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Engine Division November 1996

Engine Monitoring System (EMS)


Product News for Caterpillar® Industrial Engines

Application Caterpillar 3176B, 3406E, 3408E, 3412E Heavy Duty Electronic


Industrial Engines

Description Caterpillar is announcing the availability of the Engine


Monitoring System (EMS) electronic display panel.

Features/Benefits Key engine parameters are displayed in both analog and digital
forms. EMS undergoes an automatic self-test every time the
engine is powered up. Visibility is excellent under most lighting
conditions. The EMS offers excellent installation flexibility. The
three separate components can be individually mounted in any
configuration. One main unit is required for each engine and the
tachometer unit and gauge unit are optional.

Availability April 1, 1996

LEXH6427 Information contained in this publication may be considered © 1996 Caterpillar Inc.
confidential. Discretion is recommended when distributing. Printed in U.S.A.
All rights reserved.
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Contents

Electronic Monitoring System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6


Systems/Connector Pins/Power/Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
EMS Gauge Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Connecting the EMS Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connecting Back Light Dimming Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connecting Optional Diagnostic Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-12
Connecting Optional Remote Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting Remote Gauge Back Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-14

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PRODUCT NEWS – ENGINE MONITORING SYSTEM

Electronic Monitoring System (EMS)


EMS is an electronic monitoring system up, EMS undergoes an automatic self-test,
designed to display various engine parameters. ramping all gauges and displaying digits to
The EMS incorporates three individual gauge ensure the panel is working correctly. The
units which can be located in variable installation display technology provides excellent visibility
arrangements. Every time the engine is powered in various light conditions.

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PRODUCT NEWS – ENGINE MONITORING SYSTEM

Display Definition
EMS is used to display engine information. The Beneath the warning lamps is a digital LCD
following diagram describes the functions of display to scroll through different engine
each gauge and the LCD display. parameters:
Engine Speed
On the Main EMS Unit there are ten warning
Percent Engine Load
lamps available for system related diagnostics.
Fuel Rate
These diagnostics can be used for system
Engine Boost
performance monitoring. They are located on the
Battery Voltage
main EMS unit in two rows of five:
Coolant Temperature
Coolant Temperature
Intake Manifold Temperature
Inlet Manifold Temperature
Fuel Temperature
Fuel Temperature
Accessory Temperature
Battery Voltage
Engine Oil Pressure
Auxiliary Temperature
Fuel Pressure
Engine Oil Pressure
(Customer Installed Sensor)
Fuel Pressure (N/A on 3176B)
Accessory Pressure
Coolant Level
Engine Running Hours
Engine Derate
Auxiliary Pressure One main EMS unit is required for each engine
in each desired station. Adding the tachometer or
Inlet Manifold Temperature the quad-gauge unit is optional. The tachometer
and the quad-gauge units will not operate
Engine Coolant Ammeter without the main EMS.
Temperature Fuel (Battery)
Temperature
Auxiliary Engine
Temperature Speed Engine Engine Coolant
Oil Pressure Temperature

Engine
Oil Pressure
Derate
Engine Auxiliary Voltmeter Fuel
Coolant Level Pressure (Battery) Pressure
Fuel
Pressure Message Center
Parameters

5
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Display Definition, cont. Cat Data Link


The Tachometer Unit display is used to display Use shielded twisted pair of 18 AWG wires,
engine speed from 0 to 2500 rpm on the analog approximately three twists per 25.4 mm
gauge. (1.00 in.) to connect Cat Data Link (+) and Cat
Data Link (-) for the connections. The length of
The Quad-Gauge Unit* displays engine oil
the wires should NOT exceed 30 m.
pressure, engine coolant temperature, fuel
pressure, and battery voltage. The first gauge is 1. Connect from ECM Cat Data Link (-) to
used to display engine oil pressure 0 Kpa to 688 pin 14 of the EMS 40-pin connector.
Kpa (98 psi). When engine oil pressure reaches
2. Connect from ECM Cat Data Link (+) to
below 100 Kpa (14 psi) the engine oil pressure
pin 5 of the EMS 40-pin connector.
gauge will enter the red zone and the alarm
output will activate. The exact minimum oil
pressure will vary for each engine model. The Engine Connector CAT Data + CAT Data -
second gauge is used to display engine coolant Arrangement Number CDL + CDL -
temperature. When engine coolant temperature 3408E P3 PIN 7 PIN 6
reaches above 102° C (214° F) the gauge will 3412E P3 PIN 7 PIN 6
enter the red zone and the alarm output will
3176B P1 PIN 9 PIN 3
activate. The third gauge is used to display
3406E P3 PIN 7 PIN 6
battery voltage. When the machine’s battery
voltage drops below 18 volts the gauge will enter
the red zone and the alarm output will activate.
The fourth gauge is used to display filtered fuel
pressure to the engine. When the fuel pressure
drops below 200 Kpa (29 psi) the gauge will
enter the red zone and the alarm output will
activate.

