SENR6587 02 July1999

SENR6587-02
July 1999
Systems Operation
Testing and Adjusting
3500B Electronic Instrument Panel
2RD1-Up (Engine) 3SS1-Up (Engine)
2TD1-Up (Engine) 3TS1-Up (Engine)
2BM1-Up (Engine) 3WS1-Up (Engine)
3DM1-Up (Engine) 3XS1-Up (Engine)
4GM1-Up (Engine) 5PS1-Up (Engine)
5XM1-Up (Engine) 1NW1-Up (Engine)
6PM1-Up (Engine) 1PW1-Up (Engine)
7HM1-Up (Engine) 1TW1-Up (Engine)
7KM1-Up (Engine) 2FW1-Up (Engine)
7SM1-Up (Engine) 2GW1-Up (Engine)
8EM1-Up (Engine) 2HW1-Up (Engine)
8RM1-Up (Engine) 2JW1-Up (Engine)
4TN1-Up (Engine) 3CW1-Up (Engine)
6HN1-Up (Engine) 3DW1-Up (Engine)
6PN1-Up (Engine) 3ZW1-Up (Engine)
6WN1-Up (Engine) 4AW1-Up (Engine)
7RN1-Up (Engine) 4BW1-Up (Engine)
8CN1-Up (Engine) 5AW1-Up (Engine)
8KN1-Up (Engine) 2EZ1-Up (Engine)
9AN1-Up (Engine) 6HZ1-Up (Engine)
3LS1-Up (Engine)
3MS1-Up (Engine)
3NS1-Up (Engine)
3PS1-Up (Engine)
3RS1-Up (Engine)
i01097883
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. For a list of the most
current publication form numbers available, see the Service Manual Contents Microfiche, REG1139F.
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.
3
Table of Contents
Table of Contents CID 0819 FMI 02 Display Data Link Incorrect -

Test ..................................................................... 60
CID 0821 FMI 03 Display Power Supply Voltage
Above Normal - Test ........................................... 61
Systems Operation Section CID 0821 FMI 04 Display Power Supply Voltage
Below Normal - Test ............................................ 63
Panel Components ............................................... 4
Alert Indicator - Troubleshoot ................................ 64
Internal Panel Components .................................. 12
Level Switch (Coolant) - Troubleshoot .................. 66
Instrument Modules for Generator Set
LH/RH Switch - Troubleshoot ................................ 68
Applications ......................................................... 14
Scroll Switch - Troubleshoot .................................. 69
Instrument Modules for Marine Applications ......... 16
Clear/Mode Switch - Troubleshoot ........................ 70
Instrument Modules for Locomotive Applications .. 18
Alarm Silence Switch - Troubleshoot .................... 72
Alert Indicator Description .................................... 20
Harness Code - Troubleshoot ............................... 73
Quad Gauge Module ............................................ 22
System Self Test ................................................... 76
Senders ................................................................ 26
Module - Replace .................................................. 77
Sensors ................................................................. 27
Main Display Module Initialization - Adjust ............ 78
Action Alarm and Alarm Silence Switch ............... 28
Glossary of Terms ................................................. 78
Electronic Control Module (Engine) ...................... 28
Connector Contact Description of Main Display
Modes Of Operation ............................................. 29
Module ............................................................... 80
Normal Mode ........................................................ 29
System Schematic ................................................ 83
Numeric Readout Mode ........................................ 30
Service Mode ........................................................ 35
Tattletale Mode ..................................................... 37 Index Section
Units Mode ............................................................ 38
Harness Code Mode ............................................. 38 Index ..................................................................... 90
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 ....................................................... 44
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 .. 53
CID 0263 FMI 03 Sensor Power Supply Voltage
Above Normal - Test ........................................... 55
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 ....................................................... 57
CID 0271 FMI 06 Alarm (Action) Current Above
Normal - Test ....................................................... 59
4
Systems Operation Section

i01023272
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).
5
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
• 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)
g00574183
displays 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 applications.
all 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.
7
• 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. used to quickly stop the engine during emergency
The Instrument Panels for Locomotive Engines are situations. The emergency stop push button (10)
not equipped with the Engine Control Switch. and (32) removes power from the engine ECM
and the Main Display Module (2) and (23). Also,
1. The OFF/RESET position removes power from the emergency stop push button activates the air
the engine for an immediate engine shutdown. shutoff. 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
On Generator Set applications, the ECS must Starting Aid switch (5). The Starting Aid switch
be in the AUTO position in order to use a (5) is used to provide the method of manually
Customer Communication Module (CCM). A injecting ether during engine start-up. This switch
Customer Communication Module (CCM) is is normally in the AUTO position, which allows the
used in order to remotely start the engine. In electronic control module (ECM) to automatically
order to remotely start the engine, the operator control ether injection. If the operator holds the
must have a personal computer (PC). The Starting Aid switch in the MANUAL position, the
PC is required to have the software for the electronic control module (ECM) will signal ether
customer communication module (CCM). The injection. The injection will proceed according to the
PC may be directly connected to the customer strategy that is explained in the Engine Operation
communication module (CCM) or the PC may And Maintenance Manual.
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
reached. are 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
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
on the Main Display Module (2) and (23). The (29) once the alarm has sounded. Activating the
Main Display Module (2) or (23) will cycle switch will silence the alarm for five minutes. After
through the different modes of operation when the five minute period, if the condition that initiated
the “CLEAR/MODE” Switch (7) or (25) is held the alarm has not been corrected, the Alarm (14)
down in the MODE position. When the desired or (29) will 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
engine wiring harness to the engine connectors on
(7) and (25) up for approximately one second
the junction box.
until the 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 Customer Connector “C” (40 pin connector) (18)
available in a single mode. The Main Display provides access to all customer attachments
Module (2) and (23) will scroll through the and system enhancements. Attachments that
parameter display information that is available in interface through this connector for Generator Set
the selected mode. When the “SCROLL” switch applications include the following items.
(6) or (24) is held in the UP position, the Main
Display Module will scroll. If the continuous • Speed adjust potentiometer (when the Woodward
display of a parameter is desired, hold the Loadshare Module is not used)
“SCROLL” switch (6) or (24) in the UP position,
until the desired information is displayed. • Fuel level switch
Next, release the “SCROLL” Switch (6) or (24)
when the desired information is displayed. The • Battery charger fault switch
parameter information will remain displayed until
Main Display Module (2) or (23) receives another • Low coolant level switch
switch signal.
• Customer remote start/stop switch
3. “LH/RH” Switch (8) or (26) is used to display
both the right hand and left hand parameter • Customer remote emergency stop switch
information on a single gauge. Right hand
values and left hand values for the exhaust • Inlet air temperature sender
temperature measurements and inlet air
restriction measurements can be displayed • Engine oil temperature sender
on the Electronic Instrument boxes that are
equipped with a second Quad Gauge Module Attachments that interface through this connector
(9) or (31). When the Quad Gauge Module is for marine applications include the following items.
displaying the parameter information for the
exhaust temperature or the inlet air restriction, • Fuel level switch
the “LH/RH” switch (8) or (26) can be toggled.
• Marine gear oil pressure
Alarm • Marine gear oil temperature
The Alarm is activated by the Main Display Module.
The Alarm is turned ON when there is a parameter • Low coolant level switch
that is out of range. The Alarm is also turned ON for
active diagnostic faults. • Customer remote start/stop switch
• Customer remote emergency stop switch
9
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
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) Synchronization
is a 24 pin connector. For marine applications, Switch
this connector also provides +Battery and a
“−Battery” access. The access is for the throttle 3 Primary Throttle Switched
synchronization switch, the throttle position sensor, Position Sensor +Battery
the secondary electronic control module (ECM), 4 Backup Throttle Switched
ready lamps and active lamps. On single marine Position Sensor +Battery
engine applications, a backup throttle position
5 Secondary ECM Switched
sensor can also be powered 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.
11
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 10 Shield
“G” 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 (−)
• General alarm relay 15 Shutdown Notify (COM)

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
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
SMCS Code: 1408; 7451 even when the engine control switch is in the
OFF/RESET position. Also, the starting motors can
Switches be engaged when the engine ECM has completed
the cycle crank sequence or when the engine ECM
Inside the electronic instrument panel in the upper has completed a remote shutdown command. The
left hand corner, there are three switches. The “Manual Start 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).
This switch is used on marine propulsion engines The Engine Protection Override Switch allows the
that were built after April 1997 only. operator to override the strategies for protection 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

g00526769 the ON position, the Engine Protection Override
Illustration 4
Switch is disabled. The warnings and the overspeed
Note: The Prelube Override Switch is present only if shutdown will continue to function normally. When
the prelube pump (attachment) is part of the engine the Engine Protection Override Switch is in the ON
package. The parameter of the prelube pump must position, the engine will perform as though there
be turned ON by the electronic service tool for this are no active derates or no active shutdowns. If the
function to work. engine has already had a shutdown, the engine can
be restarted. The alarm conditions and the events
will continue to function normally.
13
When the Engine Protection Override Switch is • ECM circuit

