Instructions For EMCP II+ Field

Retrofit Onto EMCP II Equipped

Generator Sets{7490, 7451} Caterpillar

Instructions For EMCP II+ Field Retrofit Onto EMCP II Equipped Generator Sets{7490,
7451}
Usage:

All Generator Sets Equipped With EMCP II Control Panels

NOTE: Do not perform any procedure outlined in this Special Instruction until you have
read and understood this information.

Reference:

Service Manual "Electronic Modular Control Panel II (EMCP II)", SENR5809, for MUI
Engines.

Service Manual "Electronic Modular Control Panel II (EMCP II) For Electronically
Controlled Engines", SENR5827, for PEEC Engines.

Service Manual "Electronic Modular Control Panel II (EMCP II) For Electronic Unit
Injector (EUI) Engines", SENR5398.

Service Manual "Programmable Relay Control Module (PRCM)", SENR6588.

Owner's Manual "Customer Communications Module For Electronic Modular Control

Panel II (EMCP II)", SEBBU6874.

Service Manual "Electronic Modular Control Panel II+ (EMCP II+) For MUI Engines",
SENR5832.

Service Manual "Electronic Modular Control Panel II+ (EMCP II+) For PEEC Engines",
RENR1254.

Recommended Tools
Introduction
This Special Instruction provides information on the equipment and procedures necessary to
successfully upgrade into the new Electronic Modular Control Panel II+ (EMCP II+) from any
existing EMCP II equipped Caterpillar Generator Set.
Illustration 1. Location Of EMCP II+ System Components On Instrument Panel:

(1) Generator set control + (GSC+). (2) Governor switch (GS) [optional] or speed
potentiometer (SP) [optional]. (3) Starting aid switch (SAS) [optional]. (4) Engine control
switch (ECS). (5) Alarm module (ALM) [optional]. (6) Custom alarm module (CAM)
[optional] or synchronizing light module (SLM) [optional]. (7) Panel light switch (PLS)
[optional]. (8) Emergency stop push button (ESPB). (9) Voltage adjust rheostat (VAR).
Instrument Panel (Top View With Door Open). (1) Generator set control + (GSC+). (2) Governor
switch (GS) [optional] or speed potentiometer (SP) [optional]. (3) Starting aid switch (SAS)
[optional]. (4) Engine control switch (ECS). (5) Alarm module (ALM) [optional]. (6) Custom alarm
module (CAM) [optional] or synchronizing light module (SLM) [optional]. (7) Panel light switch (PLS)
[optional]. (8) Emergency stop push buttom (ESPB). (9) Voltage adjust rheostat (VAR). (10) Relay
module (RM) [part of GSC+].
Sub Panel (Front View). (11) Auxiliary terminal strip (AUX). (12) Electronic governor (EG) [optional].
(13) AC transformer box + (ATB+). (14) Fuel control timer module (FCTM) [ETS only]. (15) Circuit
breaker 2 (CB2). (16) Kilowatt level relay (KWR). (17) Engine failure relay (ENFR) [optional]. (18)
Auxiliary relay (AUXREL) [optional]. (19) Starting motor magnetic switch 1 (SMMS1). (20) Starting
motor magnetic switch 2 (SMMS2) [optional]. (21) Fuse 11 (F11). (22) Slave relay (SR) [ETR only].
(23) Ground post high voltage (GPHI). (24) Emergency fuel control relay (EFCR) [ETS only] or
auxiliary fuel control relay (AFCR). (25) Fuse 16 (F16). (26) Fuse 12 (F12).

Procedure
1. Start the engine of the generator set prior to initiating the upgrade procedure. Verify that all
systems are operational. Repair any faults that are logged prior to the conversion.
2. Shut down the generator set. Record all set point information for reprogramming of the
EMCP II+ Genset Control, including current hour meter reading. Disconnect the battery system
by either turning OFF the battery disconnect switch or removing the ground wire from the
negative terminal of the batteries.

