You are on page 1of 68

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte...

Page 1 of 68

Previous Screen

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

Publication Date -14/10/2014

Date Updated -14/10/2014

i05926752

Procedure to Upgrade the EMCP 1 to the Operator Control


Panel (OCP) 4.3{4490, 7451}
SMCS - 4490; 7451

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

Engine Monitoring Control Gp

6V-6149

Engine Monitoring Control Gp

10R-4099

Electronic Control Gp

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 2 of 68

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

ECM Part Number

3687106-01

ECM Serial Number

2071E099TW

Software Group Part Number

4241323-00

Software Group Release Date

AUG2012

Software Group Description

A5L2 English
4.2 PROD OCP
30August2012

Important Safety Information


Do not perform any procedure in this Special Instruction until you have read this Special
Instruction and you understand this information. Use only proper tools and observe all precautions
that pertain to the use of those tools. Failure to follow these procedures can result in personal
injury.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 3 of 68

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

OCP 4.3 Overview


Power Requirements
The control is designed to operate on 24 VDC. Current draw of the control package is less than 2.0
amps. External solenoids, loads driven by the controls relays, and connection of a Cat ET
communications adapter will add to the current draw.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 4 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 5 of 68

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.

Retrofit Installation Process Overview


1. Removal of the earlier control is the first process that must be accomplished.
a. Eliminate any problems or issues in the existing system. Any existing problems will
become more difficult to diagnose, troubleshoot, and repair once the existing control

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 6 of 68

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.

Original Control Removal


Resolve Existing Issues With Engine or Control System
Check for diagnostic codes stored in ECM memory.
Refer to Service Manual, SENR3535, "Diagnosed Problems" for procedures to resolve any
problems before proceeding. Refer to Service Manual, SENR3535, "Undiagnosed Problems" for
procedures to resolve any problems before proceeding.
Verify Engine Control Switch (ECS) Operation

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 7 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 8 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... Page 9 of 68

Illustration 3

g03307277

3. Confirm +Vbat is present on the terminals listed in Illustration 3.


4. Remove the connection between ECM terminal D and terminal F.
5. Correct any issues that prevented the foregoing results from occurring.
Speed Control Relay Circuit - 2301
Ignore the info in the "Speed Control Relay Circuit - 2301" section if the control system does not
use a Woodward Governor.
1. Disconnect the wire from terminal 9 that is on the Woodward Governor 2301 Speed
Control. The wire on terminal 9 is the positive lead that supplies power to the actuator.
2. Confirm +Vbat is present on terminal 2 of the Woodward Governor.
3. Confirm that no or low voltage is present on terminal 5 of the Woodward Governor.
4. On the ECM, connect terminal 16 to terminal 17.
5. Confirm that +Vbat is present on terminal 5 of the Woodward Governor.
6. Remove the connection between terminal 16 and terminal 17.
7. Connect the wire to terminal 9.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 10 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 11 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 12 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 13 of 68

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.

Determine Baseline Operating Parameter Values


1. Put the ECS switch in "Stop" mode.
2. Record the set points programmed in the ECM.
Refer to Service Manual, SENR3535 for the procedure to read ECM set points.
3. Do not change any of the set points. The set point values are changed by adjusting the
potentiometer.
Do not adjust the potentiometer.
The rotary switch position will be in the "RUN" mode, which will be either position 0 or 1.
4. Record the "Run" mode switch position before changing the switch position. Mark which
position, in Table 4, that the run mode switch was found in, either 0 or 1.
Table 4
Rotary Switch Position
Switch Position Set Point Description
Initial run mode switch position

Set Point Value


0

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 14 of 68

ECS

Engine Control Switch

ESCM

Engine Status Control Module

AFRC

Air Fuel Ratio Control

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 15 of 68

Illustration 6

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 16 of 68

5. Record the set points for rotary switch position 02 through 15. Refer to Illustration 6.

Controls that are Not Equipped with an Air Fuel Ratio


Control (AFRC) Module
Overview
The following section provides information for the installation of the OCP 4.3 ( 418-6662
Instrument Panel Box Gp ) for controls that do not have an Air Fuel Ratio Control (AFRC)
module.
1. Disconnect the wiring and remove the existing control panel.
2. Physical installation of the new OCP 4.3.
3. Connect conduit and wiring for the OCP 4.3.