placed in the ON position, an event will be logged
in the ECM. An event will be logged in the ECM • Programmable Relay Control Module (PRCM)
when the switch is returned to the OFF position. No
delay is required for use of the Engine Protection • “DeNOx” (non-marine Generator Set only)
Override Switch.
• main display module circuit
The OVERSPEED VERIFY Switch (3) allows the
operator to verify that the overspeed protection • control switch circuit
system is properly working. When the switch is
activated, the engine ECM will perform an engine • alternator circuit
overspeed shutdown at 75 percent of the engine
overspeed trip point. The overspeed verify switch • customer power circuit
is intended to be used for troubleshooting and
verification of engine protection systems. • secondary ECM circuit
The “HIGH/LOW” Idle Switch (1) allows the operator Relays are used in order to control the following
of the Generator Set to hold the engine speed at subsystem power requirements.
the low idle setting. The electronic service tool is
used to program the low idle setting. When the • mag relays for starter circuits
“HIGH/LOW” Idle Switch is activated, the engine
speed will be governed at the low idle setting. If the • relays for air shutoff circuits (not available on
“HIGH/LOW” Idle Switch is deactivated, the engine Locomotive)
speed will be governed to the high idle setting. The
“HIGH/LOW” Idle Switch is intended to be used for • master relays and slave relays for prelube
troubleshooting. pump circuits (attachment) (not available on
Locomotive)
The PRELUBE OVERRIDE Switch (1) allows the
operator of a marine propulsion engine to override • relay for the main display module circuit (not
the prelube pump sequence during normal engine available on Locomotive)
start-up. The override will occur if there is an
attached prelube pump as part of the engine • relay for ECM circuit (not on Locomotive)
system. The engine ECM will not initiate an engine
prelube sequence prior to cranking the engine, • relay for secondary ECM circuit (Marine only)
when the prelube override switch is activated. The
engine ECM will immediately begin to crank the • relays for ether starting aid pull-in circuits and
engine without prelubing first. The prelube override ether hold-in circuits (non-marine Generator Sets
switch is intended to be used for immediate engine only) (attachment)
starting during emergency situations.
• shutdown notify
Note: Inside the Locomotive Junction Box, there is
one switch in the middle of the box. The switch is • Programmable Relay Control Module (PRCM) (not
used for verification of engine overspeed. on Locomotive)
Circuit Breakers, Relays, and • “DeNOx” (non-marine Generator Set only)

(attachment)
Wiring
• customer power (marine only) (not on Locomotive)
A number of circuit breakers are inside the
electronic instrument panel that are used to protect • General Alarm (Locomotive only)
the electrical system and the electrical wiring. The
following circuits are protected by circuit breakers.
• starting circuit
• battery circuit
• relay circuit
• starter relay circuit
14
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
(JWAC) without marine gear sensors include the from the switches, sensors and other electronic
following items. controls that are on the engine that uses the CAT
Data Link. The main display module processes this
• A main display module information and the main display module outputs the
information to the gauge clusters or the alarm. The
• Up to three gauge modules engine systems status and the system diagnostic
information are shown to the operator through the
• Various switches and sensors components of the display.
• An alarm The display window on the main display module

indicates the following items.
15
• 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
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
• Main display module of information that is shown is dependent on the
display mode. The display components show the
• Up to three gauge modules engine systems status to the operator. Also, the
display components show the system diagnostic
• Various switches information 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
17
• kPa
• PSI
• RPM
• LITER
• “GAL/H”
• −10
• VOLTS
• Hour Meter symbol
• “SERV CODE”
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
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
• Main display module Display Module processes this information and
the Main Display Module outputs the information
• Three gauge modules to the gauge clusters. The Main Display Module
also outputs the information to the Alarm. The
• Various switches engine systems status and the system diagnostic
information are shown to the operator through the
• Various sensors components of the display. The type of information
that is shown is dependent on display mode.
• Action Alarm
19
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”
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
i01033507
Alert Indicator Description

SMCS Code: 7451
g00532229
Illustration 8
The operator is notified of abnormal engine This lamp indicates that there is an active diagnostic
operating conditions by the Main Display Module. code present, an event present, or the engine ECM
The Main Display Module flashes the Alert Indicators has initiated a shutdown. The information is received
ON and OFF. The Main Display Module uses the from the engine ECM through the CAT Data Link.
signals from 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
• sensor inputs the 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.
21
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. Low Fuel Pressure - red
The information is received from the ECM through
the CAT data link. For more information about This lamp illuminates when the fuel pressure is low.
the engine ECM and the setpoints, refer to the The information is received from the engine ECM
Troubleshooting Guide. through the CAT Data Link.
Overcrank - red High Aftercooler Coolant Temperature - amber
Generator Set Only - This lamp illuminates when the This lamp illuminates when the engine aftercooler
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
engine ECM through the CAT data link. from 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 Note: The default value for the trip point is
is received from the engine ECM through the CAT programmed in the factory. The default value is
Data 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 is reprogramming the trip point. The information is
received from the Marine Gear Transmission Oil received from the engine ECM through the CAT
Temperature Sensor. For more information about the Data Link. For more information about programming
default values, refer to the Troubleshooting Guide. the trip point, refer to the Troubleshooting Guide.
Engine System Status - red Low Coolant Temperature - amber
This lamp illuminates when the engine ECM This lamp illuminates when the engine coolant
has detected an active diagnostic code that is temperature is low.
present. An active event may also be present.
The information is received from the engine ECM Note: The default value for the trip point is
through the CAT Data Link. programmable. The Electronic Service Tool can be
used to reprogram the trip point. The information
Fuel Filter Restriction - red is received from the engine ECM through the CAT
Data Link. For more information about programming
the trip point, refer to the Troubleshooting Guide.
22
Low Coolant Level - amber
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.
23
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 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
24
Engine Oil Pressure (1) Quad Gauge Module For Prime

This module displays engine oil pressure over a
range of 100 kPa (14.5 psi) to 600 kPa (87 psi).
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

Engine Coolant Temperature (2)
This engine coolant temperature gauge displays

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

for the gauge equals 90C (194F). The information
is received from the engine ECM through the CAT
Data Link.
System Voltage(3)
This gauge displays battery voltage or charging g00530412

Illustration 10
system voltage over a range of 18 DCV to 32 DCV.
“RH/LH” Exhaust Temperature (1)
for the gauge equals 26 DCV. This module displays the exhaust temperature over
a range of 400C (752F) to 750C (1382F).
through the CAT Data Link. When the needle is pointing straight up, the value
for the gauge equals 600C (1112F).
Fuel Pressure (4)
This gauge displays fuel pressure over a range of through the CAT Data Link.
200 kPa (29 psi) to 600 kPa (87 psi).
“RH/LH” Air Inlet Restriction (2)
for the gauge equals 500 kPa (72.5 psi) for all This module displays engine air inlet filter restriction
applications except the Locomotive engine. over a range of 0 kPa (0 psi) to 10 kPa (1.45 psi).
When the needle is pointing straight up, the value When the needle is pointing straight up, the value
for the gauge is 400 kPa (58 psi) for Locomotive for the gauge equals 3 kPa (.44 psi).
applications .
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).

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).
25
When the needle is pointing straight up, the value When the gauge is pointing straight up, the value
for the gauge equals 60 kPa (8.7 psi). for the gauge equals 75C (167F).
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.
Quad Gauge Module For Premium Engine Oil Temperature (4)
Generator Set And Locomotive This module displays engine oil temperature over a
Applications range of 60C (140F) to 120C (248F).
When the gauge is pointing straight up, the value


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).

for the gauge equals 190 kPa (27.6 psi). g00530416
Illustration 12

Inlet Air Pressure (Boost) (1)
Aftercooler Coolant Temperature (2) This module displays the turbo compressor outlet
pressure (boost) over a range of 0 kPa (0 psi) to
400 kPa (58 psi).
This module displays aftercooler coolant
temperature over a range of 20C (68F) to 120C
(248F).
for the gauge equals 190 kPa (27.6 psi).
Inlet Air Temperature (3)
Aftercooler Coolant Temperature (2)
This module displays inlet air temperature over a
range of 60C (140F) to 120C (248F).
26
This module displays aftercooler coolant The Engine Oil Temperature Sender provides
temperature over a range of 20C (68F) to 120C measurements of the engine oil temperature after
(248F). These temperatures are displayed for filtering. The Engine Oil Temperature Sender also
all Marine engines except the engines that have aids in the detection of degraded of the oil cooler
“JWAC” applications. performance. Temperatures that are greater than
107C (225F) will have a negative impact on the
For JWAC applications, the module displays engine life.
temperatures over a range of 60C (140F) to 120C
(248F). A resistive signal which corresponds to the oil
temperature is sent from the sender to the Main
The information is received from the engine ECM Display Module. Typically, the resistance range of
through the CAT Data Link. the sender is 70 to 800 Ohms ( ). The Main Display
Module converts the resistive signal and the Main
Marine Gear Transmission Oil Temperature (3) Display Module displays the value on the Premium
Quad Gauge Electronic Module.
This module displays marine gear transmission oil
temperature over a range of 20C (68F) to 120C Air Inlet Temperature Sender For
(248F).
Generator Set Applications And
When the gauge is pointing straight up, the value Locomotive Applications
The information is received from the Marine Gear

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
g00574503
Illustration 14
Senders
The Air Inlet Temperature Sender provides
SMCS Code: 1408-UN; 7451-UN measurements of the Air Inlet temperature prior to
entering the cylinder head. The Air Inlet Temperature
Engine Oil Temperature Sender For Sender also aids in the detection of the following
conditions that occur in the area that is located next
Generator Set Applications And to the engine air filters.
Locomotive Applications
• Degraded aftercooler performance
• High ambient air temperatures
• Poor air ventilation
Temperatures that are 30C (86F) 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
the sender is 70 Ohms ( ) to 800 Ohms ( ). The
Main Display Module converts the resistive signal
Illustration 13 g00574503 and the Main Display Module displays the value on
the Premium Gauge Cluster Module.
27
i01034059 Temperature Sensor For Marine