1 P10-GSC-10 (VAN OUT),

2 P11-GSC-11 (VBN OUT),
3 P12-GSC-12 (VCN OUT),
4 P4-GSC-4 (1A OUT),
5 P5-GSC-5 (1B OUT),
6 P6-GSC-6 (1C OUT),
7 P16-GSC-16 (AC GROUND),
8 NC.
NOTE: T11 and T13 connect to the synchronizing light resistors (SLR1, SLR2) of the optional
synchronizing light module (SLM).

NOTE: For the Delta connected generators, DO NOT provide "TO" connection for the Delta
generators.

3. Disconnect all AC wiring and the 8-Pin Deutsch connector on the AC Transformer Box.
Remove the ATB by removing the four locknuts securing the ATB to the EMCP II Sub Panel. A
straight blade screwdriver, 7/16 inch socket, extension, and ratchet wrench are needed.

Install the new ATB+ (13) into the same location. (Refer to Illustration 3.) Verify that all four
locknuts are installed and tightened to 5.7 to 8.2 N·m (50 to 73 lb in). Reconnect the AC wiring
to the ATB+ (13) at the same points as on the original ATB. Install three fuses into the fuse
block at the ATB+ (13). (If possible, use the fuses from the original ATB.)

If an optional Synchronizing Light Module (SLM) (6) is installed in the Panel, remove the L1
wire (28) and L3 wire (31) connected to the TS1 in the generator terminal box and provide
direct connection from TS1 to SS-4 and SS-6, respectively, on the SLM (6). If no SLM (6) is
installed in the Panel, isolate and insulate the unused L1 wire (28) and L3 wire (31) for possible
future use. If the generator wiring is a Wye configuration, a connection from the ATB+ (13)
terminal strip location H21-H22-H23 (a-b-c) to the generator neutral (TO) must be made. The
wire should be a minimum of 16 gauge. If the generator is wired in a Delta configuration, the
additional wire should NOT be added.

NOTE: Ignore the ATB+ (13) chassis ground wire on Pin-8 Deutsch to Pin-17 GSC because it
is not used on the EMCP II+. Remember to insulate and protect wires L1 (28) and L3 (31)
because they are not used.

4. Document and label the wiring scheme on the GSC Relay Module (10). Disconnect all wiring
to the GSC Relay Module (10). Loosen and disconnect the 40-Pin connector plug. A 4 mm Hex
wrench, straight blade screwdriver and either a 7/16 inch open end wrench or a 7/16 socket,
extension, and ratchet wrench are needed. After all the wiring is disconnected, loosen the six
locknuts on the back of the Genset Control mounting flange holding the GSC in place on the
Panel face. Install the new GSC+ (1) and tighten the six locknuts to 5.7 to 8.2 N·m (50 to 73 lb
in). Reinstall all shield grounding terminals to the stud of the GSC+ (1) during installation.

5. Reconnect and tighten the 40-Pin connector to the GSC+ (1). Reconnect the wiring on the
Relay Module (10) exactly as it came off the original GSC. Ensure the Relay Module fuses are
installed on the GSC+ (1) from the original GSC.

6. No modifications are necessary to the Data Link available for the optional Customer
Communication Module (CCM) unless the EMCP II+ is installed into a multiple EUI Engine
application where the engines are connected to a single CCM on the same data link. If so, the
following procedure should be completed.

a. Extract the wire in Location 19 with the 121-9587 Removal Tool from the 40-Pin Panel wiring
connector that mates to the GSC.

b. Move the wire to Location 21.

c. Repeat this process for the wire in Location 20 by extracting it and moving it to Location 22.

d. The new location of these wires is designated as the CCM Data Link. It will be available on
the auxiliary terminal strip (11). The CCM Data Link will communicate to the Customer
Communication Module. The former Location 19 and Location 20 will be the Caterpillar Data
Link for communication with additional Caterpillar Electronic Controls (i.e., ADEM). If the
generator set incorporates a local Caterpillar Data Link network, then this network must be
connected to the CDL+ (Pin-19) and CDL- (Pin-20) at the closest possible location. For this
task, the 9U-7246 Connector Service Kit is needed.

