SENR6587-03

June 2007

Systems Operation
Testing and Adjusting
3508, 3508B, 3512, 3512B,
3516 and 3516B Engines
Caterpillar Monitoring System
2RD1-Up (Engine) 3LS1-Up (Engine) 4BW1-Up (Engine)
2TD1-Up (Engine) 3MS1-Up (Engine) 5AW1-Up (Engine)
2BM1-Up (Engine) 3NS1-Up (Engine) 2EZ1-Up (Engine)
3DM1-Up (Engine) 3PS1-Up (Engine) 6HZ1-Up (Engine)
4GM1-Up (Engine) 3RS1-Up (Engine)
5XM1-Up (Engine) 3SS1-Up (Engine)
6PM1-Up (Engine) 3TS1-Up (Engine)
7HM1-Up (Engine) 3WS1-Up (Engine)
7KM1-Up (Engine) 3XS1-Up (Engine)
7SM1-Up (Engine) 5PS1-Up (Engine)
8EM1-Up (Engine) 1NW1-Up (Engine)
8RM1-Up (Engine) 1PW1-Up (Engine)
4TN1-Up (Engine) 1TW1-Up (Engine)
6HN1-Up (Engine) 2FW1-Up (Engine)
6PN1-Up (Engine) 2GW1-Up (Engine)
6WN1-Up (Engine) 2HW1-Up (Engine)
7RN1-Up (Engine) 2JW1-Up (Engine)
8CN1-Up (Engine) 3CW1-Up (Engine)
8KN1-Up (Engine) 3DW1-Up (Engine)
9AN1-Up (Engine) 3ZW1-Up (Engine)
CBN1-Up (Engine) 4AW1-Up (Engine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SENR6587-03 3
Table of Contents

Table of Contents CID 0821 FMI 04 Display Power Supply Voltage

Below Normal - Test ............................................ 63
Alert Indicator - Troubleshoot ................................ 64
Level Switch (Coolant) - Troubleshoot .................. 66
Systems Operation Section LH/RH Switch - Troubleshoot ............................... 67
Scroll Switch - Troubleshoot ................................. 68
Panel Components ............................................... 4
Clear/Mode Switch - Troubleshoot ........................ 70
Internal Panel Components .................................. 12
Alarm Silence Switch - Troubleshoot .................... 72
Instrument Modules for Generator Set
Harness Code - Troubleshoot ............................... 73
Applications ......................................................... 14
System Self Test ................................................... 76
Instrument Modules for Marine Applications ......... 16
Module - Replace .................................................. 77
Instrument Modules for Locomotive Applications .. 18
Main Display Module Initialization - Adjust ........... 77
Alert Indicator Description ..................................... 20
Glossary of Terms ................................................. 78
Quad Gauge Module ............................................ 22
Connector Contact Description of Main Display
Senders ................................................................ 26
Module ............................................................... 80
Sensors ................................................................. 27
System Schematic ................................................ 83
Action Alarm and Alarm Silence Switch ................ 28
Electronic Control Module (Engine) ...................... 28
Modes Of Operation ............................................. 28 Index Section
Normal Mode ........................................................ 29
Numeric Readout Mode ........................................ 29 Index ..................................................................... 90
Service Mode ........................................................ 35
Tattletale Mode ..................................................... 37
Units Mode ............................................................ 38
Harness Code Mode ............................................. 38
Warning Operation ................................................ 39

Testing and Adjusting Section

Testing and Adjusting
General Information .............................................. 40
Service Tools ........................................................ 40
Electrical Components And Connector Locations .. 41
Accessing Diagnostic Information ......................... 41
Troubleshooting Diagnostic Codes ....................... 42
Initial Troubleshooting Procedure ......................... 43
CID 0096 FMI 03 Level Switch (Fuel) Voltage Above
Normal - Test ....................................................... 43
CID 0127 FMI 08 Pressure Sensor (Transmission
Oil) Abnormal Signal - Test ................................. 45
CID 0172 FMI 04 Temperature Sender (Inlet Air)
Voltage Below Normal - Test ............................... 47
CID 0175 FMI 04 Temperature Sender (Engine Oil)
Voltage Below Normal - Test ............................... 48
CID 0175 FMI 08 Temperature Sender (Engine Oil)
Abnormal Signal - Test ........................................ 49
CID 0177 FMI 08 Temperature Sensor (Transmission
Oil) Abnormal Signal - Test ................................. 51
CID 0248 FMI 02 Cat Data Link Incorrect - Test ... 54
CID 0263 FMI 03 Sensor Power Supply Voltage
Above Normal - Test ........................................... 55
CID 0263 FMI 04 Sensor Power Supply Voltage
Below Normal - Test ............................................ 56
CID 0271 FMI 03 Alarm (Action) Voltage Above
Normal - Test ....................................................... 57
CID 0271 FMI 05 Alarm (Action) Current Below
Normal - Test ....................................................... 58
CID 0271 FMI 06 Alarm (Action) Current Above
Normal - Test ....................................................... 59
CID 0819 FMI 02 Display Data Link Incorrect -
Test ..................................................................... 60
CID 0821 FMI 03 Display Power Supply Voltage
Above Normal - Test ........................................... 61
4 SENR6587-03
Systems Operation Section

Systems Operation Section

i02784782

Panel Components
SMCS Code: 7451

General Information

g00525916
Illustration 1
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).
SENR6587-03 5
Systems Operation Section

g00574173
Illustration 2
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.
6 SENR6587-03
Systems Operation Section

• 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
g00574183
the following items.
Illustration 3
Junction Box For Locomotive Engines. • Engine oil pressure
(32) Emergency Stop Button
(33) Stop Button • Engine coolant temperature
(34) Overspeed Verify Switch
(35) Engine Connectors
(36) Customer Connector “G” • DC voltage of the system
(37) Power Connector
(38) Service Connector • Fuel pressure in the engine
(39) Instrumentation Connector
Standby Package Generator Sets display the items
The 3500B Electronic Panel is the control center for that are listed above on the Quad Gauge Electronic
gathering information. The 3500B Electronic Panel Module. The following items are displayed on
gathers information from the Generator Set engine the Quad Gauge Electronic Module (9) for other
that is equipped with switchgear conversion and all applications.
other engine applications. The 3500B Electronic
Panel contains the items that are found in the • Right hand and left hand exhaust temperature
following list.
• Right hand and left hand air inlet restriction
• 3500B Instrument Modules
• Fuel filter restriction
• Emergency Stop Push Button
• Oil filter restriction
• Normal Stop Push Button (Locomotives Engines)
There is an option that allows the customer to add a
• Instrument Module Control Switches Premium Gauge Cluster Module (15). The Premium
Gauge Cluster Module (15) for the Generator Set
• Alarm applications displays the following items.

• Alarm Silence Switch • Inlet air pressure (boost)

• Various Circuit Breakers • Aftercooler coolant temperature
• Relays and Wiring • Inlet air temperature
• Interface Connector For The Electronic Service • Engine oil temperature
Tool
The Premium Gauge Cluster Module (15) for Marine
• Interface Connector For Customers applications displays the following items.
SENR6587-03 7
Systems Operation Section

• Inlet air pressure (boost) Note: The customer uses connector “C” (18) to wire
the remote start/stop switch into the system. This
• Aftercooler coolant temperature allows the customer to control the engine from a
remote location. Customer connector “C” (18) and
• Marine gear oil temperature customer connector “D” (17) are used to wire the
customer communication module (CCM) into the
• Marine gear oil pressure system.

Engine Control Switch Emergency Stop Push Button

The Engine Control Switch (ECS) (20) has four The Emergency Stop Push Button (10) and (32) is
positions. The ECS is used to control the engine. The used to quickly stop the engine during emergency
Instrument Panels for Locomotive Engines are not situations. The emergency stop push button (10)
equipped with the Engine Control Switch. and (32) removes power from the engine ECM and
the Main Display Module (2) and (23). Also, the
1. The OFF/RESET position removes power from emergency stop push button activates the air shutoff.
the engine for an immediate engine shutdown. The air shutoffs may not be installed.
Fault indicators are reset.
Note: The Emergency Stop Push button is NOT to
2. The AUTO position allows a remote start/stop be used for normal, non-emergency shutdowns.
switch to be used to power up the ECM from a
remote location. See the NOTE that follows Step Normal Stop Push Button
4. Three modes are available from the remote
switch.
This button is located on the junction box of
Locomotive Engines. The button is used for normal
• STOP sleep mode (low power consumption). stopping. When this button is pressed, fuel injection
is disabled.
• COOLDOWN/STOP engine cooldown (if
programmed to cooldown) - stop mode.
Starting Aid Switch
• MAN/START cycle crank sequence - engine
running mode. If the ether system is ordered with an engine package,
the instrument panel will include the Starting Aid
On Generator Set applications, the ECS must be switch (5). The Starting Aid switch (5) is used to
in the AUTO position in order to use a Customer provide the method of manually injecting ether during
Communication Module (CCM). A Customer engine start-up. This switch is normally in the AUTO
Communication Module (CCM) is used in order to position, which allows the electronic control module
remotely start the engine. In order to remotely start (ECM) to automatically control ether injection. If the
the engine, the operator must have a personal operator holds the Starting Aid switch in the MANUAL
computer (PC). The PC is required to have the position, the electronic control module (ECM) will
software for the customer communication module signal ether injection. The injection will proceed
(CCM). The PC may be directly connected to the according to the strategy that is explained in the
customer communication module (CCM) or the Engine Operation And Maintenance Manual.
PC may be equipped for remote communications
with a modem. Control Switches For The Main
3. The MAN/START position begins the cycle crank Display Module
sequence. The engine is allowed to continue
running once the crank terminate speed is The electronic panel contains three switches that are
reached. used for controlling the Main Display Module (2).

4. If the engine is programmed for cooldown mode,

the COOLDOWN/STOP position places the
engine in cooldown mode. Fuel injection is then
terminated in order to stop the engine.
8 SENR6587-03
Systems Operation Section

1. The “CLEAR/MODE” switch (7) or (25) is used to Alarm Silence Switch

move between the available modes of operation.
Also, the “CLEAR/MODE” switch is used to Alarm Silence Switch (13) or (28) is a push button
clear the information that is currently displayed that allows the operator to turn off Alarm (14) or (29)
on the Main Display Module (2) and (23). The once the alarm has sounded. Activating the switch
Main Display Module (2) or (23) will cycle will silence the alarm for five minutes. After the five
through the different modes of operation when minute period, if the condition that initiated the alarm
the “CLEAR/MODE” Switch (7) or (25) is held has not been corrected, the Alarm (14) or (29) will
down in the MODE position. When the desired sound again.
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
Locomotive Engine Connectors
until the “CLEAR/MODE” Switch (7) or (25) is
The junction box can be connected directly to the
held down again. If the information that is being
engine wiring harness that is located next to the
displayed by Main Display Module (2) or (23)
engine ECM. The junction box may be installed
is not needed, then the information should be
remotely from the engine. The Locomotive OEM
removed from memory. The information can be
connects the interconnect wiring harness from the
cleared by holding the “CLEAR/MODE” Switch (7)
engine wiring harness to the engine connectors on
and (25) up for approximately one second until the
the junction box.
information disappears from Main Display Module
(2) or (23).
Customer Connector “C”
2. The “SCROLL” Switch (6) and (24) is used to scroll
through the various parameters that are available Customer Connector “C” (40 pin connector) (18)
in a single mode. The Main Display Module (2) provides access to all customer attachments and
and (23) will scroll through the parameter display system enhancements. Attachments that interface
information that is available in the selected mode. through this connector for Generator Set applications
When the “SCROLL” switch (6) or (24) is held include the following items.
in the UP position, the Main Display Module will
scroll. If the continuous display of a parameter is • Speed adjust potentiometer (when the Woodward
desired, hold the “SCROLL” switch (6) or (24) in Loadshare Module is not used)
the UP position, until the desired information is
displayed. Next, release the “SCROLL” Switch (6) • Fuel level switch
or (24) when the desired information is displayed.
The parameter information will remain displayed • Battery charger fault switch
until Main Display Module (2) or (23) receives
another switch signal. • Low coolant level switch
3. “LH/RH” Switch (8) or (26) is used to display both • Customer remote start/stop switch
the right hand and left hand parameter information
on a single gauge. Right hand values and left hand • Customer remote emergency stop switch
values for the exhaust temperature measurements
and inlet air restriction measurements can be • Inlet air temperature sender
displayed on the Electronic Instrument boxes
that are equipped with a second Quad Gauge • Engine oil temperature sender
Module (9) or (31). When the Quad Gauge Module
is displaying the parameter information for the Attachments that interface through this connector for
exhaust temperature or the inlet air restriction, the marine applications include the following items.
“LH/RH” switch (8) or (26) can be toggled.
• Fuel level switch
Alarm • Marine gear oil pressure
The Alarm is activated by the Main Display Module.
The Alarm is turned ON when there is a parameter • Marine gear oil temperature
that is out of range. The Alarm is also turned ON for
active diagnostic faults. • Low coolant level switch
• Customer remote start/stop switch
• Customer remote emergency stop switch
SENR6587-03 9
Systems Operation Section

Table 1 Table 2
Generator Set Applications - Customer Marine Applications - Customer Connector “C”
Connector “C”
Pin Number Function
Pin Number Function
1 - 2 Throttle Synchronization Switch
1 - 13 Unassigned
3 Primary Throttle Position Sensor Signal
14 Generator Set Online
4 Backup Throttle Position Sensor Signal
15 Unassigned
5 Secondary ECM Ready Lamp Signal
16 Battery Charger Fault
6 Secondary ECM Active Lamp Signal
17 Unassigned
7 Connect to other engine Customer
18 Fuel Level Switch Connector “C” Pin 8
19 - 21 Digital Return 8 Connect to other engine Customer
Connector “C” Pin 7
22 - 24 Unassigned
9 Connect to other engine Customer
25 Sensor Supply Voltage (Coolant Level) Connector “C” Pin 10
26 Unassigned 10 Connect to other engine Customer
27 Sender (Air Inlet Temperature) Connector “C” Pin 10

28 Sensor Signal (Coolant Level) 11 CAT Data Link (−)

29 - 32 Remote Start/Stop Switch 12 CAT Data Link (+)

33 - 34 Remote Shutdown Switch 13 Shutdown Notify Relay Common

35 Engine Oil Temperature Sensor 14 Unassigned

36 Engine Speed Signal From Woodward 15 Shutdown Notify Relay Normally

Loadshare Module Pin 19 Closed

37 - 39 Speed Adjust Potentiometer 16 Unassigned

Connections To Speed Control 17 Shutdown Notify Relay Normally Open
40 Optional DeNox System Power 18 Fuel Level Switch
19 - 21 Digital Return
22 Unassigned
23 Sensor Supply Voltage (Transmission
Oil Pressure)
24 Sensor Voltage (Transmission
Oil Temperature)
25 Sensor Supply Voltage (Coolant Level)
26 Sensor Signal (Transmission
Oil Pressure)
27 Sensor Signal (Transmission
Oil Temperature)
28 Sensor Signal (Coolant Level)
29 - 32 Remote Starting Switch
33 - 34 Remote Shutdown Switch
35 - 40 Unassigned
10 SENR6587-03
Systems Operation Section

Customer Connector “D” Table 4

Marine Applications - Customer Connector “D”
There are two customer connectors that are located
on the bottom of the electronic instrument panel. Pin Number Function Type
Customer Connector “D” provides access to the 1 - 2 Throttle Switch +Battery
battery ground. Customer Connector “D” (17) is Synchronization
a 24 pin connector. For marine applications, this Switch
connector also provides +Battery and a “−Battery”
access. The access is for the throttle synchronization 3 Primary Throttle Switched
switch, the throttle position sensor, the secondary Position Sensor +Battery
electronic control module (ECM), ready lamps and 4 Backup Throttle Switched
active lamps. On single marine engine applications, a Position Sensor +Battery
backup throttle position sensor can also be powered
5 Secondary ECM Switched
from this connector.
Ready Lamp +Battery
Table 3 6 Secondary ECM Switched
Generator Set Applications - Customer Ready Lamp +Battery
Connector “D” 7 - 12 Unassigned Unswitched
Pin Number Function Type +Battery

1 - 16 Unassigned Unassigned 13 - 14 Throttle −Battery

Synchronization
17 - 20 Ground −Battery Switch
21 - 24 Unassigned Unassigned 15 Primary Throttle −Battery
Position Sensor
16 Backup Throttle −Battery
Position Sensor
17 Fuel Level Switch −Battery
18 Transmission Oil −Battery
Pressure Switch
19 Transmission −Battery
Oil Temperature
Sensor
20 Coolant Level −Battery
Sensor
21 - 24 Unassigned −Battery

Locomotive Power Connector “F”

NOTICE
The use of a power supply that is not isolated may
result in failure of the eletronic control module (ECM).

The ECM must be powered by isolated power only.

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.
SENR6587-03 11
Systems Operation Section

Table 5 Table 6
Locomotive Applications - Customer Connector “F” Locomotive Applications - Customer Connector “G”
Pin Number Function Type Pin Number Function
1 Unassigned 1 Start Enable
2 Power Minus +Battery 2 Start Enable
3 Battery Positive +Battery 3 Emergency Shutdown C
4 Unassigned 4 Engine Shutdown
5 Battery Negative −Battery 5 Start Enable
6 Power Plus +Battery 6 Engine Shutdown
7 Emergency Shutdown D
Customer Connector “G” 8 General Alarm

Connector “G” (36) is the primary interface between 9 Global CAT Link + (not used)
the locomotive control and the engine. Connector “G” 10 Shield
provides the interface for the items that are listed
below. 11 CAN −
12 CAN +
• Shut down notify relay
13 General Alarm
• Start enable relay 14 Local CAT Data Link (−)
15 Shutdown Notify (COM)
• General alarm relay
16 Shutdown Notify (NC)
• Throttle
17 Shutdown Notify (NO)
• Fuel position multiplier 18 General Alarm (COM)

• Feedback for the load 19 Load Feedback

20 - 23 Not Used
• Serial data links
24 Torque Limit
• A speed signal that is independent of the engine 25 Global CAT Data Link (−)
ECM
26 Not Used
• Communication with the engine ECM for the 27 Local CAT Data Link (+)
remote emergency shutdown and normal engine
shutdown 28 Not Used
29 Throttle
• Engine protection override switch
30 Magnetic Pickup (+)
31 Magnetic Pickup (−)
32 Shield
33 - 36 Not Used
37 Digital Reference
12 SENR6587-03
Systems Operation Section

i01024778 The MANUAL START CRANK SWITCH (2) permits

cranking of the engine by the operator while other
Internal Panel Components controls or protection systems are being overridden.
Therefore, the starting motors can be engaged even
SMCS Code: 1408; 7451 when the engine control switch is in the OFF/RESET
position. Also, the starting motors can be engaged
Switches when the engine ECM has completed the cycle crank
sequence or when the engine ECM has completed
Inside the electronic instrument panel in the upper a remote shutdown command. The “Manual Start
left hand corner, there are three switches. The Crank” switch has the following uses.
switches are used to perform the functions below for
Generator Set applications. • System troubleshooting

• Manual Start Crank Switch (MANCS) (2) • Engine maintenance

• Overspeed Verify Switch (OSS) (3) • On engines that are equipped with two electronic
control modules, the switch will restart the engine
• High/Low Idle Switch (LIS) (1) when the backup engine control module (ECM) is
in control. the switch will restart the engine.
For marine applications, the switches are used for
the functions that are listed below. Only marine propulsion engines are equipped with
more than one ECM (two). Otherwise, the Manual
• Manual Start Crank Switch (MANCS) (2) Start Crank switch should not be used for normal
operation of the engine.
• Overspeed Verify Switch (OSS) (3)
Note: The Manual Start Crank Switch must be used
• Prelube Override Switch (PLOS) (1) to start the engine when the backup ECM is in control.

• Engine Protection Override Switch (EPOS) (4). The Engine Protection Override Switch allows the
This switch is used on marine propulsion engines operator to override the strategies for protection
that were built after April 1997 only. of the propulsion engine Caterpillar Monitoring
System. The switch is provided for use in emergency
situations when the engine must be operated at
full capacity immediately. The switch may be used
during a derate condition or a shutdown condition.
The switch may not be used during an overspeed
shutdown. The switch may also be used to prevent
an engine shutdown during critical maneuvers.

The Engine Protection Override Switch is a

two-position ON/OFF switch. When the Engine
Protection Override Switch is in the OFF position, the
Caterpillar Monitoring System will operate normally.

When the Engine Protection Override Switch is in the

ON position, the Engine Protection Override Switch is
Illustration 4
g00526769 disabled. The warnings and the overspeed shutdown
will continue to function normally. When the Engine
Note: The Prelube Override Switch is present only if Protection Override Switch is in the ON position, the
the prelube pump (attachment) is part of the engine engine will perform as though there are no active
package. The parameter of the prelube pump must derates or no active shutdowns. If the engine has
be turned ON by the electronic service tool for this already had a shutdown, the engine can be restarted.
function to work. The alarm conditions and the events will continue
to function normally.

When the Engine Protection Override Switch is

placed in the ON position, an event will be logged in
the ECM. An event will be logged in the ECM when
the switch is returned to the OFF position. No delay
is required for use of the Engine Protection Override
Switch.
SENR6587-03 13
Systems Operation Section

The OVERSPEED VERIFY Switch (3) allows the • alternator circuit

operator to verify that the overspeed protection
system is properly working. When the switch is • customer power circuit
activated, the engine ECM will perform an engine
overspeed shutdown at 75 percent of the engine • secondary ECM circuit
overspeed trip point. The overspeed verify switch
is intended to be used for troubleshooting and Relays are used in order to control the following
verification of engine protection systems. subsystem power requirements.

The “HIGH/LOW” Idle Switch (1) allows the operator • mag relays for starter circuits
of the Generator Set to hold the engine speed at the
low idle setting. The electronic service tool is used to • relays for air shutoff circuits (not available on
program the low idle setting. When the “HIGH/LOW” Locomotive)
Idle Switch is activated, the engine speed will be
governed at the low idle setting. If the “HIGH/LOW” • master relays and slave relays for prelube pump
Idle Switch is deactivated, the engine speed will be circuits (attachment) (not available on Locomotive)
governed to the high idle setting. The “HIGH/LOW”
Idle Switch is intended to be used for troubleshooting. • relay for the main display module circuit (not
available on Locomotive)
The PRELUBE OVERRIDE Switch (1) allows the
operator of a marine propulsion engine to override • relay for ECM circuit (not on Locomotive)
the prelube pump sequence during normal engine
start-up. The override will occur if there is an attached • relay for secondary ECM circuit (Marine only)
prelube pump as part of the engine system. The
engine ECM will not initiate an engine prelube • relays for ether starting aid pull-in circuits and ether
sequence prior to cranking the engine, when the hold-in circuits (non-marine Generator Sets only)
prelube override switch is activated. The engine (attachment)
ECM will immediately begin to crank the engine
without prelubing first. The prelube override switch is • shutdown notify
intended to be used for immediate engine starting
during emergency situations. • Programmable Relay Control Module (PRCM) (not
on Locomotive)
Note: Inside the Locomotive Junction Box, there is
one switch in the middle of the box. The switch is • “DeNOx” (non-marine Generator Set only)
used for verification of engine overspeed. (attachment)

Circuit Breakers, Relays, and • customer power (marine only) (not on Locomotive)
Wiring • General Alarm (Locomotive only)
A number of circuit breakers are inside the electronic
instrument panel that are used to protect the electrical
system and the electrical wiring. The following circuits
are protected by circuit breakers.