Existing Control Panel Removal


1. Disconnect the battery charger from the AC line.
2. Disconnect the battery.
3. Inspect the wiring coming out of the conduit that enters the bottom of the panel. All of the
wires must be labeled with the number of the terminal block that the wiring is connected to.
4. When all of the wires have been accurately labeled, disconnect the wires from the terminal
blocks. Leave the wires in the conduit, remove the conduit from the bottom of the panel.
Note: Save the original mounting hardware in order to reuse the hardware for the
installation of the OCP 4.3 panel.
5. If the Woodward Governor is going to be used in the new panel, the Woodward Governor
must be removed from the old panel now.
6. Disconnect the wires from the Woodward Governor terminal strip.
7. Remove the four mounting screws for the Governor from the control panel. Set the
Woodward Governor aside for installation in the new OCP 4.3 control panel. Remove the
earlier panel from the four mounting points. Save the fasteners for use with the OCP 4.3
panel.

Installation of the OCP 4.3 Control Panel


The OCP 4.3 control panel has been designed to "drop-in" fit. The OCP 4.3 utilizes the same
mounting points and the same conduit entrance as the original panel.
Note: If changes have been made to the old panel installation, modifications may be necessary to
install the new panel. Refer to the wiring requirements section of Application and Installation
Guide, LEBE0007 for information regarding wiring requirements.
The oil pressure sensor, fuel temperature sensor, engine speed sensor, the required connectors and
cable for these sensors are not included in the kit. The sensors, connectors, and cables must be

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 17 of 68

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.

Controls Equipped with an AFRC Module


Overview
The following section provides information for the installation of the OCP 4.3 ( 418-6662
Instrument Panel Box Gp ) for controls that have an Air Fuel Ratio Control (AFRC) module.
Note: The OCP 4.3 panel must be mounted to the existing control panel. Wiring from the OCP 4.3
to the existing control panel is not provided with the 418-6662 Instrument Panel Box Gp .
1. Removal of old wiring in existing control.
2. Physical installation of new OCP 4.3 control.
3. Installation of control wiring from OCP 4.3 to existing control panel.
The following items must be procured for proper installation of the OCP 4.3 control. Refer to the
Illustration 8.

Conduit and Fittings


Use 1 inch Electrical Metallic Tubing (EMT), Intermediate Metallic Tubing (IMC) or Galvanized
Rigid Conduit (GRC). The fittings and lengths of conduit that will be required are dependent upon
where the OCP 4.3 control is located with respect to the original control. Location of the panel
will need to be determined by the installer.

Removal of Old Wiring in Existing Control


Tables 6 through 16 specify which wires are to be removed from the existing control panel. The
wire number, as well as the two points where the wire connects, are shown for clarity.
Many of the devices (lamps, switches, controls) will be left without any wires attached to the
devices. The unused devices can be removed from the panel. Any holes in the panel must be
covered to keep dust, moisture, and vermin out of the control panel.
Table 6
Remove Shutdown Indicator Light Wiring
Term Point

Wire Number

Term Point

Shutdown lamp (+)

P762-RD

Warning lamp (+)

Shutdown lamp (-)

J440-BK

Term Block 213

Table 7
Remove Warning Indicator Light Wiring
Term Point

Wire Number

Term Point

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 18 of 68

Warning lamp (+)

P673-RD

Power lamp (+)

Warning lamp (-)

J430-BK

Term Block 212

Table 8
Remove Power Indicator Light Wiring
Term Point

Wire Number

Term Point

Warning lamp (+)

P677-RD

Term Block 105

Warning lamp (-)

P389-BK

Term Block 152

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)

ECS (4) P628

P684-BK

Term Block 180

ECS (5)

P622-BK

ESCM (10)

ECS (6)

P288-RD

ESCM (+)

ECS (7)

P628-RD

Term Block 208

ECS (8)

------

------

ECS (9)

P686-RD

Term Block 103

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 19 of 68

ESCM (1)

S270-BK

Term Block 206

ESCM (2)

D240-GN/YL

Term Block 163

ESCM (3)

D970-CU

Term Block 254

ESCM (3)

D970-BK

Term Block 253

ESCM (4)

D970-RD

Term Block 252

ESCM (5)

D970-WH

Term Block 251

ESCM (6)

D240-RD

Term Block 162

ESCM (7)

S270-RD

Term Block 205

ESCM (8)

