Installation Guide for Industrial Electronic Engine Displays Caterpillar

Test Step 1. Inspect Electrical Connectors and Wiring

1. Turn the keyswitch to the "OFF" position.

2. Check the following ECM connectors and wiring for damage or incorrect attachment.
   • 3412E connectors that are J1/P1, J2/P2, and J3/P3

   • 3126B, C-9, C-10, C-12, C-15, and C-16 connectors that are J1/P1, J2/P2, and J61/P61

3. Check for the correct installation of the wires for the CAT Data Link. Refer to Installation Guide, "Wiring (Cat Data Link (CDL))" for additional information.

4. Check the following components for abrasion, corrosion, or incorrect attachment.
   • Engine Monitoring System (EMS)

   • Wiring

5. Verify that each individual ECM is programmed to the proper engine location.

6. Verify that the -battery connections are secure and free from corrosion.

7. Verify that the belts and all connections for the charging system are secure and tight.

Expected Result:

All connectors, pins and sockets should be completely coupled and/or inserted and the harness and wiring should be free of corrosion, abrasion or pinch points.

Results:

• OK - Proceed to Test Step 2.

• Not OK -

  Repair: Perform the following repair:Repair the connectors or wiring and/or replace the connectors or wiring. Ensure that all of the seals are properly in place and ensure that the connectors are completely coupled.Verify that the repair eliminates the problem.

  Stop.

Test Step 2. Verify the Problem

The tachometer for the EMS intermittently displays an "EE" message and the tachometer needle swings back and forth.

Note: This module may operate properly at times. The module may then begin to display the symptom in unison with the main module of the EMS.

OR

The needles on the module for the EMS Quad Gauge swing back and forth.

Note: This module may operate properly at times. The module may then begin to display the symptom in unison with the main module of the EMS.

Expected Result:

The display modules show symptoms that are described in the above descriptions.

Results:

• YES -

  Repair: The problem is not in the ECM or the display modules. Refer to Installation Guide, "CAT Data Link Circuit - Test" for additional information.

  Stop.

• NO - Proceed to Test Step 3.

Test Step 3. System Check for the Main EMS Display Module

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The 10 Warning lights on the main EMS display module will light and the lights will flash for two seconds.

Results:

• YES - Proceed to Test Step 4.

• NO - Proceed to Test Step 8.

Test Step 4. System Check for the EMS Tachometer

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The needle for the tachometer module swings from 0 rpm to 3000 rpm.

Results:

• YES - Proceed to Test Step 5.

• NO - Proceed to Test Step 10.

Test Step 5. System Check for the EMS Quad Gauge

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The needles on the Quad Gauge swing from the low gauge point to the high gauge point.

Results:

• YES - Proceed to Test Step 6.

• NO - Proceed to Test Step 17.

Test Step 6. System Check for the EMS

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the scroll switch in order to monitor the various parameters.

Expected Result:

The parameters on the EMS match the parameters on the electronic service tool.

Results:

• YES - There is no problem at this time. Stop.

• NO - Proceed to Test Step 7.

Test Step 7. Check the Harness Code for the EMS

1. Turn the keyswitch to the OFF position.

2. Verify the proper harness code for a particular application on the EMS 40 Pin Connector.
   Show/hide table

   Table 2

   Application	Harness Code Pin
   Industrial	Pin 22

3. Measure the voltage between the harness code pin and Pin 2 on the EMS 40 Pin Connector.

Expected Result:

The voltage is less than 0.4 VDC.

Results:

• YES - There is no problem at this time. Stop.

• NO -

  Repair: The EMS can not read the harness code.Make necessary repairs.Verify that the repair eliminated the problem.

  Stop.

Test Step 8. System Check for the EMS Display Module

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The following occurrences take place on the main EMS Display Module.

• The 10 Warning Lights will light and the lights will flash for two seconds.

• All text that is in the display window lights for two seconds.

Results:

• YES - There is no problem at this time. Stop.

• NO - Proceed to Test Step 9.

• Lights or Text is Missing -

  Repair: Repeat this Test Step.If the problem returns, replace the main EMS Display Module.Verify that the problem is resolved.

  Stop.

Test Step 9. Check the Voltage at the EMS

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the signal reading probes in order to measure the voltage between Pin 1 and Pin 2 of the 40 Pin EMS connector.

Expected Result:

The measured voltage is between 18 VDC and 32 VDC.

Results:

• YES - The EMS Display Module is receiving the proper voltage.

  Repair: Perform the following repair.

  1. Temporarily connect another main EMS Display Module.

  2. Repeat the Test Step.
  If the replacement for the main EMS Display Module resolves the problem, reconnect the suspect EMS Display Module and verify the return of the problem.If the problem returns, replace the suspect EMS Display Module.Verify that the problem is eliminated.