Sensors Gear Oil
SMCS Code: 1408-NS; 7451-NS
Low Coolant Level Sensor
g00574503
Illustration 16
The Marine Gear Oil Temperature Sensor provides

the operator with an indication of the oil temperature.
g00574577
The Marine Gear Oil Temperature Sensor aids in
Illustration 15 monitoring the proper marine gear oil temperature.
The operator can receive a Marine Gear Oil
The Low Coolant Level Sensor provides an Temperature High Warning indication from the
indication of the coolant level to the operator. This Programmable Relay Control Module “PRCM” with
indicator aids the operator in monitoring the proper the aid of this sensor.
coolant volume in the engine which prevents the
engine from overheating. The operator can also The sensor sends a pulse width modulated signal
receive an Engine Low Coolant Level Warning (PWM) with a duty cycle that varies as the Marine
indication from the “PRCM” with the aid of this Gear Oil Temperature changes from the sensor to
sensor. the Main Display Module. The sensor frequency
is 4.2 kHz. The Main Display Module displays the
The signal of the Low Coolant Level Sensor is pulled value of the PWM signal on the Premium Quad
to battery negative while the sensor is submerged Gauge Electronic Module.
in coolant. The signal stays at 5.0 DCV if the coolant
level falls below the tip of the sensor probe. The
Main Display Module converts the signal and the Low Fuel Level Switch
Main Display Module indicates the event by flashing
the Low Coolant Level Indicator Lamp. The sensor
is supplied with +8 DCV from the Main Display
Module.
g00574581
Illustration 17
28
The Low Fuel Level switch provides an indication i01034111

of a low fuel level to the operator. The Low Fuel
Level switch aids the operator in preventing an Electronic Control Module
unexpected shutdown because of an empty fuel (Engine)
supply tank. The operator can also receive an
Engine Low Fuel Level Warning from the “PRCM” SMCS Code: 1901; 7451
with the aid of the Low Fuel Level switch.
The engine ECM supplies the following information
The Low Fuel Level Switch is closed while the to the Main Display Module for an indication of the
switch is submerged in fuel. The switch is open if following items.
the fuel level falls below the tip of the switch. The
Main Display Module converts the signal. The Main • Engine Speed
Display Module indicates the event by flashing the
Low Fuel Level Warning Lamp. • Engine Hours
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 Alarm provides an audible indication to the 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 that an abnormal engine condition exists.
The operator can use the Alarm Silence Switch (2) to

turn off the Alarm (1) once the alarm has sounded.
Activating the Alarm Silence Switch (2) will silence
the Alarm (1) for five minutes. After the five minute
period, if the condition that initiated the alarm has
not been corrected, the Alarm (1) will sound again.
If a new condition occurs during the five minute
period, then the Alarm (1) will sound again.
29
i01034163 • A value for the system condition is shown. The

Main Display Module continuously monitors
Modes Of Operation engine systems. The needles in the Quad Gauge
Electronic Modules indicate a normal operating
SMCS Code: 7451 condition when the needles are pointing straight
up. Also, a normal operating condition may be
The Caterpillar Monitoring System has six different represented when the needle is not pointing
possible modes of operation. Each mode provides straight up.
important information regarding the conditions of
the engine. In this manual, all six modes are given • The system shows if an engine problem exists.
a name. Also, a number represents the modes. When an abnormal condition (problem) exists,
The mode of operation is changed by holding the the corresponding Indicator Lamp flashes and
“CLEAR/MODE” switch down. The available modes the Alarm sounds. For more information on
are listed in the following chart. this subject, see Systems Operation, “Warning
Operation”.
Table 8
Modes Of Operation For The Main Display Module • The system shows if a diagnostic code exists.
The Main Display Module continuously checks
Mode Of Operation Mode Number
for diagnostic codes in the Caterpillar Electronic
Normal 0 Control Module (ECM). When a diagnostic code is
detected, the display area shows “SERV CODE”
Numeric Readout 1
and the “Shutdown/Diagnostic” Alert Indicator
Service 2 lights.
Tattletale 3
• The Tachometer Parameter is shown in Illustration
Units 4 19. Engine speed is displayed on the six digit
display area, when the units indicator shows
Harness Code 5
“RPM”. The Main Display Module receives engine
speed information from the engine ECM through
When power is applied, the Caterpillar Electronic the CAT Data Link. Use the “SCROLL” switch
Monitoring System performs a Self-Test. The in order to toggle between the Tachometer
Self-Test causes all of the display elements and Parameter and the Service Meter Parameter.
gauges to briefly operate. After the Self-Test, the
Main Display Module enters Mode 0.
i01034193
Normal Mode
SMCS Code: 7451 g00532879
Illustration 19
Normal Mode or Mode 0 is used during normal
engine operation. The Quad Gauge Electronic • The Service Meter Parameter is shown in
Module shows the conditions that are listed below Illustration 20. The engine ECM records the total
to the operator when the Main Display Module is in number of hours of operation for the engine. This
Normal Mode. information is sent to the Main Display Module
through the CAT Data Link. The total engine
• Proper operation of the monitoring system is operating hours are shown on the six digit display
shown. A Self-Test is performed. The Self-Test area. The service meter symbol is ON in order
causes all of the display elements and gauges to indicate that the display is functioning as a
to operate briefly. For more information on this Service Meter. While the engine is operating, the
subject, see Systems Operation, “System Self value is continuously updated. Use the “SCROLL”
Test”. switch in order to toggle between the Tachometer
Parameter and Service Meter Parameter.
30
Table 9
Modes Of Operation For The Main Display Module
System Quad Gauge Parameter
Identifier Cluster
Module(1)
“LOAd” Display Area % Load
Only (15)
g00532883
Illustration 20
“FO-2” Display Area Fuel Consumption Rate
Only (15)
i01034293
“FL-1” Display Area Total Fuel Consumption
Numeric Readout Mode Only (15)
“GA-1” (9) Engine Oil Pressure
SMCS Code: 7451
“GA-2” (10) Engine Coolant
Temperature
Numeric Readout Mode (Mode 1) assists Service
Personnel with information about Load Consumption “GA-3” (8) System Voltage
and the troubleshooting of sensor inputs. The
“GA-4” (14) Fuel Pressure
information about Load Consumption is displayed
on the Display Area only. The CAT Data Link and the “GA-5” (16) “RH/LH” Exhaust
sensor inputs supply information for the positions of Temperature
the needles that are on the gauge cluster modules.
“GA-6” (19) “RH/LH” Air Inlet
Restriction
Mode 1 more accurately shows the same information
that is shown on the gauges in Mode 0. The system “GA-7” (18) Fuel Filter Restriction
identifier “LOAd”, “FO-X” or “GA-X” precedes the “GA-8” (20) Oil Filter Restriction
value that is shown on the display area. In addition
to the parameter value that is shown on the display “GA-9” (21) Inlet Air Pressure Boost
area, the gauge needle for the parameter value that “GA-10” (17) Aftercooler Coolant
is displayed is active while all other gauges fall to Temperature
the minimum position.
Generator Set Only
In order to enter Mode 1, hold down the “GA-11” (22) Inlet Air Temperature
“CLEAR/MODE” Switch until “−1-” appears on the
Display Area. Use the “SCROLL” Switch in order to “GA-12” (23) Engine Oil Temperature
advance the display to the next parameter value. Marine Propulsion Only
The Display Area will momentarily show the system
identifiers “LOAd”, “FO-X” or “GA-X”. After the “GA-11” (22) Marine Gear Transmission
system identifier appears, the Display Area shows Oil Temperature
the parameter value. “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.
g00532993
Illustration 21
Only the system identifiers for the gauge cluster

modules that are present are shown. For example, if
only one gauge cluster module is present, system
identifiers “GA-1”, “GA-2”, “GA-3” and “GA-4” will
be shown. If additional gauge cluster modules are
present, “GA-5”, “GA-6”, “GA-7” and “GA-8” will be
shown, etc. The following charts match the system
identifier to the parameter value of the gauge.
31
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)
32
g00533010 g00533062
Illustration 31 Illustration 36
Fuel Filter Restriction (GA-7) Engine Oil Temperature (GA-12) Generator Set And Locomotive
Engines
g00533010
Illustration 32
g00533064
Oil Filter Restriction (GA-8) Illustration 37
Marine Gear Oil Temperature (GA-11) Marine Propulsion Only
g00533014
Illustration 33
g00533066
Boost Pressure (GA-9) Illustration 38
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
33
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
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.
35
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 Service Mode (Mode 2) assists service personnel

with the troubleshooting of diagnostic codes. All the
Service Mode recorded diagnostic codes can be cleared from
memory while the operator is in Mode 2.
SMCS Code: 7451
Note: Events can not be viewed through the main
display module. Events can only be viewed using
the CAT ET Service Tool.
g00532879
Illustration 42
Mode 0: Service Code Indicator ON
36
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 and the CID FMI. Identifiers include the
following items.
Module Identifier (MID) – The MID is a three digit

code that is shown on the six digit Display Area.
The MID is displayed for approximately one second, g00533391
before the CID FMI is shown in place of the MID. Illustration 43
The MID helps the operator to determine the
electronic control module that has generated the Failure Mode Identifier (FMI) – The FMI is shown
diagnostic code. Some values that may be seen for on the last two digits of the six digit Display Area.
the MID are given in the following list. The FMI begins with the decimal point or an “F”.
The FMI ends with the two digit code. The CID
• Main Display Module 030 FMI is displayed immediately after the MID. The
diagnostic code that is generated is revealed to the
• Primary Engine Control Module 033, 034 or 036 operator through the FMI. A listing of the codes that
are used for the FMI may be found on the left side
• Secondary Engine Control Module 047 of the Electronic Instrument Panel. The example
that follows is for “THROTTLE SIGNAL OUTPUT IS
• De-Nox Control 076 ABNORMAL”.
• Customer Communication Module 097 Note: “F” is used on the earlier models in order
to distinguish between the digits of the CID and
• Programmable Relay Control Module 099 the digits of the FMI. The “F” has been removed
in order to allow the fourth digit in the CID to be
Component Identifier (CID) – The CID is shown added, and the decimal point is the separation
on the first four digits or the first three digits of between the CID and the FMI.
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.