P270-RD

Term Block 216

ESCM (9)

P625-BK

Term Block 179

ESCM (10)

------

------

ESCM (11)

------

------

ESCM (12)

------

------

ESCM (13)

C267-BK

Term Block 157

ESCM (14)

C251-BK

Term Block 211

ESCM (15)

J420-BK

Term Block 256

ESCM (16)

------

------

ESCM (17)

------

------

ESCM (18)

M281-BK

Term Block 173

ESCM (19)

C866-WH

Term Block 177

ESCM (20)

C875-BK

Term Block 174

ESCM (21)

------

------

ESCM (22)

C270-BK

Term Block 159

ESCM (23)

A220-RD

Term Block 260

ESCM (24)

M200-BK

Term Block 255

ESCM (25)

P220-RD

Term Block 209

ESCM (26)

P780-RD

Term Block 101

ESCM (27)

------

------

ESCM (A)

------

------

ESCM (D)

------

------

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 20 of 68

ESCM (E)

------

------

ESCM (F)

------

------

ESCM (G)

C866-BK

Term Block 178

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

Term Block 262

ESCM (B-)

A220-BK

Term Block 261

Table 12
Remove 270 Ohm Resistor R1
Term Point
Term Block 264

Wire Number
R1

Term Point
Term Block 265
Table 13

Remove the ESCM MPU Wiring


Note: The following terminal blocks are located in the Engine Mounted Gauge
Panel/Terminal Box
Term Point

Wire Number

Term Point

ESCM MPU-SHLD

S270-CU

Term Block 207

ESCM MPU-B

S270-BK

Term Block 206

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 21 of 68

ESCM MPU-A

S270-RD

Term Block 205

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

Term Block 155

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

Term Block 151

Table 16
Remove the XDUCER Wiring
Term Point

Wire Number

Term Point

XDUCER-2 (BK)

D970-BK

Term Block 253

XDUCER-1 (OR)

D970-RD

Term Block 252

XDUCER-3 (PK)

D970-WH

Term Block 251

XDUCER-SHLD

D970-CU

Term Block 254

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 22 of 68

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

Flat washer, 1/2 inch

Nut, 1/2 inch -13

Lock washer, 1/2 inch

Spacer, 9/16 inch ID x 3/4 inch OD x 1 inch long

Bolt, 1/2 inch -13 x 2-1/2 inch

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 23 of 68

Illustration 8

g03359124

(1) Flat washer


(2) Nut
(3) Lock washer
(4) Spacer
(5) Enclosure side
(6) Bolt

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.

Installation of Control Wiring from OCP 4.3 to Existing Control Panel

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 24 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 25 of 68

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

179, 180, 201

Remote Shutdown

256, 158, 157

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.

Flashing and Configuring the OCP 4.3


In order to flash software into the OCP 4.3, the engine must be stopped. If upgrading software, the
suggested process is to back up the current configuration, if a backup has not already been done.
Refer to the note in the Introduction section of this pub. 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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 26 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 27 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 28 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 29 of 68

Illustration 15

5. The new file information will be displayed. Refer to 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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 30 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 31 of 68

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".

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 32 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 33 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 34 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 35 of 68

Illustration 27

g03311466

9. The software will confirm programming the ECM.


Configuring the Annunciator ECM
The annunciator ECM is only accessible through the CAN 2 port or accessory data link. In the
case of the annunciator, ECM replacement must be used via the CAN 2 port or accessory data link
only.
Saving the Current Annunciator ECM Configuration
1. Connect to the OCP 4.3 using the Cat Service Tool to the CAN 2 port.

Illustration 28

2. From the "Service Tool" menu, select "Service", "Copy Configuration", then click "ECM
Replacement".

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 36 of 68

Illustration 29

g03311469

3. The dialog will display "No data is available. Load from the ECM now?" Click "Yes".

Illustration 30

g03311470

4. Select "Alarm Module #1" from the given list of ECMs. The selection will allow the
software to connect to the annunciator.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 37 of 68

Illustration 31

g03311471

5. The software will load the annunciator configuration.

Illustration 32

6. After the software loads the data, the current file parameters will be shown.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 38 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 39 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 40 of 68

Illustration 38

g03311470

9. Select "Alarm Module #1" from the list of ECMs.

Illustration 39

g03311496

10. Allow time for the software to configure the set parameters to the annunciator.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 41 of 68

Illustration 40

g03311466

11. The software will confirm the programming of the ECM.

Validate Installation of the Control


Initial Electrical Checkout
1. Ensure that there is no electrical short circuit between +Vbat and ground.
2. Measure the resistance between terminal block 5, which is ground and terminal block 1,
which is +Vbat.
Note: The resistance should be greater than 10 ohms.
3. Correct any short circuit conditions before proceeding.
Battery Installation

Illustration 41

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 42 of 68

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.