  Stop.

• NO -

  Repair: The main EMS Display Module is not receiving the proper voltage.Make the necessary repairs.Verify that the problem is eliminated.

  Stop.

Test Step 10. System Check for the Tachometer

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The needle for the tachometer module swings from 0 rpm to 3000 rpm.

All text in the Tachometer Gauge Display for the EMS lights for two seconds.

Results:

• YES - There is no problem at this time. Stop.

• NO - Proceed to Test Step 11.

• Text is Missing or Needle is stationary -

  Repair: Perform the following repair.

  1. Temporarily connect another main EMS Display Module.

  2. Repeat the Test Step.
  If the replacement for the main EMS Display Module resolves the problem, reconnect the suspect EMS Display Module and verify the return of the problem.If the problem returns, replace the suspect EMS Display Module.Verify that the problem is eliminated.

  Stop.

• Needle moves from 0 rpm to 1500 rpm. - Proceed to Test Step 15.

Test Step 11. Check the Voltage at the Tachometer

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the signal reading probes in order to measure the voltage between Pin 1 and Pin 2 of the 6 Pin connector for the tachometer P2.

Expected Result:

The measured voltage is between 8 VDC and 10 VDC.

Results:

• OK -

  Repair: Perform the following repair.

  1. Temporarily connect another EMS Tachometer Module.

  2. Repeat the Test Step.
  If the replacement for the EMS Tachometer Module resolves the problem, reconnect the suspect EMS Tachometer Module and verify the return of the problem.If the problem returns, replace the suspect EMS Tachometer Module.Verify that the problem is eliminated.

  Stop.

• Not OK - Proceed to Test Step 12.

Test Step 12. Check the Voltage at the EMS Display

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the signal reading probes in order to measure the voltage between Pin 34 and Pin 2 of the 40 Pin EMS connector.

Expected Result:

The measured voltage is between 8 VDC and 10 VDC.

Results:

• OK - The correct voltage exists at the main EMS Display Module. The correct voltage is not present at the tachometer. Proceed to Test Step 13.

• Not OK -

  Repair: Perform the following repair.

  1. Temporarily connect another main EMS Display Module.

  2. Repeat the Test Step.
  If the replacement for the main EMS Display Module resolves the problem, reconnect the suspect EMS Display Module and verify the return of the problem.If the problem returns, replace the suspect EMS Display Module.Verify that the problem is eliminated.

  Stop.

Test Step 13. Check the Resistance Through the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between the following pins.
   • Pin 34 (40 Pin EMS Connector) and Pin 1 (6 Pin Tachometer connector)

   • Pin 2 (40 Pin EMS Connector) and Pin 2 (6 Pin Tachometer connector)

   Note: Wiggle the harness during the measurement in order to reveal an intermittent open condition.

Expected Result:

The resistance is less than 10 Ohms through the harness for each measurement.

Results:

• YES - The resistance is less than 10 Ohms. Proceed to Test Step 14.

• NO - The resistance is greater than 10 Ohms. There is an open circuit in the harness.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.

Test Step 14. Check for a Short Circuit in the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between Pin 34 (+V Mod) and Pin 2 (- battery) of the 40 Pin EMS connector.

   Note: Wiggle the harness during the measurement in order to reveal an intermittent open condition.

Expected Result:

The measured resistance is greater than 20k Ohms through the harness.

Results:

• OK - A short circuit does not exist in the harness.

  Repair: Perform the following repair.

  1. Temporarily connect another EMS Tachometer Module.

  2. Repeat the Test Step.
  If the replacement for the EMS Tachometer Module resolves the problem, reconnect the suspect EMS Tachometer Module and verify the return of the problem.If the problem returns, replace the suspect EMS Tachometer Module.Verify that the problem is eliminated.

  Stop.

• Not OK - The measured resistance is less than 20k Ohms through the wires. There is a short circuit in the harness.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.

Test Step 15. Check the Resistance Through the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between the following pins.
   • Pin 25 (40 Pin EMS Connector) and Pin 3 (6 Pin Tachometer connector)

   • Pin 35 (40 Pin EMS Connector) and Pin 4 (6 Pin Tachometer connector)

   • Pin 15 (40 Pin EMS Connector) and Pin 5 (6 Pin Tachometer connector)

   Note: Wiggle the harness during the measurement in order to reveal an intermittent open condition.

Expected Result:

The resistance is less than 10 Ohms through the harness for each measurement.

Results:

• YES - The resistance is less than 10 Ohms for all measurements. Proceed to Test Step 16.

