Installation Guide for Industrial Electronic Engine Displays Caterpillar

Overview of the Display for the Engine Monitoring System

Illustration 1	g00999867
Typical display

The Engine Monitoring System (EMS) displays various parameters for the engine and the transmission. EMS provides excellent visibility in various conditions of lighting. EMS also supports the connections for the backlights.

The engine ECM monitors the following information.

• Operating parameters for the engine

• Diagnostic information

The engine ECM processes this information and the information is then transmitted to the Engine Monitoring System through the CAT Data Link. The main EMS display unit receives information and this unit also displays information. Only two wires are required from the ECM to the display. The two wires receive all of the operating parameters for the engine and the diagnostic information.

The EMS incorporates three individual gauge units. The EMS can be installed in various locations.

One Main EMS Gauge Unit is required for each desired operator station. The Tachometer and Quad Gauge Modules are optional. These gauges will NOT operate without a connection to a Main EMS Gauge Unit.

The Main EMS Gauge Unit has ten indicators (two rows of five) which display diagnostics that are related to the system. A digital LCD display shows the parameters for the engine and the parameters for the transmission that are monitored.

Monitored parameters include the following parameters.

• Engine speed

• Engine oil pressure

• Engine coolant temperature

• Inlet manifold temperature

• Engine boost

• Battery voltage

• Fuel rate

• Fuel pressure

• Fuel temperature

• Engine hours

• Engine load (percent load)

• Accessory temperature

• Accessory pressure

The Quad Gauge Module has warning zones that are on a scale. This module displays the following functions in an analog format.

• Engine oil pressure

• Engine coolant temperature

• Fuel pressure

• Battery voltage

Installation

Required Parts

Use the following chart in order to determine the parts that are required for the installation of the Engine Monitoring System (EMS).

Note: NO additional connections are allowed to any wires that are detailed and described in this publication without the approval of Caterpillar.

Table 1

Required Parts for Display Module
Main Station with 121-4017 Wiring Harness
Part Number	Description	Qty
Gauge Modules
198-9749	Main Gauge Display	1
133-4860	Film	1
190-3484	Tachometer Module	1
166-6936	Quad Gauge Module	1
117-6601	Bezel	3
7Y-7388	Screw (M5)	12
8T-3992	Screw (M6)	9
143-5018	Data Link Cable (Fabricate Cable to Length)	N/A
Hardware Description for the 121-4017 Wiring Harness
186-3736	Connector Socket	13
121-4017	Wiring Harness	1
155-2255	Connecting Plug Kit (12 Socket)	1
3E-5177	Plug Lock Wedge	1
118-5075	Miniature Lamp (Backlight Lamp)	4
3E-8775	Switch (Scroll Forward and Backward)	1
165-5674	Diode Lamp (Switch Backlight)	3
155-2705	Rocker Actuator	1
2N-2371	Indicator Lamp	1
7N-5876	Lamp (24V)	1
3E-8766	US/Metric Display Switch (Illuminated)	1
155-2706	Rocker Actuator	1
(1)	Dimmer Potentiometer	1
123-9694	Horn	1
OR
9G-9813	Alarm	1
Remote Station
190-3484	Tachometer Module	1
OR
166-6941	Quad Gauge Module	1
AND
117-6601	Bezel	1
7Y-7388	Screw (M5)	4
8T-3992	Screw (M6)	3
155-2274	Connecting Plug Kit	1
3E-5177	Plug Lock Wedge	1
(2)	16 AWG wire	N/A
155-2265	Connecting Plug Kit	1
155-2259	Plug Lock Wedge	1
186-3736	Connector Socket	7
Main Station without 121-4017 Wiring Harness
8T-9834	Connector Plug (40 Pin)	1
186-3736	Connector Socket	24
155-2274	Connecting Plug Kit	2
3E-5177	Plug Lock Wedge	2
186-3735	Connector Pin	19
102-8801	Receptacle Kit	1
3E-5180	Receptacle Lock Wedge	1
118-5075	Miniature Lamp (Backlight)	10
113-5184	Lamp Terminal (Backlight)	12
118-5077	Socket (Lamp)	6
102-8806	Receptacle Kit	1
3E-3389	Receptacle Lock Wedge	1
(2)	16 AWG wire	N/A
155-2255	Connecting Plug Kit	1
3E-5177	Plug Lock Wedge	1
3E-8775	Switch (Scroll Forward and Backward)	1
155-2705	Rocker Actuator	1
2N-2371	Indicator Lamp	1
7N-5876	Lamp (24V)	1
3E-8766	US/Metric Display Switch	1
155-2706	Rocker Actuator	1
(1)	Dimmer Potentiometer	1
123-9694	Horn	1
OR
9G-9813	Alarm	1

( 1 )	OEM supplied 75 ohm 10 watt
( 2 )	Fabricate Cable to Length.

