Certificacion Cat

ADS – Dealer Training Service Training
CERTIFICATION MATERIAL
Americas Distribution Services Division
Electric Power Generation Technician Certification Program

Revision: January-2013
Participant Name _____________________________________ Date __________

Dealer _____________________________________
TABLE OF CONTENTS
CERTIFICATION PROCESS .......................................................................................... 1
MODULE #1: ENGINE SYSTEMS .................................................................................. 4
ENGINE SYSTEM QUESTIONNAIRE 7

TASK EXECUTION PREPARATION 21
TASK SHEET 01: LOCALIZATION OF ENGINE COMPONENTS 22
TASK SHEET 02: VERIFICATION/ADJUSTMENT OF ENGINE INJECTOR HEIGHT 23
TASK SHEET 03: INTAKE AND EXHAUST VALVE VERIFICATION/ADJUSTMENT 24
TASK SHEET 04: ELECTRIC AND ELECTRONIC COMPONENT VERIFICATION 25
TASK SHEET 05: CYLINDER CUTOUT TEST 26
TASK SHEET 06: ENGINE INJECTOR CALIBRATION AND ELECTRIC TESTS 27
TASK SHEET 07: ELECTRIC COMPONENT TROUBLESHOOTING 28
MODULE #2: ALTERNATORS AND VOLTAGE REGULATORS................................ 29
ALTERNATOR AND VOLTAGE REGULATOR QUESTIONNAIRE: 31

TASK SHEET 01: SR4B/SR5 GENERATOR FUNCTIONAL TEST 62
TASK SHEET 02: RECTIFIER BLOCK OPERATIONAL TEST 63
TASK SHEET 03: ALTERNATOR WINDING TEST 64
TASK SHEET 04: AVR VR6 STABILITY AND VOLTAGE ADJUSTMENT 65
TASK SHEET 05: AVR VR6 INFLECTION FREQUENCY ADJUSTMENTS 66
TASK SHEET 06: AVR VR6 FUNCTIONAL TEST 67
TASK SHEET 07: AVR R448 MAXIMUM EXCITATION ADJUSTMENT 68
TASK SHEET 08: AVR DVR PARAMETER VERIFICATION 69
TASK SHEET 09: AVR CDVR PROGRAMMING 70
MODULE #3: CONTROL PANELS .............................................................................. 71
CONTROL PANEL QUESTIONNAIRE 73

TASK SHEET 01: SECURITY LEVELS PROGRAMMING – EMCP 3 143
TASK SHEET 02: PARAMETER VERIFICATION – EMCP II+ 147
TASK SHEET 03: ENGINE PROTECTION SYSTEM TESTS – EMCP II+ 150
TASK SHEET 04: ATB PARAMETER VERIFICATION – EMCP II+ 151
TASK SHEET 05: EMCP 3 DIGITAL INPUT PROGRAMMING 152
TASK SHEET 06: ENGINE PROTECTION SYSTEM VERIFICATIONS – EMCP 3 153
TASK SHEET 07: EMCP 3 DISCRETE OUTPUT PROGRAMMING 154
TASK SHEET 08: PROGRAMMABLE CYCLE TIMER PROGRAMMING 155
TASK SHEET 09: EXTERNAL INPUT AND OUTPUT MODULE PROGRAMMING 156
TASK SHEET 10: THERMOCOUPLE/RTD MODULE PROGRAMMING 157

TASK SHEET 11: THERMOCOUPLE/RTD MODULE PROGRAMMING 158
TASK SHEET 12: RS-485 ALARM MODULE PROGRAMMING 159
TASK SHEET 13: EMCP 4 DISCRETE INPUT AND OUTPUT PROGRAMMING 160
TASK SHEET 14: EMCP 4 ANALOG INPUT PROGRAMMING 161
MODULE #4: START UP AND PREVENTIVE MAINTENANCE ................................ 162
START UP AND PREVENTIVE MAINTENANCE QUESTIONNAIRE 165

TASK SHEET 01: SAFETY VERIFICATION AND SERVICE ACCESS 183
TASK SHEET 02: AUTOMATIC TRANSFER START (ATS) 184
TASK SHEET 03: BATTERY CONDITION VERIFICATION TEST 185
TASK SHEET 04: OIL SAMPLING FOR S•O•S ANALYSIS 186
TASK SHEET 05: VENTILATION AND EXHAUST SYSTEM VERIFICATION 187
TASK SHEET 06: ELECTRIC STARTING SYSTEM TEST 189
TASK SHEET 07: GENERATOR SET ALARM VERIFICATION 190
TASK SHEET 08: GENERATOR SET VIBRATION TESTS 191
TASK SHEET 09: GENERATOR SET LOAD PROFILE TEST 193
ADS Dealer Training Service Training
CERTIFICATION PROCESS
PROCESS DESCRIPTION
PROCESS Each participant will receive an assessment schedule

during the opening event of the Program. This schedule
specifies the time at which participants should be at the
assessment station with the Facilitator that has been
assigned to them.
This module is divided into two assessment sessions. One

of them consists of an Interview with the Facilitator, and the
other one consists of Task Execution. The interview lasts
40 minutes as a maximum, and the Task Execution lasts
80 minutes.
Interview:
During the Interview, the Facilitator will randomly ask ten to
fifteen questions about the topics of each module. The
participant should answer the questions based on valid
information sources, such as the SIS, TMI, STMGs or ITTPs.
The participant will have 5 attempts to answer each

question during the certification process. Each question
should be answered correctly and based on the service
literature. For each failed attempt, the participant will be
discounted 20% of each question score (each question has
a score of 2 points.)
The participant must complete the questionnaire before

starting the certification process. If the participant does not
complete the questionnaire, 5 points will be discounted
from the module assessment.
This Section represents 30% of the total grade of the
Module.
Task Execution:
During the Task Execution Assessment, the participant
must demonstrate their ability to perform tasks described in
this material. The Facilitator will randomly assign 4 tasks
defined in this material. The participant must finish the
assigned tasks within the stipulated 80 minutes, unless the
Facilitator notes that he/she needs more time because of
factors beyond the participant's control, which prevent
him/her from finishing the assessment successfully.
1
The assessment criteria for this section will be as follows:

Confidence Failure: For each confidence failure,
the participant will be discounted 3 points.
Facilitator Intervention: For each facilitator
intervention, the participant will be discounted
1 point.
This Section represents 40% of the final grade of the Module.
Service Report:
Each participant must submit a Service Report in digital
format with the results of the performed Tasks to the
Facilitator. Each executed task must be identified as an
individual Report.
The assessment criteria for this section are as follows:

Team Information: The participant must include in
the service report all the information required for
properly recording the service data sheet in the log
of his/her life. For each missing information, the
participant will be discounted 0.6 points.
Test Procedures: The participant must clearly detail
the procedure followed in the test and the
references to the corresponding service literature.
For each missing information in the report, the
participant will be discounted 1 point.
Tool List: The participant must include in their
report the complete list of tools for all the tasks
performed during the assessment. For each used
tool and its correct part number that are not
mentioned in the service report, the participant will
be discounted 0.4 points.
Specifications: As for tasks in which the participant
must use reference values to adjust components,
these tasks must be clearly detailed in the service
report together with the references to service
literature. For each omitted specification, the
Test Points: As for tasks in which the participant
must identify the test points of the task, these
points must be clearly detailed in the service report.
For each test point omitted in the service report, the
Results: The participant must clearly detail the
results obtained in each executed task, as defined
in the worksheet. For each result omitted in the
service report, the participant will be discounted
1 point.
2
Observations/Recommendations: The participant

must detail any observation that has been detected
during the task execution. Also, he/she must
provide recommendations about the equipment
condition based on the tasks performed. If the
observations are not clearly detailed, or if the
provided recommendations are wrong, the
participant will be discounted 1 point for each one.
The service report must be submitted before 12:00 h of the
last day of the Certification Program.
This Section represents the 30% of the final grade of the

Module.
CONTACT INFORMATION General Information:

Sandra P. Latour, Visit Coordinator
+1 305-816-3346
Latour_Sandra_P@cat.com
Technical Information:
Alfonso Riley – Program Coordinator
+507 305-2215
Riley_alfonso@cat.com
3
MODULE #1: ENGINE SYSTEMS
Objectives The objectives of this module are the following:
Demonstrating the ability to carry out the mechanical adjustments required

for correct operation of engines in the application of Electric Power
Generation.
Demonstrating the ability to carry out the electronic adjustments required

for correct operation of engines in the application of Electric Power
Generation.
Demonstrating the ability to diagnose electric and electronic engine

components.
Demonstrating the ability to make a Service Report about the work done
according to Caterpillar standards.
Tasks The Tasks to be done in this module are:

Identifying components in the engine
Calibrating the engine in Top Dead Center
Adjusting injector height or injector timing, and verifying injection timing
Verifying calibration of intake and exhaust valves
Carrying out tests and calibrations of the generator set with the electronic
service tool ET
Locating faults in electric and electronic components
Tools 1U-9087 Governor Repair Tool Group
178-8615 Turning Tool
139-7063 Pin Timing
139-7063 Adapter
147-5482 Valve Lash Adjustment Tool Group
9U-5132 Timing & Fuel Setting Tool Group
164-3310 Infrared Thermometer
4
257-9141 Fluke 87 Multimeter
171-4400 Communication Adapter Group II
Caterpillar Electronic Technician Software version 2011C or above
Literature RENR9955 C2.2 Engine and C1.5 Generator Set - System Operation
and Testing & Adjusting
RENR9953 C4.4 Engine - System Operation and Testing & Adjusting
KENR8785 C6.6 Generator Set - System Operation and Testing &

Adjusting
SENR9868 C9 Generator Set Engines - System Operation and Testing

& Adjusting
SENR9708 C15 and C18 Generator Set Engines - System Operation

RENR9968 C27 and C32 Generator Set Engines - System Operation

RENR9338 C175-16 and C175-20 Generator Set Engines - System

Operation and Testing & Adjusting
SENR7939 G3304 and G3306 Engines - System Operation and

Testing & Adjusting
RENR5953 G3406 and G3412 Engines - System Operation and

Testing & Adjusting
RENR5923 G3500 Engines for Caterpillar Built Generator Sets -

System Operation and Testing & Adjusting
KENR9737 G3512E and G3520E Generator Set Engines - System

RENR2268 G3500B Engines - System Operation and Testing &

Adjusting
KENR6834 G3516C and G3516E Engines - System Operation and

Testing & Adjusting
5
RENR5978 G3520C and G3520E Generator Set Engines - System

RENR1287 3306B Generator Set Engine - System Operation and

Testing & Adjusting
RENR1293 3406C Generator Set Engines - System Operation and

Testing & Adjusting
RENR2303 3406E and 3456 Generator Sets - System Operation and

Testing & Adjusting
RENR1388 3412C Generator Set Engines - System Operation and

Testing & Adjusting
RENR5058 3500B Generator Set Engines - System Operation and

Testing & Adjusting
RENR4963 3500 Engines for Caterpillar Built Generator Sets - System

SERV1877 Reference Material - Electrical/Electronic Troubleshooting

Service Training Course
REHS0126 Diagnostic Code Information for Caterpillar Electronic

Control
REHS1003 Performing a Multiple Cylinder Cutout Test
SEPD1044 Service Magazine - Using Injector Trim Files
SEBD0640 Oil and your engine
SEBD0717 Diesel Fuels and your engine
SEBD0518 Know your cooling system
6
Engine System Questionnaire
Instructions: Answer this questionnaire completely before meeting the Facilitator for
the interview. The Facilitator will indicate the questions you should provide support to. If
you do not have this questionnaire complete at the time of the assessment, 5 points will
be discounted from the total assessment of the module.
Fuel, Inlet and Exhaust System
1. The injector TRIM Code must be calibrated every time the following occurs:
a. _______________________________________________.
b. _______________________________________________.
2. A problem with the “FRC fuel limit” will cause:
a. A limit in the maximum horsepower

b. Black smoke during acceleration
c. Black smoke during operation in stationary state
d. Low power until oil pressure rises
3. The fuel system requires priming when the following conditions occur:
a. Fuel filters are changed.

b. Fuel manifold is drained.
c. Fuel injectors are replaced.
d. All of the above
4. In a C18 Engine, the temperature of fuel entry into fuel transfer pump must not exceed ___________
when the motor has reached the normal operation temperature, as the life of fuel transfer pump check
valves will be reduced.
a. 79 °C (175 °F)
b. 40 °C (104 °F)
c. 69 °C (156 °F)
d. 30 °C (86 °F)
5. High temperature of fuel entry may cause:
a. Reduction of engine horsepower

b. Damage to auxiliary water pump
c. Premature wearing
d. All of the above
6. The temperature at which the fuel starts generating wax or paraffin that typically occurs in petroleum
products is called:
a. Flash point
b. Pour point
c. Cloud point
d. Cetane number
7
7. What is the API gravity recommended by Caterpillar for the distilled diesel fuels, and what temperature should
they be measured at?
a. 40 API @ 30 °F
b. 35 API @ 60 °F
c. 40 API @ 60 °F
d. 35 API @ 30 °F
8. Which of the following can cause a complaint about low performance?
a. Very low fuel cloud point

b. 37.2 API gravity and 90 °F
c. Very high cetane number
d. Excessive altitude
9. A fuel with low cetane number may result in:
a. Difficulty in starting
b. White smoke when starting
c. Black smoke during load
d. Options “a” and “b”
10. Secondary fuel filters must be installed:
a. Full
b. Empty, and then ignite the engine
c. Empty, and then use the priming pump
d. They mustn't be changed
11. What type of Electronic Control Module do C4.4/C6.6 Engines have?
a. ADEM III
b. A4:E4
c. A4:E2
d. None of the above
12. In order to calibrate inlet valves of cylinder number 5 in a C6.6 Engine, the following must be done:
a. Crank the crankshaft until inlet valve #1 is completely open.

b. Crank the crankshaft until inlet valve #5 is completely open.
c. Crank the crankshaft until inlet valve #7 is completely open.
d. Crank the crankshaft until inlet valve #11 is completely open.
13. At valve guide inspection in a C6.6 Engine, the maximum gap between the input valve stem and the
valve guide, with a valve elevation of 15.0 mm (0.60 inch), is:
a. 0.09 mm (0.0035 inch)

b. 0.08 mm (0.0031 inch)
c. 0.07 mm (0.0027 inch)
8
14. In a C9 Engine, the injection pressure is approximately ________ greater than the actuation
pressure.
a. Twice
b. Three times
c. Six times
d. Eight times
15. In a C9 Engine, the HEUI pump control valve has the following stages:
a. ____________________________
b. ____________________________
c. ____________________________
16. After a complete scheduled repair to the C32 SXC Engine, the injectors must be calibrated.
Which of the following calibrations apply?
a. Injector height of 78.0 mm ± 0.2 mm (3.07 inch ± 0.01 inch)

b. Injector height of 64.34 mm ± 0.2 mm (2.53 inch ± 0.01 inch)
c. Injector height of 74.24 mm ± 0.2 mm (2.92 inch ± 0.01 inch)
17. Engine performance and correct pressure of the intake manifold are provided in the TMI.
The conditions that were applied to define them are based on:
• Dry barometric pressure: 96 kpa (28.8 inches of mercury)
• Exterior temperature: 25 ºC (77 ºF)
• Fuel range: 35º API
a. True b. False (explain your answer)
18. In order to clean a 3512B Engine aftercooler, Caterpillar recommends using:
a. Just water
b. Hydrosolv 4165
c. Diesel 2
19. A dirty aftercooler will result in high temperatures of air intake. Every 1° (°F) increase in air intake
temperature, the exhaust gas temperature will:
a. Increase 1 (°F)
b. Increase 3 (°F)
c. Decrease 3 (°F)
d. Remain the same
20. For a C18 Engine, the air flow through a new air cleaner must not have a restriction greater
than the following amount:
a. 4.5 kPa (18 inH2O)

b. 3.7 kPa (15 inH2O)
c. 6.2 kPa (25 inH2O)
d. Filter is new, so there is no restriction.
9
21. For a 3500B Engine, the maximum exhaust backpressure is:
a. 4.5 kPa (18 inH2O)

b. 3.7 kPa (15 inH2O)
c. 6.5 kPa (27 inH2O)
d. Filter is new, so there is no restriction.
22. Identify the components of C18 Engine inlet and exhaust systems:
1.
2.
3.
4.
5.
6.
7.
8.
23. The air cleaner element must be cleaned or replaced when the filter service indicator presents
the following conditions:
a. The yellow diaphragm enters into the red area.

b. The red diaphragm enters into the yellow area.
c. The red piston locks in the visible position.
d. Options “a” and “c”
24. For a 3500B Generator Set, Prime classification, the turbocharger must be inspected:
a. Every 3 years
b. Every 2,000 hours
c. Every 3,000 hours
d. None of the above (explain your answer)
25. In a C6.6 Engine, what is the function of the wastegate valve?

________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
________________________________________________________________________________
26. In a C9 Engine, what conditions determine the air heater performance?
a. _____________________________
b. _____________________________
c. _____________________________
d. _____________________________
e. _____________________________
10
27. When the air intake sensor of a C9 Engine has an open circuit, the engine will operate in
the following way:
a. The air heater will be activated when the coolant temperature is below 20 °C (68 °F.)
b. The air heater will be activated when the addition of the coolant temperature and the
intake air temperature has decreased below 25 °C (109 °F.)
c. The air heater will be activated when the coolant temperature is below 40 °C (104 °F.)
d. The air heater will be activated when the addition of the coolant temperature and the
intake air temperature does not reach 35 °C (127 °F.)
28. Identify the components of the C9 Engine HEUI fuel system.
(1) ____________________ (2) _____________________ (3) _____________________

(4) ____________________ (5) _____________________ (6) _____________________
(7) ____________________ (8) _____________________ (9) _____________________
(10) ____________________ (11) _____________________ (12) _____________________
(13) ____________________ (14) _____________________ (15) _____________________
(16) ____________________ (17) _____________________ (18) _____________________
(19) ____________________ (20) _____________________ (21) _____________________
(22) ____________________ (23) _____________________ (24) _____________________
29. In order to check if there is air in the engine fuel, Caterpillar recommends installing a 2P-8278 Sight
Gauge near the relief valves.
a) True b) False (explain your answer)
30. For a C32 Engine, the following injectors can be calibrated in the compression stroke:
4, 5, 6, 9, 10 and 12.
a) True b) False (explain your answer)
11
Cooling and Oil System
1. What level of NBT is recommended in a C18 Engine, with a fuel sulfur content of 0.8%?
a. 8
b. 32
c. 24
d. 16
2. What causes a low oil pressure?
a. High oil viscosity

b. Excessive engine heating
c. Worn bearings
d. Options “b” and “c”
3. The following diagram represents the C18 Engine oil system. Identify its components and trace the
engine oil flow.
1. ________________________
2. ________________________
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
8. ________________________
9. ________________________
10. ________________________
11. ________________________
12. ________________________
13. ________________________
14. ________________________
4. Which of the following tasks would you include in a complaint due to high oil consumption?
a. Checking the turbocharger

b. Checking external leakage
c. Checking piston ring wear
d. All of the above
12
5. The presence of fuel insoluble debris partially burned is called:
a. Soot
b. Total Base Number (TBN)
c. Oxidation
d. Wear
6. ______________ prevent increase in viscosity.
a. Alkaline agents
b. Anti-wear agents
c. Oxidation inhibitors
d. Sulphated ash
7. In a 3500B s/n: ZAH Engine oil system, what is the function of sequence valves?
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
8. Caterpillar DEO Multigrade oil, with API CH-4, CG-4 and CF-4 15W40 viscosity rate, is applied at the
following temperatures:
a. –20 °C (-4 °F) - 40 °C (104 °F)

b. –18 °C (-22 °F) - 40 °C (104 °F)
c. –9.5 °C (-5 °F) - 50 °C (122 °F)
d. –30 °C (-22 °F) - 50 °C (122 °F)
9. If there is a speed of 1,200 RPM and an oil pressure of 15 PSI in a C18 STD Engine, this condition is:
a. Acceptable b. Not acceptable (explain your answer)
10.Oil with a high value of TBN can produce excessive deposits in pistons. These deposits can cause
lack of control of fuel consumption and cylinder polishing.
a. True b. False (explain your answer)
11.What are the factors that contribute to the reduction of oil TBN?
a. ____________________________
b. ____________________________
c. ____________________________
d. ____________________________
e. ____________________________
f. ____________________________
g. ____________________________
12.The SAE specification classifies oils according to:
a. Viscosity
b. Service type
c. Additives
d. Emissions
13
13.The following components are found in 3500 Engine oil system. Match the component with the correct
description in the right column.
A. Main relief valve 1 - It distributes oil to engine mobile parts.

