Event
Response
Config
Event Input
Function
#3 High
Warning Event
Response
Config
Event Input
Function
#3 High
Shutdown
Event
Response
Config
Event Input
Function
#3 Low
Warning Event
Response
Config
Event Input
Function #3
Low Shutdown
Event
Response
Config
Event Input
Function
#3 Event
Response
Config
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Soft
Shutdown
Active
Only
(continued)
120
RENR7902
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
Event Input
Function
#4 High
Warning Event
Response
Config
Event Input
Function
#4 High
Shutdown
Event
Response
Config
Event Input
Function
#4 Low
Warning Event
Response
Config
Event Input
Function #4
Low Shutdown
Event
Response
Config
Event Input
Function
#4 Event
Response
Config
Event Input
Function
#5 High
Warning Event
Response
Config
Event Input
Function
#5 Low
Warning Event
Response
Config
Hard
Shutdown
Event Input
Function
#5 High
Shutdown
Event
Response
Config
Soft
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
RENR7902
121
(Table 46, contd)
Setpoint
Name
Warning
Event Input
Function #5
Low Shutdown
Event
Response
Config
Event Input
Function
#6 High
Warning Event
Response
Config
Event Input
Function
#6 High
Shutdown
Event
Response
Config
Event Input
Function
#6 Low
Warning Event
Response
Config
Audible
Alert
Soft
Shutdown
Hard
Shutdown
Event Input
Function #6
Low Shutdown
Event
Response
Config
Event Input
Function
#6 Event
Response
Config
Event Input
Function
#7 High
Warning Event
Response
Config
Event Input
Function
#7 High
Shutdown
Event
Response
Config
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(continued)
122
RENR7902
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
Event Input
Function
#7 Low
Warning Event
Response
Config
Event Input
Function #7
Low Shutdown
Event
Response
Config
Event Input
Function
#7 Event
Response
Config
Event Input
Function
#8 High
Warning Event
Response
Config
Event Input
Function
#8 High
Shutdown
Event
Response
Config
Event Input
Function
#8 Low
Warning Event
Response
Config
Event Input
Function #8
Low Shutdown
Event
Response
Config
Event Input
Function
#8 Event
Response
Config
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Soft
Shutdown
Active
Only
(continued)
RENR7902
123
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
High Fire
Extinguisher
Pressure
Warning Event
Response
Config
High Fire
Extinguisher
Pressure
Shutdown
Event
Response
Config
Low Fire
Extinguisher
Pressure
Warning Event
Response
Config
Low Fire
Extinguisher
Pressure
Shutdown
Event
Response
Config
Soft
Shutdown
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
Generator
Control Not
in Automatic
Warning Event
Response
Config
Loss of
Utility Event
Response
Config
Utility to
Generator
Transfer
Failure
Warning Event
Response
Config
(continued)
124
RENR7902
(Table 46, contd)
Setpoint
Name
Warning
Audible
Alert
Soft
Shutdown
Utility to
Generator
Transfer
Failure
Shutdown
Event
Response
Config
Generator to
Utility Transfer
Failure
Warning Event
Response
Config
Hard
Shutdown
Loss
of
Utility
Breaker
Trip #1
Breaker
Trip #2
FPT
Active
Only
(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.
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.
Table 47
Setpoints - Event Input Functions(13)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Event Input
Function #NN Active
State Configuration
N/A
N/A
N/A
N/A
Settings for event input

functions #1- #8
Event Input
Function #NN
Event Notification
Delay Time
250
sec.

functions #1- #8
Event Input
Function #NN
Suspect Parameter
Number
N/A
N/A
N/A
107

functions #1- #8
Event Input
Function #NN
Failure Mode
Identifier
20
N/A
2.0

functions #1- #8
(13)
Event Output Functions

The Event Output function block provides a method
to access the active status of an event for use in
configuration logic
RENR7902
125
Table 48
Setpoints - Event Output Functions(14)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Event Output
Function #NN
Trigger Condition
N/A
N/A
N/A
Settings for event output

functions #1- #30
Event Output
Function #NN
Suspect Parameter
Number
N/A
N/A
N/A
100
Settings for event output

functions #1- #30
(14)
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 49
Setpoints - Event System(20)

