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Welcome: m400mwz
Product: GAS ENGINE
Model: G3516 GAS ENGINE 4EK
Configuration: G3516 Engine Electronic Ignition System 4EK00001-UP
Special Instruction
Procedure to Upgrade the EMCP 1 to the Operator Control Panel (OCP) 4.3{4490,
7451}
Media Number -REHS7350-06
i05926752
Engine:
G3408C (S/N: 8YR1-UP; BAZ1-UP)
G3412C (S/N: 6ZM1-UP)
G3508 (S/N: 4WD1-UP; 9TG1-UP; CPJ1-UP; 2TJ1-UP; CPY1-UP)
G3512 (S/N: 5JD1-UP; 7NJ1-UP; CRN1-UP; CSP1-UP)
G3516 (S/N: L6A1-UP; ZBA1-UP; 8LD1-UP; L6F1-UP; CPG1-UP; L6G1-UP; 4EK1UP; CSZ1-UP; ZAZ1-UP)
Introduction
This Special Instruction provides information about the installation of the Operator Control Panel
(OCP) 4.3. The EMCP 1 status controllers, that are listed below, will be obsolete by the end of
December 2012. The EMCP 1 panels, that are listed below, will also be obsolete by the end of
December 2012.
The OCP 4.3 is the "drop-in replacement" for the following control panels. All of the panels and
controls listed in Tables 1 and 2 will be replaced by the 418-6662 Instrument Panel Box Gp .
Table 1
EMCP 1 Status Controller to be Obsolete
Part Number
Description
6V-6148
6V-6149
10R-4099
Electronic Control Gp
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Table 2
EMCP 1 Panels to be Obsolete
Part Number
Description
4P-9566
Control Panel Gp
103-6193
Control Panel Gp
109-4032
Electrical Shutoff Gp
108-6424
Electrical Shutoff Gp
The controls listed in Table 2 incorporated an EMCP 1 spark ignited (SI) status control module
(SCM). The 6V-6149 Engine Monitoring Control Gp also contain an optional Woodward 2301
speed control. The Woodward 2301 has been used for natural gas, spark ignited engines that were
used primarily for gas compression applications.
The OCP 4.3 upgrade kit is not for application on electric power generation or refrigeration
systems. In addition to the control replacement, the procedure will involve the replacement of the
oil pressure sensor and the coolant temperature sensor. The oil pressure sensor and the coolant
temperature sensor, along with electrical connectors are not included in the OCP 4.3 kit. The OCP
4.3 control has been pre-configured for these sensors.
Note: If upgrading software, the suggestion is to back up the current configuration. Flashing
application software does not affect the set points. However, if a problem occurs during flashing,
the configuration backup can be used to configure a replacement module. Record the current
software version information as shown in Illustration below. The information is useful to obtain
the correct flash file if the desired is to return to the previous version of software after flashing.
Table 3
ECM Summary Information for Original Configuration
Description
Value
3687106-01
2071E099TW
4241323-00
AUG2012
A5L2 English
4.2 PROD OCP
30August2012
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Work safely. Most accidents that involve product operation, maintenance, and repair are caused by
failure to observe basic safety rules or precautions. An accident can often be avoided by
recognizing potentially hazardous situations before an accident occurs.
A person must be alert to potential hazards. This person should also have the necessary training,
skills, and tools in order to perform these functions properly.
Safety precautions and warnings are provided in this instruction and on the product. If these
hazard warnings are not heeded, bodily injury or death could occur to you or to other persons.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
Therefore, the warnings in this publication and the warnings that are on the product are not all
inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not
recommended by Caterpillar is safe.
Ensure that the product will not be damaged or made unsafe by the operation, lubrication,
maintenance, or repair procedures used.
When servicing or repairing electric power equipment:
1. Shut down the engine and manually disconnect the unit from any external loads and power
sources.
2. Disconnect the battery. Tape the battery cable leads to ensure that the leads do not contact
the battery posts.
3. Use proper lock out and tag out procedures.
4. Allow all stored energy in the system to dissipate before working on the unit.
Reference Information
The following documents are available on the Caterpillar Service Information System web site.
Review the publications that are listed below. There are sections of the publications that will be
needed for reference prior to installation of the OCP 4.3 upgrade kit.
Service Manual, SENR3535 for the electronic modular control panel (EMCP)
Application and Installation Guide, LEBE0007 for the EMCP 4.3/4.4 generator set control
Systems Operations Troubleshooting Testing and Adjusting, UENR 1210 for the EMCP
4.3/4.4 generator set control
Systems Operation Troubleshooting Testing and Adjusting, UENR3193 for the gas
compression operator control panel
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New Features
As implemented, the OCP 4.3 control offers more features than what was available with the
original EMCP 1.
Engine operating state displays for starting, running, cool down, stopped, idling
Engine coolant temperature, oil pressure, speed, and operating hours
Battery voltage
Engine counters screen to display total engine cranks, starts, and hours remaining until
service
The units for temperature in Fahrenheit and Celsius and units for pressure in kilopascals and
pounds per square inch can be selected
The time and date are maintained
The local CAN annunciator will display engine warnings and faults as pre-programmed
with the default configuration file (*.xml)
Communication Options
The OCP 4.3 control includes the following range of communications options:
CAN 1 - A J1939 network
CAN 2 - A second J1939 network
Ethernet Port
RS-485 long-distance annunciator
MODBUS interface
CAN 1 - Serves the OCP 4.3, optional Product Link PL421, and the CAN 1 Data link connector.
