The following items are included with the instrument panel:
- Parts for an interconnect wiring harness that is assembled by the OEM of the locomotive
- Additional connections in the engine junction box
- Two additional sensors on the engine
The instrument panel provides information about engine operation. The panel displays the following information:
- Parameters of engine operation
- Warning indicators
- Shutdown indicators
- Diagnostics
- Records of engine operation
The operator obtains information from these components of the instrument panel:
- Gauge cluster modules
- Main display module
- Action alarm
Note: Only one gauge panel may be connected to the engine.
The switches on the instrument panel enable the operator to display the information. Each component of the instrument panel is described below.
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| Illustration 1 | g00830348 |
Instrument panel (1) Gauge cluster module (2) Gauge cluster module (3) Gauge cluster module (4) Main display module (5) Annunciator panel | |
Gauge Cluster Modules
The gauge needles are controlled by information that is processed by the main display module. For more information on the gauges, see this Operation and Maintenance Manual, "Gauges and Indicators" topic (Operation Section).
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| Illustration 2 | g00830363 |
Gauge cluster module (1) displays the following parameters: (A) Engine oil pressure (B) Jacket water coolant temperature (C) System voltage (D) Fuel pressure | |
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| Illustration 3 | g00830354 |
Gauge cluster module (2) displays the following parameters: (E) Exhaust temperature (right side and left side) (F) Inlet air restriction (right side and left side) (G) Fuel filter differential pressure (restriction) (H) Oil filter differential pressure (restriction) | |
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| Illustration 4 | g00830351 |
Gauge cluster module (3) displays the following parameters: (I) Inlet manifold air pressure (boost pressure) (J) Aftercooler coolant temperature (K) Inlet manifold air temperature (L) Engine oil temperature | |
Annunciator Panel
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| Illustration 5 | g00830371 |
(1) "SCROLL" switch (2) "CLEAR/MODE" switch (3) "LH/RH" switch (4) Action alarm (4) (5) "ALARM SILENCE" switch (6) Potentiometer | |
"SCROLL" switch (1) - The main display module is capable of five different modes of operation. The "SCROLL" switch is used to display the various parameters that are within each mode. See the "Main Display Module" topic.
"CLEAR/MODE " switch (2) - This switch is used for selecting among the main display module's five modes of operation. This switch is also used for clearing information from the main display module.
"LH/RH" switch (3) - This switch can be toggled in order to display the following parameters for the left side or the right side of the engine: exhaust temperature and inlet air restriction.
Action alarm (4) - An alarm condition will not shut down the engine. However, an alarm may precede a shutdown. An alarm indicates a serious condition that requires immediate attention. Annunciation of the alarm informs the operator of an abnormal operating condition or a problem with the monitoring system. The alarm is activated by the main display module when the following conditions occur:
- A diagnostic code is active.
- An LED indicator on the main display module flashes.
- The monitoring system detects an active event. Events can include an alarm, a derating, and shutdown.
"ALARM SILENCE" switch (5) - This switch enables the operator to silence the alarm for five minutes. If the condition that initiated the alarm is not corrected within the five minutes, the alarm will sound again.
Potentiometer (6) - The potentiometer enables the operator to control the brightness of the lighting for the instrument panel.
Main Display Module
The main display module is the brain of the system. This module receives information from the following sources:
- Electronic Control Module (ECM)
- Sensors
- Switches
The display on this module includes LED indicators and a liquid crystal display.
Indicators
The indicators illuminate in response to information that is received from the ECM via the CAT Data Link.
Note: The indicators will illuminate if a setpoint that is programmed into the monitoring system for a parameter is reached. For information on the setpoints, see this Operation and Maintenance Manual, "Monitoring System" topic (Operation Section).
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| Illustration 6 | g00830366 |
Indicators for the main control module (1) Active diagnostic code and engine shutdown (2) Low system voltage (3) Engine overspeed (4) High fuel filter differential pressure (restriction) (5) Low fuel pressure (6) Low oil pressure (7) High jacket water coolant temperature (8) Low jacket water coolant temperature (9) High aftercooler coolant temperature (10) High inlet manifold air temperature | |
| Active Diagnostic Code and Engine Shutdown (1) - This RED indicator illuminates when any of the following conditions occur: |
- An engine shutdown is initiated by the ECM.
- A diagnostic code is active.