The fourth digit has been added to the CID in order
to provide the ability to develop four digit codes.
g00533497
Illustration 44
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”.
37
The “SERV CODE” indicator signifies if the Tattletale Mode or Mode 3 is a tool that is used
diagnostic code is active or logged. The diagnostic for management. The history of the engine may
code is logged when the “SERV CODE” indicator is be found by using Mode 3. The Main Display
OFF. The Alarm will sound if a diagnostic code goes Module records the extreme values for each engine
from the logged status to the active status during condition that is monitored. The values come from
the display of Mode 2. This will assist the service the sensor input and the engine ECM through the
personnel in finding intermittent problems. CAT Data Link. The Tattletale values are updated
whenever a more extreme value occurs than the
Use the “SCROLL” switch in order to advance value that is previously recorded. These values are
to the next recorded diagnostic code. Using the ignored for a short period of time after each engine
“SCROLL” switch will show all of the diagnostic start-up. This allows the engine systems to stabilize
codes that were recorded one at a time in the before old values can be updated with new values.
Display Area.
The gauges show the highest value or the gauges
The service personnel must clear the diagnostic show the lowest value that has been attained by
code from memory when a diagnostic code is the corresponding engine subsystem. The highest
corrected. A diagnostic code is corrected when the reading is for values that abnormally decrease.
“SERV CODE” is OFF. A diagnostic code that is
logged may be cleared from memory by pushing In order to more accurately show the information
the “MODE/CLEAR” switch to the UP position while that is represented on the gauges, use the
the code is displayed in the Display Area. “SCROLL” switch in order to advance the Display
Area to the first tattletale value. The Display Area will
Note: When no diagnostic codes are detected, the momentarily show the system identifier “GA-X”. The
Display Area will show the following reading. system identifier is then followed by the tattletale
value. See the chart that is located in Systems
Operation, “Numeric Readout Mode”.
g00533498
Illustration 45
g00533586
Illustration 47
i01034928
Tattletale Mode Press the “SCROLL” switch again for each

succeeding tattletale value. Only the system
SMCS Code: 7451 identifiers for the quad gauge electronic modules
that are present are shown on the Display Area.
In order to enter Mode 3, hold down the For example, if only one quad gauge electronic
“CLEAR/MODE” switch until “-3-” appears in the module is present, system identifiers “GA-1”,
Display Area. After the operator enters Mode 3 the “GA-2”, “GA-3” and “GA-4” will be shown. If an
Display Area will show the following reading. additional quad gauge electronic module is present,
“GA-5”, “GA-6”, “GA-7” and “GA-8” will be shown.
The pattern continues for additional quad gauge
electronic modules. The system identifier “GA-X”
precedes the value that is shown in the Display
Area. In addition to the tattletale 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.
g00533585
Illustration 46 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.
38
Information about the Tattletale is retained until the i01035048

information is cleared from the memory of the Main
Display Module. Clearing all information about the Harness Code Mode
Tattletale from the memory of the Main Display
Module is done by pushing the “MODE/CLEAR” SMCS Code: 7451
switch to the UP position while “- -” is displayed
in the Display Area. After clearing, all information In order to enter Harness Code Mode (Mode 5),
about the tattletale is reset to a nominal value and hold down the “CLEAR/MODE” switch until “-5-”
the recording of new extreme values can begin. appears in the Display Area. When the Display
Individual gauge tattletale values can be cleared Area is in Harness Code Mode, the engine code is
one at a time by pushing the “MODE/CLEAR” switch shown on the Display Area. The engine code must
to the UP while the gauge tattletale value is being correspond to the engine sales model. The engine
displayed in the Display Area. code is a two-digit representation of the harness
code input.
Note: The date, time or duration of the occurrence
of the tattletale value is not recorded. Note: Harness Code Mode 5 is only available on
155-8653 Engine Monitoring Control (Caterpillar
Monitoring Systems) and newer Caterpillar
i01035010 Monitoring System modules.
Units Mode Table 11
Mode 5 Application
SMCS Code: 7451
Harness Code
Display
In order to enter Mode 4, hold down the
“CLEAR/MODE” switch until “-4-” appears in the 03 Generator Engine (1) with Standby
Display Area. Units Mode (Mode 4) is used to toggle Panel
the display of the Caterpillar Monitoring System 05 Generator Engine(1) With Prime Panel
between US units and Metric units of measure.
When the Main Display enters Units Mode, the 06 Generator Engine(1) With Premium
Display Area will show the current setting. The Panel And “SCAC”
Display Area shows “US” when the Display Area is 07 Generator Engine With Premium
set to US units. The Display Area shows “SI” when Panel And JWAC “JWAC”
the Display Area is set to Metric units. See the
examples that are provided below. 09 Marine Propulsion Engine With
Premium Panel And “SCAC”
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
g00533649 contains problems that the operator may encounter:
Illustration 48
the loss of event notification, incorrect data displays,
Press the “SCROLL” switch in order to toggle the incorrect gauge needle position, and incorrect
units between US units and SI units. activation of diagnostic codes. CID 127 FMI 08, CID
177 FMI 08, and CID 819 FMI 02 are commonly
caused by harness codes that are not correct for
the application on new installations. Troubleshooting
procedures are given for these diagnostic codes in
the Testing And Adjusting Section of this Manual.
An example of Harness Code Mode (Mode 5) is

provided below.
39
• 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.
g00533697
Illustration 49
Display Area
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.
40
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
Testing and Adjusting cause incorrect diagnosing of problems.
During troubleshooting, inspect all components

i01035068 and harness connections before any component
General Information is replaced. If these connections are not clean
and tight, the connections can cause permanent
electrical problems or intermittent electrical
SMCS Code: 7451
problems. Check that the wires are pushed into
Table 12 the connectors all the way. Perform a pull test on
the connector and the wires in order to confirm
Troubleshooting Quick Reference that the contacts are snapped into place. Make
Go To Accessing Diagnostic Information sure that the connections are tight before any other
For Troubleshooting tests are performed. Problems with one electrical
component can cause problems with one or more
Action Alarm CID 0271 Procedure(1) other electrical components. The operator should
CAT Data Link CID 0248 Procedure(1) always attempt to find the cause of the electrical
system problems and the operator should correct
+8 DCV Sensor Supply CID 0263 Procedure(1) the cause of the electrical system problems before
Gauges CID 0096, CID 0127, the operator replaces the 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 SMCS Code: 0785
Indicators
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 • 7X-1710 Multimeter Probe
“CLEAR/MODE” switch
“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)
• 4C-4075 Crimp Tool
41
Use the 146-4080 Digital Multimeter (RS-232) or i01035207

the equivalent for making resistance measurements.
For instructions on the use of the 146-4080 Accessing Diagnostic
Digital Multimeter (RS-232), see Operator’s Manual, Information
NEHS0678. The 7X-1710 Multimeter Probe is used
to make measurements at connectors. The halves SMCS Code: 7451-038
of the connector do not need to be disconnected.
The probe is pushed into the wire entry side of the
connector alongside the wire. The 7X-6370 Adapter Changing Modes
Cable is a 3 pin DT connector breakout cable that
Table 13
is used to make measurements in the circuits of the
sensors. The 4C-4071 Contact Removal Tool (4-6 Activation Of Display Operations
Gauge), the 4C-4072 Contact Removal Tool (8-10 (Quick Reference)
Gauge), the 4C-4073 Connector Removal Tool and Display Service Clear Contact(1)
the 4C-4074 Contact Removal Tool (16-18 Gauge) Operation Contact(1)
are wire removal tools for the CE connectors. The
4C-4075 Crimp Tool is used for 4 AWG through 10 Changing Modes:
AWG pins (sockets) that are used on CE connectors. To Scroll (Mode Ground Ground
Switch)
Note: The use of continuity testers, or voltage testers
are not recommended for use on present day To Hold Open Open
Caterpillar electrical circuits. The continuity testers Service Mode
and the voltage testers may be used in harness
tests. The harness tests include the 8T-0500 To Scroll (Scroll Ground Ground
Continuity Tester and the 5P-7277 Voltage Tester. Switch)
To Hold Open(2) Open
Main Display Module Connector To Clear(3) (Clear Open Ground
Contact Numbers Switch)
Tattletale Modes
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.
g00533857 See Systems Operation, “Modes Of Operation” for a

Illustration 50
detailed explanation of the different modes.
i01035103
Electrical Components And

Connector Locations
SMCS Code: 1408-546-CY; 7451-546-CY
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
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.
SMCS Code: 7451-038 The 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
g00533879 Go to the procedure which corresponds to the CID
Illustration 51
FMI that is shown in the Display Area.
Use the following procedure when a diagnostic code
is detected. When a diagnostic code is detected, Note: The procedures for the CID FMI that are
the Display Area shows the “SERV CODE” indicator found in Testing And Adjusting may cause some
while the Main Display Module is in Normal Mode. diagnostic codes to be logged by the Main
Display Module. Therefore before performing any
1. Enter Service Mode (Mode 2). procedures, record the diagnostic codes in order
to determine the problems that are in the system.
2. A single diagnostic code is shown and the At the completion of each procedure, clear the
code is on hold at this time. The display toggles diagnostic codes that were caused by the test
between the MID and the CID FMI. When the procedure.
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.