CAN 2 - Serves the OCP 4.3, annunciator, and the CAN 2 Data Link connector.
Ethernet port - Allows the OCP 4.3 control to be connected to a "Local Area Network" (LAN) or
the Internet.
RS-485 long-distance annunciator - Allows addition of optional annunciators at distances of up
to 4000 ft from the control. Refer to Systems Operations Troubleshooting Testing and Adjusting,
UENR 1210, "Annunciator Module" for information about RS-485, I/O, and data acquisition
modules that are available.
MODBUS interface - allows connection of the OCP 4.3 control system to a user computer.
Interface software is available on the Cat Power Net website. Refer to Systems Operations
Troubleshooting Testing and Adjusting, UENR 1210 EMCP 4 SCADA data links as well as
EMCP Modbus register list for more information.
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General information
The OCP 4.3 supports "flashing" (field-programming) of software for all of the modules. Flashing
is accomplished by the use of Cat Service Tool software and a Cat Communication Adapter. The
primary datalink, CAN 1, service connector must be used for modules connected to the primary
data link. The accessory datalink, CAN 2, service connector must be used for modules connected
to the accessory data link. Refer to the generator set package documentation for the location of the
service connectors. Flashing the OCP 4.3 requires the following hardware and software:
Cat Service Tool software installed and licensed on a PC
Cat Communication Adapter
9-pin deutsch connector for the primary datalink, CAN 1
9-pin deutsch connector for the connection to the accessory datalink, CAN 2
Software flash file for the OCP 4.3
Flash Files
The following files are to be used when flashing or configuring the system.
Note: All flashing and configuring of the OCP 4.3 ECM must be done using the CAN 1 service
connector. Do not flash or configure the OCP 4.3 over CAN 2 accessory datalink.
OCP 4.3 ECM
1. OCP 4.3 ECM flash file: "4231323_00.fls".
2. Configuration file: "OCP4.3_CAN1_Not Programmed_FLTCFG_2012-0926_14.12.07.xml"
Note: The configuration file is most recent .xml file and is subject to change.
Annunciator ECM
1. Annunciator ECM flash file: "2978331.fls"
2. File: "Annunciator_1812B091HW_ECMREP_2012-09-26_14.15.05.xml"
Note: The configuration file is most recent .xml file and is subject to change.
Refer to Special Instruction, REHS7350, "Flashing and Configuring the OCP 4.3" for more
information about flashing the system.
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has been removed. If the installation of OCP 4.3 is the result of a failed control,
debugging the existing system will not be possible.
b. Collect engine performance data.
c. Determine the baseline engine operating parameters so the operating parameters can
be referenced once the new control has been installed. If the installation of OCP 4.3 is
the result of a failed control, determining the baseline engine operating parameters
will not be possible.
d. Shut down the engine and manually disconnect the generator from the AC line or any
other external loads and power sources.
e. Disconnect the battery. Tape the battery cable leads to ensure that the leads do not
contact the battery posts.
f. Use proper lock out and tag out procedures.
2. Installation of the new control is the second process that must be accomplished. That is,
either replace the old control with the OCP 4.3 or add the OCP 4.3 to the old control.
Replacement of the original control panel or addition of the OCP 4.3 depends on whether
the original control possesses an air fuel ratio control (AFRC) module.
a. Validate installation of the new control.
b. Configuration of the engine operating parameters in the new control.
c. Validation testing of the operational aspects of the new control.
d. Switch the manual disconnects to the closed position.
3. Maintenance and operation of the new control is the last process that must be finished.
a. Confirm CAN annunciator operation.
b. Flash and configuration of the OCP 4.3.
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Illustration 1
1. Put the engine control switch (ECS) switch in the Off/Reset position. Use terminal point 5
as ground. Confirm that +Vbat is present at the following terminals shown in Illustration 1.
Illustration 2
2. Use terminal point 5 as ground. Confirm that there is continuity, near zero ohms and volts,
to each of the following terminals shown in Illustration 2.
Starting Motor Relay (SMR) Circuit
1. Put the ECS into "Stop" mode.
2. Observe that the battery charger is supplying current to the battery.
3. Disconnect the wire from terminal 26 on the ECM.
Note: The battery charger current should drop to zero.
4. Reconnect the wire to terminal 26 on the ECM.
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5. Use terminal strip test point 5 as voltmeter ground. Disconnect the +Vbat wire from the
starting motor solenoid.
6. Confirm that terminal 209 is not powered. Terminal 209 is the supply circuit to the starting
motor solenoids.
7. Use a jumper to connect ECM terminal 25 to ECM terminal W. Terminal 209 must go to
+Vbat. The starting motor solenoid will energize.
8. Remove the jumper connection between ECM terminal test point 25 and terminal W.
Reconnect the +Vbat wire to the starting motor solenoid. Correct any issues that prevented the
foregoing results from occurring.