Power Requirements for the Engine Monitoring System

Illustration 2	g00787944
127-8853 Electrical Converter Group (12 VDC to 24 VDC (12/24 ))

24 VDC is required to power the EMS display. If an electrical system that is 12 VDC is used, the display will require 127-8853 Electrical Converter Group (12 VDC to 24 VDC ( 12/24 )). This converter is capable of supplying 5 Amps at 24 VDC. Therefore, the circuit that includes the converter must have circuit protection of at least 5 Amps. This converter can also be used in installations for the EMS on installations that have an electrical system that is 12 VDC.

Note: Avoid splicing or soldering wire connections. All connections should be terminated at terminal strips. This will help in order to ensure the reliability of the engine. Also, this will help to ensure the reliability of the communication systems.

Engine Monitoring System Gauge Unit

Illustration 3	g00748502
Dimensions for the gauge module All of the modules have identical dimensions.

Each module can be mounted from either the front or rear. Each module has a 5 mm tapped hole in each corner (four holes), a 4 mm clearance hole in each corner, and four 6 mm tapped holes in the back of the housing.

Front Mount

The mounting bracket is NOT required for applications that have a front mount.

Bezels must be installed over the front of the module. Install 7Y-7388 Screws (M5) in the four corners of the bezel, through the dash panel, and into the tapped holes in the gauge module.

Rear Mount

A U-shaped bracket is required for applications which are rear mounted. The bracket should push up against the inside of the dash panel in order to pull the module tightly against the outside of the dash panel. Use 8T-3992 Screws (M6) to attach the bracket to the holes in the rear of the module.

Note: The bracket that is shown is a reference. The length of the bracket legs must be adjusted in order to fit your dash panel.

The bezel can be attached to the gauge module with 7Y-7388 Screws (M5). Install the screws through the bezel and into the tapped holes in the flange of the module.

Note: The bezel screws must not exceed 12 mm (0.47 inch) in length. If a longer screw is used, the screw will protrude through the module and into the dash panel.

Connecting the EMS Display Modules

Illustration 4	g00748526
Schematic for EMS

Connecting the Harness

Table 2

Required Parts
Part Number	Description	Qty
160-1050	Harness (EMS)	1

1. Connect the P1 connector to the main EMS module.

2. Torque the allen head screw to 2.25 ± 0.25 N·m (20 ± 2 lb in).

3. Plug the tachometer into the P2 connector.

4. Plug the quad gauge into the P3 connector.

Battery Connections for 12 Volt Systems

Table 3

Required Parts
Part Number	Description	Qty
127-8853	Electrical Converter (12/24)	1
186-3736	Connector Socket	2
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

Illustration 5	g00750943
12 Volt Battery Connections

1. Run a wire from the "RUN" terminal of the Engine Control Switch (ECS) to the "+V IN" terminal of the 12/24 converter.

2. Run a wire from the negative battery to the "-V IN" terminal of the 12/24 converter.

3. Run a wire from the "+V OUT" terminal of the 12/24 converter to terminal 1 of the J1 EMS Customer connector.

4. Install a jumper wire between the "-V IN" and the "-V OUT" terminals on the 12/24 converter.

5. Run a wire from the "-V OUT" terminal of the 12/24 converter to terminal 2 of the J1 EMS Customer connector.

Battery Connections for 24 Volt Systems

Table 4

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	2
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

Illustration 6	g00750945
24 Volt Battery Connections

1. Run a wire from the "RUN" terminal of the Engine Control Switch (ECS) to terminal 1 of the J1 EMS Customer connector.

2. Run a wire from the negative battery to terminal 2 of the J1 EMS Customer connector.

Connecting CAT Data Link

Illustration 7	g00999869
Connections for the Data Link

Table 5

Engine	Customer Connector	CAT Data Link +	CAT Data Link -
3126B/ C-9/ C-10/ C-12/ C-15/ C-16	P61	P61:7	P61:6
3412E	P3	P3:7	P3:6

Table 6

Required Parts
Part Number	Description	Qty
186-3736	Connector Socket	2
143-5018	Cable (Twisted Pair)	(1)

( 1 )

Fabricated to length

Note: Refer to table 5 for the proper pin numbers for an engine.