Communication Data Link


The Main EMS unit communicates with the
ECM over the Cat Data Link. EMS provides two
output pins that are dedicated to the Cat Data
Link. The link is available to share data with
other modules on the link. The Electronic
Control Module (ECM) processes engine
parameters such as pressures, temperatures,
percent load, engine speed, and diagnostic
information. These engine parameters will then
be transmitted to EMS through Cat Data Link.
The main EMS unit will receive this information
and display the information on various gauges.
Only two wires from the ECM to EMS are
required to transmit all parameters.

6
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Systems/Connector Pins/Power/Environment
U.S./Metric Input Power Supply
The default operation mode displays U. S. 1. Supply range: 18 to 32 Volts DC, 24 Volts
customary units. A customer provided switch can DC nominal
be installed to provide a ground path to change 2. EMI/RFI compatibility: EMI/RFI emissions
the display from U. S. customary to metric units. and susceptibility levels of 100 Volt/Meter.
Power-Up Test Function Environmental Specifications
On power-up, the EMS system will undergo an 1. Operating temperature range: -40° to +85° C
automatic self-test. While executing this internal
test, the display will also provide a visual 2. Storage temperature range: -55° to +85° C
indication by ramping gauges and displaying all 3. Vibration: 4.0 g peak, 24 Hz to 2000 Hz, all
digits to the operator that the panel is, or is not, planes
properly functioning.
4. Humidity: 0 to 100%
System Packaging 5. Sealing: The control panel is sealed to
Each EMS display module is contained within a 35 Kpa (5 psi).
sealed box. Refer to attached EMS drawing for
dimensions and mounting. Connector Pin Identification
The electrical connector used is the rectangular
style 40 pin Deutsch. Following is the connector
pin-out identification and wiring diagram. The
EMS display must be connected to the same
supply that powers the ECM.

Wire Code
Std Eng Wire Harness
Customer Option Wiring
P7 P6 P5 P4

P1 (40-Pin)
Gauge
22

13
12
11
10

23
20
35
34
25
15
14
6
5
4
3
2
1

9
8
7
6
4
3

5
2
1

J3 P2 Connector
8
7
6
5
4
3
2
1

P3
8
7
6
5
4
3
2
1
indicator link
Aux Circuit (Lamp Power)

indicator link

Aux circuit (lamp pwr)


indicator link
(-) battery (illumination)

Harness Cade

Scroll
US/Metric
Mod Data
(+) V Mod
Mode Clock
Mod Load
Data (-)
Data (+)
(-) batt
(+) batt
MOD load
MOD data
MOD clock
(-) battery
(+) V MOD

indicator link
(-) battery (illumination)

Warning Lamp/Alarm
Monitor Trans
6
5
4
3
2
1
6
5
4
3
2
1

P3
MOD load
MOD data
MOD clock
(-) battery
(+) V MOD

6 Data (+)
5 Data (-)
(-) batt 2
(+) batt 1
10
3
4
8
J2
7
1 9
(+) V MOD 2 11
MOD clock 3 12 (-) battery
MOD data 4
MOD load 5 J1 (12-Pin)
(-) battery
6 Customer
7
(+) battery 8 Connection