B. Sequence valve 2 - It drains when there is more oil than what the
engine needs.
C. Cooler bypass valve 3 - Oil entry to the pump.
D. Filter bypass valve 4 - It supplies engine oil flow.
E. Oil sprays 5 - It allows oil flow into the sprays.
F. Oil pump 6 - They cool and lubricate the piston.
G. Main gallery 7 - It allows flow of oil without filtering into the engine.
H. Suction bell 8 - It allows oil flow directly into the filters.
A. B. C. D. E. F. G. H.
14.In a 3512B ZAH Engine, the crankcase oil filling level for a standard crankcase is of approximately:
a. 227 L (60 US gal)

b. 318 L (84 US gal)
c. 405 L (107 US gal)
d. None of the above (please explain your answer)
15.The typical oil pressure of a C32 Engine is:
a. 314 kPa (45.4 psi) at low speed, and 400 kPa (58 psi) at rated speed.
b. 214 kPa (31 psi) at low speed, and 400 kPa (58 psi) at rated speed.
c. 114 kPa (16.5 psi) at low speed, and 400 kPa (58 psi) at rated speed.
d. 14 kPa (2 psi) at low speed, and 400 kPa (58 psi) at rated speed.
16.For a C32 SXC Engine, indicate the oil quantity to calibrate the oil level dipstick with the marks
ADD and FULL:
a. ADD: 82 QT (78 L) – FULL: 100 QT (95 L)

b. ADD: 87 QT (82 L) – FULL: 95 QT (90 L)
c. ADD: 87 QT (82 L) – FULL: 100 QT (95 L)
d. ADD: 100 QT (95 L) – FULL: 87 QT (82 L)
17.According to the following information, determine the percentage of ethylene glycol concentration
necessary for an engine with protection against boiling until reaching 106 °C (223 °F), and protection
against freezing at -37 ºC (-34 ºF):
a. 30 %
b. 40 %
c. 50 %
d. 60 %
18.For better results, the pH level (acidity) in cooling system must be kept between:
a. 7 and 11
b. 1 and 14
c. 8.5 and 10.5
d. 5 and 11
14
19.A practical formula to add concentration extender to ELC Cat is: V x 0,002 = X
a. TRUE b. FALSE (explain your answer)
20.The 245-5829 Tool is used for:
a. Measuring the coolant boiling point

b. Measuring the glycol freezing level in coolant
c. The coolant temperature
d. The cooling system pressure
21.In order to test a C18 Engine water pump and verify it is operating correctly, the engine speed must
be at _____, and the pump pressure must be __________.
a. 1,800 RPM – greater than 100 kpa (15 psi)

b. 1,200 RPM – less than 100 kpa (15 psi)
c. 1,400 RPM – greater than 100 kpa (15 psi)
d. 1,400 RPM – less than 100 kpa (15 psi)
22.Engine overcooling may be a serious problem if the engine operates for a long time below:
a. 99 °C (210 °F)
b. 80 °C (175 °F)
c. 77 °C (170 °F)
d. 85 °C (185 °F)
23.Which of the following liquids has the highest specific heat?
a. Coolant conditioner
b. Pure water
c. Extended life coolant
d. A 50% mixture of DEAC and pure water
24.What is the water boiling point at an altitude of 1,829 m (6,000 ft), with a pressure cap of 6 psi?
a. 99 °C (212 °F)
b. 103 °C (220 °F)
c. 104 °C (222 °F)
d. 95 °C (204 °F)
25.What is the 9S8140 Tool in the cooling system used for? Explain the procedure to conduct the test for
which this tool was designed.
_________________________________________________________________________________
_________________________________________________________________________________
26.C27/C32 Engines (ATAAC system) require at least ______________ of glycol to prevent water pump
cavitation.
a. 20%
b. 50%
c. 30%
15
27.If ELC is used and the cooling system needs cleaning, Caterpillar recommends using:
a. “Standard” Caterpillar Cooling System Cleaner

b. Just water
c. “Quick Flush” Caterpillar Cooling System Cleaner
d. No cleaning needed
28.The jacket water temperature regulator of a C18 STM Engine is completely opened at the following
temperature:
a. 80 °C (176 °F)
b. 82 °C (180 °F)
c. 88 °C (190 °F)
d. 98 °C (208 °F)
29.The following diagram represents the C6.6 Engine cooling system. Identify its components and trace
the engine coolant flow.
1. ________________________
2. ________________________
3. ________________________
4. ________________________
5. ________________________
6. ________________________
7. ________________________
30.What is the maximum flow (GPM) of the jacket water pump in a C32 SXC Engine?
a. 30.91 GPM
b. 217.94 GPM
c. 253.34 GPM
d. 172.5 GPM
16
Electric and Electronic Components:
1. In Caterpillar engines, a magnetic pickup is used to monitor:
a. Temperature
b. Pressure
c. Position
2. The types of output signal that can be sent by temperature sensors used in Caterpillar equipment are:
a. ___________________________
b. ___________________________
c. ___________________________
3. The types of output signal that can be sent by pressure sensors used in Caterpillar equipment are:
a. ____________________________
b. ____________________________
4. The types of output signal that can be sent by position sensors used in Caterpillar equipment are:
a. _____________________________.
b. _____________________________,
c. _____________________________.
5. The types of output signal that can be sent by level sensors used in Caterpillar equipment are:
a. _______________________________.
b. _______________________________.
6. Passive sensors do not require a battery supply to operate.
a. True
b. False (explain your answer)
7. Passive sensors can have three or four cables.
c. True
d. False (explain your answer)
8. In a passive sensor, pin 1 is:
a. Voltage supply
b. Common or return
c. Signal
9. Active sensors can have two, three and up to four cables.
a. True
10. Digital active sensors send a signal that switches between two different levels.
a. True
17
11. The typical operation range of analogous sensors with a direct current voltage output will be of:
a. 0.5 to 4.5 VDC

b. 0.2 to 4.5 VDC
c. 0.2 to 4.8 VDC
d. 0.2 to 8.0 VDC
12. The signal of Hall Effect sensor is:
a. Analogous
b. Digital
13. The duty cycle of a Hall Effect sensor will be:
a. 80%
b. Between 5% and 95%
c. 50%
d. Duty cycle is not measured
14. An example of a sensor that sends a Pulse Width Modulation (PWM) signal is:
a. Engine coolant temperature sensor

b. Acceleration pedal position sensor
c. Oil pressure sensor
15. An example of a passive speed sensor is:
a. Pulse Width Modulation

b. Magnetic pickup
c. Variable resistance
d. Hall Effect
16. An example of an active speed sensor is:
a. Magnetic pickup
b. Variable resistance
c. Hall Effect
d. Capacitive
17. The “pull-up” voltage is supplied within an ECM to monitor the signal status of a circuit.
a. True
18
18. The pull-up voltage for a three-wire sensor with a power supply of 5 V is typically of:
a. 5.5 VDC
b. 12 VDC
c. 6.5 VDC
d. It depends on the equipment model; refer to Testing and Adjusting Manual.
19. During a sensor diagnosis, the three components that can be the root cause of the condition are:
a. ______________________________.
b. ______________________________.
c. ______________________________.
20. If there is a code with FMI 04 in Cat ET window of active codes, it means that the component has:
a. Voltage below normal condition

b. Current above normal condition
c. Voltage above normal condition
a. Voltage above normal condition

c. Current below normal condition
a. Current below normal condition

c. Abnormal frequency, Pulse Width or Period
a. Voltage above normal condition

b. Voltage below normal condition
c. Current below normal condition
24. If a 22-13 code is generated in Cat ET window of active codes, it means that:
a. The oil temperature sensor has voltage above normal condition.

b. The boost pressure sensor has voltage below normal condition.
c. The timing sensor is out of calibration.
d. The injector solenoid 4 has current above normal condition.
19
a. The speed and timing sensor has an abnormal or erratic signal.

b. The oil pressure sensor has voltage below normal condition.
c. The pedal position sensor has an abnormal or erratic signal.
d. The pressure sensor of fuel without filtering has voltage below normal condition.
a. The speed and timing sensors have an abnormal or erratic signal.

b. The oil pressure sensor has voltage below normal condition.
c. The pedal position sensor has an abnormal or erratic signal.
d. The boost pressure sensor has voltage above normal condition.
27. The function of a vibration test (Wiggle Test) is:
a. Verifying the magnitude of engine longitudinal vibrations on the engine base in the
machine.
b. Finding intermittent faults in machine or equipment harnesses.
c. Detecting problems in engine speed and timing sensors.
d. None of the above (explain your answer.)
28. The speed/timing sensor calibration must be performed when:
a. ________________________________________.
b. ________________________________________.
c. ________________________________________.
29. When carrying out a copy of the ECM replacement configuration, the additional parameters that
are copied in the file are:
a. Results of cylinder cutout tests

b. Logs of programmed data with a trigger for a particular event
c. Calibrations of sensors and injectors
d. Assurance reports
30. The Test ECM mode is:

______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
20
Task Execution Preparation
1. In the blank provided, write down the service literature that you need to perform the tasks
to be executed:
2. In the blank provided, list the required tools to perform the tasks to be executed:
3. List the potential risks during the execution of the tasks together with the actions to be taken to
prevent accidents:
Risk Prevention Protocol
21
Task Sheet 01: Localization of Engine Components
1. Procedure:
Instructions: In this task, the participant will identify the engine components designated by the facilitator.
The participant must have the service literature and the tools corresponding to the procedure before
starting the task. Component identification must be detailed in the service report according to the
literature applied. (Use schematics to make a clearer report.)
 Perform a visual inspection of the equipment to be examined. Make sure you can access
safely to the different listed components and eliminate any possible risks.
 Identify the components according to the table described below. If the selected engine is not
made up of a particular component, identify it as N/A in the results chart.
 Once you have identified all the components for the facilitator, return the equipment to its
initial state. Include your observations and comments about the identified components in the
service report together with the function of each of them.
 End of Task.
2. Results:
Generate a Service Report in the STW with the task procedures and results together with the necessary
comments/observations about them.
____ Primary and secondary fuel filters ____ Ether injection control solenoid
____ Electric fuel priming pump and switch ____ Inlet air pressure sensor
____ Fuel transfer pump ____ Atmospheric pressure sensor
____ Engine oil level and filler dipstick ____ Inlet air temperature sensor
____ Engine oil filter ____ Fuel temperature sensor
____ Engine oil intake port (S•O•S) ____ Fuel pressure sensor
____ Engine oil pressure test port ____ Fuel filter differential pressure switch
____ Engine oil pressure sensor ____ Engine oil pressure sensor
____ Motor and engine prelube pump ____ Turbo inlet pressure sensor
____ Engine oil cooler ____ Injection interrupting connector
____ Air filter (right – left) ____ Crankshaft speed and timing sensor (primary)
____ Turbocharger (right – left) ____ Camshaft speed and timing sensor (secondary)
____ AMOCS radiator and bypass tank ____ Starter
____ Engine coolant intake port (S•O•S) ____ Coolant temperature sensor
____ Jacket water pump ____ Coolant flow switch
____ Temperature regulator housing ____ Timing calibration test probe connector
____ General electric main switch ____ Block heater element
____ Engine ECM A4 ____ Alternating current socket
3. Assessment Criteria: 10 points

4. Maximum Time: 20 minutes
22
Task Sheet 02: Verification/Adjustment of Engine Injector Height
1. Procedure:
Instructions: In this task, the participant will adjust the engine injector height designated by the
facilitator. The participant must have the service literature and the tools corresponding to the procedure
before starting the task. The participant must document the procedure together with any inconveniences
they have had during task execution.
 Perform a visual inspection of the equipment. Make sure the work area is safe so as to be
able to execute the task without any personal risk or equipment potential risk, or damage to
the tools.
 Using the service literature, group the necessary tools for verification/adjustment of injector
height.
 Carry out the test/adjustment procedure. If injector heights must be adjusted, proceed
according to the equipment specification data.
 Document the equipment injector heights in your service report, together with your
observations/comments. Indicate the data specified for the equipment and the data found in
such equipment. (If changes were made, document the injector height data after the
adjustment.)
 End of Task
2. Results:
Cylinder Measured/Adjusted Cylinder Measured/Adjusted

Number Value Number Value
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16

23
Task Sheet 03: Intake and Exhaust Valve Verification/Adjustment
1. Procedure:
Instructions: In this task, the participant will adjust the engine intake and exhaust valves designated by
the Facilitator. The participant must have the service literature and the tools corresponding to the
procedure before starting the task. The participant must document the procedure together with any
inconveniences they have had during task execution.
the tools.
 Using the service literature, group the necessary tools for the verification/adjustment of
intake and exhaust valve opening/closing.
 Carry out the test/adjustment procedure. If valve opening/closing must be adjusted, proceed
according to the equipment specification data.
 Document the opening gaps of the equipment intake and exhaust valves in the service
report, together with your observations/comments. Indicate the data specified for the
equipment and the data found in such equipment. (If changes were made, document the
adjusted valve opening data after the adjustment.)
 End of Task.
2. Results:
Cylinder Intake Exhaust Cylinder Intake Exhaust

Number Valve Valve Number Valve Valve
1 9
2 10
3 11
4 12
5 13
6 14
7 15
8 16

24
Task Sheet 04: Electric and Electronic Component Verification
1. Procedure:
Instructions: In this task, the participant will verify the engine electric and electronic components
designated by the Facilitator. The participant must have the service literature and the tools
corresponding to the procedure before starting the task. The participant must document the procedure
together with any inconveniences they have had during task execution.
the tools.
 Using the service literature, group the necessary tools for verifying the electric and
electronic components designated in the results chart.
 Start the verification process of each component and complete the table. If there are no
components described in the table for the equipment designated by the Facilitator, complete
the table with N/A.
 Document the data measured for each component in the service report and make your
observations/comments according to the specification data of such components. Identify
those components that are being operated out of their specification range, and/or those that
are faulty or damaged.
 End of Task.
2. Results:
TESTS Sensor Type Signal Type OK or Not OK
Battery Voltage
Input Voltage into the ECM Control Module
Acceleration Sensor Supply Voltage
Acceleration Sensor Output %
Deceleration Sensor Pull-up Voltage
Speed and Timing Sensor Supply Voltage
Speed and Timing Sensor Output Frequency at Start Up
TESTS Sensor Type Signal Type OK or Not OK
Speed and Timing Sensor Output Frequency with Engine at

High RPM
Oil Pressure Sensor Supply Voltage
Oil Pressure Sensor Output Voltage with Decelerated Engine
Pull-up Voltage to Oil Pressure Sensor

25
Task Sheet 05: Cylinder Cutout Test
1. Procedure:
Instructions: In this task, the participant will perform an engine cylinder cutout test designated by the
Facilitator. The participant must have the service literature and the tools corresponding to the procedure
before starting the task. The participant must document the procedure together with any inconveniences
they have had during task execution.
the tools.
 Using the service literature, group the necessary tools to conduct the cylinder cutout test.
 Before starting the cylinder cutout test, program a Data Logger to record data about the
engine RPM, Fuel Pedal Position, Inlet Manifold Pressure or Boost Pressure, and Fuel
Position.
 Start the cylinder cutout test. Attach the test results to the service report.
 In the service report, detail your observations and comments about the engine operation,
and explain the purpose of the cylinder cutout test together with the information of the Data
Logger. Explain what is happening to the four registered parameters, and determine
whether the equipment operation is correct or not during the execution of cylinder
cutout test.
 End of Task.
2. Results:
26
Task Sheet 06: Engine Injector Calibration and Electric Tests
1. Procedure:
Instructions: In this task, the participant will calibrate the injector trim code and will conduct the
operational solenoid test of engine injector designated by the Facilitator. The participant must have the
service literature and the tools corresponding to the procedure before starting the task. The participant
must document the procedure together with any inconveniences they have had during task execution.
the tools.
 Using the service literature, group the necessary tools to carry out the verification/calibration
of injector trim code.
 Carry out the verification/calibration according to the equipment service literature.
 Record the trim codes of each injector in the service report; compare them with the ones
programmed in the engine ECM. Make your observations/comments about the procedure.
 Conduct the solenoid test for engine injector. Attach the test results to the service report.
 In the service report, detail your observations and comments about the engine operation,
and explain the purpose of trim code calibration as well as the solenoid test of injectors.
Make your comments/observations about the equipment condition according to test results.
 End of Task.
2. Results:

27
Task Sheet 07: Electric Component Troubleshooting
1. Procedure:
Instructions: In this task, the participant will perform the procedure of electric fault identification in engine
electric and electronic components designated by the Facilitator. The participant must have the service
literature and the tools corresponding to the procedure before starting the task. The participant must
document the procedure together with any inconveniences they have had during task execution.
the tools.
 Using the service literature, group the necessary tools to carry out the verification of the
engine electric and electronic system.
 Connect the engine ECM. Generate a Product Condition Report that shows the active codes
found originally in the equipment. Record it as Initial Equipment Condition.
 Diagnose the trouble codes and determine if the fault is generated in the sensor or harness,
or whether it comes from the engine ECM. Complete the table according to each diagnosed
code in the results section of this task.
 Once all trouble codes have been solved, generate a Product Condition Report that shows
the active codes. Record it as Final Equipment Condition.
 In the service report, include the Product Condition Report and the results in the designated
table. Make your comments and observations about the diagnosis process, and mention the
possible causes of these codes.
 Conduct the solenoid test for engine injector. Attach the test results to the service report.
 End of Task.
2. Results:
CID FMI Fault Location

Sensor / Harness / ECM

28
MODULE #2: ALTERNATORS AND VOLTAGE REGULATORS
Demonstrating the ability to perform operational tests of Caterpillar

alternator components.
Demonstrating the ability to perform maintenance tasks for

Caterpillar alternators.
Demonstrating the ability to make connections, adjustments and

verifications of voltage regulators VR3, VR6, R448, CDVR.
Demonstrating the ability to make a Service Report about the work

done according to Caterpillar standards.