• starting circuit
• battery circuit
• relay circuit
• starter relay circuit
• ECM circuit
• Programmable Relay Control Module (PRCM)
• “DeNOx” (non-marine Generator Set only)
• main display module circuit
• control switch circuit
14 SENR6587-03
Systems Operation Section

i01025043

Instrument Modules for

Generator Set Applications
SMCS Code: 7450; 7451

g00527017
Illustration 5
Generator Set Main Display Module - Caterpillar Monitoring System
(1) Shutdown/Diagnostic. (2) System DC Voltage. (3) Overspeed. (4) Low Coolant Level. (5) Overcrank. (6) Not in AUTO. (7) Low Fuel Level.
(8) System DC Voltage. (9) Oil Pressure. (10) Coolant Temperature. (11) Low Oil Pressure. (12) High Coolant Temperature. (13) Low Coolant
Temperature. (14) Fuel Pressure. (15) Display Area. (16) Exhaust Temperature. (17) Aftercooler Temperature. (18) Fuel Filter. (19) Air Inlet
Restriction (“RH/LH”). (20) Oil Filter Restriction. (21) Inlet Air Pressure (Boost). (22) Inlet Air Temperature. (23) Engine Oil Temperature.

The Caterpillar Monitoring System for Generator Set The main display module is the brain of the system.
applications and Jacket Water Aftercooler Systems The main display module receives information from
(JWAC) without marine gear sensors include the the switches, sensors and other electronic controls
following items. that are on the engine that uses the CAT Data Link.
The main display module processes this information
• A main display module and the main display module outputs the information
to the gauge clusters or the alarm. The engine
• Up to three gauge modules systems status and the system diagnostic information
are shown to the operator through the components
• Various switches and sensors of the display.

• An alarm The display window on the main display module

indicates the following items.
SENR6587-03 15
Systems Operation Section

• °F
• °C
• kPa
• PSI
• RPM
• LITER
• GALLON PER HOUR (GPH)
• −10
• VOLTS
• “Hour Meter system”
• “SERV CODE”
• Six digit display area
The type of information that is shown is dependent
on the display mode. The indicators are turned
ON or the indicators are turned OFF in order to
correspond with the information that is shown on the
six digit readout. The diagnostic codes for the engine
ECM and the Caterpillar Monitoring System can be
displayed on the six digit display area. The display
also provides the number of operational hours for the
engine, engine speed (RPM), and information for the
individual gauges. An active system diagnostic fault is
indicated by illuminating the “SERV CODE” indicator.
16 SENR6587-03
Systems Operation Section

i01025233

Instrument Modules for Marine

Applications
SMCS Code: 7450; 7451

g00527132
Illustration 6
(1) Shutdown/Diagnostic. (2) System Voltage. (3) Overspeed. (4) Low Coolant Level. (5) Marine Gear Oil Pressure. (6) Marine Gear Oil
Temperature. (7) Low Fuel Level. (8) System Voltage. (9) Oil Pressure. (10) Coolant Temperature. (11) Low Oil Pressure. (12) High Coolant
Temperature. (13) Low Coolant Temperature. (14) Fuel Pressure. (15) Display Area. (16) Exhaust Temperature. (17) Aftercooler Coolant
Temperature. (18) Fuel Filter Restriction. (19) Air Inlet Restriction. (20) Oil Filter Restriction. (21) Inlet Air Pressure (Boost). (22) Marine Gear
Oil Temperature. (23) Marine Gear Oil Pressure.

The Caterpillar Monitoring System for Marine The Main Display Module processes this information
applications consists of the items that are listed and the Main Display Module outputs the information
below. to the gauge clusters. The Main Display Module also
outputs the information to the alarm. The type of
• Main display module information that is shown is dependent on the display
mode. The display components show the engine
• Up to three gauge modules systems status to the operator. Also, the display
components show the system diagnostic information
• Various switches to the operator. The display area on the Main Display
Module indicates the following items.
• Various sensors
• °F
• Other electronic controls on the engine that use
the CAT Data Link • °C
SENR6587-03 17
Systems Operation Section

• kPa
• PSI
• RPM
• LITER
• “GAL/H”
• −10
• VOLTS
• Hour Meter symbol
• “SERV CODE”
• Six digit display area
These indicators are turned ON or these indicators
are turned OFF in order to correspond with the
information that is being shown on the six digit
display area. The six digit display area is used to
show Diagnostic Codes for the engine ECM and
the Caterpillar Monitoring System. The engine
operational hours, engine speed, and numerical
values for the gauges can also be displayed.
An active system diagnostic fault is indicated by
illuminating the “SERV CODE” indicator.
18 SENR6587-03
Systems Operation Section

i01033309

Instrument Modules for

Locomotive Applications
SMCS Code: 7450; 7451

g00533383
Illustration 7
(1) Low Oil Pressure. (2) Engine Systems Status. (3) High Coolant Temperature. (4) System Voltage. (5) Low Coolant Temperature. (6)
Overspeed. (7) High Aftercooler Coolant Temperature. (8) Fuel Filter Restriction. (9) Inlet Air Temperature. (10) Fuel Pressure. (11) Display
Area. (12) Coolant Temperature. (13) Fuel Pressure. (14) Engine Oil Pressure. (15) System Voltage. (16) Air Inlet Restriction. (17) Oil Filter
Restriction. (18) Fuel Filter Restriction. (19) Exhaust Temperature. (20) Oil Pressure. (21) Inlet Air Temperature. (22) Aftercooler Coolant
Temperature. (23) Inlet Air Pressure.

The Caterpillar Electronic Monitoring System for The Main Display Module is the brain of the system.
Locomotive applications contains the items that are This module receives information from the switches,
listed below. sensors and other electronic controls that are on the
engine through the CAT Data Link. The Main Display
• Main display module Module processes this information and the Main
Display Module outputs the information to the gauge
• Three gauge modules clusters. The Main Display Module also outputs the
information to the Alarm. The engine systems status
• Various switches and the system diagnostic information are shown to
the operator through the components of the display.
• Various sensors The type of information that is shown is dependent
on display mode.
• Action Alarm
SENR6587-03 19
Systems Operation Section

The display area on the main module indicates the

following items.

• °F
• °C
• kPa
• psi
• RPM
• LITER
• “GAL/H”
• −10
• VOLTS
• Hour Meter symbol
• “SERV CODE”
• Six digit display area
The six digit display area displays Diagnostic
Codes for the engine ECM and the Caterpillar
Monitoring System. The display also provides the
engine operational hours and engine speed (RPM).
Numerical values for the individual gauges are also
displayed on the six digit display area. An active
system diagnostic fault is indicated when the “SERV
CODE” is ON.
20 SENR6587-03
Systems Operation Section

i01033507

Alert Indicator Description

SMCS Code: 7451

g00532229
Illustration 8

The operator is notified of abnormal engine operating This lamp indicates that there is an active diagnostic
conditions by the Main Display Module. The Main code present, an event present, or the engine ECM
Display Module flashes the Alert Indicators ON and has initiated a shutdown. The information is received
OFF. The Main Display Module uses the signals from from the engine ECM through the CAT Data Link.
the following sources.
Note: Diagnostics can be viewed from the main
• switch inputs display module. Events can not be viewed from the
main display module. Events can be viewed with the
• sensor inputs CAT Electronic Service Tool.

• sender inputs Low System Voltage - red

• engine ECM This lamp indicates that the DC Voltage of the system
or the voltage of the alternator is low.
The Main Display Module receives information from
the engine ECM through the CAT Data Link. The Note: The default value for the trip point is
information is used to determine when a condition programmable. The Electronic Service Tool can
requires flashing a lamp. When an indicator flashes, be used to reprogram this setting to values that
an abnormal engine condition exists. are between 20 DCV and 22 DCV. The information
about the low system voltage is received from the
Engine System Status - red engine ECM through CAT Data Link. The information
about the system voltage may also be received
Active System Diagnostic/Shutdown - red from a “Battery Charger Failure” switch input that is
connected to pin 20 of the connector for the Main
Display Module. The “Battery Charger Fault” switch
must be installed by the customer.
SENR6587-03 21
Systems Operation Section

Engine Overspeed - red This lamp illuminates when the fuel filter restriction
pressure is high. The filter is plugged when the
This lamp indicates that the engine ECM has pressure is high. The information is received from
detected an engine overspeed condition. the engine ECM through the CAT Data Link. The
default value for the trip point is programmable. For
Note: The default value for the trip point is more information about the default values, refer to
programmable. The Engine Overspeed can be the Troubleshooting Guide.
reprogrammed to a value that is between 1200 rpm
and 2400 rpm with the Electrical Service Tool. The Low Fuel Pressure - red
information is received from the ECM through the
CAT data link. For more information about the engine This lamp illuminates when the fuel pressure is low.
ECM and the setpoints, refer to the Troubleshooting The information is received from the engine ECM
Guide. through the CAT Data Link.

Overcrank - red High Aftercooler Coolant Temperature - amber

Generator Set Only - This lamp illuminates when This lamp illuminates when the engine aftercooler
the engine ECM detects that the engine did not start coolant temperature is high. The information is
after cranking or the engine did not start after cycle received from the engine ECM through the CAT
cranking for the programmed limit. If the engine Data Link. The default value for the trip point is
fails to start within a programmed amount of time, programmable. For more information about the
the engine ECM will stop the starting sequence. default values, refer to the Troubleshooting Guide.
The Main Display Module flashes the Overcrank
fault indicator. Another attempt to start the engine High Inlet Air Temperature - amber
cannot be made without placing the Engine Control
Switch (ECS) in the OFF/RESET position first. The This lamp illuminates when the Inlet Air temperature
information about an Overcrank is received from the in the air is too high. The information is received from
engine ECM through the CAT data link. a temperature sender.

Not In AUTO - red Low Oil Pressure - amber

Generator Set Only - This lamp indicates that the This lamp illuminates when the engine oil pressure
Engine Control Switch is not in the AUTO position. is low.
Remote starting of the engine is only possible when
the ECS is in the AUTO position. The information is Note: The default value for the trip point is
received from the engine ECM through the CAT Data programmed in the factory. The default value is
Link. based on a map of minimum oil pressure versus
engine speed. This value cannot be reprogrammed.
Marine Gear Oil Pressure - red The information is received from the engine ECM
through the CAT Data Link.
Marine Propulsion Only - This lamp indicates that the
marine gear transmission oil pressure is low. High Coolant Temperature - amber

Note: The default value for the trip point is Note: The trip point for this value is programmable.
programmable. The default value is reprogrammed The Electronic Service Tool may be used for
with the Electronic Service Tool. The information reprogramming the trip point. The information is
is received from the Marine Gear Transmission Oil received from the engine ECM through the CAT Data
Temperature Sensor. For more information about the Link. For more information about programming the
default values, refer to the Troubleshooting Guide. trip point, refer to the Troubleshooting Guide.

Engine System Status - red Low Coolant Temperature - amber

This lamp illuminates when the engine ECM has This lamp illuminates when the engine coolant
detected an active diagnostic code that is present. temperature is low.
An active event may also be present. The information
is received from the engine ECM through the CAT Note: The default value for the trip point is
Data Link. programmable. The Electronic Service Tool can be
used to reprogram the trip point. The information is
Fuel Filter Restriction - red received from the engine ECM through the CAT Data
Link. For more information about programming the
trip point, refer to the Troubleshooting Guide.

Low Coolant Level - amber

22 SENR6587-03
Systems Operation Section

This lamp illuminates when the engine coolant level

sensor is not submerged in coolant. The engine
coolant level sensor is customer supplied. The
information is received from the Coolant Level
Sensor.

Low Fuel Level - amber

This lamp illuminates when the contacts for the fuel

level switch open. The contacts for the low fuel level
switch are customer supplied. The information is
received from the Fuel Level Switch.

i01029663

Quad Gauge Module

SMCS Code: 7450; 7451

The Quad Gauge Electronic Modules show the

information that is received from the sensors.
Information that is received through the CAT data link
from the sensors, senders, or the engine ECM is
used to drive the gauge needles. The needles will
point straight up under normal conditions.

Harness Codes are used by the Main Display Module

to determine the number of Gauge Cluster Modules
that are present. Harness Codes also indicate
whether optional sensors are installed and whether
the engine is “JWAC” or “SCAC”. Engine applications
that are equipped with Prime Gauge Cluster Modules
imply that the Standby Gauge Cluster Modules are
also present. The Standby Quad Gauge Cluster
includes gauge 1 through gauge 4. The Prime Quad
Gauge Cluster includes gauge 1 through gauge 8.
The Premium Quad Gauge Cluster includes gauge
1 through gauge 12. The following charts show the
Harness Codes for Standby options, Prime options,
and Premium options.

A panel is provided that gives the technician access

to Terminal Block 2 (TB-2) to change the harness
code. The harness code is changed by selecting
which pins are open and which pins are grounded.
Grounds can be left open while selecting the harness
code. The grounds should not be left open on the
harness code pins.
SENR6587-03 23
Systems Operation Section

Table 7
Application Mode 5 Harness Connections On The 40 Pin Caterpillar Monitoring System Connector
Code Display
Pin 31 Pin 03 Pin 12 Pin 22 Pin 16 Pin 6
Generator Engine (1) 3 Open Open Ground Ground Ground Ground
with Standby Panel
Generator Engine(1) 5 Open Ground Open Ground Ground Ground
with Prime Panel
Generator Engine(1) 6 Ground Open Open Ground Ground Ground
with Premium Panel
And SCAC
Generator Engine(1) 7 Open Open Open Ground Ground Ground
with Premium Panel
And JWAC
Marine Propulsion 9 Open Ground Ground Open Ground Ground
Engine with Premium
Panel And SCAC
Marine Propulsion 10 Ground Open Ground Open Ground Ground
Engine with Prime
Panel And Marine
Gear Sensors
Marine Propulsion 11 Open Open Ground Open Ground Ground
Engine with Prime
Panel And No Marine
Gear Sensors
Marine Propulsion 12 Ground Ground Open Open Ground Ground
Engine with Premium
Panel And JWAC
Locomotive Engine 35 Open Open Ground Ground Ground Open
(1) Includes Marine Auxiliary

Note: Reference Testing And Adjusting, “Connector Quad Gauge Module For Standby
Contact Description Of Main Display Module” for
more information about the Connector Contacts for
Generator Set Applications
Generator Sets. Reference Testing And Adjusting,
“Connector Contact Description Of Main Display
Module” for more information about the Connector
Contacts for Marine Engines. Reference Testing
And Adjusting, “Connector Contact Description Of
Main Display Module” for more information about
Locomotive Engines.

g00530411
Illustration 9

Engine Oil Pressure (1)

24 SENR6587-03
Systems Operation Section

This module displays engine oil pressure over a Quad Gauge Module For Prime
range of 100 kPa (14.5 psi) to 600 kPa (87 psi).
Generator Set Applications
When the needle is pointing straight up, the value for
the gauge equals 400 kPa (58 psi).

The information is received from the engine ECM

through the CAT Data Link.

Engine Coolant Temperature (2)

This engine coolant temperature gauge displays

engine coolant temperature over a range of 60°C
(140°F) to 120°C (248°F).

When the needle is pointing straight up, the value

for the gauge equals 90°C (194°F). The information
is received from the engine ECM through the CAT
Data Link.

System Voltage(3)

This gauge displays battery voltage or charging

system voltage over a range of 18 DCV to 32 DCV.
g00530412
Illustration 10
When the needle is pointing straight up, the value for
the gauge equals 26 DCV. “RH/LH” Exhaust Temperature (1)

The information is received from the engine ECM This module displays the exhaust temperature over a
through the CAT Data Link. range of 400°C (752°F) to 750°C (1382°F).

Fuel Pressure (4) When the needle is pointing straight up, the value for
the gauge equals 600°C (1112°F).
This gauge displays fuel pressure over a range of
200 kPa (29 psi) to 600 kPa (87 psi). The information is received from the engine ECM
through the CAT Data Link.
When the needle is pointing straight up, the value
for the gauge equals 500 kPa (72.5 psi) for all “RH/LH” Air Inlet Restriction (2)
applications except the Locomotive engine.
This module displays engine air inlet filter restriction
When the needle is pointing straight up, the value over a range of 0 kPa (0 psi) to 10 kPa (1.45 psi).
for the gauge is 400 kPa (58 psi) for Locomotive
applications . When the needle is pointing straight up, the value for
the gauge equals 3 kPa (.44 psi).

The information is received from the engine ECM

through the CAT Data Link.

Fuel Filter Restriction(3)

This module displays fuel filter restriction over a

range of 20 kPa (2.9 psi) to 140 kPa (20.3 psi).

The information is received from the engine ECM

through the CAT Data Link.

Oil Filter Restriction (4)

This module displays oil filter restriction over a range

of 20 kPa (2.9 psi) to 150 kPa (21.75 psi).
SENR6587-03 25
Systems Operation Section

When the needle is pointing straight up, the value for The information is received from the engine ECM
the gauge equals 60 kPa (8.7 psi). through the CAT Data Link.

The information is received from the engine ECM Engine Oil Temperature (4)
through the CAT Data Link.
This module displays engine oil temperature over a
range of 60°C (140°F) to 120°C (248°F).
Quad Gauge Module For Premium
Generator Set And Locomotive When the gauge is pointing straight up, the value for
Applications the gauge equals 105°C (221°F).

The information is received from the engine ECM

through the CAT Data Link.

Quad Gauge Cluster Module For

Premium Marine Applications

g00530415
Illustration 11

Inlet Air Pressure (Boost) (1)

This module displays turbo compressor outlet

pressure (boost) over a range of 0 kPa (0 psi) to
400 kPa (58 psi). g00530416
Illustration 12

When the gauge is pointing straight up, the value for

Inlet Air Pressure (Boost) (1)
the gauge equals 190 kPa (27.6 psi).
This module displays the turbo compressor outlet
The information is received from the engine ECM
pressure (boost) over a range of 0 kPa (0 psi) to
through the CAT Data Link.
400 kPa (58 psi).
Aftercooler Coolant Temperature (2)
When the gauge is pointing straight up, the value for
This module displays aftercooler coolant temperature the gauge equals 190 kPa (27.6 psi).
over a range of 20°C (68°F) to 120°C (248°F).
The information is received from the engine ECM
The information is received from the engine ECM through the CAT Data Link.
through the CAT Data Link.
Aftercooler Coolant Temperature (2)
Inlet Air Temperature (3)
This module displays aftercooler coolant temperature
over a range of 20°C (68°F) to 120°C (248°F). These
This module displays inlet air temperature over a
range of 60°C (140°F) to 120°C (248°F). temperatures are displayed for all Marine engines
except the engines that have “JWAC” applications.
When the gauge is pointing straight up, the value for
the gauge equals 75°C (167°F). For JWAC applications, the module displays
temperatures over a range of 60°C (140°F) to 120°C
(248°F).
26 SENR6587-03
Systems Operation Section

The information is received from the engine ECM A resistive signal which corresponds to the oil
through the CAT Data Link. temperature is sent from the sender to the Main
Display Module. Typically, the resistance range of
Marine Gear Transmission Oil Temperature (3) the sender is 70 to 800 Ohms (Ω). The Main Display
Module converts the resistive signal and the Main
This module displays marine gear transmission oil Display Module displays the value on the Premium
temperature over a range of 20°C (68°F) to 120°C Quad Gauge Electronic Module.
(248°F).

When the gauge is pointing straight up, the value for

Air Inlet Temperature Sender For
the gauge equals 65°C (149°F). Generator Set Applications And
The information is received from the Marine Gear
Locomotive Applications
Oil Temperature sensor.

Marine Gear Transmission Oil Pressure (4)

This module displays marine gear transmission

oil pressure over a range of 150 kPa (21.8 psi) to
2875 kPa (417.9 psi).

The information is received from the Marine Gear

Oil Pressure sensor.

i01033986

Senders g00574503
Illustration 14
SMCS Code: 1408-UN; 7451-UN
The Air Inlet Temperature Sender provides
measurements of the Air Inlet temperature prior to
Engine Oil Temperature Sender For entering the cylinder head. The Air Inlet Temperature
Generator Set Applications And Sender also aids in the detection of the following
Locomotive Applications conditions that occur in the area that is located next
to the engine air filters.

• Degraded aftercooler performance

• High ambient air temperatures
• Poor air ventilation
Temperatures that are 30°C (86°F) greater than the
Aftercooler Water Temperature will have a negative
impact on engine performance.

A resistive signal which corresponds to the Air Inlet

temperature is sent from the sender to the Main
Display Module. Typically, the range of resistance of
Illustration 13
g00574503 the sender is 70 Ohms (Ω) to 800 Ohms (Ω). The
Main Display Module converts the resistive signal
The Engine Oil Temperature Sender provides and the Main Display Module displays the value on
measurements of the engine oil temperature after the Premium Gauge Cluster Module.
filtering. The Engine Oil Temperature Sender also
aids in the detection of degraded of the oil cooler
performance. Temperatures that are greater than
107°C (225°F) will have a negative impact on the
engine life.
SENR6587-03 27
Systems Operation Section

i01034059 The Marine Gear Oil Temperature Sensor provides

the operator with an indication of the oil temperature.
Sensors The Marine Gear Oil Temperature Sensor aids in
monitoring the proper marine gear oil temperature.
SMCS Code: 1408-NS; 7451-NS The operator can receive a Marine Gear Oil
Temperature High Warning indication from the
Low Coolant Level Sensor Programmable Relay Control Module “PRCM” with
the aid of this sensor.

The sensor sends a pulse width modulated signal

(PWM) with a duty cycle that varies as the Marine
Gear Oil Temperature changes from the sensor to
the Main Display Module. The sensor frequency is
4.2 kHz. The Main Display Module displays the value
of the PWM signal on the Premium Quad Gauge
Electronic Module.

Low Fuel Level Switch

g00574577
Illustration 15

The Low Coolant Level Sensor provides an indication

of the coolant level to the operator. This indicator
aids the operator in monitoring the proper coolant
volume in the engine which prevents the engine
from overheating. The operator can also receive an
Engine Low Coolant Level Warning indication from
the “PRCM” with the aid of this sensor.

The signal of the Low Coolant Level Sensor is pulled

to battery negative while the sensor is submerged in Illustration 17
g00574581
coolant. The signal stays at 5.0 DCV if the coolant
level falls below the tip of the sensor probe. The Main The Low Fuel Level switch provides an indication of
Display Module converts the signal and the Main a low fuel level to the operator. The Low Fuel Level
Display Module indicates the event by flashing the switch aids the operator in preventing an unexpected
Low Coolant Level Indicator Lamp. The sensor is shutdown because of an empty fuel supply tank. The
supplied with +8 DCV from the Main Display Module. operator can also receive an Engine Low Fuel Level
Warning from the “PRCM” with the aid of the Low
Temperature Sensor For Marine Fuel Level switch.
Gear Oil The Low Fuel Level Switch is closed while the switch
is submerged in fuel. The switch is open if the fuel
level falls below the tip of the switch. The Main
Display Module converts the signal. The Main Display
Module indicates the event by flashing the Low Fuel
Level Warning Lamp.

g00574503
Illustration 16
28 SENR6587-03
Systems Operation Section

i01034106 • % Load Display

Action Alarm and Alarm • Fuel Consumption Rate
Silence Switch
• Total Fuel Consumption
SMCS Code: 1408; 7400; 7451
• Engine Oil Pressure
• Engine Coolant Temperature
• System Voltage
• Fuel Pressure
• “RH/LH” Exhaust Temperature
• “RH/LH” Air Inlet Restriction
• Fuel Filter Differential Pressure
• Oil Filter Differential Pressure
• Boost Pressure
• Aftercooler Coolant Temperature
• Diagnostic Code Information
g00532780
Illustration 18
• Tattletale Function
(1) Alarm. (2) Alarm Silence Switch.
Note: This record is independent of tattletales on the
The Alarm provides an audible indication to the engine ECM.
operator of abnormal engine operation. The Alarm
(1) connects to an output of the Main Display Module.
The SOUNDING of the Alarm (1) tells the operator i01034163
that an abnormal engine condition exists.
Modes Of Operation
The operator can use the Alarm Silence Switch (2) to
SMCS Code: 7451
turn off the Alarm (1) once the alarm has sounded.
Activating the Alarm Silence Switch (2) will silence
The Caterpillar Monitoring System has six different
the Alarm (1) for five minutes. After the five minute
possible modes of operation. Each mode provides
period, if the condition that initiated the alarm has not
important information regarding the conditions of
been corrected, the Alarm (1) will sound again. If a
the engine. In this manual, all six modes are given
new condition occurs during the five minute period,
a name. Also, a number represents the modes.
then the Alarm (1) will sound again.
The mode of operation is changed by holding the
“CLEAR/MODE” switch down. The available modes
i01034111 are listed in the following chart.