Setpoint
Name
Min Value
Event Warning
Condition
Response Auto
Reset Enable
Status
Max Value
Units
Factory
Default
N/A
N/A
Event Audible
Alert Response
Auto Reset
Enable Status
N/A
N/A
N/A
Event Loss of
Utility Response
Auto Reset
Enable Status
N/A
N/A
N/A
Event Breaker #1
Trip Response
Auto Reset
Enable Status
N/A
N/A
N/A
Event Breaker #2
Trip Response
Auto Reset
Enable Status
N/A
N/A
N/A
(20)
Description
GEN MONITOR / PROTECT
Rear bearing temperature
Enhanced Generator Monitor
Winding #1 temperature
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
Table 50
Setpoints - Enhanced Generator Monitor(31)

Setpoint
Name
Min Value
Max Value
Generator Winding
Temp Sensor
Installation Status
Number of
Generator Bearing
Temp Sensors
(31)
Units
Factory
Default
Description
Not Installed
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
Table 51
Setpoints - Generator AC Monitor(21)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Generator Configurations can be
Star/Wye, Delta/3 Wire, Delta/4
Wire, Single Phase 2 Wire,
Single Phase 3 Wire
Generator
Connection
Configuration
N/A
N/A
N/A
Star/Wye
Generator
Potential
Transformer
Primary Winding
Rating
50000
Generator
Potential
Transformer
Secondary
Winding Rating
150
Generator Current
Transformer
Primary Winding
Rating
7000
75
Generator Current
Transformer
Secondary
Winding Rating
Number of
Generator Poles
200
N/A
Generator Rated
Frequency
N/A
N/A
Hz
60
Generator Rated
Voltage
100
50000
100
Generator Rated
Power
50000
kW
Generator Rated
Apparent Power
50000
kVA
(21)
Can only be set to 1 or 5
Frequency can be set to 50Hz,

60Hz or 400Hz
Generator AC Power Monitor
Total kVAr hours imported
The Generator AC Power Monitor Block measures

all generator power quantities following generator
values will be monitored:
Percent kVAr output
Per phase kW (for star/wye configurations)

Total kW
Total kW hours imported
Total kW hours exported
Percent kW output
Per phase kVAr (for star/wye confutations)
Total kVAr
Total kVAr hours imported
Per phase kVA (for star/wye confutations)

Total kVA
Percent kVA output
Per phase genset output Power Factor with
lead/lag indication (for star/wye confutations)
Average output Power Factor with lead/lag

indication
Note: Per phase quantities (kW, kVAr, KVA, and

Power Factor) will be monitored for 3-phase, 4-wire
star-connected configurations)
Table 52
Setpoints - Generator AC Power Monitor(31)

Setpoint
Name
Min Value
Max Value
Customer Password
Security Level to Reset
Generator Energy
Meters
(31)
Units
Factory
Default
Description

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 53
Setpoints - Generator Over Current(23)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Generator Definite
Time Over Current
(Amp) Warning
Event Percentage
Threshold
80
130
100
Threshold for the Over Current

Warning
Generator Inverse
Time Over Current
(Amp) Shutdown
Event Time
Multiplier
0.05
10.00
sec.
.27
Time multiplier setpoint
Generator Definite
Time Over Current
(Amp) Shutdown
Event Percentage
Threshold
100
300
125
If current is above this setpoint

value for the specified time
(setpoint #4) there will be an over
current shutdown.
Generator Definite
Time Over Current
(Amp) Shutdown
Event Notification
Delay Time
0.1
20.0
sec.
10
Time delay for setpoint #3
(23)
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.
Table 54
Setpoints - Generator Over / Under Frequency(24)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Generator Over
Frequency
Warning Event
Percentage
Threshold
80
120
105
Generator Over
Frequency
Warning Event
Notification Delay
Time
120
sec.
10
Generator Over
Frequency
Shutdown Event
Percentage
Threshold
80.0
120
110
Generator Over
Frequency
Shutdown Event
Notification Delay
Time
120
sec.
Generator Under
Frequency
Warning Event
Percentage
Threshold
80.0
120.0
95.0
Generator Under
Frequency
Warning Event
Notification Delay
Time
120
sec.
10
Generator Under
Frequency
Shutdown Event
Percentage
Threshold
80.0
120.0
90.0
Generator Under
Frequency
Shutdown Event
Notification Delay
Time
120
sec.
(24)
Description
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.
130
RENR7902
Table 55
Setpoints - Generator Over / Under Voltage(25)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Generator Over
Voltage Warning
Event Percentage
Threshold
100
125
105
Generator Over
Voltage Warning
Event Notification
Delay Time
120
sec.
10
Generator Over
Voltage Shutdown
Event Percentage
Threshold
100
125
110
Generator Over
Voltage Shutdown
Event Notification
Delay Time
120
sec.
Generator Under
Voltage Warning
Event Percentage
Threshold
60
100
95.0
Generator Under
Voltage Warning
Event Notification
Delay Time
120
sec.
10
Generator Under
Voltage Shutdown
Event Threshold
60
100
90.0
Generator Under
Voltage Shutdown
Event Notification
Delay Time
120
sec.
(25)
Description

