The EMCP 4.2 is a generator-set controller. It is used on generator sets from Caterpillar, including the 3512, 3516 TA, 3516B TA and 3516C-HD.
Also fitted to: Caterpillar C27 ACERT™ Diesel Oilfield Generator Set, Caterpillar Standby, Caterpillar XQ100 w/trailer.
| Symptom | Cause | Remedy |
|---|---|---|
| A strong odor of acid is present. | Reduce the rate of charging by a significant amount. Complete the charging at the reduced rate. | |
| Circulating current needed | Drying can be accomplished by circulating low voltage current through the windings. Since the voltage is low, the breakdown of the insulation will not occur as the breakdown might have occurred with normal operation and wet insulation. | |
| Dirt accumulation | Cleaning may be required at the point of installation. A vacuum cleaner should be used to pick up dry dirt, dust, and carbon. After most of the dust has been removed, a small brush may be attached to the vacuum hose in order to loosen dirt that is more firmly attached to the surface. Compressed air may be used to remove the remaining dust and dirt. | |
| Engine exhaust in an enclosed area | Start the engine and operate it in a well ventilated area. Vent the engine exhaust to the outside if started in an enclosed area. | |
| Engine overheating or accelerated wear | Stop the engine according to the procedure described in the Operation and Maintenance Manual, 'Engine Stopping' topic (Operation Section). Do not use the Emergency Stop Button for normal stopping. Correct any problem that caused an emergency stop before restarting. | |
| Engine shutdown due to certain conditions | The engine may shut down if it experiences: Engine overspeed, high aftercooler coolant temperature, high jacket water temperature, high crankcase pressure, or low engine oil pressure. Except for an overspeed shutdown, the monitoring system can be overridden. | |
| Improper grounding of the engine electrical system | Proper grounding is necessary for optimum performance and reliability. Use an engine-to-frame ground strap with a direct path to the battery. Ensure all grounds are tight and free of corrosion. | |
| Insulation breakdown | An insulation breakdown requires repair. A high pressure wash is normally an effective way to clean windings. This includes windings that have been exposed to flooding or windings that have been contaminated by salt. | |
| Insulation resistance below normal | Cleaning is advisable if heavy accumulations of dirt can be seen or if heavy accumulations of dust can be seen. If excess dirt is the cause of a restriction in the ventilation, cleaning is also advisable. | |
| Insulation resistance test failure | Heat the generator to approximately 75° C (167° F). Never exceed 75° C (167° F) until the insulation tester tests correctly for insulation resistance (at least 4 hours). | |
| Internal heating required | Generators are in damp environments and go for long periods of time without operation. Generators operate regularly in an environment with moisture laden air. | The electric space heaters should be installed as part of the generator. |
| Localized overheating | Radiant ovens sometimes cause localized overheating. | |
| Loose or frayed electrical wires | Check daily and tighten loose wires, repair frayed wires before starting the engine. See specific starting instructions in the Operation and Maintenance Manual. | |
| Overheating of the generator too quickly | Do not heat the generator too quickly. Try to limit the rise in temperature of the insulation and windings to 11.11° C (20° F) per hour. | |
| The battery emits smoke or a dense vapor (gas). | Reduce the rate of charging by a significant amount. Complete the charging at the reduced rate. | |
| The battery is very warm to the touch. | Reduce the rate of charging by a significant amount. Complete the charging at the reduced rate. | |
| Warning tag attached to the engine start switch or controls | Do NOT start the engine or move the controls. Consult with the person that attached the warning tag before starting. |
Fault codes and symptom→remedy steps extracted from this controller’s service/owner documentation; verify against the official manual before servicing. Aggregated from the service documentation of generator sets built on this controller.