Fuel Control Relay (FCR) Circuit
1. Put the ECS into stop mode.
2. Manually shut off the gas supply to the engine.
3. Observe that the Gas Shut Off valve is not energized.
4. Use a jumper to connect ECM terminal 23 to ECM terminal S.
5. Observe that the gas shut off valve is energized.
6. Remove the jumper from ECM terminals 23 and terminal S.
7. Manually turn on the gas supply to the engine.
8. Correct any issues that prevented the foregoing results from occurring.
Crank Termination Relay (CTR) Circuit
1. Put the ECS into "Off/Reset" mode.
2. Connect ECM terminal D to ECM terminal E.
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Illustration 3
g03307277
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8. Correct any issues that prevented the foregoing results from occurring.
Run Relay (RR) Circuit
1. Put the ECS into "Stop" mode.
2. Connect ECM terminal M to ECM terminal 20.
3. Confirm +Vbat is present on terminal strip 174.
4. Remove the connection between ECM terminal M and terminal 20.
5. Correct any issues that prevented the foregoing results from occurring.
Engine Failure Relay Circuit (ENFR)
1. Put the ECS into "Stop" mode.
2. Connect ECM terminal K to ECM terminal 18.
3. Confirm +Vbat is present on terminal strip 173.
4. Remove the connection between ECM terminals K and terminal 18.
5. Correct any issues that prevented the foregoing results from occurring.
Parameter Determination
Idle Speed
1. To prevent the engine from going to rated speed, disconnect the wire from terminal 5 on the
Woodward Governor. On engines that do not use an electronic governor, restrict the
governor to maintain engine speed at idle.
2. Put the ECS into Manual Mode and allow the engine to start.
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Illustration 4
g03317962
3. Read the engine idle speed operating parameters from the ECM display. Record the
parameters that are listed in Illustration 4.
4. Ensure that the hour meter is working properly. Note the hour meter reading to confirm that
the meter does advance while the engine runs. Record the following information shown in
Illustration 4.
Note: Be sure to circle the unit of measurement that is used for recording the pressure and
temperature.
5. Check the coolant temperature as the engine starts. Verify that the coolant temperature is
close to the temperature of engine block. The coolant temperature check is used as a
confirmation to determine if the coolant temperature sensor and related wiring are
functional.
6. Put the ECS into the "Stop" mode.
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7. Reconnect the wire to terminal 17 of the ECM or enable the governor to achieve rated
speed.
8. Correct any issues that prevented the engine from starting, idling, or recording the idle
speed parameters.
Rated Speed
1. Put the ECS into manual mode and allow the engine to start. Allow the engine to idle while
developing oil pressure. The ECM and Woodward Governor will bring the engine to rated
speed when the oil pressure reaches the appropriate pressure.
2. After the engine comes up to rated speed, monitor the coolant temperature as the
temperature rises.
Illustration 5
g03317987
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3. When the coolant temperature has stabilized, record the engine rated speed operating
parameters in shown in Illustration 5.
Note: Record the hour meter reading at the end of the procedure.
Note: Be sure to circle the unit of measurement that is used for recording the pressure and
temperature.
4. Put the ECS into the "Stop" mode.
5. Observe that the engine speed is reduced to idle while the engine cools down.
6. Correct any issues that prevented the engine from starting, idling, running at rated speed, or
recording the rated speed parameters.
Note: The gas shut off valve operation position is 0 for energize to run. The gas shut off
valve operation position is 1 for energize to stop.
Table 5
Acronyms
Acronym
Description
ETR
Energize To Run
ETS
Energize To Stop
Oil Pressure
Coolant Temperature
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ECS
ESCM
AFRC
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Illustration 6
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5. Record the set points for rotary switch position 02 through 15. Refer to Illustration 6.
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purchased separately. A kit can be purchased that will provide the three sensors, required
connectors, and cable. The part number of the kit is 442-2378 Communication Installation Gp .
After the panel has been installed, connect all of the conduit and wiring.