• NO - The resistance is greater than 10 Ohms. There is an open circuit in the harness.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.

Test Step 16. Check for a Short Circuit in the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between the following pins of the 40 Pin EMS connector.
   • Pin 25 and Pin 2

   • Pin 35 and Pin 2

   • Pin 15 and Pin 2

   • Pin 25 and Pin 1

   • Pin 35 and Pin 1

   • Pin 15 and Pin 1

Expected Result:

The measured resistance is greater than 20k Ohms through the harness.

Results:

• OK - There is not a short circuit in the harness.

  Repair: Perform the following repair.

  1. Temporarily connect another Quad Gauge Module.

  2. Repeat the Test Step.
  If the replacement for the Quad Gauge Module resolves the problem, reconnect the suspect Quad Gauge Module and verify the return of the problem.If the problem returns, replace the suspect Quad Gauge Module.Verify that the problem is eliminated.

  Stop.

• Not OK - There is a short circuit in the harness.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.

Test Step 17. System Check for the Quad Gauge

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

Expected Result:

The four needles on the Quad Gauge swing from the low gauge point to the high gauge point.

Results:

• YES - A problem does not exist at this time. Stop.

• NO - Proceed to Test Step 18.

• Needles swing from the low gauge point to the twelve o'clock position. - Proceed to Test Step 15.

Test Step 18. Check the Voltage at the Quad Gauge

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the signal reading probes in order to measure the voltage between Pin 1 and Pin 2 of the 6 Pin Quad Gauge connector.

Expected Result:

The measured voltage is between 8.0 VDC and 10.0 VDC.

Results:

• OK - The proper voltage is present at this time.

  Repair: Perform the following repair.

  1. Temporarily connect another Quad Gauge Module.

  2. Repeat the Test Step.
  If the replacement for the Quad Gauge Module resolves the problem, reconnect the suspect Quad Gauge Module and verify the return of the problem.If the problem returns, replace the suspect Quad Gauge Module.Verify that the problem is eliminated.

  Stop.

• Not OK - Proceed to Test Step 19.

Test Step 19. Check the Voltage at the EMS Display

1. Turn the keyswitch to the OFF position.

2. Turn the keyswitch to the ON position.

3. Use the signal reading probes in order to measure the voltage between Pin 34 and Pin 2 of the 40 Pin EMS connector.

Expected Result:

The measured voltage is between 8 VDC and 10 VDC.

Results:

• OK - The correct voltage is at the main EMS Display Module but not at the Quad Gauge. Proceed to Test Step 20.

• Not OK -

  Repair: Perform the following repair.

  1. Temporarily connect another main EMS Display Module.

  2. Repeat the Test Step.
  If the replacement for the main EMS Display Module resolves the problem, reconnect the suspect EMS Display Module and verify the return of the problem.If the problem returns, replace the suspect EMS Display Module.Verify that the problem is eliminated.

  Stop.

Test Step 20. Check Resistance Through the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between the following pins.
   • Pin 34 (40 Pin EMS Connector) and Pin 1 (6 Pin Tachometer connector)

   • Pin 2 (40 Pin EMS Connector) and Pin 2 (6 Pin Tachometer connector)

   Note: Wiggle the harness during the measurement in order to reveal an intermittent open condition.

Expected Result:

The measured resistance is less than 10 Ohms through the harness.

Results:

• YES - The resistance is less than 10 Ohms. Proceed to Test Step 21.

• NO - The resistance is greater than 10 Ohms.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.

Test Step 21. Check for a Short Circuit in the EMS Harness

1. Turn the keyswitch to the OFF position.

2. Disconnect the following components from the EMS harness.
   • Main EMS Display Module

   • Tachometer

   • Quad Gauge

3. Set an ohmmeter on the 200 Ohm scale and measure the resistance between Pin 34 (+V Mod) and Pin 2 (- battery) of the 40 Pin EMS connector.

   Note: Wiggle the harness during the measurement in order to reveal an intermittent open condition.

Expected Result:

The measured resistance is greater than 20k Ohms through the harness.

Results:

• OK - A short circuit does not exist in the harness.

  Repair: Perform the following repair.

  1. Temporarily connect another Quad Gauge Module.

  2. Repeat the Test Step.
  If the replacement for the Quad Gauge Module resolves the problem, reconnect the suspect Quad Gauge Module and verify the return of the problem.If the problem returns, replace the suspect Quad Gauge Module.Verify that the problem is eliminated.

  Stop.

• Not OK - The resistance is less than 20k Ohms. There is a short circuit in the harness.

  Repair: Make the necessary repairs.Verify that the repair eliminates the problem.

  Stop.