43
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
Illustration 52
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 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.
g00543569
Illustration 53
Use the following procedure when a diagnostic

code is detected. When a diagnostic code is
detected, the “SERV CODE” indicator is shown in
the Display Area when the Main Display Module
is in Normal Mode.
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.
44
i01035260 c. Clean corroded terminals and tighten loose

connections.
CID 0096 FMI 03 Level Switch
(Fuel) Voltage Above Normal - d. Turn the “ECS” switch to the
COOLDOWN/STOP position. The
Test “SERV CODE” indicator should be ON for the
diagnostic code CID 0096 FMI 03.
SMCS Code: 1273-038-ZS; 1408-038-ZS;
7451-038-ZS e. Disconnect the engine harness fuel level
switch signal wire and observe the “SERV
CODE” indicator that is in the Display Area.
Expected Result: The “Serv Code” indicator

should turn OFF.
Results:
g00573573
Illustration 54 • OK - The “SERV CODE” indicator turns
Schematic For Fuel Level Switch OFF. The Fuel Level Switch has a problem.
Replace the Fuel Level Switch Unit.
Note: Ensure that the desired diagnostic code (CID
FMI) is on hold. Ensure that the “SERV CODE” • Not OK - The “SERV CODE” indicator stays
indicator is ON. Use the electrical system schematic ON. The harness wiring or the Main Display
for the engine that is being serviced to find the Module has a problem. Proceed to Step 2.
connector contact on the Main Display Module that
corresponds to the CID in the Display Area. 2. Check for an Open Ground Wire.
This diagnostic code is recorded when the Main a. Turn the “ECS” switch to the
Display Module reads the signal voltage of the OFF/RESETposition.
switch as being too high. The corresponding
Indicator Lamp flashes as a result of this diagnostic b. Measure the resistance between the battery
condition. The following examples are possible ground and the ground wire for the fuel level
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 • Not OK - The resistance is greater than 5
engine harness is open or the connector is ohms or equal to 5 ohms. The ground wire
disconnected. for the harness is open. Repair the ground
wire of the harness or replace the ground
• The Main Display Module has a problem. 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 3. Measure the Voltage of the Fuel Level Switch
customer 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 Expected Result: The voltage should be 6.0
level switch. ± 0.5 DCV.
45
Results: • The marine gear oil pressure sensor signal circuit

in the engine harness is open or the connector is
• OK - The voltage is 6.0 ± 0.5 DCV. If the disconnected.
SERV CODE indicator remains ON, repeat
Step 1, Step 2 and Step 3. If the cause of • The harness code is incorrect.
the diagnostic fault is not found, replace the
Main Display Module. • The Main Display Module has a problem.
• Not OK - The voltage is less than 6.0 ± 0.5 1. Check the Display Area and the Harness.
DCV. The harness wiring has a problem.
There is an open circuit or a short to ground a. Turn the “ECS” switch to the OFF/RESET
in the Fuel Level Switch Signal Wire or a position.
poor connection. Repair the harness or
replace the harness. If the cause of the b. Check for loose terminal connections or
diagnostic fault is not found, replace the corroded terminal connections to the marine
Main Display Module. gear oil pressure sensor.
• Not OK - The voltage is greater than 6.0 ± c. Clean corroded terminals and tighten loose
0.5 DCV or the voltage is less than 0.5 DCV. connections.
The harness is shorted to a power circuit.
Repair the harness or replace the harness. d. Turn the “ECS” switch to the
If the cause of the diagnostic fault is not COOLDOWN/STOP position.
found, replace the Main Display Module.
e. The “SERV CODE” indicator should be ON for
the diagnostic code CID 0127 FMI 08.
i01035307
CID 0127 FMI 08 Pressure 2. Confirm that the harness code selection
matches the application.
Sensor (Transmission Oil)
a. Determine the CURRENT harness code
Abnormal Signal - Test selection. For more information, see
SMCS Code: 1408-038-NS; 3080-038-NS; Testing And Adjusting, “Harness Code -
Troubleshoot”.
7451-038-NS
Note: Ensure that the diagnostic code (CID FMI) is b. Determine the CORRECT harness code
selection for the application. For more
on hold. Ensure that the “SERV CODE” indicator
information, see Systems Operation, “Quad
is ON. Use the electrical system schematic of the
engine that is being serviced to find the connector Gauge Module”.
contact that is located on the Main Display Module.
c. Compare the CURRENT harness code
The connector contact should correspond to the
current CID that is shown on the Display Area. selection to the CORRECT harness code
selection.
The diagnostic code is recorded when the Main
Display Module reads an abnormal sensor signal. Expected Result: The CURRENT harness
code selection is correct for the application.
The abnormal signal means that the signal is not
identifiable by the internal circuitry of the Main
Results:
Display Module. The corresponding Indicator
Lamp begins flashing as a result of this diagnostic
condition. Also, the Gauge Needle is in the warning • OK - Proceed to 3.
region. The following examples are possible causes.
• Not OK - Correct the harness code selection
or install marine gear sensors so that the
• The marine gear oil pressure sensor has a application matches the current harness
problem.
code selection. If the marine gear sensors
are not installed, use harness code 11.
• The marine gear oil pressure sensor ground If harness code 9, harness code 10 or
circuit in the engine harness is open.
harness code 12 is selected, make sure
the marine gear sensors are installed. If
• The marine gear oil pressure sensor signal circuit the cause of the diagnostic is not found,
in the engine harness is shorted to +battery.
proceed to 3.
46
3. Measure the Voltage of the Marine Gear Oil • Not OK - : The voltage is less than 1.0
Pressure Sensor Supply Wire. DCV. The signal voltage at the sensor is not
correct. Proceed to Step 7.
a. Turn the “ECS” switch to the
COOLDOWN/STOP position. 5. Measure The Marine Gear Oil Pressure Signal
Voltage.
b. Use the 7X-1710 Multimeter Probe to
measure the voltage from the Gear Oil a. Turn the “ECS” switch to the
Pressure Sensor Ground Wire (pin B) to the COOLDOWN/STOP position.
supply wire (pin A).
Expected Result: The voltage should be 8.0 measure the voltage from the ground wire
± 0.5 DCV. contact of the Main Display Module to the
signal wire contact.
Results:
Expected Result: The voltage should be
• OK - The voltage is 8.0 ± 0.5 DCV. Proceed similar to the voltage that was measured in
to Step 4. Step 4.
• 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
supply wire for the Marine Gear Oil Pressure that was measured in Step 4. The Main
Sensor or a poor connection. Repair the Display Module is receiving a valid signal
harness or replace the harness. If the cause voltage. The Main Display Module has a
of the diagnostic fault is not found, proceed problem. Replace the Main Display Module.
to Step 4. See 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 engine harness has an open circuit in the
DCV and 7.0 DCV, the signal voltage at the signal circuits or the engine harness has an
sensor is 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.
COOLDOWN/STOP position. b. Disconnect the connector of the Main Display
Module.
measure the voltage from the Marine Gear Oil c. Use the 7X-1710 Multimeter Probe to
Pressure Sensor ground wire (pin B) to the measure the resistance that is between
supply wire (pin C). +battery and 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.
47
• Not OK - The resistance is less than 5000 Note: Ensure that the desired diagnostic code (CID
ohms. Repair the harness or replace the FMI) is on hold. Ensure that the “SERV CODE”
harness. indicator is ON. Use the electrical system schematic
for the engine that is being serviced to find the
7. Check For A Short To Ground. connector contact on the Main Display Module
which corresponds to the CID that is currently
a. Turn the “ECS” switch to the OFF/RESET shown.
position.
This diagnostic code is recorded when the Main
b. Disconnect the connector of the Main Display Display Module reads the voltage of the sender
Module and the Marine Gear Oil Pressure signal as being too low. The corresponding Gauge
Sensor connector. Needle is in the warning region as a result of this
diagnostic condition. The following examples are
c. Use the 7X-1710 Multimeter Probe to possible causes.
measure the resistance that is between the
ground wire and the signal wire (pin C) of the • The inlet air temperature sender unit has a
Marine Gear Oil Pressure Sensor. problem.
Expected Result: The resistance should be • The signal circuit for the inlet air temperature
greater than 5000 ohms. sender unit in the engine harness is shorted to
ground.
Results:
• The Main Display Module has a problem.
• OK - The resistance is greater than 5000
ohms. The resistance of the signal wire for Note: The Main Display Module is unable to
the harness is correct. Replace the Main determine when a sender or sender signal harness
Display Module. See Testing And Adjusting, is open or the resistance is too high. This condition
“Module - Replace” for more information. causes the corresponding Gauge Needle to stay at
the left side of the scale.
• Not OK - The resistance is less than 5000
ohms. Repair the harness or replace the 1. Measure the Resistance of the Sender.
harness.
position.
i01035374
CID 0172 FMI 04 Temperature b. Disconnect the engine harness from the inlet
air temperature sender unit.
Sender (Inlet Air) Voltage
Below Normal - Test c. Measure the resistance that is between
the two contacts of the sender connector.
SMCS Code: 1058-038-UN; 1408-038-UN; The following table illustrates the correct
7451-038-UN approximate resistance at various
temperatures.
Table 14
Approximate Resistances For The Sender
Connector Contacts
Temperature Resistance

25 ± 2 C (77 ± 3.6 F)
1000

100 ± 2 C (212 ± 3.6 F)
103.7
2. Check the Display Area and the Harness.