Configure Engine Operating Parameters


Refer to Systems Operation, Troubleshooting, and Testing and Adjusting, UENR1210,
"EMCP4.3/4.4" for related information about the EMCP 4.3 which is similar to the OCP 4.3
operation.
Refer to the following topics in Systems Operation, Troubleshooting, and Testing and Adjusting,
UENR1210, "EMCP4.3/4.4" if needed.
Diagnostic System Procedures - Contains information about the procedures to troubleshoot the
system.
Engine Sensor Versus Data Link - Discusses how the OCP 4.3 acquires oil pressure and coolant
temperature. For engines without an ECM, the method is referred to as "SENSOR". For engines

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 43 of 68

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.

OCP 4.3 Security


Refer to Systems Operation, Troubleshooting, and Testing and Adjusting, UENR1210,
"EMCP4.3/4.4", "Password Entry" which discusses how the OCP 4.3 has implemented security
passwords.

Time and Date Configuration


Refer to Systems Operation, Troubleshooting, and Testing and Adjusting, UENR1210,
"EMCP4.3/4.4", "Real Time Clock Programming" for information how to set the time and date on
the OCP 4.3 control. Refer to the subtitle section "Changing the Time/Date".

Battery Charger Fault Detection


The OCP 4.3 control has not allocated inputs for battery charger fault detection. If there is a need
to monitor the battery charger status and the battery charger provides status outputs, refer to
Systems Operation, Troubleshooting, and Testing and Adjusting, UENR1210, "EMCP4.3/4.4",
"Discrete Input/Output Module" for information how to implement digital inputs. Refer to the
subtitle section "Configuring Digital Inputs".

Configuring Engine Parameters


Gas Shutoff Valve Operation
1. Record the set points programmed in the ECM.
2. If the rotary switch in the EMCP 1 was set to position "0", the OCP 4.3 control is wired for
the proper operation. Position "0" is the "energize the gas shutoff valve to run".
3. If the rotary switch in the EMCP 1 was set to "Position 1", the fuel control relay (FCR) must
be rewired. "Position 1" is the "energize the gas shutoff valve to stop". Disconnect the wire
from terminal 7 of the FCR and connect the wire to terminal 3 of the FCR.
4. The gas shut off valve will now be energized to stop.
Pressure Temperature Fault Configuration
Follow the instructions in the following two steps if the pressure temperature parameter was set to
"0" or "1". Pressure temperature faults = true.
1. Set the idle speed oil pressure parameter to the same value as determined for parameter 10.
2. Set the rated speed oil pressure parameter to the same value as determined for parameter 09.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 44 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 45 of 68

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".

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 46 of 68

Illustration 47

g03310336

Illustration 47 shows the "Display Preferences" dialog.

Illustration 48

g03310339

Illustration 48 shows the "Service Maintenance Interval" dialog.


Analog Inputs
High Coolant Temperature Shutdown - The high coolant temperature shutdown can be found
listed as "Analog Input #2 High Shutdown Event Threshold". The range of the parameter is 95 C
(203 F) to 120 C (248 F). The default value is set at 108 C (226 F).
Low Shutdown Event Threshold - Low shutdown event threshold can be found listed as the
"Analog Input #1 Low Shutdown Event Threshold". The range of the parameter is 13.4 kPa (1.94
psi) to 880 kPa (127.64 psi). The default value is set at 150 kPa (22 psi). The value represents low
oil pressure at idle speed.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 47 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 48 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 49 of 68

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

Illustration 51 shows the dialog for battery voltage monitoring.


Digital Inputs

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 50 of 68

Illustration 52

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 51 of 68

Illustration 52 shows the dialog for digital input configuration.


Digital Outputs

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 52 of 68

Illustration 53

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 53 of 68

Illustration 53 shows the configuration of the digital outputs.


