3508, 3508B, 3508C, 3512, 3512B, 3512C, 3516, 3516B and 3516C Engines Caterpillar Monitoring System Caterpillar

General Information

Illustration 1	g00525916
Instrument Panel For Generator Set Engines And Marine Engines. (1) Electronic Instrument Panel. (2) Main Display Module. (3) Quad Gauge Electronic Module - STANDBY. (4) Pyrometer. (5) Ether Starting Aid Switch. (6) "SCROLL" Switch. (7) "CLEAR/MODE" switch. (8) "LH/RH" switch. (9) Gauge Cluster Module - PRIME. (10) Emergency Stop Push Button. (11) Instrument Panel Connector "A". (12) Instrument Panel Connector "B". (13) Alarm Silence Switch. (14) Alarm. (15) Gauge Cluster Module - PREMIUM. (16) Electronic Service Tool Connector. (17) Customer Connector "D". (18) Customer Connector "C". (19) Pyrometer Connector. (20) Engine Control Switch (ECS).

Illustration 2	g00574173
Instrument Panel For Locomotive Engines. (21) Electronic Instrument Panel. (22) Quad Gauge Cluster Module 3. (23) Main Display Module. (24) "SCROLL" switch. (25) "CLEAR MODE" switch. (26)" LH/RH SELECT" Switch. (27) Potentiometer (Dimmer). (28) Alarm Silence Switch. (29) Horn. (30) Gauge Cluster Module 1. (31) Gauge Cluster Module 2.

Illustration 3	g00574183
Junction Box For Locomotive Engines. (32) Emergency Stop Button (33) Stop Button (34) Overspeed Verify Switch (35) Engine Connectors (36) Customer Connector "G" (37) Power Connector (38) Service Connector (39) Instrumentation Connector

The 3500B Electronic Panel is the control center for gathering information. The 3500B Electronic Panel gathers information from the Generator Set engine that is equipped with switchgear conversion and all other engine applications. The 3500B Electronic Panel contains the items that are found in the following list.

• 3500B Instrument Modules

• Emergency Stop Push Button

• Normal Stop Push Button (Locomotives Engines)

• Instrument Module Control Switches

• Alarm

• Alarm Silence Switch

• Various Circuit Breakers

• Relays and Wiring

• Interface Connector For The Electronic Service Tool

• Interface Connector For Customers

• Engine Control Switch (ECS) (Not on Locomotive Engines)

• Dimmer (Locomotive Engines only)

Configuration

There are two standard configurations that are used with the 3500B Instrument Console. The Standby Package Generator Set with switchgear conversion has two modules that are used with the standard configuration. The other Package Generator Sets with switchgear conversion and all other engine applications will have three standard modules. There is an option for adding a fourth module and a Pyrometer (4). The two modules that are included with every instrument box are the Main Display Module (2) and the Quad Gauge Electronic Module (3). The Main Display Module (2) controls all the instruments and the Quad Gauge Cluster (3) displays the following items.

• Engine oil pressure

• Engine coolant temperature

• DC voltage of the system

• Fuel pressure in the engine

Standby Package Generator Sets display the items that are listed above on the Quad Gauge Electronic Module. The following items are displayed on the Quad Gauge Electronic Module (9) for other applications.

• Right-hand and left-hand exhaust temperature

• Right-hand and left-hand air inlet restriction

• Fuel filter restriction

• Oil filter restriction

There is an option that allows the customer to add a Premium Gauge Cluster Module (15). The Premium Gauge Cluster Module (15) for the Generator Set applications displays the following items.

• Inlet air pressure (boost)

• Aftercooler coolant temperature

• Inlet air temperature

• Engine oil temperature

The Premium Gauge Cluster Module (15) for Marine applications displays the following items.

• Inlet air pressure (boost)

• Aftercooler coolant temperature

• Marine gear oil temperature

• Marine gear oil pressure

Engine Control Switch

The Engine Control Switch (ECS) (20) has four positions. The ECS is used to control the engine. The Instrument Panels for Locomotive Engines are not equipped with the Engine Control Switch.

1. The OFF/RESET position removes power from the engine for an immediate engine shutdown. Fault indicators are reset.

2. The AUTO position allows a remote start/stop switch to be used to power up the ECM from a remote location. See the NOTE that follows Step 4. Three modes are available from the remote switch.

   • STOP sleep mode (low power consumption).

   • COOLDOWN/STOP engine cooldown (if programmed to cooldown) - stop mode.

   • MAN/START cycle crank sequence - engine running mode.

   On Generator Set applications, the ECS must be in the AUTO position to use a Customer Communication Module (CCM). A Customer Communication Module (CCM) is used toremotely start the engine. Toremotely start the engine, the operator must have a personal computer (PC). The PC is required to have the software for the customer communication module (CCM). The PC may be directly connected to the customer communication module (CCM) or the PC may be equipped for remote communications with a modem.

3. The MAN/START position begins the cycle crank sequence. The engine is allowed to continue running once the crank terminate speed is reached.

4. If the engine is programmed for cooldown mode, the COOLDOWN/STOP position places the engine in cooldown mode. Fuel injection is then terminated to stop the engine.

Note: The customer uses connector "C" (18) to wire the remote start/stop switch into the system. This allows the customer to control the engine from a remote location. Customer connector "C" (18) and customer connector "D" (17) are used to wire the customer communication module (CCM) into the system.