Identifying components that make up SR4, SR4B and SR5
Alternators.
Conducting operation verification test of diodes and varistors
installed in SR4B and SR5 Alternators.
Carrying out the isolation test for SR4B and SR5 Alternators.
Applying peak excitation current adjustment for R448 Voltage
Regulator.
Verifying DVR Voltage Regulator setpoints.
Applying inflection frequency adjustment for VR6 Voltage
Regulator.
Conducting operation verification test for VR6 Voltage Regulator.
Programming CDVR Voltage Regulator.
Tools 243-3131 Isolation Resistance Meter

257-9140 Fluke 87 Digital Multimeter
239-5260 Cable Splice Tool
4C-3029 Adjustment Tool
171-4400 Communication Adapter II Group
29
Literature LEBW4993 Generator Systems

SEHS9124 Cleaning and Drying of Electric Set Generators
RENR2480 VR6 Voltage Regulator Spec. Sys. & Op.
RENR7941 Caterpillar Digital Voltage Regulator Spec.
Sys. & Op.
SENR4794 Connection Diagrams: SR4 and SR4B
Generators, Voltage Regulator Options
SENR5833 Digital Voltage Regulator Spec. Sys. & Op.
REHS4638 Caterpillar R448 Voltage Regulator Setup
SEBU8655 C15 Petroleum Generator Set
SENR5359 SR4B Generator
KENR5284 Electric Power Generation SR5
LEKQ7119 AC Voltages Available from Caterpillar SR4
Generators
SEBU7777 C9 Marine Generator Set
LEHE4648 R448 Automatic Voltage Regulator Spec. Sheet
30
Alternator and Voltage Regulator Questionnaire:
Alternators – SR4B / SR5
1. Using the schematic below, identify the SR4B Alternator components:
1) __________________________________.
2) __________________________________.
3) __________________________________.
4) __________________________________.
5) __________________________________.
6) __________________________________.
7) __________________________________.
8) __________________________________.
31
2. Using the schematic below, identify the SR5 Alternator components:
1) __________________________________.
2) __________________________________.
3) __________________________________.
4) __________________________________.
5) __________________________________.
6) __________________________________.
7) __________________________________.
8) __________________________________.
9) __________________________________.
10) __________________________________.
11) __________________________________.
12) __________________________________.
32
3. Mention the main characteristics of SR4B Alternators:
a. ___________________________.
b. ___________________________.
c. ___________________________.
4. Mention the main characteristics of SR5 Alternators:
a. ___________________________.
b. ___________________________.
c. ___________________________.
d. ___________________________.
e. ___________________________.
5. Explain the process of SR4B Alternator internal ventilation:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
6. Explain power generation operation in SR5 Alternators:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
7. Explain PMPE excitation circuit operation in SR5 Alternators:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
33
8. Explain IE excitation circuit operation in SR5 Alternators:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
9. Using the schematic below, identify the following SR4B Alternator components:
Component(s) Description Component Description

CR1 - CR6 L5
CR7 PM
L1 R5
L2 RFA
L3 TR1
L4 T0 - T9
34
10. Using the schematic below, identify the following SR4B Alternator components:
Component(s) Description Component Description

CR1 - CR6 L3
L1 RFA
L2 TR1
L3 T0 - T9
35
11. Explain the circuit function of SR4B Alternators given in the schematic below:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
36
12. According to the given schematic, the circuit of rectifier diodes is made up of:
a. Three blocks of two rectifier diodes

b. Two blocks of three rectifier diodes
c. One block of six rectifier diodes
37
13. According to the given schematic, the circuit of rectifier diodes is made up of:
a. Three blocks of two rectifier diodes

b. Two blocks of three rectifier diodes
c. One block of six rectifier diodes
14. The function of the varistor in SR4B Alternators is:
a. Protecting the main field winding from overcharge in the main alternator.
b. Protecting the exciter frame from current peaks.
c. Protecting the block of rectifier diodes from voltage surges.
15. The function of R5 resistance in SR4B Alternators is:
a. Protecting the main field winding from overcharge in the main alternator.
b. Protecting the exciter frame from current peaks.
c. Protecting the block of rectifier diodes from voltage surges.
16. The function of space heaters in SR4B Alternators is:
a. Preventing the generation of humidity in main stator windings.

b. Keeping the temperature of alternator exciter circuits.
c. Keeping the temperature of generator windings at machine room temperature.
38
17. In the following table, determine the connections between terminals of a 4-terminal SR4B Alternator
for a Wye configuration. (Identify any connection between terminals that corresponds to the same
alternator output.)
Cable Number for Sensing Lines

Alternator Output Terminals Connections between Terminals
of Voltage Regulator
U
V
W
Neutral
for a Wye configuration. (Identify any connection between terminals that corresponds to the same
alternator output.)

U
V
W
Neutral
for a High Wye configuration. (Identify any connection between terminals that corresponds to the
same alternator output.)

U
V
W
Neutral
for a Low Wye configuration. (Identify any connection between terminals that correspond to the same
alternator output.)

U
V
W
Neutral
39
for a High Wye configuration. (Identify any connection between terminals that correspond to the same
alternator output.)

U
V
W
Neutral
for a Low Wye configuration. (Identify any connection between terminals that correspond to the same
alternator output.)

U
V
W
Neutral
for a Delta configuration. (Identify any connection between terminals that correspond to the same
alternator output.)

U
V
W
for a Delta configuration. (Identify any connection between terminals that correspond to the same
alternator output.)

U
V
W
40
25. Explain the procedure to perform the functional test of the generator for SR4B / SR5 Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
26. Explain the procedure to perform the functional test of varistors for SR4B / SR5 Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
27. Explain the procedure to perform the functional test of the rotating rectifier block for SR4B / SR5
Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
41
28. Explain the procedure to perform the test of windings for SR4B / SR5 Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
29. Explain the procedure to perform the isolation resistance test of windings for SR4B / SR5 Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
30. Explain the procedure to recover the residual field for self-excited SR4B Alternators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
42
Voltage Regulators - Analogous
1. For VR6 Voltage Regulator, the voltage range in its sensing lines is of:
a. 95 to 140 VAC
b. 180 to 280 VAC
c. 140 to 280 VAC
2. For R448 Voltage Regulator, the voltage range in its sensing lines is:
a. 95 to 520 VAC
b. 100 to 340 VAC
c. 140 to 240 VAC
3. The VR6 Voltage Regulator has single-phase and three-phase direct sensing capacity:
a. True
4. The R448 Voltage Regulator has single-phase and three-phase direct sensing capacity:
a. True
5. The VR6 Voltage Regulator allows the remote voltage adjustment in a range of:
a. ±5% of sensing voltage

b. ±20% of sensing voltage
c. ±10% of sensing voltage
6. The R448 Voltage Regulator allows the remote voltage adjustment in a range of:
a. ±5% of sensing voltage

b. ±20% of sensing voltage
c. ±10% of sensing voltage
7. For VR6 Voltage Regulator, the supply voltage range is:
a. 140 to 480 VAC

b. 180 to 280 VAC
c. 120 to 240 VAC
8. For R448 Voltage Regulator, the maximum supply voltage is:
a. 150 VAC
b. 240 VAC
c. 520 VAC
43
9. The VR6 Voltage Regulator has a minimum ignition voltage of:
a. 6 VAC
b. 10 VAC
c. 25 VAC
10. The R448 Voltage Regulator has a minimum ignition voltage of:
a. 6 VAC
b. 10 VAC
c. 25 VAC
11. The limit of peak excitation current of the R448 Voltage Regulator is:
a. 6A
b. 15 A
c. 10 A
12. The function of VR6 Voltage Regulator terminal 2 is:
a. Connecting the X:1 Ampere current transformer positive terminal.

b. Connecting the X:5 Amperes current transformer positive terminal.
c. Connecting the current transformer common terminal.
a. Connecting the X:1 Ampere current transformer positive terminal.

b. Connecting the AVR terminal 7 to use the remote voltage potentiometer.
c. Connecting to the terminal 6A so as to select low frequency slope.
14. The function of VR6 Voltage Regulator terminal 5A is:
a. Connecting the X:5 Amperes current transformer positive terminal.

c. Connecting one of the terminals of the remote voltage potentiometer.
15. The function of VR6 Voltage Regulator terminal 5A is:


b. Connecting terminal 6A to activate the AVR three-phase sensing.
44
17. Using the following schematic, explain the operation of VR6 Voltage Regulator:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
45
18. Explain the function of the inflection frequency (Knee Frequency) in VR6 Voltage Regulators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
19. Explain the function of V/Hz slope in VR6 Voltage Regulators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
20. Explain the function of the stability potentiometer in VR6 Voltage Regulators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
21. Explain the operation of over-excitation protection in VR6 Voltage Regulators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
46
22. Using the table below, identify the function of each terminal of the VR6 Regulator power circuit:
Terminal Description
20
22
24
26
28
30
F1
F2
23. Explain the R448 operation working with an AREP pilot excitation circuit:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
24. Using the diagram below, explain the function and/or operation of each one of the components
indicated for the R448 Voltage Regulator:
Identification Description Identification Description

ST1 P1
ST2 P2
ST3 P3
ST4 P5
ST5
ST6
ST9
ST10
ST11
47
25. Explain the procedure to make the Stability adjustment of VR6 Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
26. Explain the procedure to make the Knee Frequency adjustment of VR6 Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
48
27. Explain the procedure to make the Voltage Adjustment Range adjustment of VR6 Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
28. Explain the procedure to perform the operational test of VR6 Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
49
29. Explain the adjustment procedure for application of R448 Voltage Regulator as a single unit.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
30. Explain the function of the R448 Load Acceptance Mode (LAM.)
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
50
Voltage Regulators - Digital
1. For DVR Voltage Regulator, the voltage range in its sensing lines is:
a. 95 to 140 VAC
b. 180 to 280 VAC
c. 140 to 280 VAC
2. For DVR Voltage Regulator, the voltage range in its sensing lines is:
a. 79 to 124 VAC
b. 125 to 249 VAC
c. 90 to 600 VAC
3. The DVR Voltage Regulator has single-phase and three-phase direct sensing capacity.
a. True
4. The DVR Voltage Regulator admits the remote voltage adjustment in a range of:
a. ±5% of pull-up voltage

b. ±20% of pull-up voltage
c. ±10% of pull-up voltage
5. The CDVR Voltage Regulator admits the remote voltage adjustment in a range of:
a. ±5% of pull-up voltage

b. ±20% of pull-up voltage
c. ±10% of pull-up voltage
6. For DVR Voltage Regulator, the supply voltage range is:
a. 140 to 480 VAC - Single-phase - Frequency from 20 to 120 Hz

b. 70 to 120 VAC - Three-phase - Frequency from 50 to 240 Hz
c. 120 to 240 VAC - Three-phase - Frequency from 40 to 300 Hz
7. For CDVR Voltage Regulator, the supply voltage range is:
a. 140 to 480 VAC - Single-phase - Frequency from 20 to 120 Hz

b. 70 to 120 VAC - Three-phase - Frequency from 50 to 400 Hz
c. 120 to 240 VAC - Three-phase - Frequency from 40 to 300 Hz
51
8. Mention the protection systems available in the DVR Voltage Regulator:
a. __________________________________________.
b. __________________________________________.
c. __________________________________________.
d. __________________________________________.
e. __________________________________________.
f. __________________________________________.
g. __________________________________________.
h. __________________________________________.
i. __________________________________________.
j. __________________________________________.
9. Using the following schematic, complete the table and explain the function of each one of the
setpoints for the DVR Voltage Regulator during the start up profile:
Parameter
Setpoint Description
Number
Generator Output Voltage
Generator Type
Knee Frequency
Low Frequency Point
52
10. Using the schematic below, explain the operation of DVR and CDVR Voltage Regulators.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
11. Explain the operation of DVR and CDVR Voltage Regulators when they operate in Line Loss
Compensation mode.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
53
12. For DVR Voltage Regulator, explain the function of parameter 03.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
13. Explain the fault types that are announced by the DVR Voltage Regulator.
a. ___________________________________.
b. ___________________________________.
c. ___________________________________.
d. ___________________________________.
14. Explain the definition of a fault code 703 in a DVR Voltage Regulator and the process of fault
correction.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
15. Explain the definition of a fault code 901 in a DVR Voltage Regulator and the process of fault
correction.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
54
16. Using the schematic below, determine the functions of each one of the pins of this CDVR Voltage
Regulator connector.
Pin Number Function

1
2
3
4
5
6
55
Pin Number Function

1
2
3
4
5
6
7
8
9
56
Pin Number Function

1
2
3
4
5
6
7
8
9
10
11
12
19. In CDVR Voltage Regulator, the operations that can be carried out through the Caterpillar Digital
Voltage Regulator Software are:
a. ____________________________________.
b. ____________________________________.
c. ____________________________________.
d. ____________________________________.
e. ____________________________________.
57
20. Complete the following table about the frequencies of CDVR Voltage Regulator power supplies.
Type of Excitation Operation in 50 Hz Operation in 60 Hz

Self-Excited (SE)
Internally Excited (IE)
Permanent Magnet for Low or

Mid Tension
Permanent Magnet of 6 Poles
High Tension Permanent Magnet

with Frame 2600
High Tension Permanent Magnet
with Frame 2400 and 2800
21. Explain the programming procedure of setpoints that control the CDVR Voltage Regulator operation
(Main Adjustments / Setting Modes / Charge and Shutdown Profile):
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
22. Explain the function of Soft Start Mode in CDVR Voltage Regulator and how it is programmed.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
23. Explain the programming procedure of overvoltage and undervoltage protection in the CDVR Voltage
Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
58
24. Explain the programming procedure of reverse kVARs protection (loss of excitation) in the CDVR
Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
25. Explain the programming procedure of over-excitation protection in the CDVR Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
26. Explain the programming procedure of exciter diode monitor protection in the CDVR Voltage
Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
27. Explain the programming procedure of exciter diode monitor protection in the CDVR Voltage
Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
28. Explain the programming procedure of Loss of Sensing protection in the CDVR Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
59
29. Explain the programming procedure of PID gains in the CDVR Voltage Regulator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
30. Explain the procedure to adjust PID gains in the CDVR Voltage Regulator if the default values do not
bring about proper performance of the generator.
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
60
4. In the blank provided, write down the service literature that you need to perform the tasks to be
executed:
prevent accidents:
61
Task Sheet 01: SR4B/SR5 Generator Functional Test
1. Procedure:
Instructions: In this task, the participant will perform the SR4B Generator functional test according to
the corresponding Service Manual procedure. The participant must have the service literature and the
tools corresponding to the procedure before starting the task. Test results must be written down in the
Results section of this sheet and they must be included in the module Service Report.
 Perform a visual inspection of the equipment to be used. Verify the fluids and make sure the group
can be started safely.
 Make the connections according to the test procedure.
 Record the data required in the results chart according to the test procedure.
 Determine the equipment condition and report it to the Facilitator. In the service report, include the
test results together with the procedure followed.
 End of Task.
2. Results:
Measured
Generator Speed Terminals Voltage
(AC)
T1 - T2
Half of the
T1 - T3
Rated Speed
T2 - T3
T1 - T2
Speed Decrease
T1 - T3
by 10%
T2 - T3
Speed Increase T1 - T2
by 10% (without
T1 - T3
exceeding half of
the speed) T2 - T3

62
Task Sheet 02: Rectifier Block Operational Test
1. Procedure:
Instructions: In this task, the participant will perform the operational tests for the generator exciter
rectifier block. The participant must have the service literature and the tools corresponding to the
procedure before starting the task. Test results must be written down in the Results section of this sheet
and they must be included in the module Service Report.
 Perform a visual inspection of the rectifier block and make sure the test can be carried out safely.
 Carry out the tests of rectifier block diodes and varistors according to the corresponding service
literature.
 Write down the condition of the rectifier block diodes and varistors in the results chart. Include these
data in the service report. Also, explain the procedure followed and the comments about the
condition of the checked components.
 Return the equipment and/or components to their original condition.
 End of Task.
2. Results:
Diode Voltages (+): ________; ________; ________
Diode voltages (-): ________; ________; ________
Varistor Voltage: __________________

63
Task Sheet 03: Alternator Winding Test
1. Procedure:
Instructions: In this task, the participant will perform the functional tests for the alternator windings. The
participant must have the service literature and the tools corresponding to the procedure before starting
the task. Test results must be written down in the Results section of this sheet and they must be
included in the module Service Report.
 Perform a visual inspection of the equipment to be evaluated. Make sure the tests can be carried
out safely.
 Prepare the equipment to perform the different tests mentioned below.
 Perform the resistance test of the alternator main windings. Write down the results in the
corresponding chart. These results must be documented in the service report together with the
comments/observations about the condition of the windings.
 Follow the procedure for the isolation resistance test of the alternator. Write down the results in the
corresponding chart. These results must be documented in the service report together with the
comments/observations about the condition of the windings. Indicate the winding polarizing rate for
each checked winding.
 Reconnect the equipment to its initial condition.
 and graphs of the test as well as the conclusions arrived at.
2. Results:
Winding Resistance
Component Resistance
Rotor Exciter (L2)
Main Stator (L4)
Pilot Exciter Stator (L5)
Main Rotor Winding (L3)
Exciter Stator (L1)
Isolation Resistance
Resistance Resistance
Component
in 30 s in 60 s
Rotor Exciter (L2)
Main Stator (L4)
Pilot Exciter Stator (L5)
Exciter Stator (L1)

64
Task Sheet 04: AVR VR6 Stability and Voltage Adjustment
1. Procedure:
Instructions: In this task, the participant will adjust the stability and pull-up voltage of VR6 Voltage
Regulator. The participant must have the service literature and the tools corresponding to the procedure
before starting the task. Test results must be written down in the Results section of this sheet and they
must be included in the module Service Report.
 Perform a visual inspection of the equipment. Make sure you eliminate any potential danger or risk
to you or the equipment before starting the test.
 Connect the instruments according to the service literature.
 Follow the procedure to adjust the stability and voltage of AVR VR6 according to the service
literature.
 Once you have finished the adjustments, stop the equipment, disconnect the instruments and return
the equipment to its initial condition.
 In the service report, explain the procedure you followed and the condition in which the equipment
was operating when you left it.
 End of Task.
2. Results:

65
Task Sheet 05: AVR VR6 Inflection Frequency Adjustments
1. Procedure:
Instructions: In this task, the participant will adjust the inflection frequency (Knee Frequency) of VR6
Voltage Regulator. The adjustment will be made for a generator operating at 60 Hz and an output
voltage of 480 VAC. The participant must have the service literature and the tools corresponding to the
 Prepare the group to execute the adjustment procedure of inflection frequency for VR6 Regulator.
(Perform the required visual inspection, identify any risk to which you are exposed and inform this to
the Facilitator.)
 Connect the required instruments and tools for the execution of this adjustment according to the
corresponding Service Manual. Check if instruments are operating correctly.
 Start the equipment and check that the group speed control is operational. Also, test the equipment
emergency stop operation.
 Adjust the inflection frequency at __________.
 Record the voltage values corresponding to the frequencies indicated in the results chart.
 Stop the equipment and put all the corresponding guards. Perform a visual inspection around the
equipment and make sure everything is in order.
2. Results:
Frequency Regulator Sensing Voltage

58.8 Hz
58.0 Hz
57.8 Hz
57.0 Hz
The V/Hz ratio at which the voltage regulator is operating is: ________ (V/Hz.)
66
Task Sheet 06: AVR VR6 Functional Test
1. Procedure:
Instructions: In this task, the participant will perform the functional test for VR6 Voltage Regulator.
The participant must have the service literature and the tools corresponding to the procedure before
starting the task. Test results must be written down in the Results section of this sheet and they must be
included in the module Service Report.
 Perform a visual inspection of the voltage regulator to make sure the test can be carried out safely.
 Make the necessary connections according to the service literature.
 Execute the test procedure of the regulator.
 Record the maximum voltage value between F1 and F2. Make observations/comments about
the value.
 Elaborate a service report that includes the safety measures taken, test circuit, observations,
measurements and test conclusions.
 End of Task.
2. Results:
Maximum Excitation Voltage: __________ VDC

Regulator Condition: OK / Not OK

67
Task Sheet 07: AVR R448 Maximum Excitation Adjustment
1. Procedure:
Instructions: In this task, the participant will adjust the maximum excitation current for R448 Voltage
Regulator. The participant must have the service literature and all the tools required to carry out the test
in the generator set selected by the Facilitator.
 Perform a visual inspection of the equipment. Make sure you eliminate any potential danger or risk
to you or the equipment before starting the test.
 Connect the instruments according to the service literature.
 Adjust the maximum excitation current at ________ A.
 Once you have adjusted this value, test the over-excitation/sensing loss protection of the R448
Regulator.
 Once you have finished the tests, disconnect the equipment instruments and return the equipment
to its initial condition.
 In the service report, include the test procedure, clear explanations and details about what was done
during the tests, and the results obtained.
 End of Task.
2. Results:
Maximum Excitation Voltage: ________ VDC

68
Task Sheet 08: AVR DVR Parameter Verification
1. Procedure:
Instructions: In this task, the participant will verify the parameters of the DVR Voltage Regulator. The
participant must have the service literature and all the tools required to carry out the test in the generator
set selected by the Facilitator.
 Perform a visual inspection of the equipment to be checked. Make sure the task can be carried
out safely.
 Place the voltage regulator. (Before this, perform all the equipment blocking and labelling
procedure.)
 Once you have placed the regulator, remove the guards and verify the parameters identified in the
results chart.
 Once you have finished, install the group guards and make sure all the blocking and labelling
equipment is removed.
 Generate a service report and include the procedure and the equipment results. Make comments
and/or observations about the obtained results regarding the data plate of the generator set.
 End of Task.
2. Results:
Equipment Plate Data:
Generator Serial Number: ___________________.