The Generator Reverse Power block detects a
reverse power condition that persists for a duration
above a programmed level.
RENR7902
131
Table 56
Setpoints - Generator Reverse Power(26)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Generator
Reverse Power
Warning Event
Percentage
Threshold
20
Generator
Reverse Power
Warning Event
Notification Delay
Time
30
sec.
10
Generator
Reverse Power
Shutdown Event
Percentage
Threshold
20
10
Generator
Reverse Power
Shutdown Event
Notification Delay
Time
30
sec.
10
(26)
Description
DISCRETE INPUT/OUTPUT (I/O)

Digital Inputs
The Digital Input block is used to bring on/off
information such as switch closures to the EMCP 3.
Note: There are 8 digital inputs on EMCP 3.2 and
EMCP3.3. There are 6 digital inputs on EMCP 3.1.
132
RENR7902
Table 57
Setpoints - Digital Inputs(5)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
E-STOP
Active Low
Active High
N/A
Active Low
Activating the E-STOP input

will cause the generator set to
stop immediately.
Active Low
Setpoint allows for starting

and stopping the genset from
a remote location.
If input is active and the engine
mode switch is in AUTO, the
engine will attempt to start and run.
Once the input becomes in-active,
the engine will enter into cooldown
(if programmed) and then STOP.
REMOTE
INITIATE
(5)
(6)
Active Low
Active High
N/A
Digital #3(6)
Active Low
Active High
N/A
Active Low
Digital #4(6)
Active Low
Active High
N/A
Active Low
Digital #5(6)
Active Low
Active High
N/A
Active Low
Digital #6(6)
Active Low
Active High
N/A
Active Low
Digital #7
(6)
Active Low
Active High
N/A
Active Low
Digital #8(6)
Active Low
Active High
N/A
Active Low
The inputs can be set to

PRESSURES
Engine Oil Pressure
Fire Extinguisher Pressure Fuel
Filter Differential Pressure Oil
Filter Differential Pressure
TEMPERATURES
Ambient Air Temp
Engine Coolant Temp
Engine Oil Temp
Exhaust Temp
LEVELS Engine
Coolant Level Engine
Oil Level
Fuel Level External Tank
Fuel Level OTHER
Air Damper Closed
Fuel Leak Detected
Custom Event
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.
Digital Outputs
The Digital Output block is used in order to convey
on/off information from the EMCP 3 for purposes
such as operating relays, solenoids and indicator
lamps.
There are 2 digital outputs on EMCP 3.3. There is
1 digital output on EMCP 3.2. There are no digital
outputs on EMCP 3.1
RENR7902
133
Table 58
Setpoints - Digital Outputs(7)

Setpoint
Name
Min Value
Max
Value
Units
Factory Default
Digital Output #1 Active

State Configuration
N/A
N/A
N/A
Digital Output #2 Active

State Configuration
N/A
N/A
N/A
(7)
Description
Relay Outputs
The Relay Output block is used in order to convey
on/off information from the EMCP 3 for purposes
such as operating relays, solenoids and indicator
lamps.
There are 8 relay outputs on EMCP 3.2 and EMCP
3.3. Six of the EMCP 3.2 and EMCP 3.3outputs
have normally open contacts and 2 outputs have
normally open and normally closed contacts.
There are 6 normally open relay outputs on EMCP
3.1. There are no normally closed outputs on
theEMCP 3.1.
134
RENR7902
Table 59
Setpoints - Relay Outputs(29)