Emergency Stop Push Button

The Emergency Stop Push Button (10) and (32) is used to quickly stop the engine during emergency situations. The emergency stop push button (10) and (32) removes power from the engine ECM and the Main Display Module (2) and (23). Also, the emergency stop push button activates the air shutoff. The air shutoffs may not be installed.

Note: The Emergency Stop Push button is NOT to be used for normal, non-emergency shutdowns.

Normal Stop Push Button

This button is on the junction box of Locomotive Engines. The button is used for normal stopping. When this button is pressed, fuel injection is disabled.

Starting Aid Switch

If the ether system is ordered with an engine package, the instrument panel will include the Starting Aid switch (5). The Starting Aid switch (5) is used to provide the method of manually injecting ether during engine start-up. This switch is normally in the AUTO position, which allows the electronic control module (ECM) to automatically control ether injection. If the operator holds the Starting Aid switch in the MANUAL position, the electronic control module (ECM) will signal ether injection. The injection will proceed according to the strategy that is explained in the Engine Operation and Maintenance Manual.

Control Switches For The Main Display Module

The electronic panel contains three switches that are used for controlling the Main Display Module (2).

1. The "CLEAR/MODE" switch (7) or (25) is used to move between the available modes of operation. Also, the "CLEAR/MODE" switch is used to clear the information that is displayed on the Main Display Module (2) and (23). The Main Display Module (2) or (23) will cycle through the different modes of operation when the "CLEAR/MODE" Switch (7) or (25) is held down in the MODE position. When the desired mode is reached, release the "CLEAR/MODE" Switch (7) or (25). The Main Display Module (2) or (23) will remain in that mode of operation until the "CLEAR/MODE" Switch (7) or (25) is held down again. If the information that is being displayed by Main Display Module (2) or (23) is not needed, then the information should be removed from memory. The information can be cleared by holding the"CLEAR/MODE" Switch (7) and (25) up for approximately one second until the information disappears from Main Display Module (2) or (23).

2. The "SCROLL" Switch (6) and (24) is used to scroll through the various parameters that are available in a single mode. The Main Display Module (2) and (23) will scroll through the parameter display information that is available in the selected mode. When the "SCROLL" switch (6) or (24) is held in the UP position, the Main Display Module will scroll. If the continuous display of a parameter is desired, hold the "SCROLL" switch (6) or (24) in the UP position, until the desired information is displayed. Next, release the "SCROLL" Switch (6) or (24) when the desired information is displayed. The parameter information will remain displayed until Main Display Module (2) or (23) receives another switch signal.

3. "LH/RH" Switch (8) or (26) is used to display both the right-hand and left-hand parameter information on a single gauge. Right-hand values and left-hand values for the exhaust temperature measurements and inlet air restriction measurements can be displayed on the Electronic Instrument boxes that are equipped with a second Quad Gauge Module (9) or (31). When the Quad Gauge Module is displaying the parameter information for the exhaust temperature or the inlet air restriction, the "LH/RH" switch (8) or (26) can be toggled.

Alarm

The Alarm is activated by the Main Display Module. The Alarm is turned ON when there is a parameter that is out of range. The Alarm is also turned ON for active diagnostic faults.

Alarm Silence Switch

Alarm Silence Switch (13) or (28) is a push button that allows the operator to turn off Alarm (14) or (29) once the alarm has sounded. Activating the switch will silence the alarm for five minutes. After the five minute period, if the condition that initiated the alarm has not been corrected, the Alarm (14) or (29) will sound again.

Locomotive Engine Connectors

The junction box can be connected directly to the engine wiring harness that is located next to the engine 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 "C"

Customer Connector "C" (40-pin connector) (18) provides access to all customer attachments and system enhancements. Attachments that interface through this connector for Generator Set applications include the following items.

• Speed adjusts potentiometer (when the Woodward Loadshare Module is not used)

• Fuel level switch

• Battery charger fault switch

• Low coolant level switch

• Customer remote start/stop switch

• Customer remote emergency stop switch

• Inlet air temperature sender

• Engine oil temperature sender

Attachments that interface through this connector for marine applications include the following items.

• Fuel level switch

• Marine gear oil pressure

• Marine gear oil temperature

• Low coolant level switch

• Customer remote start/stop switch

• Customer remote emergency stop switch

Customer Connector "D"

There are two customer connectors that are on the bottom of the electronic instrument panel. Customer Connector "D" provides access to the battery ground. Customer Connector "D" (17) is a 24-pin connector. For marine applications, this connector also provides +Battery and a "−Battery" access. The access is for the throttle synchronization switch, the throttle position sensor, the secondary electronic control module (ECM), ready lamps, and active lamps. On single marine engine applications, a backup throttle position sensor can also be powered from this connector.

Locomotive Power Connector "F"

Note: The Locomotive OEM is responsive for ensuring that the isolated power supply is provided.

Connector "F" (37) provides 24 DCV to the junction box. Power is provided to the ECM, the service connector, and the Caterpillar 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 ether, prelube, and relays for starting the engine.

Customer Connector "G"

Connector "G" (36) is the primary interface between the locomotive control and the engine. Connector "G" provides the interface for the items that are listed below.

• Shut down 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 engine ECM

• Communication with the engine ECM for the remote emergency shutdown and normal engine shutdown

• Engine protection override switch