Wire Number
Term Point
P762-RD
J440-BK
Table 7
Remove Warning Indicator Light Wiring
Term Point
Wire Number
Term Point
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P673-RD
J430-BK
Table 8
Remove Power Indicator Light Wiring
Term Point
Wire Number
Term Point
P677-RD
P389-BK
Table 9
Remove E-Stop Pushbutton Wiring
Term Point
Wire Number
Wire Number
E-Stop (3)
C252-BK
ECS (1)
E-Stop (3)
P320-BK
ESCM (-)
E-Stop (4)
C253-BK
ESCM (14)
Table 10
Remove Engine Control Switch (ECS) Switch Wiring
Term Point
Wire Number
Wire Number
ECS (1)
-------
------
ECS (2)
P623-BK
ESCM (12)
ECS (3)
P624-BK
ESCM (11)
P684-BK
ECS (5)
P622-BK
ESCM (10)
ECS (6)
P288-RD
ESCM (+)
ECS (7)
P628-RD
ECS (8)
------
------
ECS (9)
P686-RD
ECS (10)
P620-RD
ESCM (F)
Table 11
Remove ESCM Wiring
Term Point
ESCM (1)
Wire Number
S270-GN/YL
Term Point
Term Block 207
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ESCM (1)
S270-BK
ESCM (2)
D240-GN/YL
ESCM (3)
D970-CU
ESCM (3)
D970-BK
ESCM (4)
D970-RD
ESCM (5)
D970-WH
ESCM (6)
D240-RD
ESCM (7)
S270-RD
ESCM (8)
P270-RD
ESCM (9)
P625-BK
ESCM (10)
------
------
ESCM (11)
------
------
ESCM (12)
------
------
ESCM (13)
C267-BK
ESCM (14)
C251-BK
ESCM (15)
J420-BK
ESCM (16)
------
------
ESCM (17)
------
------
ESCM (18)
M281-BK
ESCM (19)
C866-WH
ESCM (20)
C875-BK
ESCM (21)
------
------
ESCM (22)
C270-BK
ESCM (23)
A220-RD
ESCM (24)
M200-BK
ESCM (25)
P220-RD
ESCM (26)
P780-RD
ESCM (27)
------
------
ESCM (A)
------
------
ESCM (D)
------
------
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ESCM (E)
------
------
ESCM (F)
------
------
ESCM (G)
C866-BK
ESCM (H)
------
------
ESCM (S)
------
------
ESCM (T)
------
------
ESCM (U)
------
------
ESCM (V)
------
------
ESCM (W)
------
------
ESCM (X)
------
------
ESCM (Y)
------
------
ESCM (B+)
P280-RD
Term Block 1
ESCM (B+)
P28A-RD
J4-A
Note: Move the end of P28-RD from ESCM (B+) to +Vbat (Terminal Block 1)
ESCM (B-)
P370-BK
Term Block 5
ESCM (B-)
P38A-BK
J4-B
Note: Move the end of P28A-BK from ESCM (B-) to -Vbat (Terminal Block 5)
ESCM (B-)
A220-GN/YL
ESCM (B-)
A220-BK
Table 12
Remove 270 Ohm Resistor R1
Term Point
Term Block 264
Wire Number
R1
Term Point
Term Block 265
Table 13
Wire Number
Term Point
ESCM MPU-SHLD
S270-CU
ESCM MPU-B
S270-BK
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ESCM MPU-A
S270-RD
Table 14
Remove the Coolant Temperature Sensor Wiring
Note: The following terminal blocks are located in the Engine Mounted Gauge
Panel/Terminal Box
Term Point
Wire Number
Term Point
TP-1
S001/S034/S030-RD
XDUCER-1 (PU)
TP-2
S001/S034/S030-BK
XDUCER-2 (GY)
TP-SHLD
S001/SC34/S030-CU
Table 15
Remove the Oil Pressure Sensor Wiring
Note: The following terminal blocks are located in the Engine Mounted Gauge
Panel/Terminal Box
Term Point
Wire Number
Term Point
OP-B
S100-BK
XDUCER-B (YL)
OP-A
S100-RD
XDUCER-A (RD)
OP-C
S100-WH
XDUCER-C (GN)
OP-SHLD
S100-CU
Table 16
Remove the XDUCER Wiring
Term Point
Wire Number
Term Point
XDUCER-2 (BK)
D970-BK
XDUCER-1 (OR)
D970-RD
XDUCER-3 (PK)
D970-WH
XDUCER-SHLD
D970-CU
Panel Installation
The preferred location for the OCP 4.3 control would be on the side of the existing electrical panel
that contains the old control.
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Illustration 7
g03358297
Layout 4, 9/16 inch diameter holes on the OCP 4.3 panel located at each of the corners. Locate the
holes 1-1/4 inch from the edge of the panel. Refer to Illustration 7. After verifying that a
corresponding set of holes can be made in the old control electrical panel, drill the holes.
The following items are required for installation of the OCP 4.3 panel, but are not provided in the
kit.
Table 17
Item
Qty
Description
16
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Illustration 8
g03359124
Mount the OCP 4.3 panel to the old enclosure using the hardware specified in Table 17 and shown
in Illustration 8.
On the bottom of the OCP 4.3 control are two conduit fittings provided for wire entries into the
panel. Select the appropriate entry point that is nearest the old enclosure. The selection must
ensure that a conduit routed from the fitting will not cross or interfere with the second fitting.
Install a 1 inch conduit from this fitting through the side of the old enclosure to the bottom of the
old control. Select a location in the bottom of the old control that will allow easy access to the
terminal blocks in the old control.
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Illustration 9
Refer to Illustration 9 for connections to be made between the OCP 4.3 and the existing control
panel. The numbers shown denote the terminal block number in each control. Most of the terminal
blocks are wired number for number. There are few subtle differences. Use the wire sizes and
types shown on the Illustration 9.
The wiring between panels must be routed through the conduit that is connected between the two
panels. The wiring from the oil pressure transducer and coolant temperature transducer do not
necessarily have to run through the old control. Select the best path that will protect the cables and
minimize installation time. The second conduit entrance on the bottom of the OCP 4.3 may be
used for these transducer cables.
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Sensor Installation
The OCP 4.3 control does not support some of the earlier oil pressure and coolant temperature
multiplexing schemes. A sensor kit must be purchased separately. The part number for the kit is
442-2378 Communication Installation Gp . The OCP 4.3 has been configured for the latest type of
sensors.
1. Install the oil pressure and coolant temperature sensors on the engine.
2. The wires that connect the oil pressure and water temperature transducer to the control must
be replaced. Wires 251, 252, 253 and 254 (shield) must be replaced by two cables. One
cable must be used for the oil pressure sensor and the other cable must be used for engine
coolant temperature sensor. Each of the cables must be a three wire cable that is 18 AWG
with a shield.