Frame: __________________.
Voltage: __________________.
Power: _________________.
FP: ______________________.
In: _______________________.
Frequency: _______________.
Regulator Data:
Parameter Value Parameter Value

01 09
02 10
03 11
04 13
05 14
06 16
07 17
08 18

69
Task Sheet 09: AVR CDVR Programming
1. Procedure:
Instructions: In this task, the participant will program the AVR CDVR, and they will verify the AVR
CDVR operation. The participant must have the service literature and all the tools required to carry out
the test in the generator set selected by the Facilitator.
 Perform a visual inspection of the equipment. Verify the equipment fluids and make sure
the equipment can be operated safely. Minimize any safety risk.
 Install the CDVR Voltage Regulator in the indicated group.
 Configure the operation parameters according to the group plate data.
 Program the SOFT START MODE so that it starts up at 400 VAC for a period of 5 seconds.
 Program the PID gains of the Voltage Regulator. Store these data and include it in the
service report.
 Once the regulator has been configured, generate a data logger with Cat ET to view the generator
output voltage and the group operation frequency. The data logger duration must be of at least
3 minutes.
 Start the equipment with the data logger recording, and verify the operation of the equipment
inflection frequency point.
 Perform the conversion test (commute the generator output voltage from 480 to 440 VAC and vice
versa) to record the regulator performance upon voltage changes.
 Stop the equipment, disconnect the instruments and leave the equipment in its initial condition.
 Generate a service report including the graphs obtained in the data logger, and your observations
and comments about the results.
 End of Task.
2. Results:
Equipment Plate Data:
Generator Serial Number: ___________________

Frame: __________________.
Voltage: __________________.
Power: _________________.
FP: ______________________.
In: _______________________.
Frequency: _______________.

70
MODULE #3: CONTROL PANELS
Demonstrating the ability to execute the correct programming

of EMCP II+, EMCP 3 and EMCP 4 Control Panels.
Demonstrating the ability to perform the operational tests of

EMCP II+, EMCP 3 and EMCP 4 Control Panels.


Configuration of generator operation parameters through
the navigation in the EMCP II+, EMCP 3 and EMCP 4.1 / 4.2
Control Panels.
Programming of digital inputs for several events (alarms and

shutdowns) for the EMCP 3 and EMCP 4.1 / 4.2 Control Panels.
Programming of relay outputs for several events (alarms,

shutdowns and status) for the EMCP 3 and EMCP 4.1 / 4.2
Control Panels.
Verification of protection systems for EMCP II+, EMCP 3 and

EMCP 4.1 / 4.2 Control Panel.
Tools 275-5120 Communication Adapter Group II
317-7494 Communication Adapter Group 3
Literature RENR7902 EMCP 3 – System Operation, Troubleshooting.

Testing and Adjusting.
RENR1200 EMCP II+ for EUI Engines – System Operation,

Troubleshooting. Testing and Adjusting.
RENR1201 EMCP II+ for Gas Engines – System Operation,

71
SENR5832 EMCP II+ for MUI Engines – System Operation,

RENR1254 EMCP II+ for PEEC Engines – System Operation,

LEBE5255 EMCP 3.1, 3.2, 3.3 Generator Set Controls –

Application & Installation Guide.
LEHE4764 EMCP 3 Monitoring Software Specification Sheet.
LEHE5326 Remote Annunciator Specification Sheet.
LEHE4748 EMCP 3.3 Specification Sheet.
LEHX8338 Customer Interface Module Specification Sheet.
LEHX9590 EMCP II+ Specification Sheet.
LEHE1663 Customer Communication Module

Specification Sheet.
LEBE0001 EMCP 3 Monitoring Software Application and

Installation Guide.
SEBU6874 Customer Communication Module (CCM) For

Diesel Engines.
UENR1209 EMCP 4.1 / 4.2 - System Operation,

Troubleshooting, Testing and Adjusting.
LEBE0006 EMCP 4.1 / 4.2 - Application and

Installation Guide.
REHS5544 EMCP 3 to EMCP 4.1 / 4.2 Retrofit Special

Instruction.
72
Control Panel Questionnaire
EMCP II+ Control Panels:
1. Using the following schematic, identify each of the components that are indicated:
(1) _______________________________________.
(2) _______________________________________.
(3) _______________________________________.
(4) _______________________________________.
(5) _______________________________________.
(6) _______________________________________.
(7) _______________________________________.
(8) _______________________________________.
(9) _______________________________________.
73
2. Using the following schematic, identify each of the components that are indicated:
(1) (8) (15) (22)
(2) (9) (16) (23)
(3) (10) (17) (24)
(4) (11) (18) (25)
(26)
(5) (12) (19)
(6) (13) (20)
(7) (14) (21)
74
3. Using the following schematic, identify the function of these indicators:
(1) __________________________________________.
(2) __________________________________________.
(3) __________________________________________.
(4) __________________________________________.
(5) __________________________________________.
(6) __________________________________________.
(7) __________________________________________.
75
4. Describe the functions and main characteristics of GSC+ (EMCP II+):
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
5. The importance of adjusting parameter P023 correctly lies in avoiding:
a. Problems in the generator set starting system.

b. Problems of incorrect value display in engine monitoring.
c. Problems in the injection control of the Mechanical Injection Engine (MUI).
d. None of the above (please explain your answer.)
6. The conditions that activate the five lights announcing GSC fault events are:
a. __________________________________________________________.
b. __________________________________________________________.
c. __________________________________________________________.
d. __________________________________________________________.
e. __________________________________________________________.
7. The parameters that are displayed in the GSC top display are:
a. All the parameters of the generator electric power output.

b. All the parameters of the engine condition.
c. All the parameters of the generator current and voltage, and the fault codes.
8. The parameters that are displayed in the GSC lower display are:
a. All the instrumentation parameters of the generator current and voltage.

b. Generator output power and fault codes.
c. Engine conditions, relay states and data about the generator output power.
76
9. The function of K1 relay is:
a. To control the starter.

b. To control electronic governor activation.
c. To control fuel delivery.
a. To control electronic governor activation.

b. To announce that a generator shutdown event has occurred.
c. To announce that start up of the generator set has initiated.
a. To announce that the engine has started successfully, and that it is ready for being
disconnected from the starter.
b. To control electronic governor activation when the minimum preset oil pressure in P003 is
reached.
c. To announce that the ECS, ATS or CCM sent a start up signal to the engine.
a. To announce that the engine has started successfully, and that it is ready for being
disconnected from the starter.
b. To control starter activation.
c. To announce that a generator set shutdown event has occurred.
a. To announce that a start up command has been received and that the set start up sequence
is initiating.
b. To announce that the set has started successfully and that it is able to charge and unhook
the starter.
c. To control starter activation.
is initiating.
c. To control fuel throttling solenoid activation.
a. To announce that the set has started successfully and that it is able to charge and unhook
the starter.
77
is initiating.
b. To announce that the set has started successfully and that it is able to charge and unhook
the starter.
17. In the case of MUI engines, the control panel reads oil pressure for:
a. Engine oil pressure sensor, which is connected to the engine governor.

b. Oil pressure digital sensor, which is directly connected to the panel.
c. The panel does not need to monitor engine oil pressure because the engine has its own
protection system.
18. In the case of EUI engines, the control panel reads oil pressure for:
a. Engine oil pressure sensor, which is connected to the engine governor.

b. Oil pressure digital sensor, which is directly connected to the panel.
c. The panel does not need to monitor engine oil pressure because the engine has its own
protection system.
19. In the case of MUI engines, the control panel reads coolant temperature for:
a. Engine coolant temperature sensor, which is connected to the engine governor.

b. Coolant temperature digital sensor, which is directly connected to the panel.
c. The panel does not need to monitor engine coolant temperature because the engine has its
own protection system.
20. In the case of EUI engines, the control panel reads coolant temperature for:
a. Engine coolant temperature sensor, which is connected to the engine governor.

b. Coolant temperature digital sensor, which is directly connected to the panel.
c. The panel does not need to monitor engine coolant temperature because the engine has its
own protection system.
21. In the case of MUI engines, engine hours displayed in the panel are stored in:
a. Control panel memory.

b. The panel reads them from the machine ECM.
c. The panel does not read engine hours.
22. In the case of EUI engines, engine hours displayed in the panel are stored in:
a. Control panel memory.

b. The panel reads them from the engine ECM.
c. The panel does not read engine hours.
78
23. The control panel is on Normal mode when:
a. All the dedicated shutdown event indicators are off.

b. All the alarm indicators are off.
c. All the client event indicators are off.
d. All of the above
24. The functions that the GSC performs when operating on normal mode are:
a. __________________________________.
b. __________________________________.
c. __________________________________.
d. __________________________________.
e. __________________________________.
25. The GSC initiates the start up sequence when:
a. _____________________________________.
b. _____________________________________.
c. _____________________________________.
26. Once the GSC receives the start up signal, it:
a. Activates starter and fuel solenoid.

b. Verifies that there are no existing fault events and that all shutdown events have been reset.
c. Activates engine run relay.
27. During start up sequence, the GSC activates engine start up through the following relays:
a. K4 and K7
b. K2 and K1
c. K5 and K8
28. During engine start up sequence, the GSC activates K5 relay when:
a. When it activates fuel control relay.

b. When it activates starter relay.
c. When it activates air shut-off relay.
29. During start up sequence, the setpoint that determines start up termination speed for the GSC is:
a. P002
b. P018
c. P010
79
30. During start up sequence, the setpoint that determines the start up attempt duration (energizing the
starter) for the GSC is:
a. P011
b. P023
c. P018
31. During start up sequence, the GSC will activate the Electronic Governor Relay (EGR) when:
a. Engine speed is equal to or higher than the setpoint value for start up termination speed.
b. Oil pressure is equal to or higher than the low oil pressure point for engine oil at low
idle speed.
c. Coolant temperature is within the range set by coolant operating temperature setpoints.
32. During Normal mode operation, the GSC will activate engine shutdown sequence when:
a. _________________________________________.
b. _________________________________________.
c. _________________________________________.
33. Once the GSC start up signal is removed, the GSC will:
a. Deactivate Fuel Control Relay (FCR.)

b. Activate engine cooldown timer.
c. Deactivate engine Run Relay (RR.)
34. During engine normal shutdown sequence, the GSC deactivates engine Run Relay (RR) when:
a. Engine speed is below P023 value.

b. Cooldown timer expires.
c. K3 relay deactivates.
35. During engine normal shutdown sequence, the GSC deactivates K3 relay when:
a. Oil pressure is lower than the one set in setpoint P023.

b. Engine speed is lower than the one set in setpoint P011.
c. Engine speed is equal to 0 RPM.
d. Oil pressure is equal to 0 PSI.
36. The GSC activates Shutdown Event mode when:
a. One of the engine protection systems is triggered.

b. One of the relay protection systems is triggered.
c. One of the scheduled client shutdown events is triggered.
d. All of the above
80
37. During an engine shutdown sequence generated by a shutdown event, the GSC will:
a. Deactivate K4 relay and activate K1.

b. Deactivate K7 relay and activate K2.
c. Deactivate K3 relay and activate K8.
d. Deactivate K5 relay and activate K6.
38. The events that cause activation of K6 relay are:
a. ________________________________________.
b. ________________________________________.
c. ________________________________________.
39. In order to activate GSC Service mode, the ECS must not be in the following position:
a. AUTO
b. MANUAL
c. STOP/COOLDOWN
d. OFF/RESET
40. While on Service mode, OP1 function is:
a. The option on the control panel where engine protection systems values are set.
b. The option on the control panel where engine/generator operation setpoint values are
displayed.
c. The option on the control panel where stored diagnostic codes are displayed.
d. The option on the control panel where engine operation hours are displayed.
41. While on Service mode, OP2-0 function is:
a. The option on the control panel where engine protection systems values are set.
displayed.
c. The option on the control panel where stored diagnostic codes are displayed.
a. The option on the control panel where relay protection system setpoints are displayed.
displayed.
c. The option on the control panel where engine operation hours are displayed.
81
displayed.
c. The option on the control panel where alternating current calibration setpoints and factory
data are displayed.
b. The option on the control panel that allows entering the access password for menus
OP4 to OP10.
b. The option on the control panel where stored diagnostic codes are displayed.
a. The option on the control panel where engine/generator operation setpoint values are set.
b. The option on the control panel where stored inactive diagnostic codes are deleted.
a. The option on the control panel where relay protection system setpoints are set.
b. The option on the control panel where engine/generator operation setpoint values are set.
b. The option on the control panel where engine/generator operation setpoint values are set.
82
b. The option on the control panel where free inlets and outlets are set.
a. The option on the control panel where engine/generator operation setpoint values are set.
b. The option on the control panel where free inlets and outlets are set.
51. Considering GSC setpoints, the parameter that defines activation mode of fuel throttling solenoid for
the GSC is:
a. P005
b. P006
c. P002
52. Considering GSC setpoints, the parameter used to command the GSC not to execute an engine
shutdown action when a low oil pressure or high coolant temperature shutdown event is generated is:
a. P005
b. P003
c. P002
53. Considering GSC setpoints, the function of P004 parameter is:
a. To define K2 relay operation.

b. To define GSC answer to a fault code in one of the GSC sensors.
c. To define K3 relay operation.
a. To define triggering value for low oil pressure shutdown event.

b. To define delay time value for low oil pressure shutdown event activation.
c. To define delay time value for low oil pressure shutdown event activation.
a. To define triggering value for a low oil pressure at rated speed event.
b. To define triggering value for a low oil pressure at low speed event.
c. To define crank cycle duration time.
83
a. To define FCR relay active status.

b. To define start up termination speed.
c. To define K7 relay active status.

b. To define monitoring changeover point according to engine speed.
a. To define generator set power.

b. To define generator set voltage display scale.
c. To define generator set current display scale.

a. To define generator set power.

b. To define generator set peak outlet current.

a. To define triggering value for high coolant temperature shutdown event.

b. To define triggering value for low oil pressure alarm event.
c. To define engine cooldown cycle duration time.
84

c. To define triggering value for low oil pressure shutdown event.

d. To define triggering value for high coolant temperature alarm event.
e. None of the above (please explain your answer.)
a. To define generator set peak power.

c. To define generator set voltage display scale.


d. To define generator set current display scale.
e. None of the above (please explain your answer.)

b. To define generator set voltage display scale.

85

b. To define triggering value for low oil pressure shutdown event.
c. To define triggering value for high coolant temperature alarm event.
71. Considering GSC setpoints, the parameter that defines the triggering value for an overvoltage alarm
event is:
a. P105
b. P025
c. P102
a. To define triggering value for low voltage alarm event.

b. To define triggering value for overcurrent shutdown event.
c. To define delay time value for low voltage shutdown event activation.
a. To define delay time value for low frequency alarm event activation.
b. To define delay time value for low voltage shutdown event activation.
c. To define delay time value for overvoltage alarm event activation.
a. To define the response to a low voltage shutdown event.

b. To define the response to an over frequency shutdown event.
c. To define the response to an overcurrent shutdown event.
75. If GSC setpoint SP01 has a value of 1, this means that:
a. When switch 1 (SW1) is closed and grounded, the fault is active.

b. When switch 1 (SW1) is open and grounded, the fault is active.
c. When switch 2 (SW2) is open and grounded, the fault is active.
a. When free input 1 is active, the GSC response will be a shutdown event.
b. When free input 2 is active, the GSC response will be an alarm event.
c. When free input 2 is not active, the GSC response will be a shutdown event.
86
77. Considering GSC setpoints, the function of SP12 parameter is:
a. To define delay time for free input 1 customer event activation.

b. To define delay time for free input 2 customer event activation.
c. To define delay time for free input 3 customer event activation.
d. To define delay time for free input 4 customer event activation.
a. When free input 3 is active, the GSC response will be a shutdown event.
b. When free input 4 is active, the GSC response will be an alarm event.
c. When the replacement output for EMCP II+ becomes active, it will operate as a normally
open contact.
a. To define K8 relay activation moment.

b. To define K8 relay operation logic.
c. To define K7 relay operation logic.
a. To define K7 relay activation condition.

b. To define K8 relay activation condition.
c. To define free input 4 operation logic.
81. The functions in which SP14 parameter can be programmed are:
(0) ______________________________________________.
(1) ______________________________________________.
(2) ______________________________________________.
(3) ______________________________________________.
(4) ______________________________________________.
(5) ______________________________________________.
(6) ______________________________________________.
(7) ______________________________________________.
(8) ______________________________________________.
(9) ______________________________________________.
(10)______________________________________________.
(11)______________________________________________.
82. When the verification test for engine overspeed protection system is conducted, the parameter that
needs to be temporally modified is:
a. P003
b. P005
c. P010
87
83. When the verification test for low oil pressure protection system is conducted, the parameter that
needs to be temporally modified is:
a. P022
b. P003
c. P013
84. When the verification test for low oil pressure protection system is conducted, the alarm indicator will
become active when:
a. Oil pressure is equal to or lower than the value for P013 parameter.
b. Oil pressure is equal to or lower than the value for P012 parameter.
c. Oil pressure is 441 kPa (10 psi) above the value for P012 parameter.
85. When the verification test for high coolant temperature protection system is conducted, the alarm
indicator will become active when:
a. Coolant temperature is equal to or lower than the value for P014 parameter.
b. Coolant temperature is equal to or lower than the value for P015 parameter.
c. Coolant temperature is 11 ºC (19 ºF) above the value for P015 parameter.
86. The parameter used to enable the kilowatt level relay is:
a. P102
b. P104
c. P138
87. If the GSC has a CID 100 FMI 2 diagnostic code, the possible causes for this problem are:
a. _______________________________________________.
b. _______________________________________________.
88. For the oil pressure sensor, the measured percent duty cycle when pressure is 0 kPa (0 psi) is
approximately:
a. 19%.
b. 13%.
c. 10%.
89. For the oil pressure sensor, the measured percent duty cycle when pressure is 690 kPa (100 psi) is
approximately:
a. 70%.
b. 92%.
c. 85%.
88
90. For the coolant temperature sensor, the measured percent duty cycle when temperature is -40 ºC
(–40 ºF) is approximately:
a. 10%.
b. 14%.
c. 18%.
91. For the coolant temperature sensor, the measured percent duty cycle when temperature is 135 ºC
(275 ºF) is approximately:
a. 95%.
b. 93%.
c. 90%.
92. The base frequency for the coolant temperature sensor signal is:
a. 550 Hz
b. 455 Hz
c. 1,050 Hz
93. The base frequency for the oil pressure sensor signal is:
a. 500 Hz 150 Hz
b. 370 Hz 150 Hz
c. 1,050 Hz 150 Hz
94. If the GSC has a “190 E 3” diagnostic code, this means that:
a. There is a fault in the engine ECM oil pressure sensor.

b. There is a fault in the GSC coolant temperature sensor.
c. There is a fault in the coolant leakage sensor.
95. CID 268 FMI 2 diagnostic code is generated when:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
96. When the GSC has an active CID 566 FMI 7 code, the first verification that needs to be conducted,
after verifying that there are no other active codes, is:
a. Verifying fuel level and fuel quality.

b. Verifying engine speed sensor.
c. Verifying oil pressure sensor.
89
97. The GSC kW level relay will deactivate when:
a. The read kW value is lower than 20% of plate power.