Engine Coolant Temperature Monitor

Illustration 54

g03310576

Illustration 54 shows that the default value is set at "Sensor".


Engine Oil Pressure Monitor

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 54 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 55 of 68

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.

Engine Start and Idle Checkout


Cranking Cycle Tests
1. Disconnect the wire from the fuel control relay (FCR) terminal 14.
Note: Removal of the wire will prevent the gas shut off valve from opening, the engine
from starting, and allow full testing of the cranking cycle.
2. Push the RUN button on the OCP 4.3 control.
The engine should crank for the time set in the "Crank Cycle Time Configuration". At the
end of the crank time, the engine should stop cranking for the rest time set in the "Cycle
Crank Time Configuration". The cycle should repeat the number of times set in the "Cycle
Crank Time Configuration". If the engine cranking cycle is not what is desired, review the
times that have been set in the "Cycle Crank Time configuration".
The battery charger gets disconnected while the engine is cranking.
3. Observe the battery charger and note that the battery charging current drops to zero when
the engine is cranking.
4. Acknowledge the cranking cycle faults and reset the OCP 4.3 control.
Cranking Cycle, E-Stop Test
The cranking cycle/E-Stop test will verify that the engine cranking cycle can be stopped with the
E-Stop button. The engine should not start since the FCR has been previously disabled.
1. Push the "RUN" button and allow the engine to go through the first crank/rest cycle.
2. When the second crank cycle begins, press the E-Stop button to verify that the engine can
be stopped.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 56 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 57 of 68

Illustration 58

g03319113

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 58 of 68

2. After the engine comes up to rated speed, monitor the coolant temperature as the
temperature rises.

Illustration 59

g03319273

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 59 of 68

Remote Operation Tests


The remote operation tests will validate the control capability to start and stop the engine using the
remote control inputs. Each of the following tests will require a jumper wire connected to ground.
Connect a wire to terminal 5 to use for this purpose.
E-Stop Test
1. Use the OCP 4.3 "Run" button to start the engine.
Allow the engine to come up to speed. Do not allow the engine to warm up.
2. Use a jumper wire to connect terminal 211 to ground. Verify that the engine stops running.
3. If a remote E-Stop switch is part of the installation, connect the remote E-Stop switch to the
control. The remote E-Stop switch must be connected to either terminal 211 in the OCP 4.3
control panel or terminal 211 in the engine mounted terminal box.
4. Start the engine and allow the engine to come up to rated speed.
5. Initiate an E-Stop command using the remote E-Stop switch. Verify that the switch works as
intended.
6. Correct any issues that prevented the engine from starting, idling, running at rated speed,
cooling down or stopping.
Remote Initiate Test
1. Stop the engine.
2. The OCP 4.3 control must be in "Auto".
3. Use a jumper wire to short terminal 179 to ground. Only a touch of the jumper wire will be
enough to create the situation.
The engine will crank, start, idle, and run at rated speed.
4. If a remote initiate switch is part of the installation, connect the remote initiate switch to the
control. The remote initiate switch must be connected to either terminal 179 in the OCP 4.3
panel or the engine mounted terminal box.
5. Initiate a remote initiate with the remote initiate switch and verify that this switch works as
intended.
6. Stop the engine using the Stop button on the OCP 4.3 control panel.
7. Correct any issues that prevented the engine from starting, idling, running at rated speed,
cooling down or stopping.
8. Terminals 180 and 201 provide the same function as terminal 179. If 180 or 201 terminals
are to be used, use the same procedure as terminal 179 to verify the functionality of
terminals 180 and 201.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 60 of 68