Note: Use a 143-5018 Cable (Twisted Pair) for connections of the CAT Data Link.

1. Connect the terminal for the CAT Data Link + of the Customer connector to the terminal for the CAT Data Link + on the terminal strip for the industrial application.

2. Connect the terminal for the CAT Data Link - of the Customer connector to the terminal for the CAT Data Link - on the terminal strip for the industrial application.

3. Connect the terminal for the CAT Data Link + on the terminal strip to the terminal for the CAT Data Link + on the operator station.

4. Connect the terminal for the CAT Data Link - on the terminal strip to the terminal for the CAT Data Link - on the operator station.

5. Connect the terminal for the CAT Data Link + of the operator station to pin 6 of the J1 12 pin Customer connector.

6. Connect the terminal for the CAT Data Link - of the operator station to pin 5 of the J1 12 pin Customer connector.

Note: The total length of the cable should not exceed 30 m (100 ft).

Connecting Multiple EMS Displays

Illustration 8	g00999871

Additional EMS display modules can be installed for a multiple station installation. Refer to Illustration 8 for proper connections of the EMS display module for each station. For additional stations, make multiple connections to the CAT Data Link. The total combined cable length should be kept as short as possible. The preferred method is through terminal strips.

Note: Use 143-5018 Cable (Twisted Pair) for all connections to the CAT data link. The total length of the cable should NOT exceed 30 m (100 ft).

Optional Switches

Illustration 9	g00748530
Schematic for optional switches

Scroll Switch

Table 7

Required Parts
Part Number	Description	Qty
3E-8775	(SPDT Momentary) Scroll Switch	1
155-2705	Rocker Actuator (Scroll Switch)	1
3E-7996	Connector Plug (for the Scroll Switch)	1
065-7187	Female Terminal (for the Scroll Switch)	(1)
186-3736	Connector Socket	(1)
N/A	16 AWG Wire	(2)

( 1 )	The application determines the quantity.
( 2 )	Fabricated to length

When the scroll switch is actuated, the display on the main EMS module will scroll through the parameters. Refer to illustration 9 in order to connect a 3E-8775 Switch (SPDT Momentary).

US/Metric Display Switch

Table 8

Required Parts
Part Number	Description	Qty
3E-8768	(SPST Momentary) US/Metric Display Switch	1
155-2706	Rocker Actuator (US/Metric Display Switch)	1
3E-7996	Connector Plug (US/Metric Display Switch)	1
065-7187	Female Terminal (US/Metric Display Switch)	(1)
186-3736	Connector Socket	(1)
N/A	16 AWG Wire	(2)

( 1 )	The application determines the quantity.
( 2 )	Fabricated to length

The default setting for the EMS display is Metric units (SI). If Metric units (SI) are desired, no connection is needed. If US units is desired, a permanent connection to the negative battery is required. If both US units and Metric units are desired, install a 3E-8768 Switch (SPST). Refer to illustration 9 for pin numbers.

Optional Warning Lamp/Alarm Outputs

Note: The maximum current draw on the outputs is 0.3 Amp.

Diagnostic outputs are provided at the J1 EMS Customer connector which may be used to drive a relay, an audible alarm, or an alarm lamp.

The diagnostic outputs may be used to warn the operator of any engine diagnostics and/or engine warnings that are present. An additional switch may be installed. This switch can enable the alarm or the switch can disable the alarm.

Warning Lamp

Table 9

Required Parts
Part Number	Description	Qty
2N-2371	Indicator Lamp	1
7N-5876	Lamp	1
2L-8074	Terminal	2
186-3736	Connector Socket	1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

1. Connect a wire from terminal 8 (Warning Lamp) of the J1 EMS Customer connector to one of the terminals on the lamp.

2. Connect the other terminal of the lamp to the negative battery.

Warning Alarm

Table 10

Required Parts
Part Number	Description	Qty
9G-9813 or 123-9694	Alarm Indicator Horn	1
2L-8074	Terminal	2
186-3736	Connector Socket	1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

1. Connect a wire from terminal 9 (Warning Alarm) of the J1 EMS Customer connector to the positive terminal on the alarm.