Each sensor has a ground (black), power (red) and signal (white) wire.
Note: Do not use a common ground or power wire for the sensors.
3. Install the magnetic pickup unit (MPU) that was included with the kit.
On some engines, the Woodward Governor shared the engine speed MPU with the EMCP 1.
The new MPU has been included with the kit to allow the OCP 4.3 and the Woodward
Governor to have a dedicated MPU.
For installation and setup of the latest MPU Refer to Service Manual, SENR3535, "Service
Procedure F - Speed Sensor Adjustment" for the procedure.
4. Mount the new panel in the same location as the old panel. Use the four mounting tabs at
the corners of the panel. Install the conduit in the bottom of the panel. Connect the wiring to
the terminal strip ensuring that the wire labels are connected to the correct terminal labels.
Do not connect the wiring for the following functions:
Table 18
Function
Wire Number
E-Stop
211
Remote Initiate
Remote Shutdown
The functions listed in Table 18 will be installed and tested in the "Remote Operation Tests".
Install the original Woodward Governor onto the subpanel with the mounting screws that are
provided. Connect the wires to the correct terminals.
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Illustration 10
Record the current software version information. An example is shown in Illustration 10. The
information is useful to obtain the correct flash file if there is a desired to return to the previous
version of software after flashing.
Note: All flashing and configuring of the OCP 4.3 ECM must be done using the CAN 1 service
connector. Do not flash or configure the OCP 4.3 over CAN 2 accessory datalink.
Flashing the OCP 4.3
Illustration 11
1. Connect to the OCP 4.3 using the Cat Service Tool over the CAN 1 data link.
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Illustration 12
2. Enter the "WinFlash Utility" by clicking the "WinFlash" icon or by selecting "Utilities",
then click "Winflash".
Illustration 13
3. Allow WinFlash to find the ECM. When the WinFlash dialog appears, click "Browse for a
File". Refer to Illustration 13.
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Illustration 14
Note: If WinFlash does not find all of the modules on the J1939 data link that are connected
to the data link, scan the data link again. Scan the data link by pressing "F8" or selecting
"File", then click "Update ECM List".
4. Browse for the appropriate flash file (.fls) and click "Open". Refer to Systems Operation,
Test and Adjust, UENR1210, "Flash Files" for the most recent .fls file. Refer to Illustration
14.
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Illustration 15
Illustration 16
g03311437
6. Click "Begin Flash" to begin the software installation. Refer to Illustration 16.
Illustration 17
g03311439
7. A progress meter will show the status of the flash. The OCP 4.3 display will show that
software installation is occurring.
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Illustration 18
8. When the flashing process is complete, the ECM that was flashed will reboot. Also, a
WinFlash will appear. The dialog will provide options for what to do next. The appearance
of the dialog indicates that the software has finished flashing, and is ready to use.
9. On startup, the OCP 4.3 will display the software part number. Verify that the software part
number matches the new application software that was flashed.
Flashing the Annunciator ECM
The annunciator is flashed with required software at the factory. If required, the flash file can be
found via SISWeb. Refer to Systems Operation, Test and Adjust, UENR1210, "Flash Files" for
the most recent .fls file. Follow procedures in Systems Operation, Test and Adjust, UENR1210,
"Flashing the OCP 4.3" to flash the CAN annunciator.
Configuring the OCP 4.3 ECM
The Cat Service Tool is used to save an OCP 4.3 configuration. The OCP 4.3 configuration must
be saved upon initial access or after any configuration change. The configuration will be required
for future accessibility when exchanging or replacing the OCP 4.3 module in the event of an OCP
4.3 module failure. After connecting to the OCP 4.3, navigate to "Service", then select "Copy
Configuration". There are two options:
Fleet Configuration
ECM Replacement
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Illustration 19
Use "ECM Replacement" only if the OCP 4.3 requires warranty replacement.
Note: ECM replacement is not discussed in this publication.
Select "FLEET CONFIGURATION" when there is a need to save and copy general data to several
ECMs. The fleet configuration option is not module-specific. The fleet configuration tool works
similarly to the ECM replacement tool. The exception is that the fleet configuration tool ignores
module-specific data such as engine serial number and engine operating hours. In the case of the
OCP 4.3, fleet configuration is used for the OCP 4.3 ECM via the CAN 1 port only.
Saving the Current OCP 4.3 Configuration
1. Connect to the OCP 4.3 using the Cat Service Tool to the CAN 1 port.
2. From the "Service Tool" menu, select "Service", then select "Copy Configuration", and
finally click "Fleet Configuration". Refer to Illustration 19.
Illustration 20
g03311456
3. The dialog will display "No data is available. Load from the ECM now?" Click "Yes".
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Illustration 21
4. After the software loads the data, the current file parameters will be shown. Refer to
Illustration 21.
5. Select which ECM configuration data that is to be viewed and/or saved for future. Select the
ECM configuration data by adding or removing the check mark next to the boxes to the left
of the parameter.
Illustration 22
6. After any selection changes are completed, the changes must be saved. Click "Save to File"
that is located at the bottom of the ECM replacement screen to save the .xml file.
Note: The configuration data must be saved to a file before disconnecting from the service tool or
the data WILL BE LOST. If the data is lost, the data must be loaded again from the source
module.