Electronic Control Module Table 8

(Engine) Modes Of Operation For The Main Display Module

Mode Of Operation Mode Number
SMCS Code: 1901; 7451
Normal 0
The engine ECM supplies the following information Numeric Readout 1
to the Main Display Module for an indication of the
following items. Service 2
Tattletale 3
• Engine Speed
Units 4
• Engine Hours Harness Code 5
SENR6587-03 29
Systems Operation Section

When power is applied, the Caterpillar Electronic

Monitoring System performs a Self-Test. The
Self-Test causes all of the display elements and
gauges to briefly operate. After the Self-Test, the
Main Display Module enters Mode 0.

i01034193

Normal Mode Illustration 19

g00532879

SMCS Code: 7451 • The Service Meter Parameter is shown in

Illustration 20. The engine ECM records the total
Normal Mode or Mode 0 is used during normal number of hours of operation for the engine. This
engine operation. The Quad Gauge Electronic information is sent to the Main Display Module
Module shows the conditions that are listed below through the CAT Data Link. The total engine
to the operator when the Main Display Module is in operating hours are shown on the six digit display
Normal Mode. area. The service meter symbol is ON in order to
indicate that the display is functioning as a Service
• Proper operation of the monitoring system is Meter. While the engine is operating, the value is
shown. A Self-Test is performed. The Self-Test continuously updated. Use the “SCROLL” switch in
causes all of the display elements and gauges order to toggle between the Tachometer Parameter
to operate briefly. For more information on this and Service Meter Parameter.
subject, see Systems Operation, “System Self
Test”.

• A value for the system condition is shown. The

Main Display Module continuously monitors
engine systems. The needles in the Quad Gauge
Electronic Modules indicate a normal operating
condition when the needles are pointing straight
g00532883
up. Also, a normal operating condition may be Illustration 20
represented when the needle is not pointing
straight up.
i01034293

• The system shows if an engine problem exists. Numeric Readout Mode

When an abnormal condition (problem) exists, the
corresponding Indicator Lamp flashes and the SMCS Code: 7451
Alarm sounds. For more information on this subject,
see Systems Operation, “Warning Operation”. Numeric Readout Mode (Mode 1) assists Service
Personnel with information about Load Consumption
• The system shows if a diagnostic code exists. and the troubleshooting of sensor inputs. The
The Main Display Module continuously checks information about Load Consumption is displayed on
for diagnostic codes in the Caterpillar Electronic the Display Area only. The CAT Data Link and the
Control Module (ECM). When a diagnostic code is sensor inputs supply information for the positions of
detected, the display area shows “SERV CODE” the needles that are on the gauge cluster modules.
and the “Shutdown/Diagnostic” Alert Indicator
lights. Mode 1 more accurately shows the same information
that is shown on the gauges in Mode 0. The system
• The Tachometer Parameter is shown in Illustration identifier “LOAd”, “FO-X” or “GA-X” precedes the
19. Engine speed is displayed on the six digit value that is shown on the display area. In addition
display area, when the units indicator shows to the parameter value that is shown on the display
“RPM”. The Main Display Module receives engine area, the gauge needle for the parameter value that
speed information from the engine ECM through is displayed is active while all other gauges fall to the
the CAT Data Link. Use the “SCROLL” switch in minimum position.
order to toggle between the Tachometer Parameter
and the Service Meter Parameter.
30 SENR6587-03
Systems Operation Section

In order to enter Mode 1, hold down the Table 9

“CLEAR/MODE” Switch until “−1-” appears on the Modes Of Operation For The Main Display Module
Display Area. Use the “SCROLL” Switch in order to
advance the display to the next parameter value. System Quad Gauge Parameter
The Display Area will momentarily show the system Identifier Cluster
identifiers “LOAd”, “FO-X” or “GA-X”. After the Module(1)
system identifier appears, the Display Area shows “LOAd” Display Area % Load
the parameter value. Only (15)
“FO-2” Display Area Fuel Consumption Rate
Only (15)
“FL-1” Display Area Total Fuel Consumption
Only (15)
“GA-1” (9) Engine Oil Pressure
“GA-2” (10) Engine Coolant
g00532993 Temperature
Illustration 21
“GA-3” (8) System Voltage
Only the system identifiers for the gauge cluster
“GA-4” (14) Fuel Pressure
modules that are present are shown. For example,
if only one gauge cluster module is present, system “GA-5” (16) “RH/LH” Exhaust
identifiers “GA-1”, “GA-2”, “GA-3” and “GA-4” will Temperature
be shown. If additional gauge cluster modules are
“GA-6” (19) “RH/LH” Air Inlet
present, “GA-5”, “GA-6”, “GA-7” and “GA-8” will be Restriction
shown, etc. The following charts match the system
identifier to the parameter value of the gauge. “GA-7” (18) Fuel Filter Restriction
“GA-8” (20) Oil Filter Restriction
“GA-9” (21) Inlet Air Pressure Boost
“GA-10” (17) Aftercooler Coolant
Temperature
Generator Set Only
“GA-11” (22) Inlet Air Temperature
“GA-12” (23) Engine Oil Temperature
Marine Propulsion Only
“GA-11” (22) Marine Gear Transmission
Oil Temperature
“GA-12” (23) Marine Gear Transmission
Oil Pressure
(1) Refer to Tables at the end of this section for the callouts
for the Generator Set applications, Marine applications, and
Locomotive applications.
SENR6587-03 31
Systems Operation Section

Table 10
Units
Condition Units of Measurement
Engine Load percent of rated rack
Instantaneous Fuel Liters Per Hour, Gallons
Consumption Per Hour
g00533000
Total Fuel Consumed Liters, Gallons Illustration 26
Engine Coolant Temperature (GA-2)
Pressure kPa, PSI
Temperature °C, °F
Voltage DC Volts
Air Restriction kPa, Inches of H2O

The following illustrations show typical values for the

gauge parameters in the display area. g00533002
Illustration 27
System Voltage (GA-3)

g00532995
Illustration 22
Percent Of Rated Rack (“LOAd”)
g00533003
Illustration 28
Fuel Pressure (GA-4)

g00532996
Illustration 23
Fuel Consumption Rate (FL-0)
g00533005
Illustration 29
“RH/LH” Exhaust Temperature (GA-5)

g00532998
Illustration 24
Total Fuel Consumption (FL-1)
g00533007
Illustration 30
“RH/LH” Air Inlet Restriction (GA-6)

g00533076
Illustration 25
Engine Oil Pressure (GA-1)
g00533010
Illustration 31
Fuel Filter Restriction (GA-7)
32 SENR6587-03
Systems Operation Section

g00533010 g00533064
Illustration 32 Illustration 37
Oil Filter Restriction (GA-8) Marine Gear Oil Temperature (GA-11) Marine Propulsion Only

g00533014 g00533066
Illustration 33 Illustration 38
Boost Pressure (GA-9) Marine Gear Oil Pressure (GA-12) Marine Propulsion Only

g00533016
Illustration 34
Aftercooler Coolant Temperature (GA-10)

g00533059
Illustration 35
Inlet Air Temperature (GA-11) Generator Set And Locomotive
Engines

g00533062
Illustration 36
Engine Oil Temperature (GA-12) Generator Set And Locomotive
Engines
SENR6587-03 33
Systems Operation Section

g00527017
Illustration 39
Generator Set Main Display Module - Caterpillar Monitoring System
(1) Shutdown/Diagnostic. (2) System Voltage. (3) Overspeed. (4) Low Coolant Level. (5) Overcrank. (6) Not in AUTO. (7) Low Fuel Level.
(8) System Voltage. (9) Oil Pressure. (10) Coolant Temperature. (11) Low Oil Pressure. (12) High Coolant Temperature. (13) Low Coolant
Temperature. (14) Fuel Pressure. (15) Display Area. (16) Exhaust Temperature. (17) Aftercooler Temperature. (18) Fuel Filter. (19) Air Inlet
Restriction (“RH/LH”). (20) Oil Filter Restriction. (21) Inlet Air Pressure (Boost). (22) Inlet Air Temperature. (23) Engine Oil Temperature.
34 SENR6587-03
Systems Operation Section

g00527132
Illustration 40
Main Display Module (Marine Engine) - Caterpillar Monitoring System
(1) Shutdown/Diagnostic. (2) System Voltage. (3) Overspeed. (4) Low Coolant Level. (5) Marine Gear Oil Pressure. (6) Marine Gear Oil
Temperature. (7) Low Fuel Level. (8) System Voltage. (9) Oil Pressure. (10) Coolant Temperature. (11) Low Oil Pressure. (12) High Coolant
Temperature. (13) Low Coolant Temperature. (14) Fuel Pressure. (15) Display Area. (16) Exhaust Temperature. (17) Aftercooler Coolant
Temperature. (18) Fuel Filter Restriction. (19) Air Inlet Restriction. (20) Oil Filter Restriction. (21) Inlet Air Pressure (Boost). (22) Marine Gear
Oil Temperature. (23) Marine Gear Oil Pressure.
SENR6587-03 35
Systems Operation Section

g00533383
Illustration 41
Main Display Module (Locomotive Engine) - Caterpillar Monitoring System
(1) Engine Oil Pressure. (2) Engine Systems Status. (3) High Engine Coolant Temperature. (4) System Voltage. (5) Low Coolant Temperature.
(6) Engine Overspeed. (7) Aftercooler Coolant Temperature. (8) Fuel Filter Restriction. (9) High Inlet Air Temperature. (10) Fuel Pressure.
(11) Display Area. (12) Engine Coolant Temperature. (13) Fuel Pressure. (14) Oil Pressure. (15) System Voltage. (16) Air Inlet Restriction.
(17) Oil Filter Restriction. (18) Fuel Filter Restriction. (19) Exhaust Temperature. (20) Engine Oil Temperature. (21) Aftercooler Coolant
Temperature. (22) Inlet Air Temperature. (23) Inlet Air Pressure (Boost).

i01034683 Note: Events can not be viewed through the main

display module. Events can only be viewed using the
Service Mode CAT ET Service Tool.
SMCS Code: 7451 In order to enter Mode 2, hold down the
“CLEAR/MODE” switch until “-2-” appears in the
display area. Three identifiers are used to specify
each detected diagnostic code. These identifiers
are shown on the Display Area. The Display Area
alternately shows the Module Identifier (MID). The
Component Identifier (CID) and the Failure Mode
Identifier (FMI) are then shown on the Display Area.
The Display alternates continuously between the MID
g00532879
Illustration 42 and the CID FMI. Identifiers include the following
Mode 0: Service Code Indicator ON items.

Service Mode (Mode 2) assists service personnel

with the troubleshooting of diagnostic codes. All
the recorded diagnostic codes can be cleared from
memory while the operator is in Mode 2.
36 SENR6587-03
Systems Operation Section

Module Identifier (MID) – The MID is a three digit Failure Mode Identifier (FMI) – The FMI is shown
code that is shown on the six digit Display Area. on the last two digits of the six digit Display Area.
The MID is displayed for approximately one second, The FMI begins with the decimal point or an “F”. The
before the CID FMI is shown in place of the MID. The FMI ends with the two digit code. The CID FMI is
MID helps the operator to determine the electronic displayed immediately after the MID. The diagnostic
control module that has generated the diagnostic code that is generated is revealed to the operator
code. Some values that may be seen for the MID are through the FMI. A listing of the codes that are
given in the following list. used for the FMI may be found on the left side of
the Electronic Instrument Panel. The example that
• Main Display Module 030 follows is for “THROTTLE SIGNAL OUTPUT IS
ABNORMAL”.
• Primary Engine Control Module 033, 034 or 036
Note: “F” is used on the earlier models in order to
• Secondary Engine Control Module 047 distinguish between the digits of the CID and the
digits of the FMI. The “F” has been removed in order
• De-Nox Control 076 to allow the fourth digit in the CID to be added, and
the decimal point is the separation between the CID
• Customer Communication Module 097 and the FMI.

• Programmable Relay Control Module 099

Component Identifier (CID) – The CID is shown on
the first four digits or the first three digits of the six
digit Display Area. The CID and the FMI are displayed
together. The MID is followed by the CID FMI in the
Display Area. The CID identifies the component or
the subsystem that has generated a diagnostic code.
For a listing of the CID codes, see the chart that is
attached to the left side of the Electronic Instrument
Panel. One example of a detected diagnostic is the
“THROTTLE SIGNAL OUTPUT IS ABNORMAL”.

Note: Earlier models display three digits for the CID. g00533497
The fourth digit has been added to the CID in order Illustration 44
to provide the ability to develop four digit codes.
Upon entering Service Mode or Mode 2, the MID
and the CID FMI for the first available diagnostic
code are shown in the Display Area. At this time,
the diagnostic code that is shown is “on-hold”. The
display continuously alternates between the MID and
the CID FMI when a diagnostic code is “on-hold”.

The “SERV CODE” indicator signifies if the diagnostic

code is active or logged. The diagnostic code is
logged when the “SERV CODE” indicator is OFF. The
Alarm will sound if a diagnostic code goes from the
logged status to the active status during the display
of Mode 2. This will assist the service personnel in
finding intermittent problems.

Illustration 43
g00533391 Use the “SCROLL” switch in order to advance to the
next recorded diagnostic code. Using the “SCROLL”
switch will show all of the diagnostic codes that were
recorded one at a time in the Display Area.
SENR6587-03 37
Systems Operation Section

The service personnel must clear the diagnostic In order to more accurately show the information that
code from memory when a diagnostic code is is represented on the gauges, use the “SCROLL”
corrected. A diagnostic code is corrected when the switch in order to advance the Display Area to the first
“SERV CODE” is OFF. A diagnostic code that is tattletale value. The Display Area will momentarily
logged may be cleared from memory by pushing the show the system identifier “GA-X”. The system
“MODE/CLEAR” switch to the UP position while the identifier is then followed by the tattletale value.
code is displayed in the Display Area. See the chart that is located in Systems Operation,
“Numeric Readout Mode”.
Note: When no diagnostic codes are detected, the
Display Area will show the following reading.

g00533586
Illustration 47

Illustration 45
g00533498 Press the “SCROLL” switch again for each
succeeding tattletale value. Only the system
identifiers for the quad gauge electronic modules
i01034928 that are present are shown on the Display Area. For
example, if only one quad gauge electronic module
Tattletale Mode is present, system identifiers “GA-1”, “GA-2”, “GA-3”
and “GA-4” will be shown. If an additional quad gauge
SMCS Code: 7451
electronic module is present, “GA-5”, “GA-6”, “GA-7”
and “GA-8” will be shown. The pattern continues
In order to enter Mode 3, hold down the for additional quad gauge electronic modules. The
“CLEAR/MODE” switch until “-3-” appears in the
system identifier “GA-X” precedes the value that is
Display Area. After the operator enters Mode 3 the
shown in the Display Area. In addition to the tattletale
Display Area will show the following reading. value that is shown in the Display Area, the gauge
needle for the tattletale value that is displayed is
active. All other gauges fall to minimum positions.

Note: While the Main Display Module is in Normal

Mode, the Indicator Lamps of the Main Display
Module turn ON when an abnormal condition has
occurred.
g00533585
Illustration 46 Information about the Tattletale is retained until the
information is cleared from the memory of the Main
Tattletale Mode or Mode 3 is a tool that is used for Display Module. Clearing all information about the
management. The history of the engine may be Tattletale from the memory of the Main Display
found by using Mode 3. The Main Display Module Module is done by pushing the “MODE/CLEAR”
records the extreme values for each engine condition switch to the UP position while “- -” is displayed in the
that is monitored. The values come from the sensor Display Area. After clearing, all information about the
input and the engine ECM through the CAT Data tattletale is reset to a nominal value and the recording
Link. The Tattletale values are updated whenever a of new extreme values can begin. Individual gauge
more extreme value occurs than the value that is tattletale values can be cleared one at a time by
previously recorded. These values are ignored for a pushing the “MODE/CLEAR” switch to the UP while
short period of time after each engine start-up. This the gauge tattletale value is being displayed in the
allows the engine systems to stabilize before old Display Area.
values can be updated with new values.
Note: The date, time or duration of the occurrence of
The gauges show the highest value or the gauges the tattletale value is not recorded.
show the lowest value that has been attained by
the corresponding engine subsystem. The highest
reading is for values that abnormally decrease.
38 SENR6587-03
Systems Operation Section

i01035010 Table 11

Units Mode Mode 5

Harness Code
Application

Display
SMCS Code: 7451
03 Generator Engine (1) with Standby
In order to enter Mode 4, hold down the Panel
“CLEAR/MODE” switch until “-4-” appears in the 05 Generator Engine(1) With Prime Panel
Display Area. Units Mode (Mode 4) is used to toggle
the display of the Caterpillar Monitoring System 06 Generator Engine(1) With Premium
between US units and Metric units of measure. When Panel And “SCAC”
the Main Display enters Units Mode, the Display Area 07 Generator Engine With Premium
will show the current setting. The Display Area shows Panel And JWAC “JWAC”
“US” when the Display Area is set to US units. The
Display Area shows “SI” when the Display Area is set 09 Marine Propulsion Engine With
to Metric units. See the examples that are provided Premium Panel And “SCAC”
below. 10 Marine Propulsion Engine With Prime
Panel And Marine Gear Sensors
11 Marine Propulsion Engine With Prime
Panel And No Marine Gear Sensors
12 Marine Propulsion Engine With
Premium Panel And “JWAC”
35 Locomotive Engine
(1) Includes Marine Auxiliary

Note: If the selection for the harness code does not

match the application, the Caterpillar Monitoring
System may not operate correctly. The following list
contains problems that the operator may encounter:
the loss of event notification, incorrect data displays,
g00533649
Illustration 48 incorrect gauge needle position, and incorrect
activation of diagnostic codes. CID 127 FMI 08, CID
Press the “SCROLL” switch in order to toggle the 177 FMI 08, and CID 819 FMI 02 are commonly
units between US units and SI units. caused by harness codes that are not correct for
the application on new installations. Troubleshooting
procedures are given for these diagnostic codes in
i01035048
the Testing And Adjusting Section of this Manual.
Harness Code Mode An example of Harness Code Mode (Mode 5) is
SMCS Code: 7451 provided below.

In order to enter Harness Code Mode (Mode 5), hold

down the “CLEAR/MODE” switch until “-5-” appears
in the Display Area. When the Display Area is in
Harness Code Mode, the engine code is shown on
the Display Area. The engine code must correspond
to the engine sales model. The engine code is a
two-digit representation of the harness code input.
g00533697
Illustration 49
Note: Harness Code Mode 5 is only available on Display Area
155-8653 Engine Monitoring Control (Caterpillar
Monitoring Systems) and newer Caterpillar
Monitoring System modules.
SENR6587-03 39
Systems Operation Section

i01035057

Warning Operation
SMCS Code: 7451

The Caterpillar Monitoring System notifies the

operator of an immediate problem or an impending
problem with various engine systems operation.
Warning operation begins when the Main Display
Module receives a signal that reflects an abnormal
engine condition or the Main Display Module detects
a problem with the control system. Switches, sensors
and the engine control module (ECM) provide
information to the Main Display Module. The warning
information consists of the following elements.

• An open switch is provided. When a condition

exceeds the trip point of the switch, the switch
opens.

• A sensor signal that exceeds the limits of the

trip point is provided. The Main Display Module
determines the limits.

• Abnormal engine condition is detected and

provided by the engine control module (ECM). The
abnormal conditions are communicated over the
CAT Data Link to the Main Display Module.

Note: The trip points of the monitoring system can be

modified through the “ET” Electronic Service Tool.

The Main Display Module receives the information

and the Main Display Module processes the
information. The result of the processing is displayed
on the Indicator Lamps of the Main Display Module.
The Alarm sounds if an abnormal condition exists.
The following items are functions of the warning
indication.

• The Main Display Module will flash the appropriate

Indicator Lamp. The Lamp will flash at a rate of
nine times per second.

• The Main Display Module will sound the Alarm.

The Alarm will be ON one second and the Alarm
will be OFF for two seconds.

Use the Electronic Service Tool in order to review

the Caterpillar Monitoring System trip points. For
more information about Service Tool usage, see the
Electronic Service Tool Guide.
40 SENR6587-03
Testing and Adjusting Section

Testing and Adjusting When the troubleshooting procedure instructs the

operator to repair the harness, use the Electrical
Section System Schematic in the engine Service Manual to
trace the circuit. Less than 5 ohms of resistance is
required between the connector and ground. Ground
resistance that is greater than 5 ohms can cause
Testing and Adjusting incorrect diagnosing of problems.

During troubleshooting, inspect all components

i01035068 and harness connections before any component is
General Information replaced. If these connections are not clean and
tight, the connections can cause permanent electrical
SMCS Code: 7451 problems or intermittent electrical problems. Check
that the wires are pushed into the connectors all
Table 12 the way. Perform a pull test on the connector and
the wires in order to confirm that the contacts are
Troubleshooting Quick Reference snapped into place. Make sure that the connections
Go To Accessing Diagnostic Information are tight before any other tests are performed.
For Troubleshooting Problems with one electrical component can
cause problems with one or more other electrical
Action Alarm CID 0271 Procedure(1) components. The operator should always attempt to
CAT Data Link CID 0248 Procedure(1) find the cause of the electrical system problems and
the operator should correct the cause of the electrical
+8 DCV Sensor Supply CID 0263 Procedure(1) system problems before the operator replaces the
Gauges CID 0096, CID 0127, component.
CID 0172, CID 0175,
CID 0177, CID 0819, CID
0821 Procedures i01035106

Go To The Appropriate Section For Troubleshooting Service Tools

Indicator Lamp Troubleshooting Alert
Indicators SMCS Code: 0785

Indicator Lamp Troubleshooting Alert The following service tools should be used to make
Indicators troubleshooting the electrical system easier.
“LH/RH” switch Troubleshooting “LH/RH”
switch Note: Refer to the Electronic Troubleshooting Guide
for a complete list of service tools.
“SCROLL” switch Troubleshooting
“SCROLL” switch
• 146-4080 Digital Multimeter (RS-232)
“SCROLL” switch Troubleshooting
“SCROLL” switch • 8T-3224 Needle Tip (Multimeter)
“CLEAR/MODE” switch Troubleshooting
“CLEAR/MODE” switch • 7X-1710 Multimeter Probe
“CLEAR/MODE” switch Troubleshooting • 7X-6370 Adapter Cable
“CLEAR/MODE ” switch
“Alarm Silence” switch Troubleshooting “Alarm • 6V-3000 Connector Repair Kit (Sure Seal)
Silence” Switch
• 4C-3406 Connector Repair Kit (Deutsch)
“Alarm Silence” switch Troubleshooting “Alarm
Silence” Switch
• 9U-7246 Connector Repair Kit (Deutsch DT)
(1) A CID for the new software has four digit numbers.
• 4C-4074 Contact Removal Tool (16-18 Gauge)
Troubleshooting the Caterpillar Monitoring System
requires additional information from the engine • 4C-4073 Contact Removal Tool
Service Manual. The Electrical System Schematic,
the Electronic Troubleshooting Guide, the Parts • 4C-4072 Contact Removal Tool (8-10 Gauge)
Manual and the Operation & Maintenance Manual
are materials that are required for support. • 4C-4071 Contact Removal Tool (4-6 Gauge)
SENR6587-03 41
Testing and Adjusting Section

• 4C-4075 Crimp Tool i01035207

Use the 146-4080 Digital Multimeter (RS-232) or Accessing Diagnostic

the equivalent for making resistance measurements. Information
For instructions on the use of the 146-4080 Digital
Multimeter (RS-232), see Operator’s Manual, SMCS Code: 7451-038
NEHS0678. The 7X-1710 Multimeter Probe is used
to make measurements at connectors. The halves
of the connector do not need to be disconnected. Changing Modes
The probe is pushed into the wire entry side of the
Table 13
connector alongside the wire. The 7X-6370 Adapter
Cable is a 3 pin DT connector breakout cable that is Activation Of Display Operations
used to make measurements in the circuits of the (Quick Reference)
sensors. The 4C-4071 Contact Removal Tool (4-6 Display Service Clear Contact(1)
Gauge), the 4C-4072 Contact Removal Tool (8-10 Operation Contact(1)
Gauge), the 4C-4073 Connector Removal Tool and
the 4C-4074 Contact Removal Tool (16-18 Gauge) Changing Modes:
are wire removal tools for the CE connectors. The To Scroll (Mode Ground Ground
4C-4075 Crimp Tool is used for 4 AWG through 10 Switch)
AWG pins (sockets) that are used on CE connectors.
To Hold Open Open
Note: The use of continuity testers, or voltage Service Mode
testers are not recommended for use on present day
Caterpillar electrical circuits. The continuity testers To Scroll (Scroll Ground Ground
and the voltage testers may be used in harness tests. Switch)
The harness tests include the 8T-0500 Continuity To Hold Open(2) Open
Tester and the 5P-7277 Voltage Tester.
To Clear(3) (Clear Open Ground
Switch)
Main Display Module Connector Tattletale Modes
Contact Numbers
To Clear(3) (Clear Open Ground
Switch)
Numeric Readout Modes:
To Scroll (Scroll Ground Open
Switch)
To Hold Open Open
(1) Of The Main Display Module Connector Service Contact
(2) Open when the desired information is shown during scrolling.
(3) A diagnostic is cleared only while it is on-hold. A diagnostic
that is currently active cannot be cleared.