Setpoint
Name
Min Value
Max Value
Units
Factory
Default
Description
Relay Output
#1 Active State
Configuration
N/A
N/A
N/A
Relay Output #1 is always configured

as the Starter Motor Relay
Relay Output
#2 Active State
Configuration
N/A
N/A
N/A
Relay #2 is always configured as

the Fuel Control Relay
Relay Output #3 is controlled by

Digital Selector #1
The output can be set to Active
High or Active Low
Relay Output
#3 Active State
Configuration
N/A
N/A
Relay Output
#4 Active State
Configuration
N/A
N/A
N/A

Digital Selector #2
High or Active Low
Relay Output
#5 Active State
Configuration
N/A
N/A
N/A

Digital Selector #3
High or Active Low

Digital Selector #4
High or Active Low
Relay Output
#6 Active State
Configuration
(29)
N/A
N/A
N/A
N/A
Relay Output
#7 Active State
Configuration
N/A
N/A
N/A

Digital Selector #5
High or Active Low
Relay Output
#8 Active State
Configuration
N/A
N/A
N/A

Digital Selector #6
High or Active Low
Spare Analog Input

The Spare Analog Input block is used to convert a
resistive sender value to engineering units, detect
sender diagnostics, and detect a high or low
condition on the spare sender input.
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.
RENR7902
135
Table 60
Setpoints - Spare Analog Input(29)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Spare Analog
Input Enable
Status
N/A
N/A
N/A
Enabled
Spare Analog
Input Type
Configuration
N/A
N/A
N/A
Temperature
Spare Analog
Input Suspect
Parameter
Number(SPN)
N/A
N/A
N/A
107
Spare Analog
Input High Level
Warning Event
Threshold
100
Spare Analog
Input High
Temperature
Warning Event
Threshold
-273
1,735
Deg.
C
-273
Spare Analog
Input High
Pressure Warning
Event Threshold
-250
10,000
kPa
-250
Spare Analog
Input High
Warning Event
Notification Delay
Time
60
sec.
Spare Analog
Input High Level
Shutdown Event
Threshold
100
Spare Analog
Input High
Temperature
Shutdown Event
Threshold
-273
1,735
Deg.
C
-273
Spare Analog
Input High
Pressure
Shutdown Event
Threshold
-250
10,000
kPa
-250
Spare Analog
Input High
Shutdown Event
Notification Delay
Time
60
sec.
Spare Analog
Input Low Level
Warning Event
Threshold
100
Description
Can be set to Temperature,

Pressure, or Level .
(continued)
136
RENR7902
(Table 60, contd)
Setpoints - Spare Analog Input(29)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Spare Analog
Input Low
Temperature
Warning Event
Threshold
-273
1735
Deg.
C
-273
Spare Analog
Input Low Level
Warning Event
Threshold
-250
10000
kPa
-250
Spare Analog
Input Low Warning
Event Notification
Delay Time
60
sec.
Spare Analog
Input Low Level
Shutdown Event
Threshold
100
Spare Analog
Input Low
Temperature
Shutdown Event
Threshold
-273
1735
Deg.
C
-273
Spare Analog
Input Low
Pressure
Shutdown Event
Threshold
-250
10000
kPa
-250
Spare Analog
Input Low
Shutdown Event
Notification Delay
Time
60
sec.
(29)
Description
NETWORK
Data Link - SCADA
The SCADA Data Link block is used for
communication with a System Control and Data
Acquisition (SCADA) and 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.
RENR7902
137
Table 61
Setpoints - Data Link - SCADA(4)

Setpoint
Name
Min Value
Max
Value
Units
Factory Default
SCADA Data Link

Baud Rate
N/A
N/A
N/A
SCADA Data Link Parity
N/A
N/A
N/A
SCADA Data Link

Slave Address
247
N/A
SCADA Data Link

Access Password
0xfffff
N/A
SCADA Data Link

Connection Time-out
Interval
0.1
3600.0
sec.
30
RS485 Bias Resistor

Enable Status
N/A
N/A
N/A
(4)
Description
OTHER
Digital Selectors
The Digital Selector block is used in order to
determine what EVENTS or STATUS will cause
each of the relays to activate.
Table 62
Setpoints - Digital Selectors(8)

Setpoint
Name
Digital Selector
#1 Source
Configuration
Digital Selector
#2 Source
Configuration
Min Value
Max Value
Units
Factory Default
Description
Use Input #1
Digital Selector #1 controls

Relay Output #3
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Use Input #4