b. The read kW value is 85% of plate power.
c. The read value is below the level set in setpoint P141.
98. The GSC kW level relay can be programmed with an activation delay time in the following parameter:
a. P023
b. P017
c. P140
99. When the low oil pressure shutdown event indicator is active, it is necessary to conduct the following
verifications:
a. ______________________________________________.
b. ______________________________________________.
c. ______________________________________________.
d. ______________________________________________.
100. When the overspeed shutdown event indicator is active, it is necessary to conduct the following
verifications:
a. __________________________________________________.
b. __________________________________________________.
c. __________________________________________________.
101. Mention the optional attachments for the EMCP II+ control panel.
a. __________________________________________________.
b. __________________________________________________.
c. __________________________________________________.
d. __________________________________________________.
e. __________________________________________________.
90
102. Mention the alarm module components used with the EMCP II+ control panel:
(1) ___________________________________________________.
(2) ___________________________________________________
(3) ___________________________________________________
(4) ___________________________________________________
(5) ___________________________________________________
91
103. Using the following schematic, identify the function of each of the components that are indicated for
the alarm module provided:
2
4
(1) _______________________
(2) _______________________
(3) _______________________
(4) _______________________
104. Explain the functions included in the remote annunciator panel used with the alarm modules that
work with the EMCP II+ control panel:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
105. Mention the different versions of alarm modules available for the EMCP II+ control panel:
a. ____________________________________________________.
b. ____________________________________________________.
c. ____________________________________________________.
d. ____________________________________________________.
e. ____________________________________________________.
f. ____________________________________________________.
92
106. The difference between the alarm module versions available for the EMCP II+ control panel is:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
107. In the EMCP II+ alarm module connections, the reference for the discrete inputs that are connected
to these modules should be:
a. Grounded
b. To positive battery terminal
c. To negative battery terminal
108. Four of the events that the EMCP II+ transmits to the alarm module through the data link are:
a. ___________________________________________________.
b. ___________________________________________________.
c. ___________________________________________________.
d. ___________________________________________________.
109. In the EMCP II+, the maximum number of devices that can be connected to the serial data link is:
a. 5
b. 3
c. 2
110. The maximum distance at which a GSC+ (EMCP II+) module can be connected is:
a. 250 meters (820 feet)

b. 305 meters (1,000 feet)
c. 1,000 meters (3,280 feet)
111. Considering the EMCP II+ alarm modules, explain the way a fault is communicated in the data link
to the operator:
____________________________________________________________________________________
____________________________________________________________________________________
93
112. Explain the function of each of the Custom Alarm Module (CAM) terminals used with the EMPC II+:
Terminal Number Description
10
11
12
13
14
94
113. Explain the characteristics and the operation of the relay control module available for the EMCP II+
control panel:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
114. In the RDM used with the EMCP II+, the peak current that the relay control modules can admit,
within a voltage range of 15 to 45 VDC, is:
a. 500 mA
b. 125 mA
c. 600 mA
115. The RDM must share a common reference point with the GSC and the relay panel.
a. True
b. False (please explain your answer.)
116. The maximum distance between the GSC (EMCP II+) and the RDM is 250 m (820 ft.)
a. True
117. In the EMCP II+ RDM, if there is a problem with the data link, relay 2 will begin to switch at a ratio
of 0.5 Hz.
a. True
118. Explain the operation of the RDM relay output test:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
119. For an application with an EMCP II+ panel, the RDM can operate without a relay panel.
a. True
95
120. Explain the characteristics of the Customer Interface Module (CIM) used with the EMCP II+ control
panels:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
121. The events that the serial data link CIM can decode are:
a. _____________________________________________.
b. _____________________________________________.
c. _____________________________________________.
d. _____________________________________________.
e. _____________________________________________.
f. _____________________________________________.
g. _____________________________________________.
h. _____________________________________________.
i. _____________________________________________.
j. _____________________________________________.
122. For an application with an EMCP II+ panel, the CIM can operate without a relay panel.
a. True
123. Explain the function of the Customer Communication Module (CCM) available with the EMCP II+
control panel:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
124. The functions that can be controlled through the EMCP II+ control panel CCM are:
a. ________________________________________________________.
b. ________________________________________________________.
c. ________________________________________________________.
d. ________________________________________________________.
e. ________________________________________________________.
f. ________________________________________________________.
g. ________________________________________________________.
96
125. The maximum distance between the CCM and the EMCP II+ control panel is:
a. 305 m (1,000 ft)

b. 100 m (330 ft)
c. 458 m (1,500 ft)
97
EMCP 3 Control Panel:

1. Using the following schematic, identify the components that are indicated:
a. ___________________________________________.
b. ___________________________________________.
c. ___________________________________________.
d. ___________________________________________.
e. ___________________________________________.
f. ___________________________________________.
g. ___________________________________________.
h. ___________________________________________.
i. ___________________________________________.
j. ___________________________________________.
98
2. Using the following schematic, identify the components that are indicated:
(1) (5) (9) (13)
(2) (6) (10) (14)
(3) (7) (11) (15)
(4) (8) (12) (16)
3. Some of the functions of the EMCP 3 are:
a. ______________________________________.
b. ______________________________________.
c. ______________________________________.
99
4. The functions that can be modified/visualized from the EMCP 3 control panel display are:
a. ________________________________________________.
b. ________________________________________________.
c. ________________________________________________.
d. ________________________________________________.
e. ________________________________________________.
f. ________________________________________________.
g. ________________________________________________.
5. When the amber warning event lamp is on and flashing, this means that:
a. There is an active warning event that has not been recognized yet.
b. There is an inactive warning event that has not been recognized.
c. There is an active warning event that has been recognized.
6. When the amber warning event lamp is on and steady, this means that:
a. There is an active warning event that has not been recognized yet.
b. There is an inactive warning event that has not been recognized.
c. There is an active warning event that has been recognized.
7. When the red shutdown event lamp is on and steady, this means that:
a. There is an active shutdown event that has not been recognized yet.
b. There is an inactive shutdown event that has not been recognized.
c. There is an active shutdown event that has been recognized.
8. When the red shutdown event lamp is on and flashing, this means that:
a. There is an active shutdown event that has not been recognized yet.
b. There is an inactive shutdown event that has not been recognized.
c. There is an inactive shutdown event that has not been recognized.
9. The three types of data link networks that the EMCP 3 control panels can have are:
a. ____________________________________________.
b. ____________________________________________.
c. ____________________________________________.
10. The devices that can be connected to an EMCP 3.1 in its data link(s) are:
a. ____________________________________________.
b. ____________________________________________.
c. ____________________________________________,
100
11. The devices that can be connected to an EMCP 3.2 in its data links are:
a. ________________________________________.
b. ________________________________________.
c. ________________________________________.
d. ________________________________________.
12. The devices that can be connected to an EMCP 3.3 in its data links are:
a. ___________________________________.
b. ___________________________________.
c. ___________________________________.
d. ___________________________________.
e. ___________________________________.
f. ___________________________________.
13. In the case of applications with EUI engines, the generator start up and stop signals are transmitted
through:
a. Dry contact relays directly connected to the starter and the fuel solenoid.
b. The starter relay is used, and the fuel bomb activation/deactivation signal is transmitted
through the data link.
c. The generator start up and stop activation information is sent to the engine governor through
data link.
14. In the case of applications with EUI engines, the desired speed signal can be derived from one of the
following two inputs:
a. _____________________________________________.
b. _____________________________________________.
15. In the case of applications with MUI engines, the EMCP 3 controls engine start up and shutdown
through:
a. __________________________________________,.
b. __________________________________________.
c. __________________________________________.
16. In the case of applications with MUI engines, the EMCP 3 directly monitors the following parameters:
a. ______________________________________.
b. ______________________________________.
c. ______________________________________.
d. ______________________________________.
17. The commands that cause the EMCP 3 to initiate the engine start up sequence are:
a. _______________________________________.
b. _______________________________________.
c. _______________________________________
d. _______________________________________.
101
18. Once the EMCP 3 verifies that it can initiate engine start up, it performs engine initial sequence
through the following steps:
a. __________________________________________________________________________
__________________________________________________________________________
_________________________________________________________________________.
b. __________________________________________________________________________
__________________________________________________________________________
_________________________________________________________________________.
c. __________________________________________________________________________
__________________________________________________________________________
_________________________________________________________________________.
d. __________________________________________________________________________
__________________________________________________________________________
_________________________________________________________________________.
19. The necessary conditions for the EMCP 3 to begin engine normal shutdown sequence are:
a. _________________________________________________.
b. _________________________________________________.
20. To prevent the engine from cooling (COOLDOWN) after pressing the STOP button, it is necessary to:
___________________________________________________________________________________.
21. The number of EMCP 3 security passwords is:
a. 5.
b. 3.
c. 4.
d. It has no security levels.
22. EMCP 3 security levels are used to:
a. Control modification of control panel setpoints from its interface.

b. Control access to generator operation.
c. Avoid resetting recorded shutdown events.
23. The security level assigned to parameters that do not affect control panel operation is:
a. Level 1
b. Level 5
c. Level 4
d. There is no such security level.
24. The EMCP 3 security level that requires a factory password is:
a. Level 5
b. Level 2
c. Level 3
102
25. When an event status is “Present”, it means that:
____________________________________________________________________________________
26. When an event status is “Active”, it means that:
___________________________________________________________________________________.
27. The procedure to reset the events for a single Electronic Control Module (ECM) in the EMCP 3 is
the following:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
28. The procedure to reset the events for all the modules in the EMCP 3 is the following:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
29. In the EMCP 3.2 and EMCP 3.3 control panels, the free analog input is used to read parameters of:
a. Levels
b. Pressures
c. Temperatures
d. All of the above
30. For the replacement analog input, the type of sensors to be used must be PWM sensors:
a. True
b. False (if false, explain the true answer)
31. The EMCP 3.1 has 6 available discrete inputs to program different client events:
a. True
32. The EMCP 3.1 has 8 available programmable relay outputs for the control of auxiliary components or
annunciation.
a. True
33. The EMCP 3.1 has 2 available programmable digital outputs for the control of auxiliary components
or annunciation.
a. True
103
34. The EMCP 3.2 has 6 available discrete inputs to program different client events.
a. True
b. False (if false, explain the true answer.)
annunciation.
a. True
or annunciation.
a. True
37. The EMCP 3.3 has 8 available discrete inputs to program different client events.
a. True
annunciation.
a. True
or annunciation:
a. True
40. In the EMCP 3.1 control panel, the number of available programmable cycle timers is:
a. 4.
b. 2.
c. 6.
41. In the EMCP 3.2 control panel, the number of available programmable cycle timers is:
a. 5.
b. 2.
c. 7.
42. The two actions that activate the programmable cycle timers are:
a. ____________________________________________________.
b. ____________________________________________________.
104
43. In the EMCP 3 control panel, the editable sequence files are used to:
a. Change the start up sequence of the generator set.

b. Manage the control panel response to a client event.
c. Display a specific text for a custom client event.
44. In the EMCP 3.1 control panel, the parameters that are displayed on the first AC Overview
screen are:
a. _____________________________________________.
b. _____________________________________________.
c. _____________________________________________.
45. In the EMCP 3.2 control panel, the parameters that are displayed on the second Engine Overview
screen are:
a. _____________________________________.
b. _____________________________________.
c. _____________________________________.
46. In the EMCP 3.3 control panel, the parameters that are displayed on the third AC Overview
screen are:
a. ______________________________________.
b. ______________________________________.
c. ______________________________________..
d. ______________________________________.
47. In the EMCP 3.3 control panel, the parameters that are displayed on the third Engine Overview
screen are:
a. __________________________________________.
b. _____________________________________________.
48. In the EMCP 3.3 control panel, the parameters that are displayed on the tenth AC Overview screen
are:
a. ____________________________________________________.
b. ____________________________________________________.
49. In order to be able to view custom client events, you have to make sure in the control panel that:
a. The temperature parameters are programmed according to the scale used by the sensor.
b. The “Engine Fault Delay Timer” (FPT) is properly set for the event.
c. The language in the panel is defined according to the client's language.
50. In the EMCP 3.3 control panel, the number of C-type relays (with NC and NA contacts) is:
a. 2.
b. 3.
c. There are no C-type relays; only A-type relays.
105
51. Using the following schematic, draw the voltage reading connections for the EMCP 3 for a Wye
connected alternator:
Phase A
52. Using the following schematic, draw the voltage reading connections for the EMCP 3 for a Delta
Phase A
106
53. Using the following schematic, draw the voltage reading connections for the EMCP 3 for a Delta
Phase A
54. Using the following schematic, draw the voltage reading connections for the EMCP 3 for a Double
Delta connected alternator:
Phase A
107
55. Using the following schematic, draw the reading connections for the EMCP 3 for a Double Delta
Phase A
56. The EMCP 3 can be directly connected to its voltage reading terminals up to:
a. 400 VAC
b. 600 VAC
c. 1,000 VAC
108
57. For a Delta connected alternator with three output terminals, the best configuration for the potential
transformer connections to the EMCP 3 is:
a.
b.
c.
58. For the EMCP 3, in the Setpoints menu, the sections that can be found in the Control submenu are:
a. ________________________________________________________________________.
b. ________________________________________________________________________.
c. ________________________________________________________________________.
109
59. For the EMCP 3 control panel, define the function of the setpoint “Engine Start Fault Protection
Activation Delay Time”:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
60. For the EMCP 3 control panel, define the function of the setpoint “Crank Duration”:
____________________________________________________________________________________
____________________________________________________________________________________
61. For the EMCP 3 control panel, define the function of the setpoint “Crank Cycle Rest Interval”:
____________________________________________________________________________________
____________________________________________________________________________________
62. For the EMCP 3 control panel, define the function of the setpoint “Maximum Number of Crank
Cycles”:
____________________________________________________________________________________
____________________________________________________________________________________
63. For the EMCP 3 control panel, define the function of the setpoint “Crank Alert Activation Time”:
____________________________________________________________________________________
____________________________________________________________________________________
64. For the EMCP 3 control panel, in setpoint “Engine Controller Data Link J1939 Backup Configuration”,
the behavior of the control panel when it is set on “Proprietary or Enhanced Data Link” is:
____________________________________________________________________________________
____________________________________________________________________________________
65. In order to be able to perform a voltage adjustment from the EMCP 3 control panel, the generator
must have the following type of regulator installed:
a. VR3
b. VR6
c. CDVR
110
66. The conditions that are considered for the maintenance service interval are:
a. ____________________________________________.
b. ____________________________________________.
67. In the event response configuration, when the Audible Alert option becomes active, the EMCP 3 will:
a. Activate all the system audible alerts (both local and remote annunciator alerts.)
b. Generate an engine shutdown event.
c. Activate the relay output programmed for horn control.
68. When activating the option “Soft Shutdown” in an event response configuration, the EMCP 3 will:
a. Stop the engine immediately.

b. Activate an engine cooling cycle and stop the engine.
c. The generator will decrease its RPM and stop due to low speed.
69. When activating the option “Hard Shutdown” in an event response configuration, the EMCP 3 will:
a. Activate an engine shutdown event and continue to show an event until the fault is corrected.
b. Activate an engine cooling cycle and stop the engine.
c. Activate the relay output programmed for Cooldown mode.
70. In the EMCP 3, when activating the option “FTP” in an event response configuration, the EMCP 3 will:
a. Activate the local horn every time a start up fault occurs.

b. Ignore the event, if active, for a set time during start up.
c. Control the event response according to the FTP; it can be a warning or a shutdown.
71. In the EMCP 3, the function of digital input #1 in the EMCP 3 control panel is:
a. The input for the remote start up signal.

b. The signal for the coolant temperature switch.
c. The signal for the emergency stop.
72. In the EMCP 3, the function of digital input #2 in the EMCP 3 control panel is:
a. The input for the remote start up signal.

b. The signal for the emergency stop.
c. The signal for the oil pressure switch.
111
73. In the EMCP 3, in order to be able to program the digital inputs available for the EMCP 3, it is
necessary to conduct the following two procedures:
a. _________________________________________________________.
b. _________________________________________________________.
74. In the EMCP 3, in order to be able to program discrete input #3, it is necessary to program the input
event function number:
a. 3.
b. 1.
c. 4.
75. In the EMCP 3, in order to be able to program a discrete input, it is necessary to set the following
setpoints in the input event function:
a. _______________________________________________________.
b. _______________________________________________________.
c. _______________________________________________________.
d. _______________________________________________________.
76. In the EMCP 3, it is necessary to follow these steps to display a custom event in the recorded
event screen:
a. ________________________________________________________________.
b. ________________________________________________________________.
c. ________________________________________________________________.
77. In the EMCP 3, in order to be able to display a custom event and generate a shutdown event
response, it is necessary to set:
a. The custom event response for a high limit shutdown.

b. The custom event response for a low limit shutdown.
c. The custom event response for an existing condition.
78. In the EMCP 3, the relay output #1 function is:
a. To send an activation signal to the electronic governor.

b. To activate the starter.
c. To control fuel.
79. In the EMCP 3, the relay output #2 function is:
a. To send an activation signal to the electronic governor.

b. To activate the starter.
c. To generate a contact for a shutdown event annunciation.
112
80. In order to be able to program an EMCP 3.2 relay output #5, it is necessary to:
a. Program digital selector #1.

b. Program the output event function.
c. Program digital selector #2.
81. For an EMCP 3 control panel, define when a relay programmed with a “Crank Alert” event becomes
active and when it becomes inactive:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
82. For an EMCP 3 control panel, define when a relay programmed with an “Air Shutoff” event becomes
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
83. For an EMCP 3 control panel, define when a relay programmed with a “Start Aid” event becomes
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
84. For an EMCP 3 control panel, define when a relay programmed with a “Common Warning” event
becomes active and when it becomes inactive:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
85. For an EMCP 3 control panel, define when a relay programmed with a “Common Shutdown” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
86. For an EMCP 3 control panel, define when a relay programmed with a “Common Alarm” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
113
87. For an EMCP 3 control panel, define when a relay programmed with an “Engine Start Initiated” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
88. For an EMCP 3 control panel, define when a relay programmed with an “Engine Started” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
89. For an EMCP 3 control panel, define when a relay programmed with a “Rated Speed” event becomes
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
90. For an EMCP 3 control panel, define when a relay programmed with a “Horn Control” event becomes
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
91. For an EMCP 3 control panel, define when a relay programmed with an “ECU Fault Reset Alert”
event becomes active and when it becomes inactive:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
92. For an EMCP 3 control panel, define when a relay programmed with a “Disable AUX AC Supply”
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
93. For the EMCP 3 control panel, define when a relay programmed with a “Breaker Trip 1” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
114
94. For the EMCP 3 control panel, define when a relay programmed with a “Breaker Trip 2” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
95. For the EMCP 3 control panel, define when a relay programmed with an “Event Output Function”
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
96. For the EMCP 3 control panel, define when a relay programmed with a “Voltage & Hertz within Limits”
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
97. For the EMCP 3 control panel, define when a relay programmed with an “In Cooldown” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
98. For the EMCP 3 control panel, define when a relay programmed with an “Auto Mode” event becomes
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
99. For the EMCP 3 control panel, define when a relay programmed with a “Programmable Cycle Timer
Output #2” event becomes active and when it becomes inactive:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
100. For the EMCP 3 control panel, define when a relay programmed with a “High Percent kW” event
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
115
101. In an EMCP 3.2 control panel, the maximum number of discrete input and output modules that can
be connected to it is:
a. 5
b. 1
c. 2
Answer: (d) 4 discrete I/O modules – Reference – LEBE5255 – Section: Optional Modules
102. In an EMCP 3.2 control panel, the maximum number of alarm (annunciator) modules that can be
connected to it is:
a. 4
b. 5
c. 9
103. In an EMCP 3.2 control panel, the maximum number of RTD modules that can be connected to it is:
a. 1
b. 5
c. 3
104. In an EMCP 3.2 control panel, the maximum number of thermocouple modules that can be
connected to it is:
a. 3
b. 4
c. 5
105. To program an output in the discrete I/O module for the EMCP 3, it is necessary to configure these
setpoints:
a. ________________________________________________.
b. ________________________________________________.
106. The peak current that an output of the I/O module relay for an EMCP 3 can admit, at a voltage of
30 VDC, is:
a. 0.5 A
b. 200 mA.
c. 2.0 A
107. The types of thermocouples that the thermocouple module for EMCP 3 control panel can read are:
a. _________________________________________________.
b. _________________________________________________.
116
108. The information about recorded events that the thermocouple modules for EMCP 3 control panel can
store is:
a. _______________________________________________.
b. _______________________________________________.
c. _______________________________________________.
d. _______________________________________________.
e. _______________________________________________.
f. _______________________________________________.
g. _______________________________________________.
h. _______________________________________________.
i. _______________________________________________.
109. The number of thermocouples that can be connected to the thermocouple module for
EMCP 3 control panel is:
a. 15.
b. 20.
c. 40.
110. The types of thermocouple Failure Mode Identifier (FMI) codes in thermocouple modules for
EMCP 3 control panel are:
a. _______________________________________.
b. _______________________________________.
c. _______________________________________.
d. _______________________________________.
e. _______________________________________.
111. To program a thermocouple in a thermocouple module for EMCP 3 control panel, it is necessary to
configure the following setpoints:
a. __________________________________________.
b. __________________________________________.
c. __________________________________________.
d. __________________________________________.
e. __________________________________________.
f. __________________________________________.
g. __________________________________________.
h. __________________________________________.
112. Explain the function of the RTD module used in EMCP 3 control panels:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
117
113. The types of RTD Failure Mode Identifier (FMI) codes in RTD modules for EMCP 3 control
panel are:
a. _______________________________________.
b. _______________________________________.
c. _______________________________________.
d. _______________________________________.
e. _______________________________________.
114. To program an RTD in an RTD module for EMCP 3 control panel, it is necessary to configure the
following setpoints:
a. __________________________________________.
b. __________________________________________.
c. __________________________________________.
d. __________________________________________.
e. __________________________________________.
f. __________________________________________.
g. __________________________________________.
h. __________________________________________.
i. __________________________________________.
115. In the annunciator modules used in EMCP 3 control panels, if there is a “Global Acknowledge”
command programmed in the module, the events that are announced in the module are recognized
through:
a. _______________________________________________________.
b. _______________________________________________________.
c. _______________________________________________________.
116. The function of the ECU instance number in the annunciator modules configuration used with the
EMCP 3 control panel is:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
117. The parameters that must be set to define the behavior of the LEDs in the annunciator modules
used with the EMCP 3 are:
a. _______________________________________________________________.
b. _______________________________________________________________.
c. _______________________________________________________________.
d. _______________________________________________________________.
118. The maximum distance allowed between the EMCP 3 data link port connection and the annunciator
module is:
a. 100 m (330 ft)