position.
g00573143
Illustration 55
LH/RH Temperature Sender (Inlet Air) b. Check for loose connections or corroded
connections to the inlet air temperature
sender.
48
c. Replace corroded contacts and tighten loose • Not OK - If the voltage is not greater than
connections. 6.5 DCV or the voltage is not less than 0.5
DCV, the harness is shorted to a power
d. Turn the “ECS” switch to the circuit. Repair the harness or replace the
COOLDOWN/STOP position. The harness. If the cause of the diagnostic fault
“SERV CODE” indicator should be ON for the is not found, then replace the Main Display
diagnostic code CID 172 FMI 04. Module.
e. Disconnect the engine harness from the inlet

i01035804
air temperature sender unit. Observe the
“SERV CODE” indicator. CID 0175 FMI 04 Temperature
Expected Result: The “SERV CODE” indicator Sender (Engine Oil) Voltage
should turn OFF. Below Normal - Test
Results:
SMCS Code: 1408-038-UN; 1929-038-UN;
7451-038-UN
• OK - The “SERV CODE” indicator turns OFF.
The inlet air temperature sender unit has a
Note: Ensure that the desired diagnostic code (CID
problem. Replace the inlet air temperature FMI) is on hold. Ensure that the “SERV CODE”
sender unit.
indicator is ON. Find the connector contact that is
located on the Main Display Module. The electrical
• Not OK - The SERV CODE indicator stays system schematic for the engine that is being
ON. The harness wiring or the Main Display
serviced may assist the operator in finding the
Module has a problem. Proceed to Step 3.
connector contact that corresponds to the current
CID that is shown.
3. Check the Sender Wire for a Short to Ground.
a. Turn the “ECS” switch to the OFF/RESET Display Module reads a signal from the sender that
position. is too low. The Gauge Needle will be in the warning
region as a result of this diagnostic condition. The
b. Disconnect the engine harness from the inlet following examples are possible causes.
air temperature sender unit.
c. Turn the “ECS” switch to the • The engine oil temperature sender has a problem.
COOLDOWN/STOP position.
• The sender signal circuit that is located in the
engine is shorted to ground.
d. Measure the voltage of the harness signal
wire from the inlet air temperature sender unit.
The voltage should be measured from pin 1 • The Main Display Module has a problem.
to pin 2 (ground). Note: The Main Display Module is unable to
determine when a sender or the signal harness
Expected Result: The voltage should be 6.0
circuit of a sender is open or the resistance is too
± 0.5 DCV. high. As a result of this condition, a Gauge Needle
will always be on the far left of the scale. This
Results:
condition is recognized as a gauge with a needle
that is always at the far left of the scale.
• OK - The voltage is 6.0 ± 0.5 DCV. The
voltage is correct. If the SERV CODE
1. Measure the Resistance of the Sender.
indicator is still ON, repeat Step 1 through
Step 3. If the cause of the diagnostic fault is a. Turn the “ECS” switch to the OFF/RESET
not found, replace the Main Display Module.
position.
• Not OK - If the voltage is less than 0.5 b. Disconnect the engine harness from the
DCV, the harness wiring has a problem.
sender.
There is an open circuit, a short to ground
in the inlet air temperature sender wire or
a poor connection to a connector. Repair
the harness or replace the harness. If the
cause of the diagnostic fault is not found,
replace the Main Display Module.
49
c. Measure the resistance that is between the d. Measure the voltage from ground to the
threads of the terminal and the case of sender.
the sender. The following table illustrates
the correct approximate resistance for the Expected Result: The voltage should be 6.0
following temperatures. ± 0.5 DCV.
Table 15 Results:
Approximate Resistances For The Sender
Connector Contacts • OK - The voltage is 6.0 ± 0.5. If the SERV
CODE indicator is still ON, repeat Step
Temperature Resistance 1 through STEP 3. If the cause of the
54.4C (130.0F) 850 to 1050
diagnostic fault is not found, replace the
Main Display Module.

110 C (140 F)
140 to 160
• Not OK - The voltage is less than 0.5 DCV.

2. Check the Display Area and the Harness. The harness wiring has a problem. There
is an open circuit or a short to ground in
a. Turn the “ECS” switch to the OFF/RESET the signal wire for the sender, or a poor
position. terminal connection or a poorly connected
connector. Repair the harness or replace
b. Check for loose connections or corroded the harness. If the cause of the diagnostic
connections to the sender. fault is not found, replace the Main Display
Module.
c. Replace the corroded contacts and tighten
the loose connections. • Not OK - The voltage is not greater than 6.5
DCV or the voltage is not less than 0.5 DCV.
d. Turn the “ECS” switch to the The harness is shorted to a power circuit.
COOLDOWN/STOP position. The Repair the harness or replace the harness.
“SERV CODE” indicator should be ON for the If the cause of the diagnostic fault is not
diagnostic code CID 0175 FMI 04. found, replace the Main Display Module.
e. Disconnect the engine harness from the i01099816

sender.
CID 0175 FMI 08 Temperature
f. Observe the “SERV CODE” indicator.
Sender (Engine Oil) Abnormal
Expected Result: The “SERV CODE” indicator Signal - Test
should turn OFF.
SMCS Code: 1408-038-UN; 1929-038-UN;
Results: 7451-038-UN
• OK - The “SERV CODE” indicator turns Note: Ensure that the diagnostic code (CID FMI) is
OFF. The sender has a problem. Replace on hold. Ensure that the “SERV CODE” indicator
the sender. is ON. Use the electrical system schematic of the
engine that is being serviced to find the connector
• Not OK - The “SERV CODE” indicator stays contact that is located on the Main Display Module.
ON. The harness wiring or the Main Display The connector contact should correspond to the
Module has a problem. Proceed to Step 3. current CID that is shown on the Display Area.
3. Check the Sender Wire for a Short to Ground. The diagnostic code is recorded when the Main
Display Module reads an abnormal sensor signal.
a. Turn the “ECS” switch to the OFF/RESET The abnormal signal means that the signal is not
position. identifiable by the internal circuitry of the Main
Display Module. The corresponding Indicator
b. Disconnect the engine harness from the Lamp begins flashing as a result of this diagnostic
sender. condition. Also, the Gauge Needle is in the warning
region. The following examples are possible causes.
c. Turn the “ECS” switch to the
COOLDOWN/STOP position. • The engine oil temperature sensor has a problem.
50
• The ground circuit for the engine oil temperature 3. Measure The Engine Oil Temperature Sensor
sensor that is located in the engine harness is Voltage.
open.
• The signal circuit for the engine oil temperature

sensor that is located in the engine harness is • If the voltage is between approximately 1.0
shorted to +battery. DCV and 7.0 DCV, the signal voltage at the
sensor is correct. Proceed to Step 4.
• The signal circuit for the engine oil temperature
sensor that is located in the engine harness is • If the voltage is not between approximately 1.0
open or the connector is disconnected. DCV and 7.0 DCV, the signal voltage at the
sensor is not correct. If the voltage is greater
• The Main Display Module has a problem. than 7.0 DCV, proceed to Step 5. If the voltage
is less than 1.0 DCV, proceed to Step 6.
a. Turn the “ECS” switch to the OFF/RESET COOLDOWN/STOP position.
position.
b. Check for loose terminal connections or measure the voltage from the ground wire for
corroded terminal connections to the engine the Engine Oil Temperature Sensor (pin B) to
oil pressure sensor. the supply wire (pin C).
c. Clean corroded terminals and tighten loose Expected Result: The voltage should be
connections. approximately between 1.0 DCV and 7.0 DCV.
d. Turn the “ECS” switch to the Results:

• OK - The voltage is between approximately
e. The “SERV CODE” indicator should be ON for 1.0 DCV and 7.0 DCV. The signal voltage at
the diagnostic code CID 0175 FMI 08. the sensor is correct. Proceed to Step 4.
2. Measure the Voltage of the Supply Wire for the • Not OK - The voltage is greater than 7.0
Engine Oil Temperature Sensor. DCV. The signal voltage at the sensor is not
COOLDOWN/STOP position. • Not OK - The voltage is less than 1.0 DCV.
The signal voltage at the sensor is not
b. Use the 7X-1710 Multimeter Probe to correct. Proceed to Step 6.
measure the voltage from the ground wire for
the Engine Oil Temperature Sensor (pin B) to 4. Measure The Signal Voltage Of The Engine Oil
the supply wire (pin A). Temperature Sensor.
Expected Result: The voltage should be 8.0 a. Turn the “ECS” switch to the
± 0.5 DCV. COOLDOWN/STOP position.
Results: b. Use the 7X-1710 Multimeter Probe to

measure the voltage from the connector
• OK - The voltage is 8.0 ± 0.5 DCV. Proceed contact of the ground wire on the Main Display
to Step 3. Module to the signal wire connector contact.
• Not OK - The voltage is less than 0.5 DCV. Expected Result: The voltage should be
The harness wiring has a problem. There is similar to the voltage that was measured in
an open circuit, a short to ground in the Step 3.
supply wire for the Engine Oil Temperature
Sensor or a poor connection. Repair the Results:
harness or replace the harness. If the cause
of the diagnostic fault is not found, proceed
to Step 3.
51
• OK - The voltage is similar to the voltage Results:

that was measured in Step 3. The Main
Display Module is receiving a valid signal • OK - The resistance is greater than 5000
voltage. The Main Display Module has a ohms. The resistance of the signal wire for
problem. Replace the Main Display Module. the harness is correct. Replace the Main
See Testing And Adjusting, “Module - Display Module. See Testing And Adjusting,
Replace” for more information. “Module - Replace” for more information.
• 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
harness. CID 0177 FMI 08 Temperature
5. Check For A Short To +Battery. Sensor (Transmission Oil)
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
indicator is ON. Find the connector contact that is
measure the resistance that is between located on the Main Display Module. The electrical
+battery and the signal wire (pin C) for the
system schematic for the engine that is being
Engine Oil 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.
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
• OK - The resistance is greater than 5000 identifiable to the input circuits of the Main Display
ohms. The signal wire for the harness is Module. As a result of this diagnostic condition, the
correct. Replace the Main Display Module.
corresponding Indicator Lamp will flash and the
See Testing And Adjusting, “Module - Gauge Needle will be located in the warning region.
Replace” for more information. The following 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.
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 is open or the connector is disconnected.
measure 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.
Expected Result: The resistance should be
52
a. Turn the “ECS” switch to the OFF/RESET Expected Result: The voltage should be 8.0
position. ± 0.5 DCV.
b. Check for loose terminal connections or Results:

corroded terminal connections to the sensor
for marine gear oil temperature. • OK - The voltage is correct. Proceed to
Step 4.
c. Clean corroded terminals and tighten loose
connections. • Not OK - The voltage is less than 0.5 DCV.
The harness wiring has a problem. There is
d. Turn the “ECS” switch to the an open circuit, a short to ground in the
COOLDOWN/STOP position. The supply wire of the sensor for marine gear
“SERV CODE” indicator should be ON for the oil pressure or a poor connection. Repair
diagnostic code CID 0177 FMI 08. the harness or replace the harness. If the
cause of the diagnostic fault is not found,
2. Confirm that the harness code selection proceed to Step 4.
matches the application.
4. Measure The Voltage of the Marine Gear Oil
a. Determine the CURRENT harness code Temperature Signal.
selection. For more information, see
Testing And Adjusting, “Harness Code - a. Turn the “ECS” switch to the
Troubleshoot”. COOLDOWN/STOP position.
b. Determine the CORRECT harness code b. Use the 7X-1710 Multimeter Probe to
selection for the application. For more measure the voltage from the Marine Gear Oil
information, see Systems Operation, “Quad Pressure Sensor Ground Wire (pin B) to the
Gauge Module”. Supply Wire (pin C).
c. Compare the CURRENT harness code Expected Result: The voltage should be
selection to the CORRECT harness code between 1.0 DCV and 7.0 DCV.
selection.
Results:
Expected Result: The CURRENT harness
code selection is correct for the application. • OK - The signal voltage at the sensor is
Results:
• Not OK - The signal voltage at the sensor
• OK - Proceed to 3. is not correct. If the voltage is greater than
7.0 DCV, proceed to Step 6. If the voltage
• Not OK - Correct the harness code selection is less than 1.0 DCV, proceed to Step 7.
or install marine gear sensors so that the
application matches the current harness 5. Measure The Voltage of the Marine Gear Oil
code selection. If the marine gear sensors Temperature Signal Voltage.
are not installed, use harness code 11.
If harness code 9, harness code 10 or a. Turn the “ECS” switch to the
harness code 12 is selected, make sure “COOLDOWN/STOP” position.
the marine gear sensors are installed. If
the cause of the diagnostic is not found, b. Use the 7X-1710 Multimeter Probe to
proceed to 3. measure the voltage from the ground wire of
the Main Display Module (contact 2) to the
3. Measure the Voltage of the Marine Gear Oil signal wire (contact 28).
Temperature Sensor Supply Wire.
Expected Results: The voltage should be
a. Turn the “ECS” switch to the equal to the voltage that was recorded in
COOLDOWN/STOP position. Step 4.
b. Use the 7X-1710 Multimeter Probe to Results:

measure the voltage from the marine gear oil
pressure sensor ground wire (pin B) to the
supply wire (pin A).
53
• OK - The voltage is correct. The Main • OK - The resistance of the signal wire for
Display Module is receiving a valid signal the harness is correct. Replace the Main
voltage. The Main Display Module has a Display Module. For more information, see
problem. Replace the Main Display Module. Testing And Adjusting, “Module - Replace”.
See Testing And Adjusting, “Module -
Replace” for more information. • Not OK - The resistance is less than 5000
ohms. Repair the harness or replace the
• Not OK - The voltage is not equal to the harness.
voltage that was measured in Step 4. The
engine harness has an open circuit in the
i01035821
signal circuits or the ground circuits. Repair
harness.
CID 0248 FMI 02 CAT Data Link
Incorrect - Test
6. Check For A Short To +Battery.
SMCS Code: 1408-038; 7451-038
position.

Module and the connector of the Marine Gear
Oil Temperature Sensor.

measure the resistance between +battery and Illustration 56 g00530708
the signal wire (pin C) for the Marine Gear Oil Schematic For The Caterpillar Data Link
Temperature sensor.
Note: Ensure that the “SERV CODE” indicator is ON.
Expected Results: The resistance should be
greater than 5000 ohms. This diagnostic code is recorded when the
Main Display Module does not receive expected
Results: information. For example, the engine speed is not
received from the Engine Electronic Control Module
• OK - The resistance of the signal wire for (engine ECM) through the CAT Data Link. As a
the harness is correct. Replace the Main result of this diagnostic condition, the display area
Display Module. For more information, see depends on the CAT Data Link for information that
Testing And Adjusting, “Module - Replace”. indicates abnormal values. The following items are
possible causes of the readouts. The causes are
• Not OK - The resistance is less than 5000 listed in order of probability.
ohms. Repair the harness or replace the
harness.
• There is a poor electrical connection at the engine
harness connector.
7. Check For A Short To Ground.

• The CAT Data Link circuit in the engine harness
is shorted to ground.
position.

is shorted to +battery.
Module and the connector of the Marine Gear
Oil Temperature Sensor .
is open.
measure the resistance that is between
ground and the signal wire (pin C) for the
• Another electronic module (Secondary ECM,
DeNOx Controller, CCM, PRCM and other
Marine Gear Oil Temperature Sensor. modules) that also uses the CAT Data Link is
having a problem.
greater than 5000 ohms. Note: If the Main Display Module was recently
replaced, see Testing And Adjusting, “Main Display
Results: Module Initialization - Adjust” for more information.
54
1. Check the other Electronic Modules for a b. At the engine harness connector for the Main
similar diagnostic code. Display Module, measure the resistance
between +battery (contact 1) and the CAT
a. If a similar diagnostic code is found, use Data Link circuits (contact 5 and contact 14).
the procedures for that electronic module to
troubleshoot the diagnostic code. Expected Results: The resistance should be
b. If no similar diagnostic code is found, proceed
to Step 2. Results:
2. Inspect The Harness Connectors. • OK - The resistance is greater than 5000

ohms. The harness circuit resistance is
a. Turn the “ECS” switch to the OFF/RESET correct. Proceed to Step 5.
position.
b. Inspect the engine harness connectors that ohms. The engine harness has a problem.
are related to the CAT Data Link. Make sure There is a short between the battery ground
that the connections are clean and tight. and the circuit for the CAT Data Link in the
engine harness. Repair the engine harness
c. If necessary, repair the engine harness or or replace the engine harness.
replace the engine harness. Otherwise,
proceed to Step 3. 5. Check For An Open Circuit In The Harness.
3. Check For A Short To Ground. a. The “ECS” switch remains in the OFF/RESET
position. All related electronic modules remain
a. The “ECS” switch remains in the OFF/RESET disconnected from the engine harness.
position.
b. Measure the resistance of the CAT Data Link
b. Disconnect the engine harness from all circuit in the engine harness.
electronic modules that use the CAT Data
Link. c. Measure the resistance from the connector
of the Main Display Module. The resistance
c. At the engine harness connector for the Main should be taken from contact 5 and contact
Display Module, measure the resistance 14 to the connectors for each of the related
between the battery ground (contact 2) and electronic modules.
the CAT Data Link circuits (contact 5 and
contact 14). Expected Result: The resistance should be
less than 5 ohms.
Expected Result: The harness circuit
resistance should be greater than 5000 ohms. Results:
Results: • OK - The resistance is less than 5 ohms.

The resistance of the circuit for the CAT
• OK - The harness circuit resistance is Data Link in the engine harness is correct.
correct. Proceed to Step 5. The Main Display Module has a problem.
Replace the Main Display Module. For more
• Not OK - The harness circuit resistance is information, see Testing And Adjusting,
less than 5000 ohms. The engine harness “Module - Replace”.
has a problem. There is a short between
battery ground and the circuit for the CAT • Not OK - The resistance is greater than 5
Data Link in the engine harness. Repair ohms. The engine harness has a problem.
the engine harness or replace the engine The circuit for the CAT Data Link is open
harness. in the engine harness. Repair the engine
harness or replace the engine harness.
4. Check For A Short To +Battery. STOP.
a. The “ECS” switch remains in the OFF/RESET

position. All related electronic modules remain
disconnected from the engine harness.
55
i01035830 a. The “ECS” switch remains in the