See Systems Operation, “Modes Of Operation” for a

detailed explanation of the different modes.
g00533857
Illustration 50

i01035103

Electrical Components And

Connector Locations
SMCS Code: 1408-546-CY; 7553-546

The Electrical System Schematic, the Parts Manual

and the Operation and Maintenance Manual for the
engine that is being serviced should be used to
assist in locating the electrical components and the
connectors.
42 SENR6587-03
Testing and Adjusting Section

i01035212 • If the “SERV CODE” indicator is ON, then the

diagnostic code that is shown is active.
Troubleshooting Diagnostic
Codes • If the SERV CODE indicator is OFF, then the
diagnostic code that is shown is logged. The
SMCS Code: 7451-038 diagnostic code was active. Then, the diagnostic
code became inactive. The diagnostic code was
logged in memory. This may or may not indicate
an intermittent condition.

7. In order to troubleshoot the diagnostic code, go to

the procedure with the CID FMI.

8. After a diagnostic code is corrected or the

diagnostic code is not needed, clear the diagnostic
code by using the “CLEAR” switch. After clearing
the diagnostic code, the Display Area advances to
the next available diagnostic code.

9. Repeat Step 2 through Step 8 for the remaining

diagnostic codes. The operator should return to
Normal Mode when the operator is finished.

Troubleshooting Procedures
Go to the procedure which corresponds to the CID
FMI that is shown in the Display Area.
g00533879
Illustration 51
Note: The procedures for the CID FMI that are found
Use the following procedure when a diagnostic code in Testing And Adjusting may cause some diagnostic
is detected. When a diagnostic code is detected, the codes to be logged by the Main Display Module.
Display Area shows the “SERV CODE” indicator Therefore before performing any procedures, record
while the Main Display Module is in Normal Mode. the diagnostic codes in order to determine the
problems that are in the system. At the completion of
1. Enter Service Mode (Mode 2). each procedure, clear the diagnostic codes that were
caused by the test procedure.
2. A single diagnostic code is shown and the code is
on hold at this time. The display toggles between
the MID and the CID FMI. When the diagnostic
code is not active, nothing is shown for the
MID. The Display Area does not toggle showing
information on the diagnostic codes.

3. In order to see all of the detected diagnostic codes,

use the “SCROLL” switch to scroll through the
diagnostic codes. The Display Area momentarily
shows the MID. Then, the Display Area shows the
CID FMI in place of the MID. Toggle the “SCROLL”
switch in order to see each diagnostic code in
succession. The MID shows “End” after the last
diagnostic code has been shown.

4. Place the desired diagnostic code on hold by

releasing the “SCROLL” switch.

5. Make sure that the MID “030” is displayed.

6. Observe the “SERV CODE” indicator.

SENR6587-03 43
Testing and Adjusting Section

i01046906 3. In order to see all diagnostic codes, use the

“SCROLL” switch to scroll through the diagnostic
Initial Troubleshooting codes. The Display Area momentarily shows
Procedure the MID. Then, the CID FMI replaces the MID.
Toggle the “SCROLL” switch in order to see the
SMCS Code: 7451-038 diagnostic codes in succession. “End” is shown
in the Display Area after the last diagnostic code
has been shown.

4. Place the desired diagnostic code on hold. The

diagnostic code is placed on hold by releasing the
“SCROLL” switch.

5. Make sure that the MID 030 is displayed.

6. Observe the “SERV CODE” indicator.

• If the “SERV CODE” indicator is ON, then the

diagnostic code that is shown is active.

• If the “SERV CODE” indicator is OFF, then the

diagnostic code that is shown is logged. The
diagnostic code was active. The diagnostic code
then became inactive. Finally, the diagnostic
code was logged into memory. This may or may
not indicate an intermittent condition.

g00533879 7. In order to troubleshoot the diagnostic code, go to

Illustration 52
the procedure with the CID FMI.

8. After a diagnostic code is corrected or the

diagnostic code is not needed, clear the diagnostic
code with the “CLEAR” switch. After clearing,
the Display Area advances to the next available
diagnostic code.

9. Repeat Step 2 through Step 8 for the remaining

diagnostic codes. Return the Main Display Module
to Normal Mode when all of the diagnostic codes
are cleared.

i01035260

Illustration 53
g00543569
CID 0096 FMI 03 Level Switch
Use the following procedure when a diagnostic code (Fuel) Voltage Above Normal -
is detected. When a diagnostic code is detected, the Test
“SERV CODE” indicator is shown in the Display Area
when the Main Display Module is in Normal Mode. SMCS Code: 1273-038-ZS; 1408-038-ZS;
7451-038-ZS
1. Enter the Service Mode (Mode 2).

2. A single diagnostic code is shown and the

diagnostic code is on hold at this time. The display
toggles between the MID and CID FMI. Nothing is
shown in the Display Area for the MID when there
are no active diagnostic codes. The Display Area
does not toggle in order to show information about
the CID FMI. Illustration 54
g00573573

Schematic For Fuel Level Switch

44 SENR6587-03
Testing and Adjusting Section

Note: Ensure that the desired diagnostic code (CID • Not OK - The “SERV CODE” indicator stays
FMI) is on hold. Ensure that the “SERV CODE” ON. The harness wiring or the Main Display
indicator is ON. Use the electrical system schematic Module has a problem. Proceed to Step 2.
for the engine that is being serviced to find the
connector contact on the Main Display Module that 2. Check for an Open Ground Wire.
corresponds to the CID in the Display Area.
a. Turn the “ECS” switch to the
This diagnostic code is recorded when the Main OFF/RESETposition.
Display Module reads the signal voltage of the switch
as being too high. The corresponding Indicator Lamp b. Measure the resistance between the battery
flashes as a result of this diagnostic condition. The ground and the ground wire for the fuel level
following examples are possible causes. switch unit.

• The fuel level switch has a problem. Expected Result: The resistance should be
less than 5 ohms.
• The fuel level switch unit ground circuit in the
engine harness is open. Results:

• The fuel level switch unit signal in the engine • OK - The resistance is less than 5 ohms.
harness is shorted to +battery. Proceed to Step 3.

• The fuel level switch unit signal circuit in the engine • Not OK - The resistance is greater than 5
harness is open or the connector is disconnected. ohms or equal to 5 ohms. The ground wire for
the harness is open. Repair the ground wire
• The Main Display Module has a problem. of the harness or replace the ground wire of
the harness for the Fuel Level Switch Unit.
• The fuel level switch is not used. The jumper for
the fuel level switch is not installed on the customer 3. Measure the Voltage of the Fuel Level Switch
connector. Signal Wire.

1. Check the Display Area and the Harness. a. Turn the “ECS” switch to the OFF/RESET
position.
a. Turn the “ECS” switch to the OFF/RESET
position. b. Measure the voltage from the ground to the
Fuel Level Switch Unit Signal Wire.
b. Check for loose terminal connections or
corroded terminal connections to the fuel level Expected Result: The voltage should be 6.0
switch. ± 0.5 DCV.

c. Clean corroded terminals and tighten loose Results:

connections.
• OK - The voltage is 6.0 ± 0.5 DCV. If the
d. Turn the “ECS” switch to the SERV CODE indicator remains ON, repeat
COOLDOWN/STOP position. The “SERV Step 1, Step 2 and Step 3. If the cause of
CODE” indicator should be ON for the the diagnostic fault is not found, replace the
diagnostic code CID 0096 FMI 03. Main Display Module.

e. Disconnect the engine harness fuel level switch • Not OK - The voltage is less than 6.0 ± 0.5
signal wire and observe the “SERV CODE” DCV. The harness wiring has a problem.
indicator that is in the Display Area. There is an open circuit or a short to ground
in the Fuel Level Switch Signal Wire or a poor
Expected Result: The “Serv Code” indicator connection. Repair the harness or replace
should turn OFF. the harness. If the cause of the diagnostic
fault is not found, replace the Main Display
Results: Module.

• OK - The “SERV CODE” indicator turns

OFF. The Fuel Level Switch has a problem.
Replace the Fuel Level Switch Unit.
SENR6587-03 45
Testing and Adjusting Section

• Not OK - The voltage is greater than 6.0 ± d. Turn the “ECS” switch to the
0.5 DCV or the voltage is less than 0.5 DCV. COOLDOWN/STOP position.
The harness is shorted to a power circuit.
Repair the harness or replace the harness. If e. The “SERV CODE” indicator should be ON for
the cause of the diagnostic fault is not found, the diagnostic code CID 0127 FMI 08.
replace the Main Display Module.
2. Confirm that the harness code selection
matches the application.
i01035307

CID 0127 FMI 08 Pressure a. Determine the CURRENT harness code

selection. For more information, see Testing
Sensor (Transmission Oil) And Adjusting, “Harness Code - Troubleshoot”.
Abnormal Signal - Test b. Determine the CORRECT harness code
selection for the application. For more
SMCS Code: 1408-038-NS; 3080-038-NS;
information, see Systems Operation, “Quad
7451-038-NS
Gauge Module”.
Note: Ensure that the diagnostic code (CID FMI) is
c. Compare the CURRENT harness code
on hold. Ensure that the “SERV CODE” indicator
selection to the CORRECT harness code
is ON. Use the electrical system schematic of the
selection.
engine that is being serviced to find the connector
contact that is located on the Main Display Module.
Expected Result: The CURRENT harness
The connector contact should correspond to the
code selection is correct for the application.
current CID that is shown on the Display Area.
Results:
The diagnostic code is recorded when the Main
Display Module reads an abnormal sensor signal.
The abnormal signal means that the signal is not • OK - Proceed to 3.
identifiable by the internal circuitry of the Main Display
Module. The corresponding Indicator Lamp begins • Not OK - Correct the harness code selection
or install marine gear sensors so that the
flashing as a result of this diagnostic condition. Also,
application matches the current harness
the Gauge Needle is in the warning region. The
code selection. If the marine gear sensors
following examples are possible causes.
are not installed, use harness code 11. If
harness code 9, harness code 10 or harness
• The marine gear oil pressure sensor has a code 12 is selected, make sure the marine
problem.
gear sensors are installed. If the cause of the
diagnostic is not found, proceed to 3.
• The marine gear oil pressure sensor ground circuit
in the engine harness is open.
3. Measure the Voltage of the Marine Gear Oil
Pressure Sensor Supply Wire.
• The marine gear oil pressure sensor signal circuit
in the engine harness is shorted to +battery.
a. Turn the “ECS” switch to the
COOLDOWN/STOP position.
• The marine gear oil pressure sensor signal circuit
in the engine harness is open or the connector is
b. Use the 7X-1710 Multimeter Probe to measure
disconnected.
the voltage from the Gear Oil Pressure Sensor
Ground Wire (pin B) to the supply wire (pin A).
• The harness code is incorrect.
Expected Result: The voltage should be 8.0
• The Main Display Module has a problem. ± 0.5 DCV.
1. Check the Display Area and the Harness.
Results:
a. Turn the “ECS” switch to the OFF/RESET
position. • OK - The voltage is 8.0 ± 0.5 DCV. Proceed
to Step 4.
b. Check for loose terminal connections or
corroded terminal connections to the marine
gear oil pressure sensor.

c. Clean corroded terminals and tighten loose

connections.
46 SENR6587-03
Testing and Adjusting Section

• Not OK - The voltage is less than 0.5 DCV. Results:

The harness wiring has a problem. There
is an open circuit, a short to ground in the • OK - The voltage is similar to the voltage that
supply wire for the Marine Gear Oil Pressure was measured in Step 4. The Main Display
Sensor or a poor connection. Repair the Module is receiving a valid signal voltage.
harness or replace the harness. If the cause The Main Display Module has a problem.
of the diagnostic fault is not found, proceed Replace the Main Display Module. See
to Step 4. Testing And Adjusting, “Module - Replace”
for more information.
4. Measure The Marine Gear Oil Pressure Sensor
Voltage. • Not OK - The value is not similar to the
voltage that was measured in Step 4. The
• If the voltage is between approximately 1.0 DCV engine harness has an open circuit in the
and 7.0 DCV, the signal voltage at the sensor is signal circuits or the engine harness has an
correct. Proceed to Step 5. open circuit in the ground circuits. Repair
the engine harness or replace the engine
• If the voltage is not between approximately 1.0 harness.
DCV and 7.0 DCV, the signal voltage at the
sensor is not correct. If the voltage is greater 6. Check For A Short To +Battery.
than 7.0 DCV, proceed to Step 6. If the voltage
is less than 1.0 DCV, proceed to Step 7. a. Turn the “ECS” switch to the OFF/RESET
position.
a. Turn the “ECS” switch to the
COOLDOWN/STOP position. b. Disconnect the connector of the Main Display
Module.
b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the Marine Gear Oil Pressure c. Use the 7X-1710 Multimeter Probe to measure
Sensor ground wire (pin B) to the supply wire the resistance that is between +battery and
(pin C). the signal wire (pin C) for the Marine Gear Oil
Pressure sensor.
Expected Result: The voltage should be
approximately between 1.0 DCV and 7.0 DCV. Expected Result: The resistance should be
greater than 5000 ohms.
Results:
Results:
• OK - : The voltage is between approximately
1.0 DCV and 7.0 DCV. The signal voltage at • OK - The resistance is greater than 5000
the sensor is correct. Proceed to Step 5. ohms. The signal wire for the harness is
correct. Replace the Main Display Module.
• Not OK - : The voltage is greater than 7.0 See Testing And Adjusting, “Module -
DCV. The signal voltage at the sensor is not Replace” for more information.
correct. Proceed to Step 6.
• Not OK - The resistance is less than 5000
• Not OK - : The voltage is less than 1.0 ohms. Repair the harness or replace the
DCV. The signal voltage at the sensor is not harness.
correct. Proceed to Step 7.
7. Check For A Short To Ground.
5. Measure The Marine Gear Oil Pressure Signal
Voltage. a. Turn the “ECS” switch to the OFF/RESET
position.
a. Turn the “ECS” switch to the
COOLDOWN/STOP position. b. Disconnect the connector of the Main Display
Module and the Marine Gear Oil Pressure
b. Use the 7X-1710 Multimeter Probe to measure Sensor connector.
the voltage from the ground wire contact of the
Main Display Module to the signal wire contact. c. Use the 7X-1710 Multimeter Probe to measure
the resistance that is between the ground wire
Expected Result: The voltage should be and the signal wire (pin C) of the Marine Gear
similar to the voltage that was measured in Oil Pressure Sensor.
Step 4.
SENR6587-03 47
Testing and Adjusting Section

Expected Result: The resistance should be • The Main Display Module has a problem.
greater than 5000 ohms.
Note: The Main Display Module is unable to
Results: determine when a sender or sender signal harness
is open or the resistance is too high. This condition
• OK - The resistance is greater than 5000 causes the corresponding Gauge Needle to stay at
ohms. The resistance of the signal wire for the left side of the scale.
the harness is correct. Replace the Main
Display Module. See Testing And Adjusting, 1. Measure the Resistance of the Sender.
“Module - Replace” for more information.
a. Turn the “ECS” switch to the OFF/RESET
• Not OK - The resistance is less than 5000 position.
ohms. Repair the harness or replace the
harness. b. Disconnect the engine harness from the inlet
air temperature sender unit.
i01035374
c. Measure the resistance that is between the two
CID 0172 FMI 04 Temperature contacts of the sender connector. The following
table illustrates the correct approximate
Sender (Inlet Air) Voltage resistance at various temperatures.
Below Normal - Test Table 14

SMCS Code: 1058-038-UN; 1408-038-UN; Approximate Resistances For The Sender

7451-038-UN Connector Contacts
Temperature Resistance
25 ± 2°C (77 ± 3.6°F) 1000 Ω
100 ± 2°C (212 ± 3.6°F) 103.7 Ω

2. Check the Display Area and the Harness.

a. Turn the “ECS” switch to the OFF/RESET

position.

b. Check for loose connections or corroded

connections to the inlet air temperature sender.

c. Replace corroded contacts and tighten loose

g00573143 connections.
Illustration 55
LH/RH Temperature Sender (Inlet Air)
d. Turn the “ECS” switch to the
Note: Ensure that the desired diagnostic code (CID COOLDOWN/STOP position. The “SERV
FMI) is on hold. Ensure that the “SERV CODE” CODE” indicator should be ON for the
indicator is ON. Use the electrical system schematic diagnostic code CID 172 FMI 04.
for the engine that is being serviced to find the
connector contact on the Main Display Module which e. Disconnect the engine harness from the inlet
corresponds to the CID that is currently shown. air temperature sender unit. Observe the
“SERV CODE” indicator.
This diagnostic code is recorded when the Main
Display Module reads the voltage of the sender Expected Result: The “SERV CODE” indicator
signal as being too low. The corresponding Gauge should turn OFF.
Needle is in the warning region as a result of this
diagnostic condition. The following examples are Results:
possible causes.
• OK - The “SERV CODE” indicator turns OFF.
• The inlet air temperature sender unit has a The inlet air temperature sender unit has a
problem. problem. Replace the inlet air temperature
sender unit.
• The signal circuit for the inlet air temperature
sender unit in the engine harness is shorted to • Not OK - The SERV CODE indicator stays
ground. ON. The harness wiring or the Main Display
Module has a problem. Proceed to Step 3.
48 SENR6587-03
Testing and Adjusting Section

3. Check the Sender Wire for a Short to Ground. i01035804

a. Turn the “ECS” switch to the OFF/RESET CID 0175 FMI 04 Temperature
position. Sender (Engine Oil) Voltage
b. Disconnect the engine harness from the inlet Below Normal - Test
air temperature sender unit.
SMCS Code: 1408-038-UN; 1929-038-UN;
c. Turn the “ECS” switch to the 7451-038-UN
COOLDOWN/STOP position.
Note: Ensure that the desired diagnostic code (CID
d. Measure the voltage of the harness signal wire FMI) is on hold. Ensure that the “SERV CODE”
from the inlet air temperature sender unit. The indicator is ON. Find the connector contact that is
voltage should be measured from pin 1 to pin located on the Main Display Module. The electrical
2 (ground). system schematic for the engine that is being
serviced may assist the operator in finding the
Expected Result: The voltage should be 6.0 connector contact that corresponds to the current
± 0.5 DCV. CID that is shown.

Results: This diagnostic code is recorded when the Main

Display Module reads a signal from the sender that
• OK - The voltage is 6.0 ± 0.5 DCV. The is too low. The Gauge Needle will be in the warning
voltage is correct. If the SERV CODE region as a result of this diagnostic condition. The
indicator is still ON, repeat Step 1 through following examples are possible causes.
Step 3. If the cause of the diagnostic fault is
not found, replace the Main Display Module. • The engine oil temperature sender has a problem.

• Not OK - If the voltage is less than 0.5 • The sender signal circuit that is located in the
DCV, the harness wiring has a problem. engine is shorted to ground.
There is an open circuit, a short to ground
in the inlet air temperature sender wire or a • The Main Display Module has a problem.
poor connection to a connector. Repair the
harness or replace the harness. If the cause Note: The Main Display Module is unable to
of the diagnostic fault is not found, replace determine when a sender or the signal harness circuit
the Main Display Module. of a sender is open or the resistance is too high.
As a result of this condition, a Gauge Needle will
• Not OK - If the voltage is not greater than 6.5 always be on the far left of the scale. This condition
DCV or the voltage is not less than 0.5 DCV, is recognized as a gauge with a needle that is always
the harness is shorted to a power circuit. at the far left of the scale.
Repair the harness or replace the harness. If
the cause of the diagnostic fault is not found, 1. Measure the Resistance of the Sender.
then replace the Main Display Module.
a. Turn the “ECS” switch to the OFF/RESET
position.

b. Disconnect the engine harness from the

sender.

c. Measure the resistance that is between the

threads of the terminal and the case of the
sender. The following table illustrates the
correct approximate resistance for the following
temperatures.
SENR6587-03 49
Testing and Adjusting Section

Table 15 • OK - The voltage is 6.0 ± 0.5. If the SERV

Approximate Resistances For The Sender
CODE indicator is still ON, repeat Step
Connector Contacts 1 through STEP 3. If the cause of the
diagnostic fault is not found, replace the Main
Temperature Resistance Display Module.
54.4°C (130.0°F) 850 to 1050 Ω
• Not OK - The voltage is less than 0.5 DCV.
110°C (140°F) 140 to 160 Ω The harness wiring has a problem. There is
an open circuit or a short to ground in the
2. Check the Display Area and the Harness. signal wire for the sender, or a poor terminal
connection or a poorly connected connector.
a. Turn the “ECS” switch to the OFF/RESET Repair the harness or replace the harness. If
position. the cause of the diagnostic fault is not found,
replace the Main Display Module.
b. Check for loose connections or corroded
connections to the sender. • Not OK - The voltage is not greater than 6.5
DCV or the voltage is not less than 0.5 DCV.
c. Replace the corroded contacts and tighten the The harness is shorted to a power circuit.
loose connections. Repair the harness or replace the harness. If
the cause of the diagnostic fault is not found,
d. Turn the “ECS” switch to the replace the Main Display Module.
COOLDOWN/STOP position. The “SERV
CODE” indicator should be ON for the i01099816
diagnostic code CID 0175 FMI 04.
CID 0175 FMI 08 Temperature
e. Disconnect the engine harness from the
sender. Sender (Engine Oil) Abnormal
Signal - Test
f. Observe the “SERV CODE” indicator.
SMCS Code: 1408-038-UN; 1929-038-UN;
Expected Result: The “SERV CODE” indicator 7451-038-UN
should turn OFF.
Note: Ensure that the diagnostic code (CID FMI) is
Results: on hold. Ensure that the “SERV CODE” indicator
is ON. Use the electrical system schematic of the
• OK - The “SERV CODE” indicator turns OFF. engine that is being serviced to find the connector
The sender has a problem. Replace the contact that is located on the Main Display Module.
sender. The connector contact should correspond to the
current CID that is shown on the Display Area.
• Not OK - The “SERV CODE” indicator stays
ON. The harness wiring or the Main Display The diagnostic code is recorded when the Main
Module has a problem. Proceed to Step 3. Display Module reads an abnormal sensor signal.
The abnormal signal means that the signal is not
3. Check the Sender Wire for a Short to Ground. identifiable by the internal circuitry of the Main Display
Module. The corresponding Indicator Lamp begins
a. Turn the “ECS” switch to the OFF/RESET flashing as a result of this diagnostic condition. Also,
position. the Gauge Needle is in the warning region. The
following examples are possible causes.
b. Disconnect the engine harness from the
sender. • The engine oil temperature sensor has a problem.
c. Turn the “ECS” switch to the • The ground circuit for the engine oil temperature
COOLDOWN/STOP position. sensor that is located in the engine harness is
open.
d. Measure the voltage from ground to the sender.
• The signal circuit for the engine oil temperature
Expected Result: The voltage should be 6.0 sensor that is located in the engine harness is
± 0.5 DCV. shorted to +battery.