7
PRODUCT NEWS – ENGINE MONITORING SYSTEM

EMS Gauge Unit Dimensions

Each EMS module (main, tach, and gauge unit) Rear Mount
has identical dimensions. The mounting options The bracket is required and may be U-shaped to
with bezels are described below. Each module butt against the dash panel and pull the module
can be mounted from either the front or rear, and tightly against the dash panel. (The bracket
with or without a decorative bezel. Each module shown is a reference. The length of the bracket
has a 5 mm (0.2 in.) tapped hole in each corner legs must be adjusted to fit your dash panel.) The
(four holes), a 4 mm (0.16 in.) clearance hole in bracket can be attached to the module with the
each corner, and four 6 mm (0.24 in.) tapped 8T3992 screws [6 mm (0.24 in.)] in the holes on
holes in the back of the housing. the rear of the module. The bezel can then be
attached to the gauge module with 7Y7388
Front Mount screws [5 mm (0.2 in.)] through the bezel into
The brackets are not used. The bezel must be the tapped holes in the module flange. Screws
installed over the front of the module. The 4 mm must not exceed 12 mm (0.47 in.) long or they
(0.16 in.) screws (or smaller) mount through the will protrude through the module into the dash
bezel (four corners) and into the gauge module panel.
tapped holes and screw into the dash panel
mounting surface.

8
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Installation
Parts Required Part No. Description Quantity
The following chart is a reference for ordering
8T8737 Plug- Sealing 1
the total parts required. Refer to the individual
113-5184 Packard Terminal (P4, P5, P6 & P7) 1
charts for the specific parts (and quantity)
113-5183 Packard Connector (P4, P5, P6 & P7) 4
required for each particular installation. Items
110-3055 Temperature Sensor (Trans-P19) 2
and quantity will vary according to the
9G9813 Horn/Alarm - 24VDC 1
installation options chosen. Note: Customer
3E3379 6-pin DT Connector
(OEM) wiring and optional features are
Remote Gauge 1
recommended. Elimination of any components
3E3380 Wedge
shown in this installation guide will disable
Remote Gauge 1
certain engine features. Contact Caterpillar Inc.
3E3385 8-pin DT Connector
when considering component removal. NO
Remote Gauge 1
additional connections are allowed to any wires
3E3386 Wedge
detailed and described in this publication without
Remote Gauge 1
Caterpillar Inc. approval.
Part No. Description Quantity [Original Equipment Manufacturer (OEM) supplied]

8T8729 Pin - 16/18 AWG 13 Description Quantity


8T8730 Socket - 16/18 AWG (P1, P2 & P3) 16
Switch (Enable/Disable) - Horn Output 1
118-5075 GE Lamp (194A) (P4, P5, P6 & P7) 4
16 AWG Wire - Fabricate to Length 1
121-4017 Harness - Wiring** 1
18 AWG Wire (SAE J1128 Type SXL) 1
132-8044 Gauge - Quad 1
Cat & ATA (J1587) data link connection
117-9016 Gauge - Tachometer 1
Lamp Incandescent (24 VDC) - with holders 1
133-4850 Gauge - EMS Unit 1
Switch - SPST (U.S./Metric Input) 1
3E3382 6-pin DT Connector Q uad Gauge 1
Switch - (N/O) Momentary (Display Scroll) 1
3E3383 Wedge (For 6-pin DT Connector)
Potentiometer (Back Lamp Dimmer) 1
Quad Gauge 1
(Recommend Cat P/N 7E0859)
3E3385 8-pin DT Connector (J2) 1
3E3385 8-pin DT Connector (P3)
**(An OEM supplied wiring harness can be used in place
Quad Gauge 1 of 121-4017. For instruction on wiring when not using
3E3386 Wedge (For 8-pin DT Connector) 121-4017, see 3406E, 3408E, and 3412E Industrial
(P3) Quad 1 Engine Installation Guide SENR 1025.)
3E3386 Wedge (For 8-pin DT Connector)
(J2) 1

9
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Connecting the EMS Display*


P1 (40-Pin)
1. Connect P1 (40-pin) gauge connector to Gauge
Connector
133-4850 EMS gauge main unit. Wire Code