Relay Output #4
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(continued)
138
RENR7902
(Table 62, contd)

Setpoint
Name
Digital Selector
#3 Source
Configuration
Digital Selector
#4 Source
Configuration
Digital Selector
#5 Source
Configuration
Digital Selector
#6 Source
Configuration
Min Value
Max Value
Units
Factory Default
Description
Use Input #4

Relay Output #5
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Disabled

Relay Output #6
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Use Input #5

Relay Output #7
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Use Input #5

Relay Output #8
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
(continued)
RENR7902
139
(Table 62, contd)

Setpoint
Name
Min Value
Max Value
Units
Digital Selector
#7 Source
Configuration
Digital Selector
#8 Source
Configuration
(8)
Factory Default
Description
Use Input #1

Digital Output #1
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
Disabled

Digital Output #2
Config Options are:
Disabled
Use Input #1
Use Input #2
Use Input #3
Use Input #4
Use Input #5
Use Data Link Input
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.
Table 63
Setpoints - Electronic Control Module Reduced Power Mode(9)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Electronic Control
Module Reduced
Power Mode Enable
Status
N/A
N/A
N/A
Enabled
Allows control to go into reduced

power mode
Electronic Control
Module Reduced
Power Mode Delay
Time
120
min.
30
(9)
Remote Callback
Remote Callback is used in gensets with a modem
connection in order to allow the genset control to dial
a programmed telephone number in response to a
fault condition. A receiving PC can then query the
nature of the fault.
140
RENR7902
Table 64
Setpoints - Remote Callback(30)

Setpoint
Name
Min Value
Max Value
Units
Factory Default
Description
Remote Dial Enable

Status
N/A
N/A
N/A
Setpoints for relay Outputs

#1 - #8
Remote Dial
Command
Configuration
N/A
N/A
N/A
Setpoints for relay Outputs

#1 - #8
(30)
i01988180
Typical Generator
Abbreviations
SMCS Code: 4490
A Ammeter
ACT Actuator
CAR Custom Alarm Relay

CB Circuit Breaker
CCM Customer Communication Module
CDM Engine Cooldown Timer Module
CIM Customer Interface Module
CT Current Transformer
ADS Engine Combustion Air Damper Position

Switch
CTR Crank Termination Relay
AFCR Auxiliary Fuel Control Valve
D Diode
ALM Alarm Module
DCV DC Voltmeter
ALS Alarm Silence Push Button
DS Disconnect Switch
ALT Alternator
ECLC Engine Coolant Loss Sensor Connector
AR Arming Relay
ECLS Engine Coolant Loss Sensor
ASOS Air Shutoff Solenoid
ECS Engine Control Switch
ASR Air Shutoff Relay
ECTS Engine Coolant Temperature Sensor
ASSV Air Start Solenoid Valve
EFCR Emergency Fuel Control Relay
ATB AC Transformer Box
EFL Emergency Fuel Light
AUX Auxiliary Terminal Strip
EG Electronic Governor (Speed Sensing)
AUXREL Auxiliary Relay (Crank Termination)
EGA Electronic Governor Actuator
AWG American Wire Gauge
EGR Electronic Governor Relay
BATT Battery
EHC Ether Hold-In Coil
BCF Battery Charger Failure Switch
EHS Ether Hold-In Switch
BTB Bus Transformer Box
ENFR Engine Failure Relay
C Common
EOTC Engine Oil Temperature Sensor Connector
CAM Custom Alarm Module
EOTS Engine Oil Temperature Sensor
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
FCTM Fuel Control Timer Module
OPL Oil Pressure Light
FRB Fuel Rupture Basin
OSL Overspeed Light
FS Fuel Solenoid
OSR Oil Step Relay
FSOS Fuel Shutoff Solenoid
OVR Overvoltage Relay
GFR Generator Fault Relay
PEEC Programmable Electronic Engine Control
GOL Generator On Load
PL Panel Illumination Light
GOV Governor
PLS Panel Light Switch
GPHI Ground Post (High Voltage)
POS Positive
GPLO Ground Post (Low Voltage)
POT Potentiometer
GS Governor Switch
PP Prelube Pump
GSC Generator Set Control
PPMS Prelube Pump Magnetic Switch
GSM Governor Synchronizing Motor
PPPS Prelube Pump Oil Pressure Switch
GSOV Gas Shutoff Valve
PR Preregulator
HZ Frequency Meter
PS Pinion Solenoid
KWR Kilowatt Level Relay
PWM Electrical Converter (Pulse Width Modulated)
IC Remote Start/Stop Initiate Contact
RAN Remote Annunciator
L Load Leads
RDM Relay Driver Module
LFL Low Fuel Level Light
RPL Reverse Power Light
LFLAS Low Fuel Level Alarm Switch
RPR Reverse Power Relay
LFS Latching Fuel Control Solenoid
RPSR Reverse Power Slave Relay
LOLAS Low Oil Level Alarm Switch
RR Run Relay
LWLAS Low Water Level Alarm Switch
SASV Start Aid Solenoid Valve
LWTL Low Water Temperature Light
SATS Start Aid Temperature Switch
MAN Manual
SAS Starting Aid Switch
SEC Second
Reference: For additional information about the