Results: • The signal circuit for the engine oil temperature

sensor that is located in the engine harness is
open or the connector is disconnected.
50 SENR6587-03
Testing and Adjusting Section

• The Main Display Module has a problem. • If the voltage is not between approximately 1.0
DCV and 7.0 DCV, the signal voltage at the
1. Check the Display Area and the Harness. sensor is not correct. If the voltage is greater
than 7.0 DCV, proceed to Step 5. If the voltage
a. Turn the “ECS” switch to the OFF/RESET is less than 1.0 DCV, proceed to Step 6.
position.
a. Turn the “ECS” switch to the
b. Check for loose terminal connections or COOLDOWN/STOP position.
corroded terminal connections to the engine oil
pressure sensor. b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the ground wire for the Engine
c. Clean corroded terminals and tighten loose Oil Temperature Sensor (pin B) to the supply
connections. wire (pin C).

d. Turn the “ECS” switch to the Expected Result: The voltage should be
COOLDOWN/STOP position. approximately between 1.0 DCV and 7.0 DCV.

e. The “SERV CODE” indicator should be ON for Results:

the diagnostic code CID 0175 FMI 08.
• OK - The voltage is between approximately
2. Measure the Voltage of the Supply Wire for the 1.0 DCV and 7.0 DCV. The signal voltage at
Engine Oil Temperature Sensor. the sensor is correct. Proceed to Step 4.

a. Turn the “ECS” switch to the • Not OK - The voltage is greater than 7.0
COOLDOWN/STOP position. DCV. The signal voltage at the sensor is not
correct. Proceed to Step 5.
b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the ground wire for the Engine • Not OK - The voltage is less than 1.0 DCV.
Oil Temperature Sensor (pin B) to the supply The signal voltage at the sensor is not
wire (pin A). correct. Proceed to Step 6.

Expected Result: The voltage should be 8.0 4. Measure The Signal Voltage Of The Engine Oil
± 0.5 DCV. Temperature Sensor.

Results: a. Turn the “ECS” switch to the

COOLDOWN/STOP position.
• OK - The voltage is 8.0 ± 0.5 DCV. Proceed
to Step 3. b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the connector contact of the
• Not OK - The voltage is less than 0.5 DCV. ground wire on the Main Display Module to the
The harness wiring has a problem. There signal wire connector contact.
is an open circuit, a short to ground in the
supply wire for the Engine Oil Temperature Expected Result: The voltage should be
Sensor or a poor connection. Repair the similar to the voltage that was measured in
harness or replace the harness. If the cause Step 3.
of the diagnostic fault is not found, proceed
to Step 3. Results:

3. Measure The Engine Oil Temperature Sensor • OK - The voltage is similar to the voltage that
Voltage. was measured in Step 3. The Main Display
Module is receiving a valid signal voltage.
The Main Display Module has a problem.
Replace the Main Display Module. See
• If the voltage is between approximately 1.0 DCV Testing And Adjusting, “Module - Replace”
and 7.0 DCV, the signal voltage at the sensor is for more information.
correct. Proceed to Step 4.
SENR6587-03 51
Testing and Adjusting Section

• Not OK - The value is not similar to the • Not OK - The resistance is less than 5000
voltage that was measured in Step 3. The ohms. Repair the harness or replace the
engine harness has an open circuit in the harness.
signal circuits or the engine harness has an
open circuit in the ground circuits. Repair
i01035812
the engine harness or replace the engine
harness. CID 0177 FMI 08 Temperature
5. Check For A Short To +Battery. Sensor (Transmission Oil)
a. Turn the “ECS” switch to the OFF/RESET
Abnormal Signal - Test
position.
SMCS Code: 1408-038-NS; 3080-038-NS;
7451-038-NS
b. Disconnect the connector of the Main Display
Module.
Note: Ensure that the desired diagnostic code (CID
FMI) is on hold. Ensure that the “SERV CODE”
c. Use the 7X-1710 Multimeter Probe to measure indicator is ON. Find the connector contact that is
the resistance that is between +battery and
located on the Main Display Module. The electrical
the signal wire (pin C) for the Engine Oil
system schematic for the engine that is being
Temperature Sensor. serviced may assist the operator in finding the
connector contact that corresponds to the current
Expected Result: The resistance should be
CID that is shown.
greater than 5000 ohms.
The diagnostic code is recorded when the Main
Results:
Display Module reads a signal that is from the sensor
that is abnormal. The signal is not identifiable to
• OK - The resistance is greater than 5000 the input circuits of the Main Display Module. As a
ohms. The signal wire for the harness is
result of this diagnostic condition, the corresponding
correct. Replace the Main Display Module. Indicator Lamp will flash and the Gauge Needle
See Testing And Adjusting, “Module -
will be located in the warning region. The following
Replace” for more information.
examples are possible causes.
• Not OK - The resistance is less than 5000 • The sensor for marine gear oil temperature has
ohms. Repair the harness or replace the
a problem.
harness.

6. Check For A Short To Ground. • The ground circuit of the sensor for marine gear oil
temperature that is located in the engine harness
is open.
a. Turn the “ECS” switch to the OFF/RESET
position.
• The sensor of the signal circuit for marine gear oil
temperature that is located in the engine harness
b. Disconnect the connector for the Main Display
is shorted to +battery.
Module and the connector for the Engine Oil
Temperature Sensor.
• The sensor of the signal circuit for marine gear oil
temperature that is located in the engine harness
c. Use the 7X-1710 Multimeter Probe to measure
is open or the connector is disconnected.
the resistance that is between the ground wire
and the signal wire (pin C) of the Engine Oil
Temperature Sensor. • The Main Display Module has a problem.
1. Check the Display Area and the Harness.
Expected Result: The resistance should be
greater than 5000 ohms.
a. Turn the “ECS” switch to the OFF/RESET
position.
Results:
b. Check for loose terminal connections or
• OK - The resistance is greater than 5000 corroded terminal connections to the sensor for
ohms. The resistance of the signal wire for
marine gear oil temperature.
the harness is correct. Replace the Main
Display Module. See Testing And Adjusting, c. Clean corroded terminals and tighten loose
“Module - Replace” for more information.
connections.
52 SENR6587-03
Testing and Adjusting Section

d. Turn the “ECS” switch to the • Not OK - The voltage is less than 0.5 DCV.
COOLDOWN/STOP position. The “SERV The harness wiring has a problem. There
CODE” indicator should be ON for the is an open circuit, a short to ground in the
diagnostic code CID 0177 FMI 08. supply wire of the sensor for marine gear oil
pressure or a poor connection. Repair the
2. Confirm that the harness code selection harness or replace the harness. If the cause
matches the application. of the diagnostic fault is not found, proceed
to Step 4.
a. Determine the CURRENT harness code
selection. For more information, see Testing 4. Measure The Voltage of the Marine Gear Oil
And Adjusting, “Harness Code - Troubleshoot”. Temperature Signal.

b. Determine the CORRECT harness code a. Turn the “ECS” switch to the
selection for the application. For more COOLDOWN/STOP position.
information, see Systems Operation, “Quad
Gauge Module”. b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the Marine Gear Oil Pressure
c. Compare the CURRENT harness code Sensor Ground Wire (pin B) to the Supply Wire
selection to the CORRECT harness code (pin C).
selection.
Expected Result: The voltage should be
Expected Result: The CURRENT harness between 1.0 DCV and 7.0 DCV.
code selection is correct for the application.
Results:
Results:
• OK - The signal voltage at the sensor is
• OK - Proceed to 3. correct. Proceed to Step 5.

• Not OK - Correct the harness code selection • Not OK - The signal voltage at the sensor is
or install marine gear sensors so that the not correct. If the voltage is greater than 7.0
application matches the current harness DCV, proceed to Step 6. If the voltage is less
code selection. If the marine gear sensors than 1.0 DCV, proceed to Step 7.
are not installed, use harness code 11. If
harness code 9, harness code 10 or harness 5. Measure The Voltage of the Marine Gear Oil
code 12 is selected, make sure the marine Temperature Signal Voltage.
gear sensors are installed. If the cause of the
diagnostic is not found, proceed to 3. a. Turn the “ECS” switch to the
“COOLDOWN/STOP” position.
3. Measure the Voltage of the Marine Gear Oil
Temperature Sensor Supply Wire. b. Use the 7X-1710 Multimeter Probe to measure
the voltage from the ground wire of the Main
a. Turn the “ECS” switch to the Display Module (contact 2) to the signal wire
COOLDOWN/STOP position. (contact 28).

b. Use the 7X-1710 Multimeter Probe to measure Expected Results: The voltage should be
the voltage from the marine gear oil pressure equal to the voltage that was recorded in Step
sensor ground wire (pin B) to the supply wire 4.
(pin A).
Results:
Expected Result: The voltage should be 8.0
± 0.5 DCV. • OK - The voltage is correct. The Main Display
Module is receiving a valid signal voltage.
Results: The Main Display Module has a problem.
Replace the Main Display Module. See
• OK - The voltage is correct. Proceed to Step Testing And Adjusting, “Module - Replace”
4. for more information.
SENR6587-03 53
Testing and Adjusting Section

• Not OK - The voltage is not equal to the i02784942

voltage that was measured in Step 4. The
engine harness has an open circuit in the CID 0248 FMI 02 Cat Data Link
signal circuits or the ground circuits. Repair Incorrect - Test
the engine harness or replace the engine
harness. SMCS Code: 1408-038; 7451-038
6. Check For A Short To +Battery. S/N: 2RD1-Up

a. Turn the “ECS” switch to the OFF/RESET S/N: 2TD1-Up

position. S/N: 2BM1-Up
b. Disconnect the connector of the Main Display S/N: 3DM1-Up
Module and the connector of the Marine Gear
Oil Temperature Sensor. S/N: 4GM1-Up

c. Use the 7X-1710 Multimeter Probe to S/N: 5XM1-Up

measure the resistance between +battery and S/N: 6PM1-Up
the signal wire (pin C) for the Marine Gear Oil
Temperature sensor. S/N: 7HM1-Up

Expected Results: The resistance should be S/N: 7KM1-Up

greater than 5000 ohms.
S/N: 7SM1-Up
Results: S/N: 8EM1-Up

• OK - The resistance of the signal wire for the S/N: 8RM1-Up

harness is correct. Replace the Main Display
Module. For more information, see Testing S/N: 4TN1-Up
And Adjusting, “Module - Replace”.
S/N: 6HN1-Up
• Not OK - The resistance is less than 5000 S/N: 6PN1-Up
ohms. Repair the harness or replace the
harness. S/N: 6WN1-Up

7. Check For A Short To Ground. S/N: 7RN1-Up

S/N: 8CN1-Up
a. Turn the “ECS” switch to the OFF/RESET
position. S/N: 8KN1-Up

b. Disconnect the connector of the Main Display S/N: 9AN1-Up

Module and the connector of the Marine Gear
S/N: 3LS1-Up
Oil Temperature Sensor .
S/N: 3MS1-Up
c. Use the 7X-1710 Multimeter Probe to measure
the resistance that is between ground and the S/N: 3NS1-Up
signal wire (pin C) for the Marine Gear Oil
Temperature Sensor. S/N: 3PS1-Up
S/N: 3RS1-Up
Expected Result: The resistance should be
greater than 5000 ohms. S/N: 3SS1-Up

Results: S/N: 3TS1-Up

S/N: 3WS1-Up
• OK - The resistance of the signal wire for the
harness is correct. Replace the Main Display S/N: 3XS1-Up
Module. For more information, see Testing
And Adjusting, “Module - Replace”. S/N: 5PS1-Up

• Not OK - The resistance is less than 5000 S/N: 1NW1-Up

ohms. Repair the harness or replace the
S/N: 1PW1-Up
harness.
S/N: 1TW1-Up
54 SENR6587-03
Testing and Adjusting Section

S/N: 2FW1-Up Note: If the Main Display Module was recently

replaced, see Testing And Adjusting, “Main Display
S/N: 2GW1-Up Module Initialization - Adjust” for more information.
S/N: 2HW1-Up
1. Check the other Electronic Modules for a
S/N: 2JW1-Up similar diagnostic code.

S/N: 3CW1-Up a. If a similar diagnostic code is found, use

the procedures for that electronic module to
S/N: 3DW1-Up troubleshoot the diagnostic code.
S/N: 3ZW1-Up
b. If no similar diagnostic code is found, proceed
S/N: 4AW1-Up to Step 2.

S/N: 4BW1-Up 2. Inspect The Harness Connectors.

S/N: 5AW1-Up
a. Turn the “ECS” switch to the OFF/RESET
S/N: 2EZ1-Up position.

S/N: 6HZ1-Up b. Inspect the engine harness connectors that are

related to the Cat Data Link. Make sure that the
connections are clean and tight.

c. If necessary, repair the engine harness or

replace the engine harness. Otherwise,
proceed to Step 3.

3. Check For A Short To Ground.

g00530708
Illustration 56
a. The “ECS” switch remains in the OFF/RESET
Schematic For The Caterpillar Data Link
position.
Note: Ensure that the “SERV CODE” indicator is ON.
b. Disconnect the engine harness from all
electronic modules that use the Cat Data Link.
This diagnostic code is recorded when the Main
Display Module does not receive expected
c. At the engine harness connector for the Main
information. For example, the engine speed is not
Display Module, measure the resistance
received from the Engine Electronic Control Module
between the battery ground (contact 2) and the
(engine ECM) through the Cat Data Link. As a result
Cat Data Link circuits (contact 5 and contact
of this diagnostic condition, the display area depends
14).
on the Cat Data Link for information that indicates
abnormal values. The following items are possible
Expected Result: The harness circuit
causes of the readouts. The causes are listed in
resistance should be greater than 5000 ohms.
order of probability.
Results:
• There is a poor electrical connection at the engine
harness connector.
• OK - The harness circuit resistance is
correct. Proceed to Step 5.
• The Cat Data Link circuit in the engine harness is
shorted to ground.
• Not OK - The harness circuit resistance is
less than 5000 ohms. The engine harness
• The Cat Data Link circuit in the engine harness is has a problem. There is a short between
shorted to +battery.
battery ground and the circuit for the Cat
Data Link in the engine harness. Repair
• The Cat Data Link circuit in the engine harness is the engine harness or replace the engine
open.
harness.
• Another electronic module (Secondary ECM, 4. Check For A Short To +Battery.
DeNOx Controller, CCM, PRCM and other
modules) that also uses the Cat Data Link is having
a problem.
SENR6587-03 55
Testing and Adjusting Section

a. The “ECS” switch remains in the OFF/RESET i01035830

position. All related electronic modules remain
disconnected from the engine harness. CID 0263 FMI 03 Sensor Power
Supply Voltage Above Normal
b. At the engine harness connector for the Main
Display Module, measure the resistance - Test
between +battery (contact 1) and the Cat Data
Link circuits (contact 5 and contact 14). SMCS Code: 1408-038-NS; 7451-038-NS

Expected Results: The resistance should be

greater than 5000 ohms.

Results:

• OK - The resistance is greater than 5000

ohms. The harness circuit resistance is
correct. Proceed to Step 5. Illustration 57
g00573764

Schematic For Sensor Power Supply

• Not OK - The resistance is less than 5000
ohms. The engine harness has a problem. Note: The procedures that are used to troubleshoot
There is a short between the battery ground this diagnostic code may cause additional diagnostic
and the circuit for the Cat Data Link in the codes to be generated. Find the cause and repair the
engine harness. Repair the engine harness cause of this diagnostic code before troubleshooting
or replace the engine harness. any new diagnostic codes.
5. Check For An Open Circuit In The Harness. This diagnostic code is recorded when the Main
Display Module reads the voltage of the sensor
a. The “ECS” switch remains in the OFF/RESET supply voltage circuit as above normal. Also, the
position. All related electronic modules remain diagnostic code is recorded when the Main Display
disconnected from the engine harness. Module is shorted to +battery.
b. Measure the resistance of the Cat Data Link 1. Measure the Voltage at the Main Display
circuit in the engine harness. Module.
c. Measure the resistance from the connector a. Turn the “ECS” switch to the
of the Main Display Module. The resistance COOLDOWN/STOP position.
should be taken from contact 5 and contact
14 to the connectors for each of the related b. Use the 7X-1710 Multimeter Probe to measure
electronic modules. the voltage at the Main Display Module from
Contact 24 to Contact 2 (ground). Do not
Expected Result: The resistance should be disconnect the harness from the Main Display
less than 5 ohms. Module.
Results: Expected Result: The voltage should be 8.0
± 0.5 DCV.
• OK - The resistance is less than 5 ohms.
The resistance of the circuit for the Cat Results:
Data Link in the engine harness is correct.
The Main Display Module has a problem. • OK - The voltage is 8.0 ± 0.5 DCV. The
Replace the Main Display Module. For more sensor supply voltage is correct. If the SERV
information, see Testing And Adjusting, CODE indicator remains ON, replace the
“Module - Replace”. Main Display Module. For more information,
see Testing And Adjusting, “Module -
• Not OK - The resistance is greater than 5 Replace”.
ohms. The engine harness has a problem.
The circuit for the Cat Data Link is open in the • Not OK - The voltage is not 8.0 ± 0.5 DCV.
engine harness. Repair the engine harness The sensor supply voltage is not correct.
or replace the engine harness. STOP. Proceed to Step 2.

2. Disconnect The Sensors.

a. The “ECS” switch remains in the

COOLDOWN/STOP position.
56 SENR6587-03
Testing and Adjusting Section

b. Disconnect all sensors and senders that • Not OK - The resistance is less than 5000
receive +8 DCV from the Main Display Module. ohms. The engine harness has a problem.
There is a short between ground and the
c. Use the 7X-1710 Multimeter Probe to measure sensor supply voltage circuit in the engine
the voltage that is from connector contact 2 harness. Repair the engine harness or
(ground) to contact 24 of the Main Display replace the engine harness.
Module.
i01035834
Expected Result: The voltage should measure
8.0 ± 0.5 DCV. CID 0263 FMI 04 Sensor Power
Results: Supply Voltage Below Normal
• OK - The voltage measures 8.0 ± 0.5 DCV.
- Test
The voltage is correct. One of the sensors
SMCS Code: 1408-038-NS; 7451-038-NS
or one of the senders has a problem.
Individually reconnect each sensor and
reconnect each sender while the voltage
level is being monitored. The voltage
should measure 8.0 ± 0.5 DCV when each
component is connected. If the voltage is not
8.0 ± 0.5 DCV the sensor or the sender has
a problem. Replace the sensor or replace
the sender. g00573764
Illustration 58
• Not OK - The sensor supply voltage is not Schematic For Sensor Power Supply
8.0 ± 0.5 DCV. The sensor supply voltage is
not correct. Proceed to Step 3. Note: The procedures that are used to troubleshoot
this diagnostic code may cause additional diagnostic
3. Check The Harness For A Short To +Battery. codes to be generated. Find the cause of the
diagnostic code and repair the cause of the
a. Turn the “ECS” switch to the OFF/RESET diagnostic code before troubleshooting any new
position. diagnostic codes.

b. Disconnect all sensors and senders that This diagnostic code is recorded when the Main
receive +8 DCV from the Main Display Module. Display Module reads the voltage of the sensor
supply voltage circuit as below normal voltage. This
c. Disconnect the engine harness from the Main diagnostic code is also recorded when the voltage is
Display Module. shorted to ground.

d. At the engine harness connector for the Main 1. Measure the voltage at the Main Display
Display Module, measure the resistance from Module.
connector contact 24 to contact 1 (+battery).
a. Turn the “ECS” switch to the
Expected Results: The resistance should be COOLDOWN/STOP position.
greater than 5000 ohms.
b. Use the 7X-1710 Multimeter Probe to measure
Results: the voltage at the Main Display Module from
contact 24 to contact 2 (ground).
• OK - The resistance is greater than 5000
ohms. The harness resistance is correct. c. Do not disconnect the harness from the Main
The Main Display Module has a problem. Display Module.
Replace the Main Display Module. For more
information, see Testing And Adjusting, Expected Result: The voltage should be 8.0
“Module - Replace”. ± 0.5 DCV.

Results:
SENR6587-03 57
Testing and Adjusting Section

• OK - The voltage is 8.0 ± 0.5 DCV. The • OK - The resistance is greater than 5000
voltage is correct. If the “SERV CODE” ohms. The harness resistance is correct.
indicator remains ON, replace the Main The Main Display Module has a problem.
Display Module. For more information, see Replace the Main Display Module. For more
Testing And Adjusting, “Module - Replace”. information, see Testing And Adjusting,
“Module - Replace”.
• Not OK - The voltage is not 8.0 ± 0.5 DCV.
The sensor supply voltage is incorrect. • Not OK - The resistance is less than 5000
Proceed to Step 2. ohms. The engine harness has a problem.
There is a short between ground and the
2. Disconnect The Sensors. sensor supply voltage circuit in the engine
harness.
a. The ECS switch remains in the
COOLDOWN/STOP position.
i01035973

b. Disconnect all sensors and all senders that

receive +8 DCV from the Main Display Module.
CID 0271 FMI 03 Alarm (Action)
Voltage Above Normal - Test
c. Use the 7X-1710 Multimeter Probe to measure
the voltage from connector contact 2 (ground) SMCS Code: 1408-038; 7400-038; 7451-038
to contact 24 of the Main Display Module.

Expected Result: The voltage should be 8.0

± 0.5 DCV.

Results:

• OK - The sensor supply voltage is 8.0 ± 0.5

DCV. The sensor supply voltage is correct. Illustration 59
g00573861
One of the sensors or the senders has a Schematic For The Alarm.
problem. Individually reconnect each sensor
(1) Locomotive Engines - 410-WH: Marine Engines and Generator
or reconnect each sender while the voltage Set Engines - D25-GN.
is being monitored. The voltage should not
drop below 7.5 DCV. If the voltage drops This diagnostic code is recorded when the Main
below 7.5 DCV, the sensor or the sender has Display Module reads the voltage of the circuit of the
a problem. Replace the sensor or replace Action Alarm as above normal. Also, this diagnostic
the sender. code is recorded when the circuit is shorted to
+battery. As a result of this diagnostic condition, the
• Not OK - The voltage is less than 8.0 ± Action Alarm sounds continuously.
0.5 DCV. The sensor supply voltage is not
correct. Proceed to Step 3. 1. Check The Alarm Circuit.
3. Check The Harness For A Short To Ground. a. Turn the “ECS” switch to the OFF/RESET
position.
a. Turn the “ECS” switch to the OFF/RESET
position. b. Check for loose terminal connections or
corroded terminal connections to the Action
b. Disconnect all sensors and senders that Alarm.
receive +8 DCV from the Main Display Module.
c. Clean the corroded terminals and tighten the
c. Disconnect the engine harness from the Main loose connections.
Display Module.
d. Do Not disconnect the harness from the Main
d. At the engine harness connector for the Main Display Module.
Display Module, measure the resistance from
connector contact 24 to contact 2 (ground). e. Turn the “ECS” switch to the
COOLDOWN/STOP position.
Expected Result: The resistance should be
greater than 5000 ohms. f. Listen for the sounding of the Action Alarm.
Results: Expected Result: The alarm should not sound.