Programming New Configurations on the OCP 4.3
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1. Connect to the OCP 4.3 using the Cat Service Tool to the CAN 1 port.
2. From the "Service Tool" menu, select "Service", "Copy Configuration", then "Fleet
Configuration". Refer to Illustration 19.
Illustration 23
g03311460
3. The dialog will display "No data is available. Load from the ECM now?" Click "No".
Illustration 24
4. After any selection changes are completed, click "Load from File" that is located at the
bottom of the "Fleet Configuration" dialog to save the file.
5. Navigate to the location where the .xml file is stored and click "Open". Refer to Systems
Operation, Test and Adjust, UENR1210, "Flash Files" for the most recent .xml
configuration file.
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Illustration 25
6. The software will confirm opening the file. Refer to Illustration 25.
7. Select which ECM configuration data that is to be programmed into the OCP 4.3. Select the
ECM configuration data by adding or removing the check mark next to the boxes to the left
of the parameter.
Illustration 26
8. After any selection changes are completed, the changes must be saved. Click "Program
ECM" that is located at the bottom of the ECM replacement screen to load the file into the
OCP 4.3.
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Illustration 27
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Illustration 28
2. From the "Service Tool" menu, select "Service", "Copy Configuration", then click "ECM
Replacement".
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Illustration 29
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3. The dialog will display "No data is available. Load from the ECM now?" Click "Yes".
Illustration 30
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4. Select "Alarm Module #1" from the given list of ECMs. The selection will allow the
software to connect to the annunciator.
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Illustration 31
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Illustration 32
6. After the software loads the data, the current file parameters will be shown.
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7. Select which ECM configuration data is to be viewed and/or saved for future use. Select the
ECM configuration data by adding or removing the check mark next to the boxes to the left
of the parameter.
Illustration 33
8. After any selection changes are completed, the changes must be saved. Click "Save to File"
from the bottom of the ECM replacement screen to save the .xml the file.
Note: Make sure to note where the file is stored.
Programming New Configurations on the Annunciator ECM
1. Connect to the OCP 4.3 using the Cat Service Tool to the CAN 2 port.
2. From the "Service Tool" menu, select "Service", "Copy Configuration", then click "ECM
Replacement".
Illustration 34
3. After any selection changes are completed, click "Load from File" that is located at the
bottom of the ECM replacement dialog to save the file.
4. Navigate to the location where the file is stored and click "Open". Refer to Systems
Operation, Test and Adjust, UENR1210, "Flash Files" for the most recent .xml
configuration file.
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Illustration 35
g03311476
5. The software will confirm opening the file. Refer to Illustration 35.
6. Select which ECM configuration data is to be programmed into the OCP 4.3. Select the
ECM configuration data by adding or removing the check mark next to the boxes to the left
of the parameter.
Illustration 36
7. After any selection changes are completed, click "Program ECM" from the bottom of the
ECM replacement dialog to load the file into the OCP 4.3.
Illustration 37
8. The software will then prompt the user with a question in the dialog. After the dialog
appears, click "Yes". Refer to Illustration 37.
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Illustration 38
g03311470
Illustration 39
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10. Allow time for the software to configure the set parameters to the annunciator.
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Illustration 40
g03311466
Illustration 41
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1. Connect the battery. Use terminal 5 as ground. Confirm that +Vbat exists on the terminal
connections listed in Illustration 41.
Illustration 42
2. Use terminal point 5 as ground. Confirm that there is continuity, near zero ohms and near
zero volts, to each of the following terminals.
3. Correct any issues that prevented any of the foregoing results from occurring. Reconnect the
battery charger to the AC line.
4. Observe that the battery charger is supplying current to the battery.
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equipped with an ECM, the method is referred to as "Data Link". The OCP 4.3 has been set for
"SENSOR" by default.
Starting and Stopping the Generator Set - Discusses the various procedures to start and stop the
engine starting.
Set Point Programming - Discusses how to tailor the engine parameters to suit a particular
application starting.
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The following information refers to a situation where the pressure temperature parameter was set
to "2" or "3". Pressure temperature faults = false.
The oil pressure parameter will be set to a value below the idle speed rated pressure. The coolant
temperature parameter will be set to a value above the high coolant temperature threshold such
that neither will ever cause a fault. The engine will continue to run regardless of oil pressure or
coolant temperature.
Parameter Configurations Using Cat Electronic Technician (Cat ET)
Illustration 43
g03310203
Illustration 43 indicates all of the dialogs that have configuration parameter default values loaded.
The default values that do not apply to the engine must not be altered.
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Illustration 44
g03310208
Illustration 44 shows the "Crank Attempt/Successful Start Counter Configuration". The parameter
indicates the level of security required to modify the configuration parameters. The default value
is "0" which means there is "No Security".
Illustration 45
g03310216
Illustration 45 shows the "Enter the Engine Serial Number" dialog. The illustration shows that the
engine serial number has not been programmed. Program the engine serial number at this time.
Illustration 46
g03310319
Illustration 46 shows the "Engine Service Hours Configuration" dialog. The information for the
engine service hours can be found by navigating to the "Information" selection and then click
"Current Totals".
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Illustration 47
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Illustration 48
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Illustration 49
There are two analog inputs from the engine. The analog inputs are the engine oil pressure and the
engine coolant temperature. The default values of the inputs are listed below. Refer to Illustration
49.