- An event code is active.
| Low System Voltage (2) - This RED indicator illuminates if the system voltage (battery and alternator) that is supplied to the ECM is below the setpoint that is programmed. The indicator will also illuminate if the battery charger (if equipped) is not charging. |
| Engine Overspeed (3) - This RED indicator illuminates when the ECM has detected an engine overspeed condition. |
| High Fuel Filter Differential Pressure (Restriction) (4) - This RED indicator illuminates when the setpoint for fuel filter differential pressure is exceeded. This is usually an indication of a plugged fuel filter. |
| Low Fuel Pressure (5) - This RED indicator illuminates when the fuel pressure is less than the setpoint. |
| Low Oil Pressure (6) - This YELLOW indicator illuminates when the engine oil pressure is below the setpoint that is programmed at the factory. The setpoint is based on a map of minimum oil pressure versus engine speed. This value cannot be reprogrammed. |
| High Jacket Water Coolant Temperature (7) - This YELLOW indicator illuminates when the jacket water coolant temperature is above the setpoint. |
| Low Jacket Water Coolant Temperature (8) - This YELLOW indicator illuminates when the jacket water coolant temperature is below the setpoint. |
| High Aftercooler Coolant Temperature (9) - This YELLOW indicator illuminates when the aftercooler coolant temperature is above the setpoint. |
| High Inlet Manifold Air Temperature (10) - This YELLOW indicator illuminates when the inlet manifold air temperature is above the setpoint. |
Liquid Crystal Display (LCD)
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| Illustration 7 | g00380856 |
Liquid crystal display (LCD) | |
The liquid crystal display (LCD) includes the following items:
- A row of six digits and two decimal points
- Nine symbols for units of measure
- An "X10" symbol for specific applications
- A symbol for the hour meter
The operator can control the display of the LCD with switches that are on the instrument panel. The type of information that is displayed depends on the mode of the main display module.
Modes of the Main Display Module
The main display module has six different modes of operation. Each mode provides information about engine operation. To change the mode, push the "CLEAR/MODE" switch to the "MODE" position. Table 1 lists the modes.
| Modes Of The Main Display Module | |
| Mode | Mode Number |
| Normal | 0 |
| Numeric Readout | 1 |
| Service | 2 |
| Tattletale | 3 |
| Units | 4 |
| Harness Code | 5 |
Normal Mode (Mode 0)
This mode is used for normal engine operation. During Normal mode, the instrument panel performs the following functions:
- A self test is performed when the main display module is powered up. This indicates that the monitoring system is operating properly.
- The main display module continuously monitors the engine systems. The gauge needles indicate a normal operating condition when the needles are in the 12 o'clock position.
- If an abnormal operating condition occurs, the corresponding indicator flashes and the Action Alarm annunciates.
- If a diagnostic code is detected, "SERV CODE" appears on the LCD.
- When "RPM" is shown on the LCD, the engine rpm is displayed.
- When the symbol for the hour meter is shown on the LCD, the sum of the hours of engine operation are displayed.
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| Illustration 8 | g00384915 |
Tachometer (1800 rpm) | |
Tachometer - This gauge indicates the engine rpm. When the LCD shows "RPM", the LCD is functioning as a tachometer. The high idle rpm and the full load rpm are stamped on the engine Information Plate.
To display the hour meter, toggle the "SCROLL" switch.
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| Illustration 9 | g00384916 |
Hour meter (384 service hours) | |
| Hour meter - This meter indicates the hours of engine operation. When the LCD shows the symbol for the hour meter, the LCD is functioning as an hour meter. The value is continuously updated during engine operation. The ECM records the total number of service hours. |
Numeric Readout Mode (Mode 1)
Numeric Readout mode provides the operator with information about the following parameters:
- Engine load
- Fuel consumption
- Gauge readings
The information about engine load and fuel consumption is displayed on the LCD only. The gauge readings are displayed with more accuracy on the LCD.
To initiate Mode 1 operation, hold the "CLEAR/MODE" switch in the "MODE" position until "-1-" appears on the LCD.
- An identifier for the gauge will be displayed prior to a value for the parameter. The LCD will momentarily show the "GA-1"identifier. This identifies gauge 1.
- The value of the parameter will be displayed.
- When a value for a gauge is displayed, the corresponding gauge needle is active. All of the other gauge needles default to the minimum position.
Use the "SCROLL" switch to advance the display to the next parameter. The LCD will show the identifier for the gauge first. Next, the value for the parameter is displayed.