Results:
58 SENR6587-03
Testing and Adjusting Section

• OK - The alarm does not sound. The Main • Not OK - If the FMI 05 diagnostic code is
Display Module has a problem. Replace the not active, the Action Alarm has a problem.
Main Display Module. For more information, Measure the resistance across the terminals
see Testing And Adjusting, “Module - of the Action Alarm. The resistance should
Replace”. be 200 ± 100 ohms. If the resistance of the
Action Alarm is good, but the alarm does not
• Not OK - The alarm sounds. There is a sound, proceed to Step 2. If the resistance of
short between the circuit of the Action Alarm the Action Alarm is not good, then replace
and +Battery in the engine harness. Repair the Action Alarm. Proceed to Step 2.
the engine harness or replace the engine
harness. 2. Check The Harness.

a. Turn the “ECS” switch to the OFF/RESET

i01035978
position.
CID 0271 FMI 05 Alarm (Action) b. Remove the jumper wire from the harness
Current Below Normal - Test leads of the Action Alarm.

SMCS Code: 1408-038; 7400-038; 7451-038 c. Reconnect the harness leads to the Action
Alarm.

d. Disconnect the engine harness from the Action

Alarm.

e. At the engine harness connector for the Main

Display Module, measure the resistance from
contact 4 to contact 2. Contact 2 is the ground.
g00573861
Illustration 60
Schematic For Action Alarm.
Expected Result: The resistance should be
less than 300 ohms.
(1) Locomotive - 410-WH: Marine Engines and Generator Engines
- 025-GN.
Results:
This diagnostic code is recorded when the Main
Display Module reads the current of the circuit for • OK - The resistance is less than 300 ohms.
the Action Alarm as below normal current. Also, this The harness resistance is correct. Proceed
diagnostic code is recorded when the Main Display to Step 4.
Module reads an open circuit with the Action Alarm.
As a result of this action, the Action Alarm does not • Not OK - The resistance is greater than 300
sound when the Action Alarm should sound. ohms. The harness circuit is open. Proceed
to Step 3.
1. Check The Alarm.
3. Check The Harness.
a. Disconnect the engine harness from the Action
Alarm. Disconnect the engine harness from the Action
Alarm. Check for an open circuit between the
b. Place a jumper wire across the two leads of the Main Display Module (contact 4) and the lead of
Action Alarm of the engine harness. the Action Alarm (terminal 1). Also, check for an
open circuit between the lead of the Action Alarm
Expected Result: The FMI 05 diagnostic code (terminal 2) and ground. If an open circuit is found,
should remain active. repair the harness or replace the harness.

Results: 4. Check The Main Display Module.

a. Turn the “ECS” switch to the OFF/RESET

• OK - The FMI 05 diagnostic code is still position.
active. The Action Alarm is not causing the
problem. Measure the resistance across the
terminals of the Action Alarm. The resistance b. Turn the “ECS” switch to the OFF/RESET
should be 200 ± 100 ohms. If the resistance position.
of the Action Alarm is good, but the alarm
does not sound, proceed to Step 2. c. Reconnect the engine harness connector to
the Main Display Module.
SENR6587-03 59
Testing and Adjusting Section

d. Reconnect the engine harness to the Action b. Measure the resistance across the terminals of
Alarm. the Action Alarm.

e. Turn the “ECS” switch to the Expected Result: The resistance across the
COOLDOWN/STOP position. terminals is 200 ± 100 Ω.

Expected Result: The FMI 05 diagnostic code Results:

should not be active.
OK - The resistance is correct. If the Action
Results: Alarm does not sound, proceed to Step 2.

• OK - The FMI 05 diagnostic code is Not OK - The resistance across the terminals is
not active. The Main Display Module is not correct. Replace the Action Alarm. STOP.
not causing the problem. The problem
is intermittent. The probable cause is a 2. Check The Harness.
poor electrical connection at the harness
connectors or a damaged harness. Check a. Turn the “ECS” switch to the OFF/RESET
the harness for damage and clean the position.
connectors when cleaning is required.
b. Disconnect the engine harness from the Action
• Not OK - The FMI 05 diagnostic code is Alarm.
still active. The Main Display Module has a
problem. Replace the Main Display Module. c. Disconnect the engine harness from the Main
For more information, see Testing And Display Module.
Adjusting, “Module - Replace”.
d. At the engine harness connector for the Main
Display Module, measure the resistance from
i01036188
the connector contact 4 to connector contact
CID 0271 FMI 06 Alarm (Action) 2 (ground).

Current Above Normal - Test Expected Result: The resistance should be

greater than 5000 ohms.
SMCS Code: 1408-038; 7400-038; 7451-038
Results

• OK - The resistance is correct. Proceed to

Step 3.

• Not OK - The resistance is less than 5000

ohms. The engine harness has a problem.
Repair the engine harness or replace the
Illustration 61
g00573861 engine harness. STOP.
Schematic For The Alarm.
3. Check The Main Display Module.
(1) Locomotive Engines - 410-WH: Marine Engines and Generator
Set Engines - 025-GN.
a. Turn the “ECS” switch to the OFF/RESET
This diagnostic code is recorded when the Main position.
Display Module reads the current in the circuit of
the Action Alarm as above normal or the current is b. Use the correct service tools to remove contact
shorted to ground. As a result of this fault, the Action 4 from the engine harness connector for the
Alarm does not sound when the Action Alarm should Main Display Module.
sound.
c. Reconnect the engine harness connector to
1. Check the Alarm. the Main Display Module.

a. Disconnect the engine harness from the Action d. Turn the “ECS” switch to the
Alarm. COOLDOWN/STOP position.

Note: The Action Alarm has a problem if the FMI 06 Expected Result: FMI 06 should NOT be
diagnostic code is not active. The Action Alarm is not active.
causing the problem if the FMI 06 diagnostic code is
still active. Results:
60 SENR6587-03
Testing and Adjusting Section

• OK - FMI 06 is NOT active. The Main Display

Module is NOT causing the problem. The
problem is intermittent. The probable cause
is a poor electrical connection at the harness
connectors or a damaged harness. Check
the harness for damage and clean the
harness connectors as cleaning is required.
STOP.

• Not OK - FMI 06 is still active. The Main

Display Module has a problem. Replace the
Main Display Module. For more information,
see Testing And Adjusting, “Module -
Replace”.

i01036410

CID 0819 FMI 02 Display Data

Link Incorrect - Test
SMCS Code: 1408-038; 7451-038

This diagnostic code is recorded when the Main

Display Module does not receive expected
information from the Quad Gauge Cluster Modules.
When the Main Display Module sends information to
the Quad Gauge Cluster Module, the Quad Gauge
Cluster Module sends information back to the Main
Display Module. The returned information verifies
that the Quad Gauge Cluster Module has correctly
received the original information that was sent from
the Main Display Module. When the Main Display
Module does not receive the expected information,
the diagnostic code is recorded. As a result, the
Quad Gauge Cluster Modules may not respond to
the information that is sent from the Main Display
Module while the Main Display Module is in Normal
Mode (Mode 0). Check for loose connections to the
display data link or poor connections to the display
data link. Check for opens or shorts in the harness
wiring of the display data link. During the self test,
problems with the Quad Gauge Cluster Modules
can be determined. The self test occurs immediately
after turning the “ECS” switch from the OFF/RESET
position to the AUTO position, the MAN/START
position, or the COOLDOWN/STOP position. For
more information on this subject, see Testing And
Adjusting, “System Self Test”.

Note: This diagnostic code can also be caused by a

harness code that is not correct for the application.
A mismatch with the harness code is not likely to be
the cause of this diagnostic code in an application
that has been working normally in the past. In a
new installation, a mismatch with the harness code
is most likely to be the cause of the diagnostic
code. For more information regarding the selection
of harness codes, see Systems Operation, “Quad
Guage Module”.
SENR6587-03 61
Testing and Adjusting Section

i01036486

CID 0821 FMI 03 Display Power

Supply Voltage Above Normal
- Test
SMCS Code: 1408-038; 7451-038

g00573982
Illustration 62
Schematic For Display Power Supply.
(1) Locomotive Engines - A304-RD: Marine
Engines And Generator Set Engines -
049-OR.

This diagnostic code is recorded when the Main c. Do not disconnect the harness from the Main
Display Module reads the voltage of contact 34 below Display Module.
normal or the voltage is shorted to ground. Normal
supply voltage is 9.0 ± 0.5 DCV. Expected Results: The voltage should be 9.0
± 0.5 DCV.
1. Measure The Voltage At The Main Display
Module. Results:

a. Turn the “ECS” switch to the • OK - The voltage is correct. The display
COOLDOWN/STOP position. power supply is correct. If the FMI 03
diagnostic code is still active, the Main
b. Use the 7X-1710 Multimeter Probe to measure Display Module has a problem. Replace the
the voltage at the connector of the Main Display Main Display Module. For more information
Module. The voltage should be measured from on this subject, see Testing And Adjusting,
contact 34 to contact 2. “Module - Replace”.
62 SENR6587-03
Testing and Adjusting Section

• Not OK - The voltage is not correct. The

display power supply has a problem. Proceed
to Step 2.

2. Check The Harness For A Short To +Battery.

a. Turn the “ECS” switch to the OFF/RESET

position.

b. Disconnect the engine harness from the Main

Display Module.

c. At the engine harness connector for the Main

Display Module, measure the resistance from
connector contact 34 to connector contact 1
(+battery).

Expected Result: The resistance should be

less than 5000 ohms.

Results:

• OK - The resistance is correct. The engine

harness has a problem. There is a short
between +battery and the 9.0 ± 0.5 DCV. The
short is in the circuit for the display power
supply that is located in the engine harness.
STOP.

• Not OK - The resistance is NOT correct.

The Main Display Module has a problem.
Replace the Main Display Module. For more
information on this subject, see Testing And
Adjusting, “Module - Replace”.
SENR6587-03 63
Testing and Adjusting Section

i01036490

CID 0821 FMI 04 Display Power

Supply Voltage Below Normal
- Test
SMCS Code: 1408-038; 7451-038

g00573982
Illustration 63
Schematic For The Display Power Supply.
(1) Locomotive Engines - A304-RD: Marine
Engines and Generator Set Engines -
049-OR.

This diagnostic code is recorded when the Main c. Do NOT disconnect the harness from the Main
Display Module reads the voltage of contact 34 below Display Module.
normal or the voltage is shorted to ground. Normal
supply voltage is 9.0 ± 0.5 DCV. Expected Result: The voltage should measure
9.0 ± 0.5.
1. Measure the Voltage at the Main Display
Module. Results:

a. Turn the “ECS” switch to the • OK - The voltage is correct. If the FMI 04
COOLDOWN/STOP position. diagnostic code is still active, the Main
Display Module has a problem. Replace the
b. Use the 7X-1710 Multimeter Probe to Main Display Module. For more information
measure the voltage at the connector for the on this subject, see Testing And Adjusting,
Main Display Module. The voltage should be “Module - Replace”.
measured from contact 34 to contact 2.
64 SENR6587-03
Testing and Adjusting Section

• Not OK - The voltage is not correct. The • OK - The resistance of the harness circuit is
Display Power Supply has a problem. correct. The Main Display Module is faulty.
Proceed to Step 2. Replace the Main Display Module. See
Testing And Adjusting, “Module - Replace”.
2. Disconnect the Quad Gauge Cluster Modules.
• Not OK - The resistance of the harness circuit
a. Turn the “ECS” switch to the OFF/RESET is incorrect. The machine harness is faulty.
position. Repair the harness or replace the harness.

b. Disconnect the Quad Gauge Cluster Modules.

i01036642

c. Turn the ECS switch to the COOLDOWN/STOP

position.
Alert Indicator - Troubleshoot
SMCS Code: 7400-038-IND; 7451-038-IND
d. At the engine harness connector for the Main
Display Module, measure the voltage from
connector contact 34 to connector contact 2 Indicator Lamp Is Always Flashing
(ground).
This procedure is for the parameter that has the
e. Reconnect the Quad Gauge Cluster Modules indicator lamp that flashes all of the time. The
one at a time. Between reconnecting the “Always Flashing” condition is probably caused by
Modules, record the voltage of the display an undesired open circuit. Also, the Main Display
power supply. Module may cause this problem (unlikely condition).

Expected Result: The voltage should be 9.0 ± 1. Locate The Switch.

0.5 DCV after each of the Quad Gauge Cluster
Modules have been reconnected. a. Turn the “ECS” switch to the OFF/RESET
position.
Results:
b. Locate the switch that corresponds to the
• OK - The voltage is correct. The Display parameter that is always flashing the indicator
Power Supply is correct. Proceed to Step 3. lamp. If necessary, use the Electrical System
Schematic in order to assist in locating the
• Not OK - The voltage is not correct after switch.
reconnecting one of the Quad Gauge
Cluster Modules. The Quad Gauge Cluster c. Check for loose terminal connections or
Module that affected the voltage has a corroded terminal connections to the switch.
problem. Replace the Quad Gauge Cluster
Module. For more information on this d. Clean corroded terminals and tighten loose
subject, see Testing And Adjusting, “Module connections.
- Replace”STOP.
2. Check The Harness.
3. Check for a Short to Ground.
a. Disconnect the signal wire from the switch.
a. Turn the “ECS” switch to the OFF/RESET
position. b. Connect a jumper wire from the signal wire to
the ground wire. If a ground wire is not near,
b. Disconnect the machine harness from the main connect the signal wire to the battery ground.
display module.
c. Turn the “ECS” switch to the
c. At the machine harness connector for the COOLDOWN/STOP position.
Main Display Module, measure the resistance
between connector contact 34 and connector Expected Result: The indicator lamp should
contact 2. stop flashing.

Expected Results: The resistance should be Results:

greater than 5000 ohms.
• No - The engine harness is open or the Main
Results: Display Module has a problem. Proceed to
Step 3.
SENR6587-03 65
Testing and Adjusting Section

• Yes - The circuit is operating correctly. The c. Check for loose connections or corroded
switch has a problem. Check the switch or terminal connections to the switch.
replace the switch.
d. Clean corroded terminals and tighten the loose
3. Check The Harness. connections.

a. Turn the “ECS” switch to the OFF/RESET 2. Check The Harness.

position.
a. Disconnect the signal wire from the switch.
b. On the Electrical Schematic, trace the signal
wire from the switch to the Main Display b. Turn the “ECS” switch to the
Module. COOLDOWN/STOP position.

c. Determine the signal connector contact number Expected Result: The indicator lamp should
at the Main Display Module. flash.

d. Disconnect the engine harness from the Main Results:

Display Module.
• OK - The indicator lamp flashes. The circuit
e. At the engine harness connector for the Main is operating correctly. The switch has a
Display Module, measure the resistance that problem. Check the switch or replace the
is between the signal contact and contact 2 switch.
(ground).
• Not OK - The indicator lamp does not flash.
Note: Jumper wire from Step 2 is still connected. The engine harness is open or the Main
Display Module has a problem. Proceed to
Expected Result: The resistance should be Step 3.
less than 5.0 ohms.
3. Check The Harness.
Results:
a. Turn the “ECS” switch to the OFF/RESET
• No - The resistance is greater than 5.0 ohms. position.
The engine harness has a problem. Repair
the engine harness or replace the engine Note: The signal wire remains disconnected from the
harness. switch. Do Not allow the contact to touch any other
components.
• Yes - The resistance is less than 5.0 ohms.
The harness resistance is correct. The Main b. On the Electrical System Schematic, trace the
Display Module has a problem. Replace the signal wire from the switch to the Main Display
Main Display Module. For more information Module.
on this subject, see Testing And Adjusting,
“Module - Replace”. c. Determine the signal connector contact number
at the Main Display Module.
Indicator Lamp Never Flashes d. Disconnect the engine harness from the Main
Display Module.
This procedure is for the parameter that occurs
when the indicator lamp never flashes. The “Never
e. At the engine harness connector for the Main
Flashes” condition is probably caused by a short to
Display Module, measure the resistance that is
ground. Also, the Main Display Module may cause
this problem (unlikely condition). between signal contact and contact 2 (ground).

Expected Result: The resistance should be

1. Locate The Switch.
greater than 5000 ohms.
a. Turn the “ECS” switch to the OFF/RESET
Results:
position.

b. Locate the switch that corresponds to the • OK - The resistance is greater than 5000
ohms. The harness resistance is correct.
parameter that never flashes the indicator
lamp. If necessary, use the Electrical System The Main Display Module has a problem.
Replace the Main Display Module. For more
Schematic to assist in locating the switch.
information on this subject, see Testing And
Adjusting, “Module - Replace”.
66 SENR6587-03
Testing and Adjusting Section

• Not OK - The resistance is less than 5000 a. Turn the “ECS” switch to the OFF/RESET
ohm. The engine harness has a problem. position.
There is a short between ground and the
signal wire in the engine harness. Repair b. Locate the switch that corresponds to the
the engine harness or replace the engine coolant level alarm that always flashes.
harness. STOP. If necessary, use the Electrical System
Schematic to assist in locating the switch.
i01145394
c. Check for loose terminal connections or
Level Switch (Coolant) - corroded terminal connections to the switch.

Troubleshoot d. Clean corroded terminals and tighten loose

connections.
SMCS Code: 1408-035-ZS; 7422-035-CLT;
7451-035-ZS 2. Check The Harness.

The main display module is unable to identify system a. Disconnect the signal wire from the switch.
errors in simple open switch circuits or close switch
circuits. No information (CID FMI) is available to b. Connect a jumper wire from the signal wire to
assist the operator with troubleshooting. the ground wire. If a ground wire is not near,
connect the signal wire to the battery ground.
During normal operation, the possible fault conditions
for the low coolant level switch are listed below. c. Turn the ECS to the COOLDOWN/STOP
position.
• The alert indicator ALWAYS FLASHES for the
coolant level switch. In order to troubleshoot the Expected Result: The indicator lamp should
“Always FLASHING” condition, see Alert Indicator stop flashing.
Lamp Always FLASHING.
Results:
• The alert indicator NEVER FLASHES for the
coolant level switch. For the “NEVER FLASHES” • No - The engine harness is open or the main
procedure, see Alert Indicator Lamp NEVER display module has a problem. Proceed to 3.
FLASHES.
• Yes - The circuit is operating correctly. The
Note: The indicator shows the open condition or switch has a problem. Check the switch or
the ground condition of the switch inputs. When the replace the switch.
low coolant level switch is open, the alert indicator
for the low coolant level switch FLASHES. When 3. Check The Harness.
the input for the low coolant level is grounded, the
alert indicator for the low coolant level switch is a. Turn the ECS to the OFF/RESET position.
OFF. Therefore, in order to check a circuit, while the
service person is watching for the correct result on b. On the Electrical System Schematic, trace the
the alert indicator, the service person is required to signal wire from the switch (pin 32) to the Main
open switch number 6 (pin 32) and ground switch Display Module.
number 6 (pin 32).
c. Determine the connector contact number for
Alert Indicator Lamp Always the signal at the Main Display Module.

FLASHING d. Disconnect the engine harness from the Main

Display Module.
This procedure is for the coolant level switch with a
continuously flashing alert indicator. e. At the engine harness connector for the Main
Display Module, measure the resistance that
The “ALWAYS FLASHING” condition is probably is between the signal contact and contact 2
caused by an undesired open circuit or a faulty main (ground).
display module (unlikely condition).
Note: The jumper wire from 2 is still connected.
1. Locate Switch 6 that always flashes the low
coolant level indicator. Expected Result: The resistance should be
less than 5.0 ohms.
SENR6587-03 67
Testing and Adjusting Section

Results: Note: The signal wire remains disconnected from

the switch. Do NOT allow the contact to touch any
• No - The resistance is greater than 5.0 ohms. other components.
The engine harness has a problem. Repair
the engine harness or replace the engine b. On the Electrical System Schematic, trace the
harness. signal wire from the switch to the Main Display
Module.
• Yes - The resistance is less than 5.0 ohms.
The harness resistance is correct. The Main c. Determine the number for the signal contact at
Display Module has a problem. Replace the the Main Display Module.
Main Display Module. For more information
on the subject, see Testing And Adjusting, d. Disconnect the connector contact for the signal
“Module - Replace”. at the Main Display Module.

e. At the engine harness connector for the Main

Indicator Lamp Never Flashes Display Module, measure the resistance that
This procedure is for the indicator lamp of the low is between the signal contact and contact 2
(ground).
coolant level switch that NEVER FLASHES. The
“NEVER FLASHING” condition is probably caused
by a short to ground or a faulty Main Display Module Expected Result: The resistance should be
greater than 5000 ohms.
(unlikely condition).

1. Locate The Switch. Results:

a. Turn the ECS to the OFF/RESET position. • OK - The resistance is greater than 5000
ohms. The harness resistance is correct.
The Main Display Module has a problem.
b. Locate the switch that corresponds to the
Replace the Main Display Module. For more
parameter that never flashes the indicator
lamp. If necessary, use the Electrical System information on this subject, see Testing And
Adjusting, “Module - Replace”.
Schematic to assist in locating the switch.

c. Check for loose connections or corroded • Not OK - The resistance is less than 5000
ohms. The engine harness has a problem.
terminal connections to the switch.
There is a short between ground and the
d. Clean corroded terminals and tighten the loose signal wire in the engine harness. Repair
the engine harness or replace the engine
connections.
harness. STOP.
2. Check The Harness.
i01036695
a. Disconnect the signal wire from the switch.
LH/RH Switch - Troubleshoot
b. Turn the ECS to the COOLDOWN/STOP
position. SMCS Code: 1408-038-ZS; 7332-038-ZS;
7451-038-ZS
Expected Result: The indicator lamp should
flash. This procedure is for the “LH/RH” switch that will
not toggle certain values. The values that are listed
Results: below are not toggled.

• OK - The indicator lamp flashes. The circuit • Left exhaust temperature value
is operating correctly. The switch has a
problem. Check the switch or replace the • Right exhaust temperature value
switch.
• Left air inlet restriction value
• Not OK - The indicator lamp does not flash.
The engine harness is open or the Main • right air inlet restriction value
Display Module has a problem. Proceed to
Step 3. The “Doesn’t Toggle” condition for the “LH/RH” switch
is probably caused by an open circuit. Also, the Main
3. Check The Harness. Display Module has a problem (unlikely condition).

a. Turn the ECS to the OFF/RESET position. 1. Locate The Switch.

68 SENR6587-03
Testing and Adjusting Section

a. Turn the “ECS” switch to the OFF/RESET d. At the engine harness connector for the Main
position. Display Module, measure the resistance
between the signal contact and contact 2
b. Locate the “LH/RH” switch. If necessary, use (ground).
the Electrical System Schematic to assist in
locating the switch. Expected Result: The resistance should be
greater than 5000 ohms.
c. Check for loose connections or corroded
terminal connections to the switch. Results:

d. Clean corroded terminals and tighten loose • The resistance is greater than 5000 ohms.
connections. The harness resistance is correct. The Main
Display Module has a problem. Replace the
2. Check The Harness. Main Display Module. For more information
on this subject, see Testing And Adjusting,
a. Disconnect the signal wire from the switch. “Module - Replace”.

b. Turn the “ECS” switch to the • The resistance is less than 5000 ohms. The
COOLDOWN/STOP position. engine harness has a problem. There is a
short between ground and the signal wire
c. Ground the signal wire. Float the signal wire. in the engine harness. Repair the engine
Repeat Step 2.c. harness or replace the engine harness.