b. 243.8 m (800 ft)
c. 305 m (1,000 ft)
d. 504.8 m (1,657 ft)
118
119. The EMCP 3 remote monitoring software can be used with all the EMCP 3 control panels.
a. True
b. False (please explain your answer)
120. Mention the Caterpillar products that can be monitored with the EMCP 3 remote monitoring software:
a. _____________________________________________________________.
b. _____________________________________________________________.
c. _____________________________________________________________.
121. The maximum distance allowed between the EMCP 3 control panel connection port and the Modbus
network termination point is:
a. 305 m (1,000 ft)

b. 250 m (800 ft)
c. 1,200 m (4,000 ft)
d. 100 m (330 ft)
122. Define the type of cable that must be used for the Modbus network connection used by the
EMCP 3 remote monitoring software:
____________________________________________________________________________________
123. Define the default user name and password needed to log in to the EMCP 3 remote monitoring
software:
User Name:_________________________________.
Password: __________________________________.
124. In order to download the EMCP 3 remote monitoring software Quick Start Guide, you must go to:
a. TMI Web
b. SIS
c. Power.NET
d. Dealer.NET
125. What is the menu in which you have to program the direction node for the EMCP 3 control panel in
order to be able to communicate correctly with the EMCP 3 remote monitoring software?
____________________________________________________________________________________
119
EMCP 4 control panel:
1. Draw the EMCP 4.2 control panel connectivity block schematic for an EUI engine in the following box:
120
2. Draw the EMCP 4.2 control panel connectivity schematic for an MUI engine in the following box:
121
3. Identify the following EMCP 4.2 control panel buttons:
1) ___________________________________________________
2) ___________________________________________________
3) ___________________________________________________
4) ___________________________________________________
5) ___________________________________________________
6) ___________________________________________________
7) ___________________________________________________
8) ___________________________________________________
9) ___________________________________________________
10) ___________________________________________________
11) ___________________________________________________
12) ___________________________________________________
13) ___________________________________________________
14) ___________________________________________________
15) ___________________________________________________
16) ___________________________________________________
4. Mention the communication channels available in the EMCP 4 control panels:
a. ____________________________________________.
b. ____________________________________________.
c. ____________________________________________.
d. ____________________________________________.
122
5. Mention the devices that can be connected to the EMCP 4 control panel CAN 1 data link:
a. ____________________________________________.
b. ____________________________________________.
c. ____________________________________________.
d. ____________________________________________.
6. The maximum distance allowed between the CAN 1 data link backbone wiring and other devices is:
a. 75 m (246 ft)
b. 100 m (328 ft)
c. 40 m (132 ft)
7. The value of the resistances that need to be installed in the CAN 1 data link ends must be:
a. 240 ohms
b. 150 ohms
c. 60 ohms
8. Mention the devices that can be connected to the EMCP 4 control panel CAN 2 data link:
a. ____________________________________________.
b. ____________________________________________.
c. ____________________________________________.
d. ____________________________________________.
9. The maximum distance allowed between the CAN 2 data link backbone wiring and other devices is:
a. 75 m (246 ft)
b. 100 m (328 ft)
c. 40 m (132 ft)
10. The number of annunciator modules that can be installed in the EMCP 4.2 is:
a. 4
b. 8
c. 2
11. The number of discrete input/output modules that can be installed in the EMCP 4.2 is:
a. 2
b. 6
c. 8
123
12. The maximum distance at which the RS-485 remote annunciator can be connected is:
a. 305 m (1,000 ft)

b. 370 m (1,200 ft)
c. 1,200 m (4,000 ft)
13. In an MUI engine, the EMCP 4 control panel analog input #1 is used for:
a. Coolant temperature
b. Oil pressure
c. Oil temperature
14. In an MUI engine, the EMCP 4 control panel analog input #2 is used for:
a. Coolant temperature
b. Oil pressure
c. Oil temperature
15. In an MUI engine, the start system magnetic starter control is controlled by:
a. Relay output #1
b. Relay output #2
c. Sent by the primary data link only
16. In an MUI engine, the fuel solenoid activation control is controlled by:
a. Relay output #1
b. Relay output #2
c. Sent by the primary data link only
17. In an EUI engine, the EMCP 4 control panel receives engine speed information through:
a. The magnetic pickup connected directly to the control panel in case the ECM has no CEI
capacity.
b. The ECM, through the primary data link (CAN 1), if it has CEI capacity.
c. All of the above
18. For three-wire sensors connected to the EMCP 4 control panel, the wire must have a minimum
caliper of:
a. 20 AWG
b. 18 AWG
c. 16 AWG
124
19. For three-wire sensors connected to the EMCP 4 control panel, the Caterpillar part number of the
wire to be used if the connection is made through the engine harness is:
a. 4W-2256
b. 4G-2556
c. 4T-9954
20. For three-wire sensors connected to the EMCP 4 control panel, the wire temperature range must be:
a. -40 ºC (-40 ºF) to 257 ºC (495 ºF)

b. -70 ºC (-95 ºF) to 125 ºC (260 ºF)
c. -40 ºC (-40 ºF) to 100 ºC (212 ºF)
21. For magnetic pickups connected to the EMCP 4 control panel, the wire must have a minimum
caliper of:
a. 18 AWG
b. 16 AWG
c. All of the above
22. For magnetic pickups connected to the EMCP 4 control panel, mention the part numbers of the wires
that can be used to connect them:
a. ________________.
b. ________________.
c. ________________.
23. For the CAN data link cable installed at a distance of less than 60 meters (200 ft) of the
EMCP 4 control panel, the part number for the cable is:
a. 123-2376.
b. 6V-2744
c. 153-2707.
24. In EMCP 4 control panels, once a level 1 or level 2 password has been set up, it cannot be disabled.
a. True
25. Mention the modules in which the events detected can be viewed on the EMCP 4 control
panel screen:
a. _________________________________.
b. _________________________________.
c. _________________________________.
d. _________________________________.
e. _________________________________.
f. _________________________________.
g. _________________________________.
125
26. In EMCP 4 control panels, predefined event responses can be modified.
a. True
27. In order to be able to modify an event response, the ECS (Engine Control Switch) must be in the
following position:
a. RUN
b. AUTO
c. STOP
d. Event responses cannot be modified
28. The function of input 'A' in the EMCP 4 control panel is:
a. Remote Initiate
b. Remote E-Stop
c. Circuit Breaker Auxiliary Contact 'a'
29. The function of input 'B' in the EMCP 4 control panel is:
a. Remote Initiate
b. Remote E-Stop
c. Circuit Breaker Auxiliary Contact 'b'
30. Mention the available options for the types of use of EMCP 4 control panel digital inputs:
a. ________________________________.
b. ________________________________.
c. ________________________________.
d. ________________________________.
31. The number of programmable digital inputs that the EMCP 4.1 control panel has is:
a. 4.
b. 6.
c. 8.
32. All EMCP 4 digital inputs must be connected to the +battery:
a. True
33. If the digital input is connected to a contact that is normally closed, active status must be set to HIGH:
a. True
126
34. If the digital input is connected to a contact that is normally open, active status must be set to Low:
a. True
35. If the digital input is connected to a contact that is normally closed, active status must be set to HIGH:
c. True
d. False (explain your answer)
36. The number of programmable relay outputs in the ECMP 4.2 control panel is:
a. 4
b. 6
c. 8
37. The peak current that an EMCP 4 relay output can admit at 30 VDC is:
a. 150 mA
b. 300 mA
c. 200 mA
38. The peak current that an EMCP 4 discrete output can admit at 30 VDC is:
a. 150 mA
b. 300 mA
c. 200 mA
39. Mention the available options for the types of use of the EMCP 4 programmable outputs:
a. ___________________.
b. ___________________.
c. ___________________.
d. ___________________.
40. The number of programmable analog inputs in the EMCP 4.2 is:
a. 2.
b. 4.
c. 6.
41. Mention the available options for the types of use that can be set for EMCP 4 control panel analog
inputs:
a. ____________________.
b. ____________________.
c. ____________________.
127
42. If an analog sensor sending a voltage signal is connected to an EMCP 4 control panel, the sensor
impedance range must be of:
a. Min 120 / Max 10k

b. Min 100 / Max 1M
c. Min 10 / Max 1k
43. If a resistive sending sensor is connected to an EMCP 4 control panel, the sensor impedance range
must be of:
a. Min 5 / Max 2k
b. Min 100 / Max 10M
c. Min 5 / Max 10k
44. The number of available resistive sending unit maps in EMCP 4 control panels is:
a. 4
b. 6
c. 8
45. In the EMCP 4 control panel, the map to be used for a resistive sending unit used as an engine oil
pressure sensor is:
a. 1
b. 5
c. 15
46. In the EMCP 4 control panel, the map to be used for a resistive sending unit used as an engine
coolant temperature sensor is:
a. 2
b. 4
c. 18
47. In the EMCP 4.2 control panel, sensors with a voltage signal range that is not supported by the panel
cannot be used.
a. True
48. The number of relays that can be programmed in the EMCP 4.2 control panel is:
a. 2
b. 4
c. 18
128
49. Define the different modes of operation (Trigger Conditions) that the kW relays can be programmed
for in the EMCP 4.2 control panels:
a. _______________________________.
b. _______________________________.
c. _______________________________.
50. Define the steps that need to be followed in order to display a client event label in EMCP
4 control panels:
a. _______________________________.
b. _______________________________.
c. _______________________________.
51. Mention the setpoint menus that need to be checked after a configuration exchange from an EMCP 3
to an EMCP 4:
a. _______________________________.
b. _______________________________.
c. _______________________________.
d. _______________________________.
52. During the configuration exchange from an EMCP 3 to an EMCP 4, if the engine ECM sends coolant
temperature and oil pressure information through the data link, no adjustments to the EMCP 4 must
be made while the replaced EMCP 3 configuration is loading.
a. True
53. During the configuration exchange from an EMCP 3 to an EMCP 4, if coolant temperature and oil
pressure sensors were connected directly to the panel, no adjustments to the EMCP 4 must be made
while the replaced EMCP 3 configuration is loading.
a. True
54. During the configuration exchange from an EMCP 3 to an EMCP 4, digital inputs programming
is automatically updated when the configuration from EMCP 3 to EMCP 4 is loaded.
a. True
55. The active status of the Emergency Stop (E-Stop) input is set in menu:
a. Digital Inputs
b. Automatic Start/Stop
c. Events
129
56. The active status of the Remote Initiate input is set in menu:
a. Digital Inputs
b. Automatic Start/Stop
c. Events
57. If an EMCP 4 digital input is programmed for a use such as Status/Command, the setpoints to be
programmed are:
a. ______________________________________.
b. ______________________________________.
58. If an EMCP 4 digital input is programmed for a use such as System Event, the setpoints to be
programmed are:
a. ______________________________________.
b. ______________________________________.
c. ______________________________________.
d. ______________________________________.
59. If a digital input is programmed as a Status/Command of “ECS in AUTO”, explain the EMCP 4's
behavior when the input is active:
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
60. If a digital input is programmed as a Status/Command of “ECS in RUN”, explain the EMCP 4's
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
61. If a digital input is programmed as a Status/Command of “ECS in STOP”, explain the EMCP 4's
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
62. If a digital input is programmed as a Status/Command of “ECS in RUN”, explain the EMCP 4's
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
63. Explain the procedure to program a Remote Emergency Stop (Remote E-Stop) and to display it as
such in the EMCP 4 Registered Events display:
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
130
64. Explain the procedure to program a digital input to announce that the circuit breaker is closed (Genset
Breaker Closed) and to display it as such in the EMCP 4 Registered Events display:
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
65. Explain the procedure to program a digital input to announce that the circuit breaker is open (Genset
Breaker Open) and to display it as such in the EMCP 4 Registered Events display:
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
66. If an EMCP 4 digital output/relay is programmed for a use such as Status/Command, the setpoint to
be programmed is:
___________________________________________________________________________________.
67. If an EMCP 4 digital output/relay is programmed for a use such as System Event, the setpoints to be
programmed are:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
68. Explain the procedure to program a Digital Output/Relay to be activated when the ECS is in AUTO:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
69. Explain the procedure to program a Digital Output/Relay to be activated when the ECS is in RUN:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
70. Explain the procedure to program a Digital Output/Relay to be activated when the ECS is in STOP:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
71. Explain the procedure to program a Digital Output/Relay to be activated when the generator is in
Cooldown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
131
72. Explain the procedure to program a Digital Output/Relay to be activated when the generator is not in
Automatic:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
73. Explain the procedure to program a Digital Output/Relay to be activated when there is a generator
shutdown event:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
74. Explain the procedure to program a Digital Output/Relay to be activated when there is
a warning event:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
75. Explain the procedure to program a Digital Output/Relay to be activated when there is a warning
and/or shutdown event:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
76. Explain the procedure to program a Digital Output/Relay to activate an audible alarm:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
77. Explain the procedure to program a Digital Output/Relay to activate the fuel control relay:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
78. Explain the procedure to program a Digital Output/Relay to activate the starter control relay:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
79. Explain the procedure to program a Digital Output/Relay to be activated so as to control the engine
air shut-off solenoids:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
132
80. Explain the procedure to program a Digital Output/Relay to be activated when the derate mode is
inactive (Reduced Power Mode Off):
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
81. Explain the procedure to program a Digital Output/Relay to be activated when the engine reaches its
Crank Terminate Speed:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
82. Explain the procedure to program a Digital Output/Relay to be activated when the Group start
sequence begins:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
83. Explain the procedure to program a Digital Output/Relay to activate an audible alarm:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
84. Explain the procedure to program a Digital Output/Relay to be activated in order to reset a fault
generated by an engine ECM ADEM II:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
85. Explain the procedure to program a Digital Output/Relay to change the operating mode of an
electronic speed governor at Idle/Rated Speed:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
86. Explain the procedure to program a Digital Output/Relay to be activated when there is a low oil
pressure warning:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
87. Explain the procedure to program a Digital Output/Relay to be activated when there is a low oil
pressure warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
133
88. Explain the procedure to program a Digital Output/Relay to be activated when there is a high coolant
temperature warning:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
89. Explain the procedure to program a Digital Output/Relay to be activated when there is a high coolant
temperature warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
90. Explain the procedure to program a Digital Output/Relay to be activated when there is an overvoltage
warning:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
91. Explain the procedure to program a Digital Output/Relay to be activated when there is an overvoltage
warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
92. Explain the procedure to program a Digital Output/Relay to be activated when there is an
undervoltage warning:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
93. Explain the procedure to program a Digital Output/Relay to be activated when there is an
undervoltage warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
94. Explain the procedure to program a Digital Output/Relay to be activated when there is an overcurrent
warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
95. Explain the procedure to program a Digital Output/Relay to be activated when there is an active fire
alarm event:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
134
96. Explain the procedure to program a Digital Output/Relay to be activated when there is a reverse
power warning/shutdown:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
97. Explain the procedure to program a Digital Output/Relay to be activated when the EMCP 4 detects
that the circuit breaker is closed:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
98. Explain the procedure to program a Digital Output/Relay to be activated when the EMCP 4 detects
that the circuit breaker is open:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
99. Explain the procedure to program a Digital Output/Relay to be activated when the emergency stop is
active:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
100. Explain the procedure to program a Digital Output/Relay to be activated when the maintenance
service interval has expired:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________.
101. For the EMCP 4 control panels, describe the CAN annunciators supply voltage features used in
them:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
102. For the CAN annunciators used in the EMCP 4, the operating temperature range is:
a. -40 ºC to 150 ºC
b. -40 ºC to 70 ºC
c. -50 ºC to 140 ºC
135
103. Using the following schematic, identify the function of the CAN annunciator connector pins used in
the EMCP 4:
1) __________________________________________
2) __________________________________________
3) __________________________________________
4) __________________________________________
5) __________________________________________
6) __________________________________________
104. Using the following schematic, identify the CAN annunciator module pins feature used in the
EMCP 4.
1) __________________________________________
2) __________________________________________
3) __________________________________________
4) __________________________________________
5) __________________________________________
6) __________________________________________
7) __________________________________________
8) __________________________________________
105. If the CAN annunciator red communication LED in the EMCP 4 control panel is on, it is
signaling that:
a. The module is operating correctly.

b. The module is energized but it does not detect any type of communication in the CAN.
c. The module does not have the flash file installed.
136
106. If the CAN annunciator green communication LED in the EMCP 4 control panel is on,
it is signalling that:

107. If the CAN annunciator red and green communication LEDs in the EMCP 4 control panel are
flashing, they are signalling that:

108. If the CAN annunciator green communication LED in the EMCP 4 control panel is flashing, it is
signalling that:

109. CAN annunciators used with the EMCP 4 can be set by means of the ET service tool and directly
from the control panel display:
a. True
110. In order to program the CAN annunciator LEDs behavior in the EMCP 4, such programming should
be carried out by means of:
a. The Setpoint menu of the EMCP 4 control panel

b. The Cat ET Service Menu when connected to the module
c. The Attachment Menu of the EMCP 4 control panel
111. Define the operation of the setpoint “Trigger Condition” of the CAN annunciator:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
137
112. Define the operation of the setpoint “Severity Level” of the CAN annunciator:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
113. Define the operation of the setpoint “Suspect Parameter Number” of the CAN annunciator:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
138
114. Define the RS-485 Alarm module features used with the EMCP 4:
a. _____________________________________________________________.
b. _____________________________________________________________.
c. _____________________________________________________________.
d. _____________________________________________________________.
e. _____________________________________________________________.
f. _____________________________________________________________.
g. _____________________________________________________________.
h. _____________________________________________________________.
115. Mention the RS-485 Alarm module communication specifications used with the EMCP 4:
a. _____________________________________________________________.
b. _____________________________________________________________.
c. _____________________________________________________________.
116. Using the following schematic, identify the function of the RS-485 annunciator connector pins used
in the EMCP 4:
1) __________________________________________
2) __________________________________________
3) __________________________________________
4) __________________________________________
5) __________________________________________
6) __________________________________________
7) __________________________________________
8) __________________________________________
139
117. Using the following schematic, identify the RS-485 annunciator module pins used in the EMCP 4.
1) __________________________________________
2) __________________________________________
3) __________________________________________
4) __________________________________________
5) __________________________________________
6) __________________________________________
7) __________________________________________
8) __________________________________________
118. If the RS-485 announcer red communication LED in the EMCP 4 control panel is on, it is
signaling that:

b. The module has lost communication.
c. The module is connected incorrectly, or it does not have terminating resistance.
119. If the RS-485 annunciator green communication LED in the EMCP 4 control panel is on, it is
signalling that:

120. If the RS-485 annunciator red and green communication LEDs in the EMCP 4 control panel are
flashing, they are signalling that:

140
121. If the RS-485 annunciator green communication LED in the EMCP 4 control panel is flashing, it is
signalling that:

122. All RS-485 annunciator alarm groups in the EMCP 4 control panel are default:
a. True
123. For the RS-485 annunciator alarm group #3 in the EMCP 4 control panel, the 15 LED pair
feature is:
a. Emergency Stop (E-Stop)

b. Overcrank/Fail to Start
c. High Coolant Temperature (High Engine Temperature)
124. For the RS-485 annunciator alarm group #4 in the EMCP 4 control panel, the 15 LED pair
feature is:
a. Emergency Stop (E-Stop)

b. Overcrank/Fail to Start
c. High Coolant Temperature (High Engine Temperature)
125. Explain how the configuration of the RS-485 annunciator alarm groups used in the EMCP 4 control
panel is carried out:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
141
executed:
prevent accidents:
142
Task Sheet 01: Security Levels Programming – EMCP 3

1. Procedure
Carry out the following programming for access security levels to the EMCP 3 control panel parameters.
Using the EMCP 3 control panel interface, set the 1 to 10-level password followed by your
participant number (i.e., if your number is 01, 1001; if it is 13, 1013.)
Using the EMCP 3 control panel interface, set the 2 to 20-level password followed by your
participant number (i.e., if your number is 01, 2001; if it is 13, 2013.)
Select the minimum security level (Drop to Minimum) in the control panel.
Go to the Configuration Menu and check all the parameters protected by Level 1, Level 2, and Level
3 passwords for the following menus: Engine Coolant Temperature Monitoring System, Engine Oil
Pressure Monitoring System, Engine Speed Monitoring System, Generator Alternating Current
Monitoring System. Write them down in the Results Chart and add that information in your
Service Report.
Enter Level 1 password and check that Level 1 parameters are available to be changed from the
control panel interface.
Select the minimum security level (Drop to Minimum) in the control panel.
Enter Level 2 password and check that Level 2 parameters are available to be changed from the
control panel.
Disable Level 1 and Level 2 passwords.
End of Task.
143
2. Results:
ENGINE COOLANT TEMPERATURE MONITORING SYSTEM

PARAMETER LEVEL 1 LEVEL 2 LEVEL 3
Temperature sensor
configuration
Limit of high temperature
warning event
Delay notification time of high
temperature warning event
Limit of high temperature
shutdown event
Delay notification time of high
temperature shutdown event
Limit of low temperature
warning event
Delay notification time of low
temperature warning event
Limit of low temperature
shutdown event
temperature shutdown event
Temperature sensor
configuration code
ENGINE OIL PRESSURE MONITORING SYSTEM

Temperature sensor
configuration
Limit of low pressure
warning event
pressure warning event
Limit of low pressure
shutdown event
Limit of low pressure shutdown
at idle speed event
144
ENGINE OIL PRESSURE MONITORING SYSTEM

pressure shutdown event
Flow rate of engine oil low
pressure
Temperature sensor
configuration code
ENGINE SPEED MONITORING SYSTEM

Flywheel teeth
Overspeed setpoint
Limit of low speed
warning event
speed warning event
Limit of low speed
shutdown event
engine speed shutdown event
Speed sensor configuration
GENERATOR AC MONITORING SYSTEM

Generator connection
configuration
Potential transformer primary
winding classification
Potential transformer
secondary winding
classification
Current transformer primary
Current transformer secondary
Generator pole number
Generator rate frequency
Generator rate voltage
145
GENERATOR AC MONITORING SYSTEM

Generator rate power
Generator classified
apparent power

146
Task Sheet 02: Parameter Verification – EMCP II+
1. Procedure:
Instructions: The Facilitator will indicate you to look for the value of 10 setpoints in the following menus:
Engine/Generator Parameters, Generator Relay Protection Systems, Programming of Additional Inputs
and Outputs for Selected EMCP II+ Control Panel. The participant must record the number of the
Setpoint and the Value in the results chart, and they have to provide details about the function and
operation of each one in the service report.
Record the data from the generator set to be worked on. Add this information to your
Service Report.
According to the Facilitator instructions, record the value of the 10 specified setpoints that control
the Engine/Generator operation.
the Generator Relay Protection System operation.
the Control Panel Additional Inputs and Outputs operation.
Attach the results to the Service Report together with each parameter description.
End of Task.
2. Results:
Generator Serial Number: ___________________________________.
Generator Output Voltage: ____________________________________.
Generator Output Power: __________________________________.
Generator Apparent Power: ___________________________________.
Generator Connection Configuration: ___________________________.
SETPOINTS FOR ENGINE/GENERATOR PROGRAMMING

Name Parameter Value Description
Number
147
SETPOINTS FOR ENGINE/GENERATOR PROGRAMMING

Number
SETPOINTS – PROTECTIVE RELAYING PROGRAMMING

Number
SETPOINTS – SPARE INPUT/OUTPUT PROGRAMMING

Number
148
SETPOINTS – SPARE INPUT/OUTPUT PROGRAMMING

Number

149
Task Sheet 03: Engine Protection System Tests – EMCP II+
1. Procedure:
Instructions: Before beginning task execution, the participant has to record the setpoints controlling the
engine protection system operation (High Coolant Temperature, Low Oil Pressure, Overspeed.) The
participant has to show up with the procedure in order to perform the verification of these three
protection systems, and they have to explain to the Facilitator what has to occur during normal operation
of the generator set.
Look for the Engine Protection System Verification procedure for an EMCP II+ Control Panel.
Write down the programmed values for each one of the protection systems in the results chart. Add
this information to the Service Report.
Carry out the Test procedure for each protection system. Add the test results to the Service Report.
Attach group behavior to the said report when each one of the tests is performed (Delay Time,
Warning Notification, Shutdown Notification.)
End of Task.
2. Results
ENGINE PROTECTION SYSTEM PARAMETERS

Parameter
Value Description
Number
P010
P013
P014
P015
P016

150
Task Sheet 04: ATB Parameter Verification – EMCP II+
1. Procedure:
Instructions: This task is based on registering the values of the Alternating Current Transformer Box
(ATB.) All the results must be recorded in the results chart and added to the Module Service Report.
Find the alternating current transformer box of the generator set.
Record the barcode values of each Instrumentation Transformer in the results chart. Add this
information to the Service Report.
Check that the Instrumentation Transformer values are correctly programmed in the Control Panel.
Record the values found in the Control Panel. In case there is data that does not match, notify the
Facilitator, change the parameter, and record said modification in the Service Report.
End of Task.
2. Results:
VOLTMETER/AMMETER PROGRAMMING
Panel
Parameter ATB Found
Found Description
Number Value
Value
AC01
AC02
AC03
AC04
AC05
AC06

151
Task Sheet 05: EMCP 3 Digital Input Programming
1. Procedure:
Instructions: Program the generator set with the EMCP 3 Control Panel indicated by the Facilitator so
that it can work as follows. Before starting to program, copy the ECM replacement configuration.
A programmed input is required to generate a warning event due to a low level external fuel tank.
Copy menu windows to be accessed to so as to change the setpoints related to this programming
within your service report.
A programmed input is required to generate a shutdown event due to a low level external fuel tank.
A programmed input is required to generate a fire alarm event (which must be displayed in the
EMCP 3 recorded events display.) Copy menu windows to be accessed to so as to change the
setpoints related to this programming within your service report.
Copy input configuration and attach them to your service report. In your report, explain the setpoints
that need to be modified in order to achieve this programming.
Generate a Product Status Report that only portrays the Active Codes and the Recorded Codes.
Copy the Replacement ECM Original Configuration to the Control Panel.
End of Task.
2. Results:
Results must be included in the Service Report using the STW Service Report feature.

152
Task Sheet 06: Engine Protection System Verifications – EMCP 3
1. Procedure:
Instructions: The participant will carry out the Engine Protection System Verification procedure
(High Coolant Temperature, Low Oil Pressure, Overspeed.) Test results must be documented in the
Service Report.
Connect the Communication Adapter to the Generator Set.
Connect to the Control Panel through CAT ET service tool.
Copy the ECM Replacement Configuration. Save the file in your computer in an easy-
access location.
Carry out the Setpoint Test Procedure for the Engine Protection System. Remember to attach the
procedure to you service report explaining the steps performed during the test. Remember to copy
each configuration window where a change is applied to the setpoint in the service report.
Load previously stored ECM Replacement Configuration.
End of Task.
2. Results:
Results of this task must be included in the Service Report using the STW Service Report feature.

153
Task Sheet 07: EMCP 3 Discrete Output Programming
1. Procedure:
Instructions: For this task, outputs will be programmed in the group indicated by the Facilitator. Copy
the control panel ECM replacement configuration before starting the task.
Program a relay output to be activated when the ECS is in the RUN position. Copy menu windows to
be accessed to so as to change the setpoints related to this programming within your service report.
Program a relay output to be activated when the ECS is in the automatic (AUTO) position. Copy
menu windows to be accessed to so as to change the setpoints related to this programming within
your service report.
Program a relay output to be activated when the Emergency Stop (E-STOP) is active. Copy menu
windows to be accessed to so as to change the setpoints related to this programming within your
service report.
In your service report, clearly explain all the steps to carry out this programming, together with
the windows of the setpoints to be configured in order to obtain them and their references in the
Service Manual.
Load the ECM Replacement Configuration to the Control Panel again.
End of Task.
2. Results:
154
Task Sheet 08: Programmable Cycle Timer Programming
1. Procedure:
Instructions: In this task, the participant will program the programmable cycle timers. The Facilitator will
provide them with the programming data during the assessment. By the end of the programming, the
Facilitator will check it. Once checked, the participant must add the programming to their Service Report.
Connect to the Control Panel using the CAT ET service tool.
Copy the ECM Replacement Configuration. Save the file in your computer in an easy-access folder.
Program the PCT # __ with the following parameters selected by the Facilitator:
Activation Time: ________
Activation Date:
Monday
Tuesday
Wednesday
Thursday
Friday
Action To Be Performed
Start the generator by means of
Activate a relay output
Timer activation duration: ____ minutes
Load the ECM Replacement Configuration to the Control Panel again.
End of Task.
2. Results:

155
Task Sheet 09: External Input and Output Module Programming

1. Procedure:
Instructions: In this task, the participant will carry out the EMCP 3 input/output module programming.
Connect to the Input and Output Module.
Save the ECM replacement configuration.
Program an input and output set for the output to be triggered when the input is activated. Copy
Program an output to be activated when a low oil pressure warning and/or shutdown event is
generated. Copy menu windows to be accessed to so as to change the setpoints related to this
programming within your service report.
Program an output to be activated when a high coolant temperature warning and/or shutdown event
is generated. Copy menu windows to be accessed to so as to change the setpoints related to this
programming within your service report.
Copy the ECM replacement configuration. Attach it to your Service Report.
End of Task.
2. Results:

156
Task Sheet 10: Thermocouple/RTD Module Programming

1. Procedure:
Instructions: In this task, the participant will carry out the EMCP 3 Thermocouple/RTD module
programming.
Connect to the Thermocouple Module.
Save the ECM replacement configuration.
Program Thermocouple #1 so that it operates as follows (once programming is finished, let the
Facilitator know so that they can check it):
 Thermocouple type: J-Type
 SPN: Battery #1 Temperature
 High Temperature Shutdown Event Trigger: 250 F
 Event Delay Notification Time: 5 seconds
 High Temperature Warning Event Trigger: 200 F
 Low Temperature Warning Event Trigger: 88 F
Copy the ECM replacement configuration. Attach it to your Service Report.
End of Task.
2. Results:
157
Task Sheet 11: Thermocouple/RTD Module Programming

1. Procedure:
Instructions: In this task, the participant will carry out the EMCP 3 alarm module programming.
Connect to the Alarm Module.
Save the ECM Replacement Configuration.
Program a pair of annunciator lights so that the green one lights up when Discrete I/O module input
#1 is active, and the amber light illuminates when it is inactive. (Once programming is finished, let
the Facilitator know so that they can check it.)
Copy the Replacement ECM Original Configuration.
End of Task.
2. Results:
158
Task Sheet 12: RS-485 Alarm Module Programming

1. Procedure:
Instructions: In this task, the participant will carry out the EMCP 4 RS-485 alarm module programming.
Program the Annunciator according to the following table:

LEDs pair # Status LED Status LED
1 E-STOP (Active) RED Not used AMBER
2 OVERCRANK (Active) RED Not used AMBER
High Coolant High Coolant
3 Temperature (Shutdown RED Temperature (Warning AMBER
Event) Event)
Low Coolant
4 Not used RED Temperature (Warning AMBER
Event)
Low Oil Pressure Low Oil Pressure
5 RED AMBER
(Shutdown Event) (Warning Event)
6 OVERSPEED (Active) RED Not used AMBER
Low Coolant Level Low Coolant Level
7 RED AMBER
Low Fuel Level Low Fuel Level (Warning
8 RED AMBER
(Shutdown Event) Event)
Generator not in
9 Not used RED AMBER
Automatic
High Battery Voltage High Battery Voltage
10 RED AMBER
Low Battery Voltage
11 Not used RED AMBER
(Warning Event)
Low Battery Voltage at
12 Not used RED Start Up (Warning AMBER
Event)
CA Battery Charger
13 Not used GREEN AMBER
Fault
14 Not used GREEN EPS Charge AMBER
15 Not used RED Engine Operating GREEN
16 Not used RED Not used AMBER
Copy the window of the setpoint configuration to be set so as to obtain this behavior in the
annunciator. Explain the complete procedure to carry out this programming in your service report
together with the programmed setpoint windows.
End of Task.
2. Results:
159
Task Sheet 13: EMCP 4 Discrete Input and Output Programming

1. Procedure:
Instructions: In this task, the participant will perform the EMCP 4 input and output programming. Copy
the Control Panel ECM replacement configuration before starting the task.
Program a discrete input to change the ECS in AUTO position. Copy menu windows to be accessed
to so as to change the setpoints related to this programming within your service report.
Program a discrete input to disable the COOLDOWN timer. Copy menu windows to be accessed
to so as to change the setpoints related to this programming within your service report.
Program a discrete output to be activated when the ECS is in AUTO. Copy menu windows to be
accessed to so as to change the setpoints related to this programming within your service report.
Program a discrete output to be activated when the generator has received a start up signal. Copy
End of Task.
2. Results:
160
Task Sheet 14: EMCP 4 Analog Input Programming

1. Procedure:
Instructions: In this task, the participant will carry out the EMCP 4 analog input programming. Copy the
Control Panel ECM replacement configuration before starting the task.
Program EMCP 4 Control Panel #3 Analog Input for an engine oil temperature SPN. Choose the
map for sensor with this part number: # 191-6587.
Program the Alarm Events as follows:

 High Temperature Shutdown Event at 198 ºF
 High Temperature Warning Event at 190 ºF
 Low Temperature Warning Event at 60 ºF
 Low Temperature Shutdown Event at 50 ºF
Use the provided potentiometer to verify that all events are correctly activated at the set values.
End of Task.
2. Results:
161
Miami Skills Acquisition Center Service Training
MODULE #4: START UP AND PREVENTIVE MAINTENANCE
Demonstrating the ability to execute factory recommended

verifications in order to guarantee Service Safety and Accessibility
in the generator set machine room.

verifications in order to guarantee correct operation of Auxiliary
Mechanical Systems in the generator set machine room.

verifications in order to guarantee correct operation of Electrical
Systems connected to the generator set.
Demonstrating the ability to execute preventive maintenance tasks

for generator set.


Safety Verification and Service Access
Automatic Transfer Start (ATS)
Battery Condition Verification Test
Oil Sampling for S•O•S Analysis
Ventilation and Exhaust System Verification
Electric Starting System Test
Generator Set Alarm Verification
Generator Set Vibration Tests
Generator Set Load Profile Test
Tools 257-9141 Fluke 87 Multimeter
171-4400 Communication Adapter Group II
4C-4911 Battery Load Tester
177-2330 Battery Analyzer
162
Literature LEBE5294 Electric Power Engine and Generator Set Sizing –

Application & Installation Guide
LEBQ8107 Automatic Transfer Switches – Application &

Installation Guide
LEXE0047 Understanding Generator Set Ratings – System

Data Sheet
LEBW4971 Engine Room Ventilation – Application &

Installation Guide
LEBW4970 Exhaust Systems – Application &

Installation Guide
LEBW4969 Air Intake Systems – Application &

Installation Guide
LEBW4974 Mounting – Application & Installation Guide
LEBW4976 Diesel Fuel and Diesel Fuel System Application

Installation Guide
LEBW4978 Cooling Systems Application & Installation Guide
LEBW4980 Starting Systems Application & Installation Guide
SEHS7633 Battery Testing – Special Instruction
SEPD0020 Service Magazine – Testing Starter Systems
LEBW4981 Diesel Engines Control Systems – Application &

Installation Guide
LEBW4993 Generator Systems – Application &

Installation Guide
LEBW4972 Vibration – Application & Installation Guide
REHS4634 Grounding Design Guide for Electric Power

Generation Products
SEBU6918 SR4B Generators and Control Panels

Operation & Maintenance Manual
163
LEHX5299 Typical Installation Diagram Reference Guide –

Specification Sheet
LEXE0095 2009 ELECTRIC POWER START-UP Checklist
SENR2995 Safety Information
LEXE0047 Understanding Generator Set Ratings – Systems

Data Sheet
LEBW4957 Lubrication Systems - Application and

Installation Guide
PEHP6001 How To Take a Good Oil Sample
Operation & Maintenance Manuals - C1.1 / C2.2 / C6.6 / C9 / C15

/ C18 / C27 / C32 / C175 / 3500 / 3500B / 3500E / 3306 /
3406 / 3412
164
Start up and Preventive Maintenance Questionnaire
the interview. The Facilitator will indicate the questions you should provide support to.
If you do not have this questionnaire complete at the time of the assessment, 5 points
will be discounted from the total assessment of the module.
Safety and Preventive Maintenance
126. Explain the meaning of the following safety label:
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
______________________________________________________________________
127. Mention the safety precautions to be observed every time that you work with machinery or
equipment, according to Caterpillar's recommendations:
a. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
b. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
c. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
d. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
128. Mention Caterpillar's safety recommendations during battery verification:

___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
129. According to Caterpillar's recommendations, mention three pieces of personal protection

equipment that must always be used when performing tasks in machinery and equipment:
a. _______________________________________________________.
b. _______________________________________________________.
c. _______________________________________________________.
165
130. Explain Caterpillar's recommendation regarding components and equipment lifting:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
131. Describe some of the recommendations that must be followed when performing repair tasks
in a Caterpillar equipment:
a. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
b. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
c. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
d. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
132. Mention the conditions in which the generator set has to be so as to start maintenance tasks:
a. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
b. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
c. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
d. __________________________________________________________________________
__________________________________________________________________________
__________________________________________________________________________
133. Mention three of Caterpillar's recommended precautions regarding fire and explosion prevention
in generator rooms:
a. __________________________________________________________________________
b. __________________________________________________________________________
c. __________________________________________________________________________
134. Mention the type of fire extinguisher that MUST NOT BE used in Caterpillar generator rooms:
____________________________________________________________________________________
166
135. Detail the procedure to isolate a generator set in order to carry out a maintenance or repair task:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
136. Mention the precautions that have to be considered when manipulating the corrosion inhibitor,
together with the procedure to follow in case you touch it:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
137. List the recommendations provided by Caterpillar when there is the need to lift a generator unit in
order to perform routine maintenance tasks:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
138. List the considerations that must be taken into account when manipulating the engine start up
and load electrical system in a Caterpillar generator unit:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________
139. When does the emergency stop push button have to be used?
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
___________________________________________________________________________________
__________________________________________________________________________________
167
140. Which are the considerations to be taken into account when starting a generator set?
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
___________________________________________________________
141. Mention oils recommended by Caterpillar for 3500B Generators:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
___________________________________________________________________________________
142. Mention the four categories in which Caterpillar engine oil S•O•S analysis is divided:
a. _________________________________________________________________.
b. _________________________________________________________________.
c. _________________________________________________________________.
d. _________________________________________________________________.
143. In a 3508B Engine, the crankcase oil filling level for a standard crankcase is of approximately:
a. 227 L (60 US gal)

b. 443 L (117 US gal)
c. 159 L (42 US gal)
144. The glycol-water mixture ratio to be used in Caterpillar cooling systems must be:
a. 1 to 2
b. 2 to 1
c. 1 to 1
145. The Cat ELC coolant change must be done:
a. After 6,000 service hours or every six years

b. After 3,000 service hours or every three years
c. After 3,000 service hours or every two years
146. The commercial type coolant change that meets EC-1 Caterpillar specifications must be done:

c. After 3,000 service hours or every year
168
147. The Cat DEAC coolant change must be done:

b. After 3,000 service hours or every year
148. The commercial type coolant change that meets ASTM D6210 specifications must be done:
a. After 3,000 service hours or every three years

b. After 3,000 service hours or every year
149. The commercial type coolant change that meets ASTM D4985 specifications must be done:

c. After 3,000 service hours or every year
150. The Cat SCA coolant with water change must be done:

151. Mention engine coolant properties that are analyzed in a S•O•S Level I Coolant Analysis:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
152. Coolant capacity of the entire 3512B Engine cooling system is of:
a. 103 L (27.2 US gal)

b. 563 L (148.7 US gal)
c. 203 L (53.6 US gal)
169
153. Describe the daily maintenance tasks to be done to 3500B Engines in PRIME application:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
154. Mention factors determining the frequency to which a 3500B Generator Set OVERHAUL must
be done:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
155. For a 3508B Engine operating at 1,500 RPM, the average fuel consumption for 2,000 operating
hours must be of:
a. 22,700 L (6,000 US gal)

b. 89,000 L (23,500 US gal)
c. 257,000 L (68,000 US gal)
170
Auxiliary Mechanical Systems
1. Mention the three types of Start Systems that can be used in Caterpillar engines:
a. ________________________________.
b. ________________________________.
c. ________________________________.
2. In Electrical Start Systems, Caterpillar recommends to check the battery electrolyte level every:
a. 500 hours in ideal conditions; every 250 hours in warmer climates

b. 250 hours in ideal conditions; every 125 hours in warmer climates
c. 2,000 hours in ideal conditions; every 1,000 hours in warmer climates
d. 1,000 hours in ideal conditions; every 500 hours in warmer climates
3. As regards maximum time of engine continuous start attempt, Caterpillar recommends:
a. No more than 15 continuous seconds

b. No more than 2 continuous minutes
c. No more than 30 continuous seconds
d. None of the above (mention the correct recommendation if necessary)
4. Caterpillar's recommendation regarding maximum allowed circuit resistance for the starter circuit
in a 12 V system is:
a. 0.0012 ohms
b. 0.002 ohms
c. 0.030 ohms
d. 0.048 ohms
171
5. Using the following schematic and Caterpillar service literature, determine the maximum allowed
voltage drop values between the following measurement points during start up, for a 12 V system:
Test Points Voltage

Between TP10 and TP6
Between TP7 and TP5
Between TP8 and TP9
Between TP3 and TP6
6. If an engine is operating at 8 ºC, which is the allowed range for voltage drop of a 12 V battery during
start up, as per Caterpillar's recommendations?
a. Between 12 V and 15 V
b. Between 8 V and 10 V
c. Between 7 V and 9 V
d. Between 14 V and 18 V
7. If an engine is operating at 55 ºF, which is the allowed range for voltage drop of a 24 V battery during
start up, as per Caterpillar's recommendations?
a. Between 16 V and 20 V
b. Between 12 V and 14 V
c. Between 20 V and 24 V
d. Between 14 V and 18 V
172
8. The optimal charge voltage for a 12 V battery at a temperature between 20 ºC and 25 ºC,
with a system using an alternator for charging, is of:
a. 14.10/13.50 depending on the battery type

b. 13.80/13.50/13.02 depending on the battery type
c. 12.94/12.64 depending on the battery type
d. None of the above (define ranges for the different battery types used and/or approved
by Caterpillar, if necessary.)
9. Caterpillar approved solutions to clean the batteries are:
a. __________________________________.
b. __________________________________.
10. As per Caterpillar's recommendations, battery chargers for 12 V start systems must have:
a. A peak load capacity of 70 amperes

b. A polarized protection relay
c. The capacity to deliver variable voltage outputs
d. All of the above
11. The optimal charge voltage for a 12 V MFCA battery system at a temperature of 60 ºC with
an electronic charger is of:
a. 12.60 floating/14.70 equalizing

b. 12.94 floating/14.74 equalizing
c. 12.60 floating/13.80 equalizing
d. 12.90 floating/13.50 equalizing
12. If a battery does not show fault signs, it should be checked to detect the following conditions:
a. _______________________________________________________.
b. _______________________________________________________.
c. _______________________________________________________.
13. The effects of overcharging a Caterpillar free maintenance battery are:
a. __________________________________________________________.
b. __________________________________________________________.
14. The battery test duration time using the 177-2330 Tool is of:
a. 1 minute
b. 2 minutes
c. 10 seconds
d. 20 seconds
173
15. The 177-2330 Battery Analyzer can be used to analyze 6 V or 12 V batteries with the following
capacities:
a. ____________________________________.
b. ____________________________________.
c. ____________________________________.
16. Define the procedure to estimate the size of a generator set fuel supply tank:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
17. Mention the situations in which an auxiliary tank is required for a generator set, as per Caterpillar's
recommendations:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
18. Regarding fuel pressures, Caterpillar recommends that fuel pressure measured in the return line of
the fuel delivery system for 3500 Engines must not be higher than:
a. 60 kPa (8.7 psi)

b. 35 kPa (5.1 psi)
c. 27 kPa (14 psi)
19. The inlet air maximum temperature for the operation of a Caterpillar generator set must not exceed:
a. 55 ºC (131 ºF)
b. 45 ºC (113 ºF)
c. 50 ºC (122 ºF)
20. The size of the air intake duct connection flex must be between:
a. 50 mm to 200 mm (2 to 8 inches)
b. 25 mm to 125 mm(1 to 5 inches)
c. 50 mm to 125 mm (2 to 5 inches)
174
21. Explain the features of the different levels in which mufflers used in Caterpillar engines are
categorized:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
22. A machine room that has the required features for a generator set must keep air temperature
between:
a. 10 ºC to 20 ºC (18 ºF to 36 ºF) of air ambient temperature

b. 8.5 ºC to 12.5 ºC (15 ºF to 22.5 ºF) of air ambient temperature
c. 12.5 ºC to 35 ºC (22.5 ºF to 63 ºF) of air ambient temperature
23. Explain the different types of misalignments that can occur in generator sets:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
24. Mention common causes of linear vibration in generator sets:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
25. The root cause corrective action to eliminate medium order detected vibrations is:
a. Altering component mounting

b. Adjusting governor and fuel transfer pump
c. Carrying out group balancing procedure
26. The root cause corrective action to eliminate primary order detected vibrations is:
a. Altering component mounting

b. Adjusting governor and fuel transfer pump
c. Carrying out group balancing procedure
175
27. Mention the main functions of the engine oil system in generator sets:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
28. Mention the considerations to be taken into account regarding the installation of an automatic pre-
lubrication system in a generator set:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
29. As regards size ratio of air intake ducts in comparison to air outlet ducts, Caterpillar
recommends that:
a. Air inlet ducts must be 1.25 times bigger than air outlet ducts.
b. Air outlet ducts must be 2 times bigger than air inlet ducts.
c. Air outlet ducts must be 1.25 times bigger than air inlet ducts.
30. When using blinds in the machine room, Caterpillar recommends the following as regards air
inlet ducts:
a. Increasing duct size by 35%.

b. Reducing duct size by 25%.
c. Reducing duct size by 50%.
176
Electrical Systems
1. Explain the generator set operating conditions categorized as “Emergency Standby”:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
2. Explain the generator set operating conditions categorized as “Standby”:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
3. Explain the generator set operating conditions categorized as “Mission Critical Standby”:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
4. Explain the generator set operating conditions categorized as “Prime”:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
5. Explain the generator set operating conditions categorized as “Continuous”:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
6. In the required calculations to determine short circuit/fault currents, the sub-transient reactance is
used to determine:
a. Circuit Breaker Trigger Current

b. Prompt Peak Current
c. Line-to-Line Fault Current
7. In the calculations required to determine short circuit/fault currents, the transient reactance is used to
determine:

c. Stable Status Current
177
8. In the calculations required to determine short circuit/fault currents, the synchronous reactance is
used to determine:

c. Stable Status Current
9. In the calculations required to determine the short circuit/fault currents, the zero sequence reactance
is used to determine:

b. Line-to-Line Fault Current
c. Neutral-Ground Fault Current
10. In the calculations required to determine the fault/short circuit currents, the negative phase sequence
reactance is used to determine:

b. Line-to-Line Fault Current
c. Neutral-Ground Fault Current
11. Mention the seven functions of an Automatic Transfer Switch (ATS):
a. ___________________________________________________.
b. ___________________________________________________.
c. ___________________________________________________.
d. ___________________________________________________.
e. ___________________________________________________.
f. ___________________________________________________.
g. ___________________________________________________.
12. Mention the basic elements that make up an ATS:
a. ______________________________________________________.
b. ______________________________________________________.
c. ______________________________________________________.
d. ______________________________________________________.
e. ______________________________________________________.
13. Mention the advantages of a system with a grounded neutral terminal vs. a floating neutral terminal:
a. __________________________________________________________________________
_________________________________________________________________________.
b. __________________________________________________________________________
__________________________________________________________________________
c. __________________________________________________________________________
__________________________________________________________________________
d. __________________________________________________________________________
__________________________________________________________________________
e. __________________________________________________________________________
__________________________________________________________________________
178
14. Mention and explain the methods used to detect ground faults:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
15. Mention the protection features provided by type 1 ATS cabinets:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
18. Mention the protection features provided by type 3R ATS cabinets:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
19. Mention the protection features provided by type 3S ATS cabinets:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
179
20. Mention the protection features provided by type 3X ATS cabinets:

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
21. Mention the protection features provided by type 3RX ATS cabinets:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________

____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
24. Explain the operation of an ATS being operated in Open Transition:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
25. Explain the operation of an ATS being operated in Delay Transition:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
180
26. Explain the operation of an ATS being operated in Close Transition:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
27. Mention the harmonics effects in the operation of Caterpillar generator sets:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
28. Mention the advantages of having three-phase sensing vs. one-phase sensing in voltage regulators:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
29. The overspeed level to be supported by the generator set main alternator, operating at 1,800 rpm or
below, is of:
a. 15% overspeed
b. 18% overspeed
c. 25% overspeed
30. Explain how the generator (alternator) limits in a generator set are determined, and mention the
consequences derived from operating the group without complying to these limits:
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
____________________________________________________________________________________
181
executed:
prevent accidents:
182
Task Sheet 01: Safety Verification and Service Access
1. Procedure:
Instructions: In this task, the participant will inspect the generator set room based on safety
precautions and service accessibility. The participant must have the service literature and the tools
corresponding to the procedure before starting the task. Test results must be written down in the Results
section of this sheet and they must be included in the module Service Report.
 Go into the machine room and, using the chart provided below, carry out the verifications and/or
tests indicated therein. Write down your comments and/or observations in your Service Report.
 End of Task.
2. Results:
Comments:

183
Task Sheet 02: Automatic Transfer Start (ATS)
1. Procedure:
Instructions: In this task, the participant will adjust the transference setpoints based on the Facilitator's
indications. The participant must have the service literature and the tools corresponding to the
 Carry out a visual inspection of the equipment to be used. Make sure you take all area labelling and
blocking precautions before starting the procedure.
 According to the selected transference model, use its Start-up sheet and perform the corresponding
verifications/configurations. Write down the verified and/or modified setpoints in the results chart.
 Elaborate a Service Report with the task procedures and results together with your comments
and/or observations about this matter.
 End of Task.
2. Results:
Setpoint Adjusted Value Setpoint Adjusted Value
Comments:

184
Task Sheet 03: Battery Condition Verification Test
1. Procedure:
Instructions: In this task, the participant will perform the operational verification test for batteries of the
generator set designated by the Facilitator. The participant must have the service literature and the tools
 Using service literature, carry out the batteries verification test with the 177-2330 Digital Batteries
Analyzer. Record the results in the results chart.
and/or observations about the condition of generator set batteries.
 End of Task.
2. Results:
BATTERY DATA:
Parameter Specification Value
CCA (Cold Cranking Amps)
CA (Cranking Amps Rating)
A-Hr (Ampere-Hours Rating)
Battery Conditions
With a mark, select the battery condition after the test.
Good Battery
Good Battery/Low Charge
Charge and Retest
Bad Battery

185
Task Sheet 04: Oil Sampling for S•O•S Analysis
1. Procedure:
Instructions: In this task, the participant will take an oil sample to carry out the S•O•S oil analysis in
the equipment designated by the Facilitator. The participant must have the service literature and the
tools corresponding to the procedure before starting the task. Test results must be written down in the
Results section of this sheet and they must be included in the module Service Report.
 Using the service literature corresponding to the group, take an oil sample according to the required
conditions for an accurate analysis of said sample.
 In your Service Report, attach your comments and/or observations about the sampling together with
an explanation of its importance for proper maintenance of generator set.
 End of Task.
2. Results:
Engine Model:
Serial Number:
Accumulated Hours Amount since Last Oil

Change:
Oil Amount Supplied since Last Oil Change:
Comments:

186
Task Sheet 05: Ventilation and Exhaust System Verification
1. Procedure:
Instructions: In this task, the participant will carry out the inspection/verification of the ventilation and
exhaust system in the generator set room designated by the Facilitator. The participant must have the
service literature and the tools corresponding to the procedure before starting the task. Test results must
be written down in the Results section of this sheet and they must be included in the module Service
Report.
 Using the table provided below and the required service literature, carry out the mentioned
verifications. Attach your results to your Service Report.
and/or observations about this matter.
 End of Task.
2. Results:
187
Comments:

188
Task Sheet 06: Electric Starting System Test
1. Procedure:
Instructions: In this task, the participant will perform the verification/test for the electric starting system
of the generator set designated by the Facilitator. The participant must have the service literature and
the tools corresponding to the procedure before starting the task. Test results must be written down in
the Results section of this sheet and they must be included in the module Service Report.
and/or observations about them. Explain all the possible conditions that can cause a generator set
starting system fault.
 End of Task.
2. Results:
Test Points Voltage

Between TP10 and TP7
Between TP7 and TP5
Between TP8 and TP9
189
Task Sheet 07: Generator Set Alarm Verification
1. Procedure:
Instructions: In this task, the participant will perform the verification/test for the alarms and/or
annunciators of the generator set designated by the Facilitator. The participant must have the service
literature and the tools corresponding to the procedure before starting the task. Test results must be
written down in the Results section of this sheet and they must be included in the module
Service Report.
 End of Task.
2. Results:
Comments:

190
Task Sheet 08: Generator Set Vibration Tests
1. Procedure:
Instructions: In this task, the participant will perform the vibration verification of the generator set
designated by the Facilitator. The participant must have the service literature and the tools
 Using the table provided below and the required service literature, carry out the equipment charge
test. Keep each charge step for at least 5 minutes before recording the data. Attach your results to
your Service Report.
and/or observations about them. Carry out a complete analysis of the generator behavior regarding
the charge test and check if it matches the group factory data.
 End of Task.
2. Results:
Equipment Data:
Serial Number: _________________________________.
Plate Voltage: __________________________________.
Plate Current: __________________________________.
Power (ekW): ___________________________________.
Power Factor: __________________________________
Frequency: _____________________________________
Data 25% charge 50% charge 100% charge
Voltage:
Current:
Frequency:
RPM:
191
Comments:

192
Task Sheet 09: Generator Set Load Profile Test
1. Procedure:
Instructions: In this task, the participant will perform the load test for the generator set designated by
the Facilitator. The participant must have the service literature and the tools corresponding to the
 End of Task.
2. Results:
193
Comments:

194

Certificacion Cat

Transféré par

Informations du document

Description originale:

Titre original

Copyright

Formats disponibles

Partager ce document

Partager ou intégrer le document

Options de partage

Avez-vous trouvé ce document utile ?

Ce contenu est-il inapproprié ?

Droits d'auteur :

Formats disponibles

Certificacion Cat

Transféré par

Droits d'auteur :

Formats disponibles

ADS – Dealer Training Service Training

Electric Power Generation Technician Certification Program

Participant Name _____________________________________ Date __________

CERTIFICATION PROCESS .......................................................................................... 1

MODULE #1: ENGINE SYSTEMS .................................................................................. 4

ENGINE SYSTEM QUESTIONNAIRE 7

MODULE #2: ALTERNATORS AND VOLTAGE REGULATORS................................ 29

ALTERNATOR AND VOLTAGE REGULATOR QUESTIONNAIRE: 31

MODULE #3: CONTROL PANELS .............................................................................. 71

CONTROL PANEL QUESTIONNAIRE 73

TASK SHEET 10: THERMOCOUPLE/RTD MODULE PROGRAMMING 157

MODULE #4: START UP AND PREVENTIVE MAINTENANCE ................................ 162

START UP AND PREVENTIVE MAINTENANCE QUESTIONNAIRE 165

PROCESS Each participant will receive an assessment schedule

This module is divided into two assessment sessions. One

The participant will have 5 attempts to answer each

The participant must complete the questionnaire before

The assessment criteria for this section will be as follows:

The assessment criteria for this section are as follows:

Observations/Recommendations: The participant

This Section represents the 30% of the final grade of the

CONTACT INFORMATION General Information:

MODULE #1: ENGINE SYSTEMS

Objectives The objectives of this module are the following:

Demonstrating the ability to carry out the mechanical adjustments required

Demonstrating the ability to carry out the electronic adjustments required

Demonstrating the ability to diagnose electric and electronic engine

Tasks The Tasks to be done in this module are:

Calibrating the engine in Top Dead Center

Adjusting injector height or injector timing, and verifying injection timing

Verifying calibration of intake and exhaust valves

Locating faults in electric and electronic components

Tools 1U-9087 Governor Repair Tool Group

178-8615 Turning Tool

139-7063 Pin Timing

147-5482 Valve Lash Adjustment Tool Group

9U-5132 Timing & Fuel Setting Tool Group

164-3310 Infrared Thermometer

257-9141 Fluke 87 Multimeter

171-4400 Communication Adapter Group II

Caterpillar Electronic Technician Software version 2011C or above

RENR9953 C4.4 Engine - System Operation and Testing & Adjusting

KENR8785 C6.6 Generator Set - System Operation and Testing &

SENR9868 C9 Generator Set Engines - System Operation and Testing

SENR9708 C15 and C18 Generator Set Engines - System Operation

RENR9968 C27 and C32 Generator Set Engines - System Operation

RENR9338 C175-16 and C175-20 Generator Set Engines - System

SENR7939 G3304 and G3306 Engines - System Operation and

RENR5953 G3406 and G3412 Engines - System Operation and

RENR5923 G3500 Engines for Caterpillar Built Generator Sets -

KENR9737 G3512E and G3520E Generator Set Engines - System

RENR2268 G3500B Engines - System Operation and Testing &

KENR6834 G3516C and G3516E Engines - System Operation and

RENR5978 G3520C and G3520E Generator Set Engines - System

RENR1287 3306B Generator Set Engine - System Operation and

RENR1293 3406C Generator Set Engines - System Operation and

RENR2303 3406E and 3456 Generator Sets - System Operation and

RENR1388 3412C Generator Set Engines - System Operation and

RENR5058 3500B Generator Set Engines - System Operation and

RENR4963 3500 Engines for Caterpillar Built Generator Sets - System

SERV1877 Reference Material - Electrical/Electronic Troubleshooting

REHS0126 Diagnostic Code Information for Caterpillar Electronic

Participant Name ___________________________ Date

(1) __________ (2) _ (3) ___________