electrical system, refer to the Service Manual
Electrical System Schematic for the genset that is
being serviced.
SHTC Circuit Breaker Shunt Trip Coil

SIG Signal
SL Synchronizing Light
SLM Synchronizing Light Module
SLR Synchronizing Light Resistor
SM Starting Motor
SMMS Starting Motor Magnetic Switch
SMR Starting Motor Relay
SP Speed Adjust Potentiometer
SPM Synchronizing Parallel Module
SR Slave Relay
SS Synchronizing Switch
T Generator Line Leads
TD Time Delay Relay
TSC Transfer Switch Position Indicating Contact
V AC Voltmeter
VAR Voltage Adjust Rheostat
VR Voltage Regulator
WT Water Temperature
WTG Water Temperature Gauge
WTL Water Temperature Light
XDUCER Transducer
Z Zener Diode
i02148840
ECM Connections
SMCS Code: 4490; 7566
The following drawings are simplified electrical
schematics of the Electronic Control Module (ECM)
for the Generator Set. The schematics are correct
but the schematics do not show all possible harness
connectors.
Illustration 19
g01090088
Illustration 20
g01090992
Illustration 21
g01090993
146
Index Section
RENR7902
Index
A
Analog Input Circuit Fault ...................................... 74
Annunciator Module............................................... 21
Adding Optional Remote Annunciator................ 25
Basic Operation ................................................. 22
Configuration...................................................... 22
General Information ........................................... 21
C
Charging System ................................................... 75
Component Location ............................................... 6
D
Data Link ............................................................... 26
Accessory Data Link - J1939 (CAN 2) ............... 27
Data Links .......................................................... 26
Primary Data Link - J1939 (CAN 1) ................... 26
System Control and Data Acquisition (SCADA)
Data Link - Modbus RS-485 ............................. 27
Data Link Circuit Fault ........................................... 77
Diagnostic Capabilities .......................................... 42
The Caterpillar Electronic Technician (ET)......... 42
Diagnostic System Procedures ............................. 54
Diagnostic Trouble Code List ................................ 43
Digital Input Circuit Fault ....................................... 78
Digital Input Programming ..................................... 33
Programming the Active State of the Digital
Input ................................................................. 33
Programming the Event Input Functions............ 33
Digital Output Circuit Fault..................................... 79
Digital Output Programming .................................. 34
Programming the Active State of the Digital
Output .............................................................. 34
Programming the Digital Selectors .................... 34
Discrete Input/Output Module................................ 14
Configurability .................................................... 17
Inputs ................................................................. 14
Outputs .............................................................. 16
Specifications..................................................... 17
E
ECM Connections................................................ 142
Electrical Connector - Inspect................................ 85
Electronic Control Module (Engine) (EUI Engines
Only) .................................................................... 27
Electronic Control Module (Generator Set) ............. 8
Alarm Indicators ................................................... 9
Digital Inputs ........................................................ 9
Navigation Keys ................................................... 8
Electronic Control Module (Generator Set) Configure ............................................................. 89