Note: The Minimum and Maximum Data Range units for pressure are kilo Pascals (kPa). The
Minimum and Maximum Data Range units for temperature are Centigrade Degrees. All
configuration parameters are entered in SI (Metric) units even though the display may show
English units.
Automatic Start/Stop
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Illustration 50
Use Cat ET to configure the "Automatic Start/Stop" parameters shown in Illustration 50.
Cycle Crank Configuration - Cycle crank configuration can be found listed as "Crank Duration".
The range of the parameter is 1 to 60 seconds. The default value is set at 10 seconds.
Cycle Crank Rest Interval - Cycle crank rest interval range parameter is set from 1 to 60
seconds. The default value is set at 5 seconds.
Maximum Number of Crank Cycles - The maximum number of crank cycles parameter is set
from 1 to 99. The default is set to 1.
Cool down Configuration - The cool down configuration can be found listed as "Cool Down
Duration". The range of the parameter is 0 to 30 minutes. The default value is set at 5 minutes.
Crank Termination Speed Configuration - Crank termination speed configuration can be found
listed as "Crank Terminate RPM". The range of the parameter is 100 to 1000 RPM. The default
value is set at 300 RPM.
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Engine Fuel Type Configuration - The engine fuel type configuration value will always read
"Diesel" and cannot be changed. The "Diesel" selection will not affect the operation of a gas
engine.
Battery Voltage Monitor
Illustration 51
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Illustration 52
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Illustration 53
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Illustration 54
g03310576
Illustration 55
Idle Speed Oil Pressure Shutdown - The oil pressure shutdown is listed as the "Low Idle Low
Engine Oil Pressure Shutdown Event Threshold". The range of the parameter is 20 kPa (3 psi) to
420 kPa (61 psi). The default value is set at 207 kPa (30 psi).
Low Idle Low Engine Speed Oil Pressure Warning Event Threshold - The range of the low
idle low engine speed oil pressure warning event threshold parameter is 22 kPa (3 psi) to 462 kPa
(67 psi). The default value is set at 241 kPa (35 psi). The value of the parameter should be set at
least 110% of the value of the "Idle Speed Oil Pressure Shutdown" parameter.
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Oil Step Speed - The oil step speed is listed as the "Low Engine Oil Pressure Step Speed". The
range of the parameter is 400 to 1800 RPM. The default value is set at 400 RPM.
Engine Speed Monitor
Illustration 56
Ring Gear Teeth - The ring gear teeth are listed as "Flywheel Teeth". The range of the parameter
is 110 to 260. The default value is set at 183.
Overspeed - Overspeed is listed as "Engine Overspeed Setpoint". The overspeed default value is
set at 1540 RPM.
Note: The over speed value is engine-specific.
Enhanced Engine Monitor
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Illustration 57
Illustration 57 shows the default value for the "Number of Engine Cylinders" will be set at "1"
regardless of the number of cylinders in the engine.
Validation
The information in the following section is for testing the operational aspects of the control.
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3. Acknowledge the cranking cycle faults and reset the OCP 4.3 control.
4. Connect the wire that was removed from terminal 14 of the FCR.
Idle Speed Tests
Disconnect the wire on terminal 5 of the Woodward Governor to prevent the governor from
running the engine at rated speed.
Idle Speed, E-Stop Test
The idle speed/E-Stop test will verify that the engine can be stopped at idle speed with the E-Stop
button.
1. Push the "RUN" button and allow the engine to start and run at idle speed.
2. Press the E-Stop button to verify that the engine stops.
Idle Speed Parameter Validation
1. Push the "RUN" button on the OCP 4.3 control panel.
The engine will start and run at idle speed.
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Illustration 58
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2. Read the engine idle speed operating parameters from the ECM display and record the
parameters that are listed in Illustration.
3. The idle speed parameter determination must be investigated and resolved before
proceeding.
4. Check the coolant temperature as the engine starts. Verify that the coolant temperature is
close to the temperature of the engine block.
The coolant temperature check is used to determine if the coolant temperature sensor and
related wiring is functional.
5. Press the "Stop" button on the OCP 4.3. The engine will come to a controlled stop.
6. Correct any issues that prevented the engine from starting, idling, or verification of the idle
speed parameters.
Engine Speed Sensor Loss Test
The engine speed sensor loss test will verify that the engine will stop if the engine speed sensor
fails.
1. Push the "RUN" button and allow the engine to start and run at idle speed.
2. Jumper terminal 205L to terminal 206L.
The engine should shut down immediately. The loss of engine speed will result in an
"Unexpected Engine Shutdown" fault.
3. Remove the jumper installed from terminal 205L to terminal 206L.
4. In order to reset the "Unexpected Engine Shutdown" fault, the power must be removed from
the OCP 4.3.
5. Remove fuse 9 to remove power from the OCP 4.3. Wait 10 seconds and then install fuse 9.
6. Restart the engine and allow the engine to run at idle speed.
7. Disconnect the engine speed sensor from either terminal 205L or 206L.
The engine should shut down immediately.
8. Connect the engine speed sensor and cycle the power on the OCP 4.3 as discussed in Step 5.
9. Reconnect the wire on terminal 5 of the Woodward Governor.
Rated Speed Tests
1. Push the RUN button on the OCP 4.3.
The engine will crank, start, and run at idle speed while building oil pressure. The OCP 4.3
and Woodward Governor will bring the engine to rated speed once idle speed and oil
pressure conditions have been met.