Expected Result: The Display Area should

i01036785
Show the “LH” value and the “RH” value for
exhaust temperature and the Display Area
should show the “LH” value and the “RH” value
Scroll Switch - Troubleshoot
for air inlet restriction. SMCS Code: 1408-038-ZS; 7332-038-ZS;
7451-038-ZS
Results:

• OK - The Display Area alternates between The Scroll Switch Does Not Scroll
“LH” values and “RH” values for exhaust
temperature. The circuit is operating This procedure is for the “SCROLL” switch that does
correctly. The switch has a problem. Check not scroll parameter values in the Display Area. The
the switch or replace the switch. “Does Not Scroll” condition is probably caused by
an undesired open circuit. Also, the Main Display
• Not OK - The Display Area does not alternate Module may cause the problem (unlikely condition).
between “LH” values and “RH” values for
exhaust temperature. The signal wire for 1. Locate The Switch.
the engine harness is probably shorted to
ground. Proceed to Step 3. a. Turn the “ECS” switch to the OFF/RESET
position.
3. Check The Harness.
b. Locate the “SCROLL” switch. If necessary, use
a. Turn the “ECS” switch to the OFF/RESET the Electrical System Schematic to assist in
position. locating the switch.

Note: The signal wire remains disconnected from the c. Check for loose terminal connections or
switch. Do not allow the contact to touch any other corroded terminal connections to the switch.
components.
d. Clean the corroded terminals and tighten the
b. On the Electrical System Schematic, trace the loose connections.
signal wire from the switch to the Main Display
Module. The contact for the signal connector is 2. Check The Harness.
contact 19 at the Main Display Module.
a. Disconnect the signal wire from the switch.
c. Disconnect the engine harness from the Main
Display Module. b. Turn the “ECS” switch to the
COOLDOWN/STOP position.
SENR6587-03 69
Testing and Adjusting Section

c. Alternately, ground the signal wire and float the The Scroll Switch Continually
signal wire.
Scrolls
Expected Result: The Display Area should
This procedure is for the “SCROLL” switch that
scroll from one parameter value to the next
continually scrolls parameter values in the Display
parameter value.
Area. The “Continually Scrolls” condition is probably
caused by a short to ground. Also, the Main Display
Results:
Module may cause this problem (unlikely condition).
• OK - The Display Area scrolls from one 1. Locate The Switch.
parameter value to the next parameter value.
The circuit is operating correctly. The switch
a. Turn the “ECS” switch to the OFF/RESET
has a problem. Check the switch or replace
position.
the switch.
b. Locate the “SCROLL” switch. If necessary, use
• Not OK - The Display Area does not scroll the Electrical System Schematic to assist in
from one parameter value to the next
locating the switch.
parameter value. The signal wire for the
engine harness probably has an open circuit.
c. Check for loose terminal connections or
Proceed to Step 3.
corroded terminal connections to the switch.
3. Check The Harness.
d. Clean corroded terminals and tighten loose
connections.
a. Turn the “ECS” switch to the OFF/RESET
position.
2. Check The Harness.
b. Connect a jumper wire from the signal wire to
a. Disconnect the signal wire from the “SCROLL”
the ground wire. If a ground wire is not near,
switch.
connect the signal wire to battery ground.
b. Turn the ECS to the COOLDOWN/STOP
c. On the Electrical System Schematic, trace
position.
the signal wire from the switch to the Main
Display Module. The contact that is used for the
Expected Result: The Display Area should
signal connector at the Main Display Module
NOT scroll from one parameter value to the
is contact 23.
next parameter value.
d. Disconnect the engine harness from the Main
Results:
Display Module.

e. At the engine harness connector for the Main • OK - The Display Area does NOT scroll from
one parameter to the next parameter. The
Display Module, measure the resistance
circuit is operating correctly. The switch has
between the signal contact and contact 2
a problem. Check or replace the switch.
(ground).

Expected Result: The resistance should be • Not OK - The Display Area scrolls from one
parameter to the next parameter. The engine
less than 5 ohms.
harness is shorted to ground or the Main
Display Module has a problem. Proceed to
Results:
Step 3.
• OK - The resistance is less than 5 ohms. 3. Check The Harness.
The harness resistance is correct. The Main
Display Module has a problem. Replace the
a. Turn the “ECS” switch to the OFF/RESET
Main Display Module. For more information
position.
on this subject, see Testing And Adjusting,
“Module - Replace”.
Note: The signal wire remains disconnected from the
switch. Do Not allow the contact to touch any other
• Not OK - The resistance should be greater components.
than 5 ohms. The engine harness has a
problem. There is an open circuit between
b. On the Electrical System Schematic, trace the
ground and the signal wire in the engine
signal wire from the switch to the Main Display
harness. Repair the engine harness or
Module. The Signal Contact at the Main Display
replace the engine harness.
Module is 23.
70 SENR6587-03
Testing and Adjusting Section

c. Disconnect the engine harness from the Main b. Locate the “CLEAR/MODE” switch. If
Display Module. necessary, use the Electrical System
Schematic to assist in locating the switch.
d. At the engine harness connector for the Main
Display Module, measure the resistance c. Check for loose terminal connections or
between Signal Contact 23 and contact 2 corroded terminal connections.
(ground).
d. Clean corroded terminals and tighten loose
Expected Result: The resistance should be connections.
greater than 5000 ohms .
2. Check The Harness.
Results:
a. Disconnect the “CLEAR” signal wire from the
• OK - The resistance is greater than 5000 “CLEAR/MODE” switch.
ohms. The harness resistance is correct.
The Main Display Module has a problem. b. Turn the “ECS” switch to the
Replace the Main Display Module. For more COOLDOWN/STOP position.
information on this subject, see Testing And
Adjusting, “Module - Replace”. c. Alternately, ground the “CLEAR” signal wire
and float the “CLEAR” signal wire.
• Not OK - The resistance is less than 5000
ohms. The engine harness has a problem. Expected Result: The Display Area should
There is a short between ground and the clear the diagnostic codes or tattletale values.
signal wire in the engine harness. Repair
the engine harness or replace the engine Results:
harness.
• OK - The Display Area clears the diagnostic
codes or the tattletale values. The circuit
i01037665
is operating correctly. The switch has a
Clear/Mode Switch - problem. Check the switch or replace the
switch.
Troubleshoot
• Not OK - The Display Area Does Not clear
SMCS Code: 1408-038-ZS; 7332-038-ZS; logged diagnostic codes or tattletale values.
7451-038-ZS The signal wire in the engine harness
probably has an open circuit. Proceed to
The “CLEAR/MODE” Switch Does Step 3.

NOT Clear Logged Diagnostic 3. Check The Harness.

Codes and Tattletale Values or
a. Turn the “ECS” switch to the OFF/RESET
Does NOT Initiate Mode Changes position.
This procedure is for the “CLEAR/MODE” switch b. Connect a jumper wire from the “CLEAR”
that will not clear logged diagnostic codes and signal wire to the ground wire. If a ground wire
the “CLEAR/MODE” switch that will not clear is not near, connect the “CLEAR” signal wire
“tattletale values”. Also, this procedure is for the to battery ground.
“CLEAR/MODE” switch that does NOT initiate mode
changes on the Display Area. The “Does NOT Clear” c. On the Electrical System Schematic, trace the
Logged Diagnostic Codes and Tattletale Values “CLEAR” signal wire from the switch to the
or “Does Not Initiate Mode Changes” condition is Main Display Module.
probably caused by an undesired open circuit. Also,
the Main Display Module can be the cause of the d. The “CLEAR” signal is contact 33 at the Main
problem (unlikely condition). Display Module.
1. Locate The Switch. e. Disconnect the engine harness from the Main
Display Module.
a. Turn the “ECS” switch to the OFF/RESET
position.
SENR6587-03 71
Testing and Adjusting Section

f. At the engine harness connector for the Main Expected Result: The Display Area should
Display Module, measure the resistance NOT clear diagnostic codes or tattletale values.
between the “CLEAR” Signal Contact and
Contact 2 (ground). Results:

Expected Results: The resistance should be • OK - The Display Area does NOT clear
less than 5 ohms. diagnostic codes or tattletale values. The
circuit is operating correctly. The switch has
Results: a problem. Check the switch or replace the
switch.
• OK - The resistance is less than 5 ohms.
The harness resistance is correct. The Main • Not OK - The Display Area continues to clear
Display Module has a problem. There is an logged diagnostic codes or tattletale values.
open between ground and the “CLEAR” The engine harness is shorted to ground
signal wire in the engine harness. or the Main Display Module has a problem.
Proceed to Step 3.
• Not OK - The resistance is greater than 5
ohms. The engine harness has a problem. 3. Check The Harness.
There is an open between ground and the
“CLEAR” signal wire in the engine harness. a. Turn the “ECS” switch to the OFF/RESET
Repair the engine harness or replace the position.
engine harness.
Note: The “CLEAR” signal wire remains disconnected
from the switch. Do Not allow the contact to touch
The “CLEAR/MODE” Switch any components.
Automatically Clears Logged
Diagnostic Codes and Tattletale b. On the Electrical System Schematic, trace the
“CLEAR” signal wire from the switch to the Main
Values or Does Not Initiate Mode Display Module. The “CLEAR” signal contact is
Changes number 33 at the Main Display Module.

This procedure is for the “CLEAR/MODE” switch c. Disconnect the engine harness from the Main
that “Automatically Logged” Diagnostic Codes and Display Module.
Tattletale Values on the Display Area. The “Does
Not Clear Logged Diagnostic Codes” and Tattletale d. At the engine harness connector for the Main
values or “Does Not Initiate Mode Changes” is Display Module, measure the resistance that is
probably caused by an undesired open circuit. Also, between the “CLEAR” Signal Contact 33 and
the Main Display Module may cause the problem Contact 2 (ground).
(unlikely condition).
Expected Result: The resistance should be
1. Locate The Switch. greater than 5000 ohms.

a. Turn the “ECS” switch to the OFF/RESET Results:

position.
• OK - The resistance is greater than 5000
b. Locate the “CLEAR/MODE” switch. If ohms. The harness resistance is correct.
necessary, use the Electrical System The Main Display Module has a problem.
Schematic to assist in locating the switch. Replace the Main Display Module. For more
information on this subject, see Testing And
c. Check for loose terminal connections or Adjusting, “Module - Replace”.
corroded terminal connections to the switch.
• Not OK - The resistance is less than 5000
d. Clean corroded terminals and tighten loose ohms. The engine harness has a problem.
connections. There is an open between ground and the
“CLEAR” signal wire in the engine harness.
2. Check The Harness. Repair the engine harness or replace the
engine harness.
a. Disconnect the “CLEAR” signal wire from the
“CLEAR/MODE” switch.

b. Turn the “ECS” switch to the

COOLDOWN/STOP position.
72 SENR6587-03
Testing and Adjusting Section

i01037861 a. Turn the “ECS” switch to the OFF/RESET

position.
Alarm Silence Switch -
Troubleshoot Connect a jumper wire from the signal wire to
the ground wire. If a ground wire is not near,
SMCS Code: 1408-038-ZS; 7332-038-ZS; connect the signal wire to battery ground.
7451-038-ZS
b. On the Electrical System Schematic, trace the
signal wire from the switch to the Main Display
The Alarm Silence Switch Does Not Module. The Signal Contact is number 29 at
Silence The Alarm the Main Display Module.

This procedure is for the Alarm Silence switch that c. Disconnect the engine harness from the Main
will not silence the Alarm. The “Does Not Silence” Display Module.
condition is probably caused by an undesired open
circuit. Also, the Main Display Module may cause the d. At the engine harness connector for the Main
problem (unlikely condition). Display Module, measure the resistance that
is between the Signal Contact 29 and contact
1. Locate The Switch. 2 (ground).

a. Turn the “ECS” switch to the OFF/RESET Expected Result: The resistance should
position. measure less than 5 ohms.

b. Locate the Alarm Silence Switch. If necessary, Results:

use the Electrical System Schematic to assist
in locating the switch. • OK - The resistance measures less than 5
ohms. The harness resistance is correct.
c. Check for loose terminals or corroded terminal The Main Display Module has a problem.
connections to the switch. Replace the Main Display Module.

d. Clean corroded terminals and tighten loose • Not OK - The resistance is greater than 5
connections. ohms. The engine harness has a problem.
There is an open between ground and the
2. Check The Harness. signal wire in the engine harness. Repair
the engine harness or replace the engine
a. Disconnect the signal wire from the Alarm harness.
Silence switch.
The Alarm Silence Switch
b. Turn the “ECS” switch to the OFF/RESET
position. Continually Silences The Alarm
c. Ground the signal wire from the Alarm Silence This procedure is for the Alarm Silence switch that
switch. continuously silences the Alarm. The “Continually
Silences” condition is probably caused by an
Expected Result: The Alarm should become undesired open circuit. Also, the Main Display Module
quiet. may cause the problem (unlikely condition).

Result: 1. Locate The Switch.

• OK - The Alarm becomes quiet. The circuit a. Turn the “ECS” switch to the OFF/RESET
is operating correctly. The switch has a position.
problem. Check the switch or replace the
switch. b. Locate the Alarm Silence switch. If necessary,
use the Electrical System Schematic to assist
• Not OK - The Alarm does not become in locating the switch.
quiet. The signal wire in the engine harness
probably has an open circuit. Proceed to c. Check for loose terminal connections or
Step 3. corroded terminal connections to the switch.

3. Check The Harness. d. Clean corroded terminals and tighten loose

connections.
SENR6587-03 73
Testing and Adjusting Section

2. Check The Harness. i01129925

a. Disconnect the Signal Wire from the Alarm Harness Code - Troubleshoot
Silence switch.
SMCS Code: 1408-038; 7451-038
b. Turn the “ECS” switch to the
COOLDOWN/STOP position. The harness code for the Caterpillar Monitoring
System must match the application in order to
Expected Result: The Alarm should sound. function properly. If the harness code does not match
the application, the following problems may occur:
Results:
• loss of event notification
• OK - The Alarm sounds. The circuit is
operating correctly. Check the switch or • incorrect data displays
replace the switch.
• incorrect gauge needle positions
• Not OK - The Alarm does not sound. The
engine harness is shorted to ground or • activation of diagnostic codes
the Main Display Module has a problem.
Proceed to Step 3. Generally, once an engine is put into service there
is no reason to change the harness code. During
3. Check The Harness. installation, the customer may decide to install
optional sensors or optional gauges that were not
a. Turn the “ECS” switch to the OFF/RESET initially ordered with the engine. Changing these
position. components may require a different harness code.

Note: The Signal Wire remains disconnected from Check the current selection for the harness code
the switch. Do Not allow the contact to touch any and compare the current harness code with the
components. description in Systems Operation, “Quad Gauge
Module”. Determine if the harness code is correct
b. On the Electrical System Schematic, trace the for the application.
Signal Wire from the switch to the Main Display
Module. The Signal Contact at the Main Display There are six pins on the back of the Caterpillar
Module is number 29. Monitoring System that are used to select the harness
code. The pins are grounded or the pins are left open
c. Disconnect the engine harness from the Main in various combinations for each application. The
Display Module. pins that are grounded are connected to the negative
battery terminal block (“TB-2”). The negative battery
d. At the engine harness connector for the Main terminal block (“TB-2”) is located on the inside of
Display Module, measure the resistance the Instrument Panel. On the wiring schematic, the
between Signal Contact 29 and Contact 2 negative battery terminal block is labelled as “TB-2”.
(ground).
Because of the large number of wires that are
Expected Result: The resistance should be located on the inside of the Electronic Instrument
greater than 5000 ohms. Panel, determining the pins that are connected to the
ground becomes difficult to do visually. There are two
Results: accurate methods for determining the harness code.

• OK - The resistance is greater than 5000 • Harness Code Mode 5 Display (not available on all
ohms. The harness resistance is correct. versions of the Caterpillar Monitoring System)
The Main Display Module has a problem.
Replace the Main Display Module. For more • A multimeter may be used to check the harness
information on this subject, see Testing And code that is located on the Caterpillar Monitoring
Adjusting, “Module - Replace”. Systems without Mode 5.

• Not OK - The resistance is less than 5000 Note: If a ground wire is connected to “pin A”, the
ohms. The engine harness has a problem. harness code pin is not necessarily grounded. The
There is a short between ground and the other end of the wire may be tied to the harness
signal wire in the engine harness. Repair and the wire may not be connected to “TB-2”. This
the engine harness or replace the engine procedure is done so that the same wiring harness
harness. can be used during manufacturing regardless of the
harness code.
74 SENR6587-03
Testing and Adjusting Section

Procedure For Checking The

Harness Code Selection
1. Check The Harness Code Selection Of The
Caterpillar Monitoring System.

2. For 153-1929 Engine Monitoring Control

(Caterpillar Monitoring System) and earlier
modules, proceed to 5.

3. For 155-8653 Engine Monitoring Control

(Caterpillar Monitoring System) and newer
modules, turn the Engine Control Switch (ECS) to
the COOLDOWN/STOP position.

4. In order to check the harness code, use Harness

Code Mode 5. For more information about
Harness Code Mode 5, see Systems Operation,
“Harness Code Mode”. STOP.

5. For the 153-1929 Engine Monitoring Control

and earlier Caterpillar Monitoring Systems, use
a multimeter to check for continuity between the
pins for the harness code and Terminal Block 2
(TB-2). Do NOT rely on a visual inspection.

6. The pins that determine the harness code are

located on the back of the Caterpillar Monitoring
System. The harness code is identified by certain
pins of the 40 pin connector. pin 31, pin 3, pin 21,
pin 22, pin 16, and pin 6.

7. If a 7x-1708 Multimeter Probe (Red) or a

7x-1709 Multimeter Probe (Black) is available,
the continuity check can be made without
removing the wires from the 40 pin connector.

8. If the probe adapters are not available, use a

121-9587 Wire Removal Tool to remove the
harness code wire from the connector.

9. Record each measurement as the measurements

are taken. An example is given below.

Table 16
Pin 31 Pin 3 Pin 12 Pin 22 Pin 16 Pin 6
Measurement Ground Open Open Ground Ground Ground

10. After the harness code has been verified,

compare the verified harness code with the Table
that is given in Systems Operation, “Quad Gauge
Module”.

11. The harness code should match the application. If

the harness code does not match the application,
the following procedure can be used to change
the harness code.
SENR6587-03 75
Testing and Adjusting Section

Procedure For Changing The

Harness Code

g00608679
Illustration 64
Panel Interior Of 3500B Electronic Instrument Panel and Subpanel
(1) Caterpillar Monitoring System Module
(2) Quad Gauge Clusters
(3) Terminal Block 2 (TB-2)
(4) Location to tie back the Harness Code Ground Wires If the
Wires are not connected to TB-2.

1. Determine The Correct Harness Code For The

Application.

a. In order to determine the correct harness code,

refer to Testing And Adjusting, “Quad Guage
Module”.

b. Compare the current harness code to the

desired harness code.

Note: One or more of the pins for the Harness Code

may need to be grounded in order to change the
harness code. Also, one or more of the pins may
require grounding to change the harness code. An
example is given below.

Table 17
Application Mode 5 Connections On 40 Pin Connector
Harness Code
Display Pin 31 Pin 3 Pin 12 Pin 22 Pin 16 Pin 6

Generator Engine 5 Open Ground Open Ground Ground Ground

With Prime Panel
Generator Engine 7 Open Open Open Ground Ground Ground
With Premium Panel
And JWAC
76 SENR6587-03
Testing and Adjusting Section

c. Assume that the current harness code is i01046910

harness code 5 “Generator Engine With Prime
Panel” and that the desired harness code System Self Test
is harness code 7 “Generator Engine With
Premium Panel And JWAC”. Pin 3 should be SMCS Code: 1408-038; 7451-038
ungrounded in order to change from harness
code 5 to harness code 7. The Self-Test verifies that the Main Display Module
and the Gauge Cluster Modules are operating
2. Turn the Engine Control Switch (ECS) to the properly. The Main Display Module performs an
OFF/RESET position. automatic Self-Test each time that the “ECS”
switch is turned from the OFF/RESET position to
a. In order to change the Harness Code, wires the AUTO position, MAN/START position or the
must be grounded or ungrounded. COOLDOWN/STOP position.

Note: Pins are grounded by connecting the pins Note: When the “ECS” switch is in the AUTO
to the “-Battery” terminal block that is located on position, the Main Display Module receives power
the inside of the instrument panel. On the wiring only when the Remote START/STOP switch is in
schematic, the terminal block is labelled “TB-2”. the MAN/START position or the COOLDOWN/STOP
Refer to 64. A pin for the harness code is not always position.
grounded if a ground wire is connected to the pin.
The other end of the wire may be tied in the harness The internal circuits and the outputs are automatically
and the wire may not be connected to TB-2. The wire checked. The operator must observe the outputs in
is tied so that the same wiring harness can be used order to determine whether the modules and the
during manufacturing regardless of the harness code. outputs are operating properly. The Indicator Lamps
and the Display Area are tested for approximately
b. Grounding A Harness Code Pin. For this one second.
step, refer to item 4 in 64. If the wires are not
connected to TB-2,the wires can be tied back
to this location. The wire can be identified
by the printed label at the end of the wire.
The label follows the format “EMS (number)
TB-2”. “Number” represents the pin number of
the harness code. The wire terminates at the
pin. After locating the wire that needs to be
grounded, remove the heat shrink insulation
that covers the end of the wire. Ground the wire
by connecting the wire to TB-2. Replace the tie
wraps as replacement is necessary.

c. Procedure To Unground A Harness Code

Pin. Identify the wire that is described above g00543852
Illustration 65
as being connected to the pin of the Caterpillar
Monitoring System that should be ungrounded. Typical View Of Indicator Lamps
Disconnect the end of the wire that is connected
to TB-2. Insulate the newly exposed end of the
wire and tie back to the harness.

Note: The new harness code will not take effect until
power to the Caterpillar Monitoring System is cycled.

3. Verify That The Harness Code Was Changed

g00543853
Successfully. Illustration 66
Display Area With All Segments Shown
a. Check the harness code by using the
Procedure For Checking The Harness Code. Gauge Cluster Modules are tested for approximately
three seconds.
SENR6587-03 77
Testing and Adjusting Section

Note: If the Replacement Module was previously

removed from service, see Testing And Adjusting,
“Main Display Module Initialization - Adjust”.

4. Connect the engine harness to the Replacement

Module.

5. Turn the “ECS” switch to the COOLDOWN/STOP

position. Make sure that the Replacement
Module and the Quad Gauge Electronic Modules
successfully complete the Self Test. For more
information on this subject, see Testing And
Adjusting, “System Self Test”.

6. Set the display to English units or Metric units.

See Systems Operation, “Units Mode” for more
information.

i01038123

g00532834
Main Display Module
Illustration 67
Initialization - Adjust
The needles for the Gauge Cluster Modules will jump
to half scale. The needles will go back to zero, then SMCS Code: 7451-025
the needles will sweep to full scale. After reaching full
scale, the needles will return to showing the current The Main Display Module Initialization is an internal
conditions. process that occurs within the Main Display Module.
During the Main Display Module Initialization, the
The Action Alarm will sound once. Main Display Module monitors the CAT Data Link.
Also, the Main Display Module monitors the inputs for
The Main Display Module will then go into the Normal the harness code. During the Main Display Module
Mode (Mode 0) of operation. Initialization, the Main Display Module learns about
the engine that is being monitored.
If a module does not perform the Self-Test, proceed
to Testing And Adjusting, “Module - Replace”. The Main Display Module Initialization typically
occurs when the Main Display Module is replaced.
The harness code is new when the Main Display
i01038053 Module is replaced. However, when a previously used
Main Display Module is used as a replacement, the
Module - Replace procedure of initialization is necessary. Unexplained
diagnostics with the CAT Data Link can occur if the
SMCS Code: 7451-510 Main Display Module is not initialized correctly. The
service person must activate the process for the
Prior to the replacement of a module, ensure that the Main Display Module Initialization when the following
replacement is absolutely necessary. A module is condition exists or the condition is suspected.
seldom the cause of a problem. Always check that the
harness code is correct for the Main Display Module The Main Display Module that will be installed was
and that power is available to the Main Display taken out of service from an application that had the
Module. For information about a Harness Code, see same harness code as the Main Display Module that
Systems Operation, “Quad Gauge Module”. will be removed.
1. Turn the “ECS” switch to the OFF/RESET position. Perform the Main Display Module Initialization if
Disconnect the engine harness from the Main the preceding condition exists or this condition
Display Module. is expected.
2. Make sure that the Replacement Module has the
correct part number.