2. Connect the negative terminal on the alarm to the negative battery.

Optional Alarm Enable/Disable Switch

Table 11

Required Parts
Part Number	Description	Qty
3E-8768	Switch (SPST)	1
155-2706	Rocker Actuator	1
3E-7996	Connector Plug	1
065-7187	Female Terminal	(1)
N/A	16 AWG Wire	(2)

( 1 )	The application determines the quantity.
( 2 )	Fabricated to length

Connect the SPST switch between the negative battery and the negative terminal on the alarm.

Connecting Backlighting for the Display

Table 12

Required Parts
Part Number	Description	Qty
118-5075	Miniature Lamp (Backlight)	4
186-3736	Connector Socket	1
N/A	16 AWG Wire	(1)

( 1 )

Fabricated to length

1. Install a 118-5075 Miniature Lamp (Backlight) in each of the P4, P5, P6, and P7 lamp sockets.

2. Insert P4 and P5 into the tachometer module.

3. Insert P6 and P7 into the quad gauge module.

4. If a panel dimmer is being installed, proceed to "Installing a Panel Dimmer (Potentiometer)". Otherwise, connect terminal 10 (Lamp Power) of the J1 EMS Customer connector to the switched +24 VDC circuit.

Installing a Backlight Dimmer (Potentiometer)

Table 13

Required Parts
Part Number	Description	Qty
N/A	Rheostat (Dimmer for the Backlight) (3)	1
186-3736	Connector Socket	1
N/A	16 AWG Wire	(1)

( 3 )	75 Ohm, 10 Watt
( 1 )	Fabricated to length

Illustration 10	g00748575
Schematic for the potentiometer

1. Connect the wiper (output) of the potentiometer to terminal 10 (Lamp Power) of the J1 EMS Customer connector.

2. Connect the terminal for +V IN of the potentiometer to the switched +24 VDC circuit.

3. Connect the remaining terminal of the potentiometer back into the wiper.

Connecting an Optional Remote Module

Table 14

Required Parts
Part Number	Description	Qty
(1) Remote Tachometer Module
153-8059	Tachometer Module	1
117-6601	Bezel	1
7Y-7388	Screw (M5)	4
8T-3992	Screw (M6)	3
155-2274	Connecting Plug Kit	1
186-3736	Connector Socket	12
113-5183	Lamp Socket (Backlight)	2
113-5184	Lamp Terminal (Backlight)	4
118-5075	Miniature Lamp (Backlight)	2
N/A	16 AWG Wire	(2)
(1) Remote Quad Gauge Module
166-6936	Quad Gauge Module	1
117-6601	Bezel	1
7Y-7388	Screw (M5)	4
8T-3992	Screw (M6)	4
155-2265	Connecting Plug Kit	1
186-3736	Connector Socket	12
113-5183	Lamp Socket (Backlight)	2
113-5184	Lamp Terminal (Backlight)	4
118-5075	Miniature Lamp (Backlight)	2
N/A	16 AWG Wire	(2)

( 1 )	Only one remote gauge may be installed. This remote gauge can be a tachometer or the remote gauge can be a quad gauge. Both gauge modules are optional.
( 2 )	Fabricated to length

Illustration 11	g00748572
Typical schematic

1. Mount the remote module (tachometer or quad gauge).

   Note: The length of the wires between the J2 remote module connector and the remote module should NOT exceed 6 m (20 ft).

2. Remove the sealing plugs from the J2 remote module connector.

3. Connect a wire from terminal 1 of the J2 remote module connector to terminal 1 of the 155-2274 Connecting Plug Kit (Remote Tachometer) or terminal 1 of the 155-2265 Connecting Plug Kit (Remote Quad Gauge).

4. Continue connecting wires between the two connectors at terminals 2, 3, 4, and 5.

5. Refer to illustration 11 for connections of the circuit for the backlight.

6. Install the sealing plugs that were removed in Step 1 into any open cavities in the J2 remote module connector and the connector at the remote module.

7. Connect the remote module to the harness.