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2. After the engine comes up to rated speed, monitor the coolant temperature as the
temperature rises.
Illustration 59
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3. Record the engine rated speed operating parameters after the coolant temperature has
stabilized.
4. Put the OCP 4.3 into the "Stop" mode. Observe that the engine speed is reduced to idle
while the engine cools down for the period recorded as cooldown duration.
5. Correct any issues that prevented the engine from starting, idling, running at rated speed,
cooling down, or recording the rated speed parameters.
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Time" set point. Ensure that the fault protection timer has elapsed before starting this high coolant
temperature verification.
1. Start the engine and run the engine at rated speed.
2. Determine that the controller "Engine Coolant Temperature Sensor Configuration" is set for
"SENSOR".
3. Adjust the set point value for the "Analog Input #2 High Shutdown Event Threshold".
Adjust the set point value that is below the engine coolant temperature that the engine is
operating at. The minimum value for this setpoint is 49 C (120 F). The engine may have
to run for a few minutes to get the temperature above the minimum value. The shutdown
event will occur after the programmable time delay which is the "Analog Input #2 High
Shutdown Event Delay Time" set point.
4. View the event by going to the OCP 4.3 control event log.
5. Reset the event.
6. Return set point value for "Analog Input #2 High Shutdown Event Threshold" to the
original value.
Over Speed Verification
1. Start the engine and run the engine at rated speed.
2. Adjust the set point value for "Engine Over Speed Set Point" to a value that is below the
speed that the engine is running at.
An "Engine Over Speed Set Point" event will occur immediately after the set point is
changed. The engine will shut down.
3. View the event by going to the OCP 4.3 control event log. Reset the event. For more
information about how to view and reset the event, refer to Systems Operation,
Troubleshooting, and Testing and Adjusting, UENR1210, "EMCP4.3/4.4 ".
4. Return the set point value for the engine overspeed set point to the original value.
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Illustration 60
Caterpillar service tool CAN 2 annunciator default configuration values
The OCP CAN annunciator serves to display system alarm conditions and status indications. The
CAN annunciator has been designed for use on the OCP accessory CAN data link and may be
used in either local or remote applications.
The CAN annunciator options provide customers with enhanced site flexibility. In local
applications, the CAN annunciator may be mounted on the package generator set with the OCP to
provide a complete package mounted monitoring solution. The CAN annunciator may also be
mounted separately from the generator set to provide remote indication of system operating and
alarm conditions.
Refer to Systems Operation, Troubleshooting, and Testing and Adjusting, UENR1210,
"EMCP4.3/4.4", "Annunciator Module" for specifications, wiring, and a comprehensive
discussion of annunciator features.
Annunciator Icons
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Illustration 61
g03321803
Emergency Stop - When the emergency stop condition has been met, the red indicator light is
illuminated and the horn will be on.
Illustration 62
g03321991
Overcrank - When the over crank condition is met, the red indicator light is illuminated and the
horn will be on.
Illustration 63
g03322145
Low Coolant Temperature - When the low coolant temperature condition is met, the amber
indicator light is illuminated.
Illustration 64
g03322152
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High Coolant Temperature - When the high coolant shutdown condition is met, the red light is
illuminated and the horn will be on. When the high coolant warning condition is met, the amber
light is illuminated.
Illustration 65
g03322153
Low Oil Pressure - When the low oil pressure shutdown condition is met, the red light is
illuminated and the horn will be on. When the low oil pressure warning condition is met, the
amber light is illuminated.
Illustration 66
g03322154
Overspeed - When the engine over speed shutdown condition is met, the red indicator light is
illuminated and the horn will be on.
Illustration 67
g03322155
Unexpected Engine Shutdown - When the unexpected engine shutdown condition is met, the red
indicator light is illuminated and the horn will be on.
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Illustration 68
g03322156
EIS Warning - When the EIS warning condition is met, the amber indicator light is illuminated.
Illustration 69
g03322157
EIS Shutdown - When the EIS shutdown condition is met, the red indicator light is illuminated.
Illustration 70
g03322159
Control Switch Not In Auto - When the control switch is not in automatic, the amber light is
illuminated.
Illustration 71
g03322160
High Battery Voltage - When the high battery voltage shutdown condition is met, the red
indicator light is illuminated and the horn is on. When the high battery voltage warning condition
is met, the amber indicator light is illuminated.
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Illustration 72
g03322161
Low Battery Voltage - When the low battery voltage condition is met, the amber indicator light is
illuminated.
Illustration 73
g03322164
Primary Data Link J1939 #1 - When there is a diagnostic and there is no error on the CAN 1
data link, the green indicator light is illuminated. When there are no diagnostics or data link errors,
no lights are illuminated.
Illustration 74
g03322167
Module Network Status - Refer to Table 19 for CAN annunciator module and network status
LED behavior.
Table 19
Annunciator Module Status Lights
Light
Description
Red solid
CAN 2 data link diagnostic. Example: The data link module is wired
wrong, wrong cable, or no terminating resistor.
Green solid
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Green flashing
Red/Green
alternating
Illustration 75
g03311116
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