Table 2 is a list of the system identifiers that appear on the LCD and the corresponding parameters.
| Numeric Readout Mode (Mode 1) | |
| System Identifier | Parameter |
| "LOAd" | Percent of the rated rack |
| "FL-0" | Fuel consumption rate |
| "FL-1" | Total fuel consumption |
| "GA-1" | Engine oil pressure |
| "GA-2" | Coolant temperature |
| "GA-3" | System voltage |
| "GA-4" | Fuel pressure |
| "GA-5" | RH/LH Exhaust temperature |
| "GA-6" | RH/LH Air inlet restriction |
| "GA-7" | Fuel filter differential pressure (restriction) |
| "GA-8" | Oil filter differential pressure (restriction) |
| "GA-9" | Boost pressure (inlet manifold air pressure) |
| "GA-10" | Aftercooler coolant temperature |
| "GA-11" | Air inlet temperature |
| "GA-12" | Engine oil temperature |
Service Mode (Mode 2)
Note: For a list of the diagnostic codes, see the film that is supplied with the instrument panel or see the Service Manual, "Troubleshooting" module.
This mode assists service technicians with the troubleshooting of diagnostic codes. All recorded diagnostic codes can be shown on the LCD. Inactive diagnostic codes can be cleared from the main display module's memory during Mode 2 operation.
To initiate Mode 2 operation, hold the "CLEAR/MODE" switch in the "MODE" position until "-2-" appears on the LCD.
The following three identifiers are used to specify each diagnostic code. The identifiers are displayed on the LCD.
Module Identifier (MID) - The MID identifies the module that has generated a diagnostic code. The MID is a three-digit code that is shown on the LCD. The MID is displayed for approximately one second prior to display of the Component Identifier and Failure Mode Identifier (CID-FMI). The display continuously changes between displaying the MID and the CID-FMI.
Component Identifier (CID) - The CID identifies the component or the subsystem that has generated a diagnostic code. The CID is displayed by the first four digits of the LCD.
Failure Mode Identifier (FMI) - The FMI identifies the type of diagnostic code that has been generated. The FMI is displayed on the last two digits of the LCD. A decimal point separates the FMI from the CID. The CID and the FMI are displayed immediately after the display of the MID. The CID and the FMI are displayed simultaneously.
When Mode 2 operation is initiated, the LCD shows the first diagnostic code that is available. The diagnostic code that is shown is "on-hold". When a diagnostic code is "on-hold", the display continuously changes between the MID and the CID-FMI.
Note: When no diagnostic codes are available, "- - -" is shown on the LCD.
Use the "SCROLL" switch to advance to the next recorded diagnostic code. To reveal all of the recorded diagnostic codes, continue scrolling through the display. After the final diagnostic code has been displayed, "END" will show on the LCD rather than an MID.
Note: An inactive diagnostic code may indicate an intermittent fault.
The main display module activates a "SERV CODE" display for active diagnostic codes.
- If the diagnostic code is active, the "SERV CODE" display is on.
- If the diagnostic code is not active, the "SERV CODE" display is off.
Note: Active diagnostic codes cannot be cleared from memory.
The main display module records diagnostic codes. The diagnostic codes may remain stored for future reference or the codes can be cleared from memory. To clear a logged diagnostic code, push the "MODE/CLEAR" switch to the "CLEAR" position while the code is displayed on the LCD.
Tattletale Mode (Mode 3)
This mode is useful for monitoring the ranges of the engine systems operation. The information can be used for management and maintenance of the engine.
Note: The following information is not included with the values of the tattletale: date, time and duration of the occurrence.
The main display module records the extreme value for each engine system that is monitored. A value for a system is updated when a more extreme value occurs. These values are ignored for a short period of time after each engine start-up. This allows the engine systems to stabilize before the old values can be updated with new values.
To initiate Mode 3 operation, hold the "CLEAR/MODE" switch in the "MODE" position until "-3-" appears on the LCD.
All of the gauges will display values that have been attained for the corresponding subsystems of the engine. The highest gauge readings are for values that abnormally increase. The lowest readings are for values that abnormally decrease.
The values of the gauges can be more accurately displayed with the LCD. Advance the LCD to the first value by using the "SCROLL" switch. The instrument panel will show the following displays:
- An identifier for the subsystem of the engine will be displayed. The LCD will momentarily identify the gauge with a number "-GA-1-".
- The value for the tattletale will be displayed.
- The corresponding gauge needle is activated. All of the other gauge needles default to the minimum position.
Press the "SCROLL" switch again in order to review the other tattletales.
The values of the tattletales are retained until the information is cleared from the main display module's memory.
To clear all of the tattletales from the memory, push the "MODE/CLEAR" switch to the "CLEAR" position while "- -" is displayed on the LCD. After the information is cleared, all the tattletales are reset to a nominal value. Then new extreme values can be recorded.
To clear an individual tattletale, push the "MODE/CLEAR" switch to the "CLEAR" position while the value is displayed on the LCD.
Units Mode (Mode 4)
This mode is used to change the LCD between metric units and English units. To initiate Mode 4 operation, hold the "CLEAR/MODE" switch in the "MODE" position until "-4-" appears on the LCD.