7. If required, install a 102-0050 Temperature Sensor Group into the engine oil gallery using a
11/4 inch open end wrench.
NOTE: If using a generic cut-to-length harness, connect a 3-Pin Deutsch connector to the
mating connector on the sensor. Route the wire harness back down the engine inside the
existing engine harness conduit, through the generator housing, and up inside the EMCP
Panel. The sensor harness should be routed in the DC harness conduit to avoid electrical
noise in the AC Panel harness. Secure the harness with cable straps to existing harness to
avoid vibration fatigue. Connect the three wires from the sensor harness as shown in Chart 3.

8. Programmable Spare Relay (PSR) contacts are available for customer use by making the
appropriate connections to RM37 (PSR1 IN), RM38 (PSR2 IN), RM25 (PSR2 NO OUT), and
RM26 (PSR1 NC OUT). The Relay contacts are rated at 10 amperes at 24 DC volts and 110
AC volts for resistive loads. The contacts are rated at 5 amperes at 24 DC volts and 7.5
amperes at 110 AC volts for inductive loads. (RM37, RM38, RM25, and RM26 are located on
the rear of the GSC+ (1) MODULE.)

NOTE: Refer to the EMCP II+ Service Manual for additional information regarding electrical
connections and programming the GSC+ (1) to activate this function.

9. An additional Spare Fault Input (SW4) is available for use with the EMCP II+ upgrade. This
function is available for customer input connection to the 40-Pin Deutsch connector on Pin-29
on the GSC+ (1). The same guidelines and application requirements for the utilization of Spare
Inputs SW1-3 apply to SW4.

NOTE: For further information regarding the use and programming of SW4, refer to the EMCP
II+ Service Manual.

10. An optional Relay Driver Module (RDM) output is available for use with the EMCP II+
Panel. This option provides nine additional outputs for remote control through the CCM. These
outputs can be connected to an optional relay board or connected directly to horns, lamps, or
other devices. For installation, the serial data link must be connected to the 40-Pin Deutsch
connector on Pin-30 on the GSC+ (1). The operation of the RDM is controlled through the GSC
by the CCM.
NOTE: For additional information concerning the program set points to operate the CCM
Programmable Output, refer to the EMCP II+ Service Manual.

11. A programmable KW Level Output is now available with the GSC+ (1). This is a 100
milliamperes sinking output. To utilize this function, a connection to the 40-Pin Deutsch
connector on Pin-34 on the GSC+ (1) is required.

NOTE: For programming, operation, and application information, refer to the EMCP II+ Service
Manual.

12. After all hardware installation has been completed, reconnect the battery, or close the
disconnect switch. Turn the EMCP II+ Panel ON by turning the ECS (4) to the
STOP/COOLDOWN position. Once the GSC+ (1) is powered on, perform all the set point
programming as documented in the EMCP II+ Service Manual, utilizing the original GSC set
points for most of the information.

NOTE: Reference the EMCP II+ Service Manual for information regarding power metering,
protective relaying, and other additional functions available with the EMCP II+ System.

13. Once the programming of the GSC+ (1) has been completed, the Panel is ready for
operation. Start the generator set by moving the ECS switch (4) to the START/RUN position.
The generator set should start and run at rated speed. Once the generator set is at rated
speed, verify all the displayed functions are operating at the correct values and no fault codes
or diagnostic codes are active. After determining the unit is correctly operating, validate shut
down and fault condition operation of the EMCP II+ Panel according to the EMCP II+ Service
Manual. If problems occur, refer to the EMCP II+ Service Manual for assistance in
troubleshooting and repair of the generator set control system.

14. After validation of the EMCP II+ Control System, the engine can be shut down and returned
to normal service.

NOTE: For future reference, document all the programmed set points of the GSC+ (1) in case
a failure or service question should occur.

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