Initial Setup ........................................................ 89
Programming the Display Preferences .............. 91
Programming The Setpoints .............................. 92
SETPOINT TABLES .......................................... 92
Setpoints ............................................................ 90
Program ............................................................... 89
Electronic Control Module (Generator Set) Replace................................................................ 89
Replacement Procedure .................................... 89
Engine Cooldown Warning .................................... 54
Engine Overcrank Warning ................................... 54
Engine Overspeed Warning .................................. 56
Engine Speed Circuit Fault.................................... 80
Engine Speed Warning.......................................... 56
Engine Underspeed Warning ................................ 59
Event Resetting ..................................................... 31
Event Viewing ........................................................ 30
External Potential Transformer Connections ......... 86
G
General Information........................................... 4, 40
Generator Control Not in Automatic Warning ........ 61
Generator Output Sensing Circuit Fault ................ 61
Generator Overcurrent Warning ............................ 61
Generator Overfrequency Warning ....................... 62
Generator Overvoltage Warning............................ 65
Generator Reverse Power Warning ...................... 66
Generator Underfrequency Warning ..................... 68
Generator Undervoltage Warning.......................... 71
I
Important Safety Information ................................... 2
Introduction............................................................ 40
P
Password Entry ..................................................... 28
Change level 1 or level 2 password ................... 30
Drop to Minimum Security Level ........................ 29
Enter Level 1 or 2 Password.............................. 29
Enter level 3 password....................................... 29
R
Real Time Clock Programming.............................. 38
Relay Output Programming ................................... 36
Programming the Active State of the Relay
Output .............................................................. 36
Programming the Digital Selectors .................... 37
Resistive Temperature Device Module .................. 17

Diagnostics ........................................................ 17
Monitoring Features ........................................... 18
Specifications..................................................... 21
S
Service Maintenance Interval Warning .................. 73
Service Tools ......................................................... 41
Setpoint Programming........................................... 32
Main Menu ......................................................... 32
Spare Analog Input Programming ......................... 35
Programming the Spare Analog Input................ 35
Speed Sensor (Engine) - Adjust ............................ 88
System Operation.................................................. 28
Systems Operation Section ..................................... 4
T
Table of Contents..................................................... 3
Testing and Adjusting ............................................ 85
Testing and Adjusting Section ............................... 85
Thermocouple Module........................................... 10
Diagnostics ........................................................ 10
Monitoring Features ............................................ 11
Specifications..................................................... 14
Troubleshooting Section ........................................ 40
Typical Generator Abbreviations ......................... 140
U
Unexpected Engine Shutdown .............................. 83
V
Voltage and Frequency Adjustment....................... 38
W
Wiring Harness (Open Circuit) - Test ..................... 85
Wiring Harness (Short Circuit) - Test ..................... 86
2004 Caterpillar
All Rights Reserved
Printed in U.S.A.

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RENR7902

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Testing and Adjusting Section

Wiring Harness (Open Circuit) - Test .................... 85

Systems Operation Section

Either Start Aid Switch (SAS) (optional)

(8) Alarm Acknowledge/Silence Switch

(5) Discrete Input Output (I/O) Module or

Electronic Control Module

(7) Lamp Test Key

Alarm Acknowledge/Silence Pressing the Alarm

STOP Pressing the STOP Key (10) will cause

The remainder of the inputs can be configured. The

ATS in Emergency Position

The inputs can be programmed to monitor the

Battery Charger Failure

Air Filter Differential Pressure

SMCS Code: 7490

Engine Oil Pressure

Fire Extinguisher Pressure

The Thermocouple Module (TC) is capable of

Engine Oil Temperature

The Termocouple Module will read the inputs and

Rear Bearing Temperature

Table 2 shows the Thermocouple Module

Right Exhaust Temperature

diagnostics. The Thermocouple Module is capable of

Left Exhaust Temperature

Ambient Air Temperature

Engine Coolant Level

Air Damper Closed

Each of the 20 inputs have sensor diagnostics in

Diagnostic Log Entry Format Table

Time of Last Occurrence

Refer to Table 3 for possible code numbers.

FMI Codes - Thermocouple Module Diagnostics

Thermocouple Input #n High Temperature Shutdown

Thermocouple Input Sensor #n Short Circuit

Thermocouple Input Sensor #n Open Circuit

Thermocouple Input #n High Temperature Warning

Thermocouple Input #n Low Temperature Warning

SPNs Available for Configuration of Temperature Inputs

Engine Intercooler Temperature

Intake Manifold 1 Temperature

Engine Coolant Temperature

Ambient Air Temperature

Air Inlet Temperature

Exhaust Gas Temperature

Engine Oil Temperature 1

Turbo Oil Temperature

Alternator Bearing 1 Temperature

Alternator Bearing 2 Temperature

Alternator Winding 1 Temperature