23
20
Std Eng Wire Harness

13

2
1
Customer Option Wiring

Scroll
US/Metric
Warning

(-) batt
(+) batt
Connecting Tachometer and Quad

Warning Lamp/Alarm
Gauge Units
2. Connect P2 (6-pin) tachometer gauge
J1 (12-Pin)
connector to 117-9016 EMS tachometer Customer
Connector
gauge unit.
2 (–) batt

3. Connect P3 (6-pin) quad-gauge connector to US/ Metric


1

132-8044 EMS quad-gauge unit. Scroll 4


8 Warning Lamp

9 Warning Alarm +
11

Connecting Gauge Back Lighting 12

4. Insert lamps into P4 and P5 (tachometer


back lights). Connecting Inputs to EMS
5. Insert lamps into P6 and P7 (quad-gauge Display Scroll Switch
back lights). 1. Connect pin-4 of the J1 12-pin customer
6. Connect P4 and P5 (tachometer back lights) connector to the normally open terminal on
to the tachometer gauge. a momentary (display scroll) switch.
Connect the common terminal of the
7. Connect P6 and P7 (quad-gauge back lights) momentary switch to (-) battery bus bar.
to the quad-gauge. This will enable the user to scroll through
different engine/transmission parameters on
Connecting Battery to EMS the main EMS unit each time the switch is
8. Connect (+) battery bus bar to the positive closed.
terminal of the start (ignition) switch.
Connect the RUN terminal of the start U.S./Metric Display Switch (If
(ignition) switch to pin-1 of J1 12-pin Required)
customer connector. Default setting for the EMS is metric (SI) units.
9. Connect (-) battery bus bar to pin-2 of the If metric (SI) units only are required, no switch
J1 12-pin customer connector. connection is needed. U.S. (non-SI) units are
enabled when switched to (-) battery. A required,
permanent connection to (-) battery is needed.
*Using optional Caterpillar harness 121-4017. 2. Connect (-) battery bus bar to the common
terminal of a (U.S./metric) switch. Connect
open terminal to pin-3 of the J1 12-pin
customer connector. This will enable the
user to select display units (U.S./metric).
The EMS will display metric units when the
switch is connected to (-) battery bus bar
and U.S. units when the switch is open.

10
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Connecting Back Light Connecting Optional


Dimming Potentiometer Diagnostic Outputs
Parts Required The wiring harness provides diagnostic outputs,
which can be used to drive a relay, audible or
Description Quantity
visual alarm. The EMS horn output warns the
[Original Equipment Manufacturer (OEM) supplied] operator of any engine diagnostic and/or engine
warning condition present. An additional switch
Potentiometer (Dimmer) 1
can be installed to enable or disable the horn.
Wire (16 AWG) - Fabricate to length —
Horn is disabled when engine is not running.
Parts Required
P1 (40-Pin)
Gauge
Connector Wire Code
Part No. Description Quantity
23
20

2
1

Std Eng Wire Harness


Customer Option Wiring 9G9813 Horn/Alarm - 24 VDC 1
8T8730 Socket Contact 1
US/Metric

(+) batt
(–) batt
Scroll

[Original Equipment Manufacturer (OEM) supplied]

Lamp Incandescent (24 VDC) - With Holder 1


2
Switch - (Enable/Disable) - For Horn Output 1
1
Aux Circuit
US/Metric
10
3
Wire (16 AWG) - Fabricate to length —
Scroll 4

P1 (40-Pin)
11 J1 (12-Pin) Gauge
12
Customer Connector
Connection Wire Code
Std Eng Wire Harness
23
20

2
1
4

Customer Option Wiring


Scroll
US/Metric

(-) batt
(+) batt
Warning Lamp

1. Connect from Pin-10 (dimmer


potentiometer) of the J1 12-pin customer
connector to the wiper of the dimmer J1 (12-Pin)
Customer
potentiometer. Connector

2. Connect one terminal of the dimmer 2


1
(–) batt

potentiometer to the (+) battery bus bar. US/ Metric


Scroll
3
4
Warning Lamp
8

+
3. Connect one terminal to the (-) battery bus 9
11
12
Warning Alarm

bar.