When Mode 4 is activated, the LCD will indicate the current units.
- "SI" is displayed when metric units are selected.
- "US" is displayed when English units are selected.
To toggle the units between "SI" and "US", press the "SCROLL" switch.
Harness Code Mode (Mode 5)
This mode displays the machine code for the engine model. The machine code is a two-digit representation of the harness code. The code must correspond to the sales model of the monitoring system's engine. An incorrect code will result in incorrect operation of the monitoring system. This could result in the generation of excessive diagnostic service codes.
To initiate Mode 5 operation, hold the "CLEAR/MODE" switch in the "MODE" position until "-5-" appears on the LCD. The machine code will automatically be displayed.
The machine code for the 3500C Locomotive Engine is "35".
Warning Operation
The Caterpillar Electronic Monitoring System notifies the operator of problems with the engine systems. Warning operation begins if either of the following conditions occur:
- The main display module receives a signal that indicates an abnormal operating condition.
- The main display module detects a problem with the monitoring system.
A warning is indicated by the following occurrences:
- The appropriate indicator flashes approximately nine times per second.
- The Action Alarm annunciates. The alarm is on for one second and off for two seconds, etc.
Self Test
The self test verifies that the main display module and the gauge cluster modules are operating properly. The main display module performs an automatic self test when power is supplied to the instrument panel.
The internal circuits and the outputs are automatically checked. The operator must observe the following outputs in order to determine that the outputs are operating properly:
- The indicators and the LCD are tested for approximately one second. The indicators and the LCD flash on and off.
- The Gauge Cluster modules are tested for approximately three seconds. The needles of the gauges move to half scale, to zero, and then to full scale. After the needles reach full scale, the needles return to the positions that indicate the current conditions.
- The Action Alarm annunciates one time.
After the self test, the main display module defaults to the Normal mode of operation (Mode 0).
If an output does not function properly during the self test, see the Service Manual. Consult your Caterpillar dealer for assistance.
Junction Box
The electrical system of the engine includes these main components:
- Electronic control module (ECM)
- Engine wiring harness
- Junction box
The ECM controls fuel injection according to information that is sent from sensors and the throttle.
The engine wiring harness provides an interface for the ECM and the following components:
- Fuel injectors
- Sensors
- Junction box
The junction box provides the following functions:
- Distribution of electrical power
- Interface with the locomotive control
- Interface for optional attachments
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| Illustration 10 | g00830336 |
Junction box (1) Emergency Stop button (2) Stop button (3) Overspeed verify switch (4) Engine connectors (5) Customer connector (6) Power connector (7) Service connector (8) Instrumentation connector | |
Emergency Stop button (1) - This button is used to stop the engine quickly in an emergency situation. When this button is pressed, the fuel injection is disabled and the air shutoffs are activated.
Stop button (2) - This button is used for normal stopping. When this button is pressed, the fuel injection is disabled.
Note: The air shutoffs (if equipped) are activated when an overspeed shutdown occurs.
Overspeed verify switch (3) - This switch is located inside the junction box. If this switch is activated, an overspeed shutdown will occur when the engine is operating at a minimum of 75 percent of the rated rpm. This switch is used to verify that the overspeed protection system is operating properly.
Engine connectors (4) - The junction box can be connected directly to the engine wiring harness that is located next to the ECM. The junction box may be installed remotely from the engine. The locomotive OEM connects the interconnect wiring harness from the engine wiring harness to the engine connectors on the junction box.
Customer connector (5) - This connector is the primary interface between the locomotive control and the engine. This connector provides the interface for the following items:
- Shutdown notify relay
- Start enable relay
- General alarm relay
- Throttle
- Fuel position multiplier
- Feedback for the load
- Serial data links
- A speed signal that is independent of the ECM
- Communication with the ECM for the remote emergency shutdown and normal engine shutdown
- Manual override control
| NOTICE |
|---|
The use of a power supply that is not isolated may result in failure of the electronic control module (ECM). The ECM must be powered by isolated power only. |
Note: The locomotive OEM is responsible for ensuring that the isolated power supply is provided.
Power connector (6) - This connector is for the 24 volt DC power to the junction box. The power is provided to the following components: ECM, service connector and engine monitoring system. This connector is also for variable voltage that may be needed by systems that support the engine operation. Examples of the systems for support include these items: ether, prelube and relays for starting the engine.
Service connector (7) - This connector can be used with Caterpillar electronic service tools in order to communicate with the ECM.
Instrumentation connector (8) - This connector is for use with the optional Caterpillar Instrument Panel.