3. Remove the old module and install the

Replacement Module.
78 SENR6587-03
Testing and Adjusting Section

This procedure causes the process of the Main Abnormal – This word refers to an engine condition
Display Module Initialization to occur on any Main that is not normal or a signal that is not normal. The
Display Module. In order to perform the Main Display presence of an abnormal condition or signal means
Module Initialization, the Main Display Module must that a problem exists. The operator is notified when
be powered up with a valid harness code. The the warning operation is activated.
harness code must be different from the previous
harness code that was used to power down the Main CID (Component Identifier) – A diagnostic code
Display Module. For a list of valid harness codes, see identifies a component that is having a problem.
Systems Operation, “Quad Gauge Modules”. A CID may also identify a system that is having
a problem. Examples of components that may
1. Turn the “ECS” switch to the OFF/RESET position. be identified are the engine speed sensor, the oil
pressure sensor or the exhaust temperature sensor.
2. Disconnect the engine harness from the Main The CID is a four digit or three digit code that is
Display Module. Remove the socket or remove shown on the Display Area when the Main Display
the wire from one of the following holes. The holes Module is in Service Mode (Mode 2).
for the connectors are 3, 6, 12, 16, 22 or 31.
Clear – When diagnostic information is removed
3. Use black electrical tape to secure the removed from the memory of the Main Display Module, the
socket or the removed wire to the harness bundle. memory is cleared. Before clearing the information,
Make sure that the contact does not touch any the information must be “on-hold”.
metallic components. Reconnect the engine
harness to the Main Display Module. Connector Contact – A connector contact is the
component of a harness connector that makes the
4. Turn the “ECS” switch to the COOLDOWN/STOP electrical connection. Connector contacts are either
position. pins or sockets.

5. Various indicators in the Display Area illuminate. Detected Diagnostic – A detected diagnostic fault
Wait for ten seconds. is a diagnostic fault that has been discovered by
the Main Display Module. Examples of detected
6. Turn the “ECS” switch to the OFF/RESET position. diagnostic faults are an open harness or a shorted
Reinstall the socket or reinstall the wire that was harness. Also detected diagnostic faults may be
removed in Step 2 into the original position on the problems with a switch, problems with a sensor or
connector for the Main Display Module. problems with an electronic module. The diagnostic
fault is recorded and the diagnostic fault is shown on
7. Turn the “ECS” switch to the COOLDOWN/STOP the Display Area when the Main Display Module is in
position. Make sure that the Main Display Module Service Mode (Mode 2).
successfully completes the Self Test. For more
information on this subject, see Testing And Diagnostic – Showing information that is not
Adjusting, “System Self Test”. Check the harness normal is referred to as diagnostics. Also, monitoring
code for accuracy. For a list of valid harness information or recording information that is not normal
codes, see Systems Operation, “Gauge Cluster is known as diagnostics. Diagnostic information is
Modules”. available when the Main Display Module is in Service
Mode, Normal Mode, Tattletale Mode or Numeric
Mode.
i01046881

Glossary of Terms Display – The gauges, indicators, or the display

area is referred to as the display of the Caterpillar
SMCS Code: 7451 Monitoring System.

+Battery – This term refers to the harness wiring Floating – Floating is the state of a module input
that is part of the circuit that connects to the battery that is not connected to a reference. The reference
positive post. System Battery Voltage is also used may be a positive reference, a negative reference or
in place of +Battery. any other reference.

+V – +V is a constant voltage that is supplied to a FMI (Failure Mode Identifier) – A diagnostic code
component in order to provide electrical power for that tells describes the type of problem that has
the operation of a component. +V is provided by an occurred. For example, Voltage Above Normal would
electronic control module or the battery. be a problem. The FMI is a code with two-digits that
is preceded by a decimal point or the letter “F” that
is shown on the Display Area when the Main Display
Module is in Service Mode (Mode 2).
SENR6587-03 79
Testing and Adjusting Section

Harness Code – The grounded condition or the Signal Wire – The signal wire is the harness wire
open condition of the harness code input is known which connects the sensor or the switch to the Main
as the Harness Code. The contacts for the harness Display Module.
code input are given below. contact 3, contact 6,
contact 12, contact 16, contact 22, and contact 31. Switch Input – A switch input is any input of the
The harness code describes the characteristics of Main Display Module which is expecting only an open
the electronic system to the Main Display Module. (floating) or grounded signal.
The Caterpillar Monitoring System is used on various
Caterpillar products. The Caterpillar Monitoring System Voltage – The actual voltage that exists
System must know the characteristics of the between the positive battery post and the negative
electronic system that is being monitored. If the battery post is the system voltage. System voltage is
Harness Code Mode (Mode 5) is an available mode, also referred to as +battery voltage.
the decimal representation of the harness code is
shown in the Display Area when the Main Display Unnassigned/Unprogrammed – The unused inputs
Module is in Harness Code Mode (Mode 5). of the Main Display Module and the unused outputs
of the Main Display Module are not defined by the
Hold or “On-Hold” – On-Hold refers to holding a set software. Therefore, the inputs and the outputs are
of diagnostic information that is shown in the Display unavailable to the end user.
Area when the Main Display Module is in Service
Mode or Numeric Readout Mode. It is necessary
to hold the set of diagnostic information before
troubleshooting or clearing.

Indicator Lamp – An indicator lamp is a red LED or

a yellow LED that is located in the upper section of
the Main Display Module. The Indicator Lamps flash
when a problem exists. The associated pictograph
symbol identifies the abnormal engine condition.

Indicator Lamp Problem – A problem occurs with

an indicator lamp when the operation of an indicator
lamp does not correspond to a known engine
condition.

Jumper Wire – A jumper wire is a piece of wire

that is used to make an electrical connection during
troubleshooting.

MID (Module Identifier) – An MID is a diagnostic

code that tells the service person which electronic
module has diagnosed the problem. Examples of the
modules are the Main Display Module, engine control
module (ECM) and other modules. The MID is a three
digit code that is shown in the Display Area when the
Main Display Module is in Service Mode (Mode 2).

Problem – A problem refers to the presence of an

abnormal engine condition such as low engine oil
pressure. When a problem exists, warning operation
is activated and the message center notifies the
operator.

SCROLL – The process of showing (within the

Display Area) all the available sets of diagnostic
information, one set at a time. A set of diagnostic
information is shown briefly. Then, the display
automatically advances to the next set. After all sets
are shown, the sets are repeated.

Show – Show refers to the information that is located

within the Display Area of the Caterpillar Monitoring
System that is viewed by the operator or service
person.
80 SENR6587-03
Testing and Adjusting Section

i01038129

Connector Contact Description

of Main Display Module
SMCS Code: 7451-546-CY; 7553-546

Table 18
Generator Set - Description Of Main Module Connector
Pin Function Type Description
Number
1 +Battery Input Voltage (Power) +24 DCV
2 −Battery Ground 0 DCV
3 Harness Code 1 Main Module Configuration Programming Pulled Low or Floating
4 Action Alarm Output Alarm Driver
5 CAT Data Link (+) Two-way Data Transfer Medium Driver/Receiver (+)
6 Harness Code 5 Main Module Configuration Programming Harness Code 5
7 Sensor 1/Switch 11 Sensor Or Switch Input Unassigned/Unprogrammed(1)
8 Sensor 5/Switch 15 Sensor Or Switch Input Unassigned/Unprogrammed(1)
9 Sensor 10/Sender 1 Sensor Or Switch Input Unassigned/Unprogrammed(1)
10 Sensor 6/Switch 16/Sender 2 Sensor, Switch, or Sender Input Engine Oil Temperature
11 Switch 7 Switch Input Unassigned/Unprogrammed(1)
12 Harness Code 2 Main Module Configuration Programming Pulled Low or Floating
13 Action Lamp Lampdriver Output Unassigned/Unprogrammed(1)
14 CAT Data Link (−) Two-way Data Transfer Medium Driver Receiver (−)
15 Display Module Load Gauge Module Driver Output Driver For Gauge Information
16 Harness Code 4 Main Module Configuration Programming Pulled Low or Floating
17 Sensor 2/Switch 12 Sensor Or Switch Input Unassigned/Unprogrammed(1)
18 Switch 9/Sender 2 Switch or Sender Input Fuel Level
19 Switch 1 Switch Input LH/RH Switch
20 Switch 4 Switch Input Charger Fault
21 Switch 8 Switch Input Unassigned/Unprogrammed(1)
22 Harness Code 3 Main Module Configuration Programming Pulled Low or Floating
23 Service Switch Input Scroll Switch
24 Sensor Power Supply Output +8 DCV
25 Display Module Clock Gauge Module Driver Output Driver For Gauge Sequencing
26 Frequency 1 Digital Sensor Input Unassigned/Unprogrammed(1)
27 Sensor 4/Switch 14 Sensor Or Switch Input Unassigned/Unprogrammed(1)
28 Sensor 7/Switch 17/Sender 3 Sensor, Switch, or Sender Input Engine Oil Temperature
29 Switch 2 Switch Input Alarm Silence
30 Alternator “R” Terminal Sensor Input Unassigned/Unprogrammed(1)
31 Harness Code 0 Main Module Configuration Programming Pulled Low or Floating
(continued)
SENR6587-03 81
Testing and Adjusting Section

(Table 18, contd)

Generator Set - Description Of Main Module Connector
Pin Function Type Description
Number
32 Switch 6 Switch Input Coolant Level
33 Clear Switch Input Clear/Mode Switch
34 Display Module Power Gauge Module Supply Output +9 DCV
35 Display Module Data Gauge Module Data Output Unassigned/Unprogrammed(1)
36 Frequency 2 Digital Sensor Input Unassigned/Unprogrammed(1)
37 Sensor 3/Switch 13 Sensor Or Switch Input Unassigned/Unprogrammed(1)
38 Sensor 8/Switch 18/Sender 4 Sensor, Switch or Sender Input Unassigned/Unprogrammed(1)
39 Switch 3 Switch Input Unassigned/Unprogrammed(1)
40 Switch 5 Switch Input Unassigned/Unprogrammed(1)
(1) Unused I/O that is not defined by the software and is therefore unavailable to the end user.

Table 19

Marine - Description Of Main Module Connector

Pin Function Type Description
Number
1 +Battery Input Voltage (Power) +24 DCV
2 −Battery Ground 0 DCV
3 Harness Code 1 Main Module Configuration Programming Pulled Low Or Floating
4 Action Alarm Output Alarm Driver
5 CAT Data Link (+) Two-way Data Transfer Medium Driver/Receiver (+)
6 Harness Code 5 Main Module Configuration Programming Pulled Low Or Floating
7 Sensor 1/Switch 11 Sensor Or Switch Input Unassigned/Unprogrammed
8 Sensor 5/Switch 15 Sensor Or Switch Input Unassigned/Unprogrammed
9 Sensor 10/ Sender 1 Sensor Or Sender Input Unassigned/Unprogrammed
10 Sensor 6/Switch 16/Sender 2 Sensor, Switch or Sender Input Unassigned/Unprogrammed
11 Switch 7 Switch Input Unassigned/Unprogrammed
12 Harness Code 2 Main Module Configuration Programming Pulled Low Or Floating
13 Action Lamp Lampdriver Output Unassigned/Unprogrammed
14 CAT Data Link (−) Two-way Data Transfer Medium Driver Receiver (−)
15 Display Module Load Gauge Driver Module Output Driver For Gauge Information
16 Harness Code 4 Main Module Configuration Programming Pulled Low Or Floating
17 Sensor 2/Switch 12 Sensor Or Switch Input Unassigned/Unprogrammed
18 Switch 9/Sender 2 Switch Or Sender Input Fuel Level
19 Switch 1 Switch Input LH/RH Switch
20 Switch 4 Switch Input Unassigned/Unprogrammed
21 Switch 8 Switch Input Unassigned/Unprogrammed
22 Harness Code 3 Main Module Configuration Programming Pulled Low Or Floating
23 Service Switch Input SCROLL switch
24 Sensor Power Supply Output +8 DCV
(continued)
82 SENR6587-03
Testing and Adjusting Section

(Table 19, contd)

Marine - Description Of Main Module Connector
Pin Function Type Description
Number
25 Display Module Clock Gauge Module Driver Output Driver For Gauge Sequencing
26 Frequency 1 Digital Sensor Input Unassigned/Unprogrammed
27 Sensor 4/Switch 14 Sensor Or Switch Input Unassigned/Unprogrammed
28 Sensor 7/Switch 17/Sender 3 Sensor, Switch or Sender Input Transmission Oil Temperature
29 Switch 2 Switch Input Alarm Silence
30 Alternator “R” Terminal Sensor Input Unassigned/Unprogrammed
31 Harness Code 0 Main Module Configuration Programming Pulled Low Or Floating
32 Switch 6 Switch Input Coolant Level
33 Clear Switch Input Clear/Mode Switch
34 Display Module Power Gauge Module Supply Output 9 DCV
35 Display Module Data Gauge Module Data Output Data For Gauge Information
36 Frequency 2 Digital Sensor Input Unassigned/Unprogrammed
37 Sensor 3/Switch 13 Sensor Or Switch Input Unassigned/Unprogrammed
38 Sensor 8/Switch 18/Sender 4 Sensor, Switch or Sender Input Transmission Oil Pressure
39 Switch 3 Switch Input Unassigned/Unprogrammed
40 Switch 5 Switch Input Unassigned/Unprogrammed

Table 20
Locomotive - Description Of Main Display Module Connector
Pin Function Type Description
Number
1 +Battery Input Voltage (Power) +24 DCV
2 −Battery Ground 0 DCV
3 Harness Code 1 Main Module Configuration Programming Pulled Low Or Floating
4 Action Alarm Output Alarm Driver
5 CAT Data Link (+) Two-way Data Transfer Medium Driver/Receiver (+)
6 Harness Code 5 Main Module Configuration Programming Pulled Low Or Floating
7 Sensor 1/Switch 5 Sensor Or Switch Input Unassigned/Unprogrammed
8 Sensor 5/Switch 15 Sensor Or Switch Input Unassigned/Unprogrammed
9 Sensor 10/Sender 1 Sensor Or Switch Input Spare Switch Connection
10 Sensor 6/Switch 16/Sender 2 Sensor, Switch Or Sender Input Engine Oil Temperature
11 Switch 7 Switch Input Unassigned/Unprogrammed
12 Harness Code 2 Main Module Configuration Programming Pulled Low Or Floating
13 Action Lamp Lampdriver Output Unassigned/Unprogrammed
14 CAT Data Link (−) Two-way Data Transfer Medium Driver/Receiver (−)
15 Display Module Load Gauge Module Driver Output Driver For Gauge Information
16 Harness Code 4 Main Module Configuration Programming Pulled Low Or Floating
(continued)
SENR6587-03 83
Testing and Adjusting Section

(Table 20, contd)

Locomotive - Description Of Main Display Module Connector
Pin Function Type Description
Number
17 Sensor 2/Switch 12 Sensor Or Switch Input Unassigned/Unprogrammed
18 Switch 9/Sender 2 Sensor Or Sender Input Unassigned/Unprogrammed
19 Switch 1 Switch Input LH/RH Switch
20 Switch 4 Switch Input Spare Switch Connection
21 Switch 8 Switch Input Unassigned/Unprogrammed
22 Harness Code 3 Main Module Configuration Programming Pulled Low Or Floating
23 Service Switch Input Scroll Switch
24 Sensor Power Supply Output +8 DCV
25 Display Module Clock Gauge Module Driver Output Driver For Gauge
Sequencing
26 Frequency 1 Digital Sensor Input Unassigned/Unprogrammed
27 Sensor 4/Switch 14 Sensor Or Switch Input Unassigned/Unprogrammed
28 Sensor 7/Switch 17/Sender 3 Sensor, Switch Or Sender Input Intake Manifold Temperature
29 Switch 2 Switch Input Alarm Silence Switch
30 Alternator “R” Terminal Switch Input Unassigned/Unprogrammed
31 Harness Code 0 Main Module Configuration Programming Pulled Low Or Floating
32 Switch 6 Switch Input Unassigned/Unprogrammed
33 Clear Switch Input Clear/Mode Switch
34 Display Module Power Gauge Module Supply Output +9 DCV
35 Display Module Data Gauge Module Data Output Data For Gauge Information
36 Frequency 2 Digital Sensor Input Unassigned/Unprogrammed
37 Sensor 3/Switch 13 Sensor Or Switch Input Unassigned/Unprogrammed
38 Sensor 8/Switch 18/Sender 3 Sensor, Switch Or Sender Input Unassigned/Unprogrammed
39 Switch 3 Switch Input Unassigned/Unprogrammed
40 Switch 5 Switch Input Unassigned/Unprogrammed

i02782513

System Schematic
SMCS Code: 1400; 7451; 7566
84 SENR6587-03
Testing and Adjusting Section

g00574693
Illustration 68
SENR6587-03 85
Testing and Adjusting Section

System Schematic For 3500B Electronic Instrument Panel -

Marine Engines.
86 SENR6587-03
Testing and Adjusting Section

g00574696
Illustration 69
SENR6587-03 87
Testing and Adjusting Section

System Schematic For 3500B Electronic Instrument Panel -

Generator Set Engines.
88 SENR6587-03
Testing and Adjusting Section

g00574698
Illustration 70
SENR6587-03 89
Testing and Adjusting Section

System Schematic For 3500B Electronic Instrument Panel -

Locomotive Engines
90 SENR6587-03
Index Section

Index
A E

Accessing Diagnostic Information ......................... 41 Electrical Components And Connector Locations.. 41

Changing Modes................................................ 41 Electronic Control Module (Engine)....................... 28
Action Alarm and Alarm Silence Switch ................ 28
Alarm Silence Switch - Troubleshoot..................... 72
The Alarm Silence Switch Continually Silences G
The Alarm......................................................... 72
The Alarm Silence Switch Does Not Silence The General Information............................................... 40
Alarm................................................................ 72 Glossary of Terms.................................................. 78
Alert Indicator - Troubleshoot ................................ 64
Indicator Lamp Is Always Flashing .................... 64
Indicator Lamp Never Flashes ........................... 65 H
Alert Indicator Description ..................................... 20
Harness Code - Troubleshoot ............................... 73
Procedure For Changing The Harness Code .... 75
C Procedure For Checking The Harness Code
Selection .......................................................... 74
CID 0096 FMI 03 Level Switch (Fuel) Voltage Above Harness Code Mode.............................................. 38
Normal - Test ....................................................... 43
CID 0127 FMI 08 Pressure Sensor (Transmission
Oil) Abnormal Signal - Test .................................. 45 I
CID 0172 FMI 04 Temperature Sender (Inlet Air)
Voltage Below Normal - Test................................ 47 Important Safety Information ................................. 2
CID 0175 FMI 04 Temperature Sender (Engine Oil) Initial Troubleshooting Procedure .......................... 43
Voltage Below Normal - Test................................ 48 Instrument Modules for Generator Set
CID 0175 FMI 08 Temperature Sender (Engine Oil) Applications ......................................................... 14
Abnormal Signal - Test......................................... 49 Instrument Modules for Locomotive Applications .. 18
CID 0177 FMI 08 Temperature Sensor (Transmission Instrument Modules for Marine Applications ......... 16
Oil) Abnormal Signal - Test .................................. 51 Internal Panel Components ................................... 12
CID 0248 FMI 02 Cat Data Link Incorrect - Test.... 54 Circuit Breakers, Relays, and Wiring ................. 13
CID 0263 FMI 03 Sensor Power Supply Voltage Switches............................................................. 12
Above Normal - Test ............................................ 55
CID 0263 FMI 04 Sensor Power Supply Voltage
Below Normal - Test............................................. 56 L
CID 0271 FMI 03 Alarm (Action) Voltage Above
Normal - Test ....................................................... 57 Level Switch (Coolant) - Troubleshoot .................. 66
CID 0271 FMI 05 Alarm (Action) Current Below Alert Indicator Lamp Always FLASHING ........... 66
Normal - Test ....................................................... 58 Indicator Lamp Never Flashes ........................... 67
CID 0271 FMI 06 Alarm (Action) Current Above LH/RH Switch - Troubleshoot ................................ 67
Normal - Test ....................................................... 59
CID 0819 FMI 02 Display Data Link Incorrect -
Test ...................................................................... 60 M
CID 0821 FMI 03 Display Power Supply Voltage
Above Normal - Test ............................................ 61 Main Display Module Initialization - Adjust ............ 77
CID 0821 FMI 04 Display Power Supply Voltage Modes Of Operation .............................................. 28
Below Normal - Test............................................. 63 Module - Replace .................................................. 77
Clear/Mode Switch - Troubleshoot ........................ 70
The “CLEAR/MODE” Switch Automatically Clears
Logged Diagnostic Codes and Tattletale Values N
or Does Not Initiate Mode Changes ................. 71
The “CLEAR/MODE” Switch Does NOT Clear Normal Mode ......................................................... 29
Logged Diagnostic Codes and Tattletale Values Numeric Readout Mode......................................... 29
or Does NOT Initiate Mode Changes ............... 70
Connector Contact Description of Main Display
Module ................................................................. 80
SENR6587-03 91
Index Section

P Troubleshooting Diagnostic Codes........................ 42

Troubleshooting Procedures .............................. 42
Panel Components ................................................ 4
Alarm.................................................................. 8
Alarm Silence Switch ......................................... 8 U
Configuration...................................................... 6
Control Switches For The Main Display Units Mode ............................................................ 38
Module ............................................................. 7
Customer Connector “C”.................................... 8
Customer Connector “D”.................................... 10 W
Customer Connector “G”.................................... 11
Emergency Stop Push Button............................ 7 Warning Operation ................................................ 39
Engine Control Switch........................................ 7
General Information ........................................... 4
Locomotive Engine Connectors ......................... 8
Locomotive Power Connector “F” ...................... 10
Normal Stop Push Button .................................. 7
Starting Aid Switch............................................. 7

Quad Gauge Module ............................................. 22

Quad Gauge Cluster Module For Premium Marine
Applications...................................................... 25
Quad Gauge Module For Premium Generator Set
And Locomotive Applications ........................... 25
Quad Gauge Module For Prime Generator Set
Applications...................................................... 24
Quad Gauge Module For Standby Generator Set
Applications...................................................... 23

Scroll Switch - Troubleshoot.................................. 68

The Scroll Switch Continually Scrolls................. 69
The Scroll Switch Does Not Scroll ..................... 68
Senders ................................................................. 26
Air Inlet Temperature Sender For Generator Set
Applications And Locomotive Applications....... 26
Engine Oil Temperature Sender For Generator Set
Applications And Locomotive Applications....... 26
Sensors ................................................................. 27
Low Coolant Level Sensor ................................. 27
Low Fuel Level Switch ....................................... 27
Temperature Sensor For Marine Gear Oil.......... 27
Service Mode......................................................... 35
Service Tools ......................................................... 40
Main Display Module Connector Contact
Numbers........................................................... 41
System Schematic................................................. 83
System Self Test.................................................... 76
Systems Operation Section ................................... 4

Table of Contents................................................... 3
Tattletale Mode ...................................................... 37
Testing and Adjusting ............................................ 40
Testing and Adjusting Section ............................... 40
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