Diagnostic (Warning) Lamp


1. Connect from pin-8 (warning lamp) of the
J1 12-pin customer connector to the positive
terminal of the lamp.
2. Connect the (-) battery terminal to the (-)
battery bus bar.

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PRODUCT NEWS – ENGINE MONITORING SYSTEM

EMS Horn 1. Connect pin-5 (mod load) of the J2 8-pin


The horn driver is a 300 mAmp sourcing type EMS customer connector to pin-5 (mod
driver. load) of the 6-pin remote gauge connector.
3. Connect from pin-8 (warning alarm) of the
Jl 12-pin customer connector to the positive 2. Connect pin-3 (mod clock) of the J2 8-pin
terminal of the alarm. EMS customer connector to pin-3 (mod
clock) of the 6-pin remote gauge connector.
4. Connect the (-) battery terminal to the (-)
battery bus bar. 3. Connect pin-1 (+V mod) of the J2 8-pin
EMS customer connector to pin-1 (+V mod)
Connecting the Optional EMS Horn of the 6-pin remote gauge connector.
Enable/Disable Switch 4. Connect pin-4 (mod data) of the J2 8-pin
5. Connect from (-) battery terminal pin-2 of EMS customer connector to pin-4 (mod
the horn to pin-1 of the enable/disable horn data) of the 6-pin remote gauge connector.
switch.
5. Connect pin-2 (-battery) of the J2 8-pin
6. Connect pin-2 of the enable/disable horn EMS customer connector to pin-2 (-battery)
switch to the (-) battery bus bar. of the 6-pin remote gauge connector.

Connecting Optional Remote


Units
Parts Required
Part No. Description Quantity
8T8730 Socket Contact 6
8T8729 Pin - 16/18 AWG 7
8T8737 Plug-Sealing 1
3E3385 Connector (8-Pin) (J2) 1
3E3386 Wedge (for 8-Pin Connector) 1
117-9015 Tachometer or . . . 1
117-9016 Quad-Gauge 1
3E3379 6-Pin DT Connector 1
3E3380 Wedge (for 6-Pin Connector) 1

[Original Equipment Manufacturer (OEM) supplied]

Wire (16 AWG) - Fabricate to length —


The wires should be 16 AWG wire with the length not
exceeding 6 m (20 ft.)

12
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Connecting Remote Gauge Back Light


Parts Required 7. Connect pin-7 (-battery illumination) of J2
8-pin remote gauge connector to (-) battery
Part No. Description Quantity
terminal of the dimmer potentiometer.
118-5075 Lamp - GE 194A 2
8. Connect from the wiper terminal of the
113-5184 Terminal - Packard 4
dimmer potentiometer to pin-2 of one
118-5077 Connector - Packard 2
remote gauge back light.
[Original Equipment Manufacturer (OEM) supplied]
9. Connect pin-7 (-battery illumination) of J2
Wire (16 AWG) - Fabricate to length — 8-pin remote gauge connector to pin-1 of the
other remote gauge back light.
6. Connect pin-8 (+battery illumination) of J2
10. Connect pin-1 of the first remote gauge back
8-pin remote gauge connector to (+) battery
light to pin-2 of the other remote gauge back
terminal of the dimmer potentiometer.
light.

13
PRODUCT NEWS – ENGINE MONITORING SYSTEM

Additional EMS displays (up to five per engine) The preferred method is through a terminal strip.
can be installed to allow for multiple station Connect only one end of the shield to (-)
installation. The EMS for each station can be battery bus bar. Do not ground the other end of
connected as shown in the illustration below. For the shield. The length of the wires should not
additional stations, make multiple connections to exceed 40 m (130 ft.). Twisted shielded 16 AWG
the Cat Data Link (+) and Cat Data Link (-). wire should be used, approximately three twists
per 25.4 mm (1.0 in.), to connect Cat Data Link
Additional stations, make multiple connections
(+) and Cat Data Link (-).
to the Cat Data Link (+) and Cat Data Link (-).

14
© 1996 Caterpillar Inc. Printed in U.S.A.