Remote Shutdown Test


Remote shutdown will occur when any of the three terminals 179, 180, or 201 are grounded. The
system configuration provides three different means of shutting the engine down from a remote
location. Test each of the three terminals using the following procedure.
1. Touch a jumper wire, that is connected to ground, to one of the remote shutdown terminals
179, 180, or 201. Terminals 179, 180, or 201 can be accessed in the OCP 4.3 panel or the
engine mounted terminal box.
The engine will come to a controlled stop.
2. Touch a jumper wire, that is connected to ground, to one of the other remote shutdown
terminals. Once the engine has shut down, start the engine and allow the engine to come up
to rated speed again.
3. Touch a jumper wire, that is connected to ground, to the last remote shutdown terminal.
The engine will come to a controlled stop.
If remote shutdown switches are part of the installation, connect remote shutdown switches
to the control via terminals 179, 180, or 201. The terminals can be accessed in the OCP 4.3
panel or the engine mounted terminal box.
The remote shutdown must switch the terminal to the OCP 4.3 ground.
4. Start the engine. Allow the engine to come up to the rated speed.
5. Initiate a remote shutdown with the remote shutdown switch. Verify that the switch works
as intended.
6. Correct any issues that prevented the engine from starting, idling, running at rated speed,
cooling down, or stopping.
EIS Shutdown and Warning Test
The "Electronic Ignition System" (EIS) can shut down the engine. The EIS test simulates the
action of the EIS to shut down the engine.
1. Start the engine. Allow the engine to come up to the rated speed.
2. Touch the ground wire to terminal 212.
3. The EIS warning LED (amber) will illuminate on the annunciator but the engine will
continue to run.
4. Touch the ground wire to terminal 213 in the OCP 4.3 panel or the engine mounted terminal
box.
5. The EIS shutdown led (red) will illuminate on the annunciator and the engine should come
to a controlled stop.
6. Remove the ground wire from terminal 5.
7. Correct any issues that prevented the engine from starting, idling, running at rated speed,
cooling down, or stopping.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 61 of 68

Engine Set Point Verification


The engine set point verification procedure verifies that the OCP4.3 operates correctly when a low
oil pressure or high coolant temperature event occurs. The engine set point verification procedure
also verifies that the OCP4.3 operates correctly when an engine over speed event occurs.
The low oil pressure and high coolant temperature each have two events, "Warning" and
"Shutdown". The OCP4.3 will issue a warning whenever the warning threshold is reached and a
shutdown whenever the shutdown threshold is reached.
The verification procedure will modify configuration set points used in normal operation. The
steps below outline how to perform the low oil pressure shutdown and high coolant temperature
shutdown procedures. A similar process can be used for low oil pressure warning and high coolant
temperature warning, along with low idle low oil pressure.
During the procedure, each configuration set point must be recorded prior to adjustment. Return
each configuration set point back to the original setting after the set point has been verified. The
following conditions are required before the engine set points are verified.
1. The setpoints must be correct for the engine application.
2. No shutdown events should be present. If necessary, troubleshoot, correct, and reset any
shutdown events.
Low Oil Pressure Verification
Note: The low oil pressure shutdown is disabled during start-up and while the engine is not being
controlled by the fault protection timer (FPT).
The fault protection timer starts timing when crank terminate RPM is reached during the starting
sequence. The fault protection timer will then run for a programmed time which is determined by
the "Engine Start Fault Protection Activation Delay Time" set point. Make sure that the fault
protection timer has elapsed before starting the low oil pressure verification.
1. Start the engine and run the engine at rated speed.
2. Determine that the controller engine oil pressure sensor configuration is set for "Sensor".
3. Adjust the set point value for "Analog Input #1" which is the "Low Shutdown Event
Threshold". Adjust the set point to a value that is above the oil pressure at which the engine
is operating. The shutdown event will occur after the programmable time delay which is the
"Analog Input #1 Low Shutdown Event Delay Time" set point.
4. View the event by going to the OCP 4.3 event log. Reset the event.
5. Return set point value for "Analog Input #1 Low Shutdown Event Threshold" to the original
value.
High Coolant Temperature Verification
Note: The "Analog Input #2 High Shutdown" is disabled during start-up and while the engine is
not running by the fault protection timer (FTP). The fault protection timer starts timing when the
"Crank Terminate" RPM is reached during the starting sequence. The fault protection timer will
then run for a programmed time which is the "Engine Start Fault Protection Activation Delay

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 62 of 68

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.

Maintenance and Operation


CAN Annunciator Operation

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 63 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 64 of 68

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

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 65 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 66 of 68

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.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 67 of 68

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

CAN 2 data link OK

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/ful... Page 68 of 68

Green flashing

No CAN 2 data link diagnostic, but no communication detected.

Red/Green
alternating

No application software loaded

Illustration 75

g03311116

Annunciator module and network status indicator

Copyright 1993 - 2016 Caterpillar Inc.


All Rights Reserved.

Tue Jul 19 17:57:14 UTC+0100 2016


m400mwz

Private Network For SIS Licensees.

https://sis.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/sisweb/fulltext/fullte... 19/07/2016

You might also like