CID 0263 FMI 03 Sensor Power
Supply Voltage Above Normal b. Disconnect all sensors and senders that
receive +8 DCV from the Main Display
- Test Module.
SMCS Code: 1408-038-NS; 7451-038-NS c. Use the 7X-1710 Multimeter Probe to
measure the voltage that is from connector
contact 2 (ground) to contact 24 of the Main
Display Module.
Expected Result: The voltage should

measure 8.0 ± 0.5 DCV.
Results:
g00573764
Illustration 57
Schematic For Sensor Power Supply • OK - The voltage measures 8.0 ± 0.5 DCV.
The voltage is correct. One of the sensors
Note: The procedures that are used to troubleshoot or one of the senders has a problem.
this diagnostic code may cause additional Individually reconnect each sensor and
diagnostic codes to be generated. Find the cause reconnect each sender while the voltage
and repair the cause of this diagnostic code before level is being monitored. The voltage
troubleshooting any new diagnostic codes. should measure 8.0 ± 0.5 DCV when each
component is connected. If the voltage is
This diagnostic code is recorded when the Main not 8.0 ± 0.5 DCV the sensor or the sender
Display Module reads the voltage of the sensor has a problem. Replace the sensor or
supply voltage circuit as above normal. Also, the replace the sender.
diagnostic code is recorded when the Main Display
Module is shorted to +battery. • Not OK - The sensor supply voltage is not
8.0 ± 0.5 DCV. The sensor supply voltage
1. Measure the Voltage at the Main Display is not correct. Proceed to Step 3.
Module.
3. Check The Harness For A Short To +Battery.
COOLDOWN/STOP position. a. Turn the “ECS” switch to the OFF/RESET
position.
measure the voltage at the Main Display b. Disconnect all sensors and senders that
Module from Contact 24 to Contact 2 receive +8 DCV from the Main Display
(ground). Do not disconnect the harness from Module.
the Main Display Module.
c. Disconnect the engine harness from the Main
Expected Result: The voltage should be 8.0 Display Module.
± 0.5 DCV.
d. At the engine harness connector for the Main
Results: Display Module, measure the resistance from
connector contact 24 to contact 1 (+battery).
• OK - The voltage is 8.0 ± 0.5 DCV. The
sensor supply voltage is correct. If the SERV Expected Results: The resistance should be
CODE indicator remains ON, replace the greater than 5000 ohms.
Main Display Module. For more information,
see Testing And Adjusting, “Module - Results:
Replace”.
• Not OK - The voltage is not 8.0 ± 0.5 DCV. ohms. The harness resistance is correct.
The sensor supply voltage is not correct. The Main Display Module has a problem.
Proceed to Step 2. Replace the Main Display Module. For more
information, see Testing And Adjusting,
2. Disconnect The Sensors. “Module - Replace”.
56
• Not OK - The resistance is less than 5000 • OK - The voltage is 8.0 ± 0.5 DCV. The
ohms. The engine harness has a problem. voltage is correct. If the “SERV CODE”
There is a short between ground and the indicator remains ON, replace the Main
sensor supply voltage circuit in the engine Display Module. For more information, see
harness. Repair the engine harness or Testing And Adjusting, “Module - Replace”.
replace the engine harness.
• Not OK - The voltage is not 8.0 ± 0.5 DCV.
The sensor supply voltage is incorrect.
i01035834
Proceed to Step 2.
CID 0263 FMI 04 Sensor Power 2. Disconnect The Sensors.
Supply Voltage Below Normal
a. The ECS switch remains in the
- Test COOLDOWN/STOP position.
SMCS Code: 1408-038-NS; 7451-038-NS
b. Disconnect all sensors and all senders
that receive +8 DCV from the Main Display
Module.

measure the voltage from connector contact
2 (ground) to contact 24 of the Main Display
Module.
g00573764
Illustration 58 Expected Result: The voltage should be 8.0
Schematic For Sensor Power Supply ± 0.5 DCV.
Note: The procedures that are used to troubleshoot Results:

this diagnostic code may cause additional
diagnostic codes to be generated. Find the cause • OK - The sensor supply voltage is 8.0 ±
of the diagnostic code and repair the cause of the 0.5 DCV. The sensor supply voltage is
diagnostic code before troubleshooting any new correct. One of the sensors or the senders
diagnostic codes. has a problem. Individually reconnect each
sensor or reconnect each sender while the
This diagnostic code is recorded when the Main voltage is being monitored. The voltage
Display Module reads the voltage of the sensor should not drop below 7.5 DCV. If the
supply voltage circuit as below normal voltage. This voltage drops below 7.5 DCV, the sensor
diagnostic code is also recorded when the voltage or the sender has a problem. Replace the
is shorted to ground. sensor or replace the sender.
1. Measure the voltage at the Main Display • Not OK - The voltage is less than 8.0 ±
Module. 0.5 DCV. The sensor supply voltage is not
COOLDOWN/STOP position. 3. Check The Harness For A Short To Ground.
b. Use the 7X-1710 Multimeter Probe to a. Turn the “ECS” switch to the OFF/RESET
measure the voltage at the Main Display position.
Module from contact 24 to contact 2 (ground).
b. Disconnect all sensors and senders that
c. Do not disconnect the harness from the Main receive +8 DCV from the Main Display
Display Module. Module.
Expected Result: The voltage should be 8.0 c. Disconnect the engine harness from the Main
± 0.5 DCV. Display Module.
Results: d. At the engine harness connector for the Main

Display Module, measure the resistance from
connector contact 24 to contact 2 (ground).
57
Expected Result: The resistance should be e. Turn the “ECS” switch to the
greater than 5000 ohms. COOLDOWN/STOP position.
Results: f. Listen for the sounding of the Action Alarm.
• OK - The resistance is greater than 5000 Expected Result: The alarm should not
ohms. The harness resistance is correct. sound.
The Main Display Module has a problem.
Replace the Main Display Module. For more Results:
information, see Testing And Adjusting,
“Module - Replace”. • OK - The alarm does not sound. The Main
Display Module has a problem. Replace the
• Not OK - The resistance is less than 5000 Main Display Module. For more information,
ohms. The engine harness has a problem. see Testing And Adjusting, “Module -
There is a short between ground and the Replace”.
sensor supply voltage circuit in the engine
harness. • Not OK - The alarm sounds. There is a short
between the circuit of the Action Alarm
and +Battery in the engine harness. Repair
i01035973
CID 0271 FMI 03 Alarm (Action) harness.
Voltage Above Normal - Test

i01035978
SMCS Code: 1408-038; 7400-038; 7451-038
CID 0271 FMI 05 Alarm (Action)
Current Below Normal - Test
SMCS Code: 1408-038; 7400-038; 7451-038
g00573861
Illustration 59
Schematic For The Alarm.
(1) Locomotive Engines - 410-WH: Marine Engines and Generator
Set Engines - D25-GN.
g00573861
Illustration 60
This diagnostic code is recorded when the Main Schematic For Action Alarm.
Display Module reads the voltage of the circuit (1) Locomotive - 410-WH: Marine Engines and Generator Engines
of the Action Alarm as above normal. Also, this - 025-GN.
diagnostic code is recorded when the circuit is
shorted to +battery. As a result of this diagnostic This diagnostic code is recorded when the Main
condition, the Action Alarm sounds continuously. Display Module reads the current of the circuit for
the Action Alarm as below normal current. Also, this
1. Check The Alarm Circuit. diagnostic code is recorded when the Main Display
Module reads an open circuit with the Action Alarm.
a. Turn the “ECS” switch to the OFF/RESET As a result of this action, the Action Alarm does not
position. sound when the Action Alarm should sound.
b. Check for loose terminal connections or 1. Check The Alarm.

corroded terminal connections to the Action
Alarm. a. Disconnect the engine harness from the
Action Alarm.
c. Clean the corroded terminals and tighten the
loose connections. b. Place a jumper wire across the two leads of
the Action Alarm of the engine harness.
d. Do Not disconnect the harness from the Main
Display Module. Expected Result: The FMI 05 diagnostic
code should remain active.
58
Results: Disconnect the engine harness from the Action

Alarm. Check for an open circuit between the
• OK - The FMI 05 diagnostic code is still Main Display Module (contact 4) and the lead of
active. The Action Alarm is not causing the the Action Alarm (terminal 1). Also, check for an
problem. Measure the resistance across open circuit between the lead of the Action Alarm
the terminals of the Action Alarm. The (terminal 2) and ground. If an open circuit is
resistance should be 200 ± 100 ohms. If found, repair the harness or replace the harness.
the resistance of the Action Alarm is good,
but the alarm does not sound, proceed to 4. Check The Main Display Module.
Step 2.
• Not OK - If the FMI 05 diagnostic code is position.
not active, the Action Alarm has a problem.
Measure the resistance across the terminals b. Turn the “ECS” switch to the OFF/RESET
of the Action Alarm. The resistance should position.
be 200 ± 100 ohms. If the resistance of
the Action Alarm is good, but the alarm c. Reconnect the engine harness connector to
does not sound, proceed to Step 2. If the the Main Display Module.
resistance of the Action Alarm is not good,
then replace the Action Alarm. Proceed to d. Reconnect the engine harness to the Action
Step 2. Alarm.
2. Check The Harness. e. Turn the “ECS” switch to the

position. Expected Result: The FMI 05 diagnostic
code should not be active.
b. Remove the jumper wire from the harness
leads of the Action Alarm. Results:
c. Reconnect the harness leads to the Action • OK - The FMI 05 diagnostic code is
Alarm. not active. The Main Display Module is
not causing the problem. The problem
d. Disconnect the engine harness from the is intermittent. The probable cause is a
Action Alarm. poor electrical connection at the harness
connectors or a damaged harness. Check
e. At the engine harness connector for the Main the harness for damage and clean the
Display Module, measure the resistance connectors when cleaning is required.
from contact 4 to contact 2. Contact 2 is the
ground. • Not OK - The FMI 05 diagnostic code is
still active. The Main Display Module has a
Expected Result: The resistance should be problem. Replace the Main Display Module.
less than 300 ohms. For more information, see Testing And
Adjusting, “Module - Replace”.
Results:
• OK - The resistance is less than 300 ohms.

The harness resistance is correct. Proceed
to Step 4.
• Not OK - The resistance is greater than 300

ohms. The harness circuit is open. Proceed
to Step 3.
3. Check The Harness.

59
i01036188 c. Disconnect the engine harness from the Main

Display Module.
CID 0271 FMI 06 Alarm (Action)
Current Above Normal - Test d. At the engine harness connector for the Main
SMCS Code: 1408-038; 7400-038; 7451-038 the connector contact 4 to connector contact
2 (ground).

Results
• OK - The resistance is correct. Proceed to

g00573861 Step 3.
Illustration 61
Schematic For The Alarm.
(1) Locomotive Engines - 410-WH: Marine Engines and Generator ohms. The engine harness has a problem.
Set Engines - 025-GN. Repair the engine harness or replace the
engine harness. STOP.
Display Module reads the current in the circuit of 3. Check The Main Display Module.
the Action Alarm as above normal or the current
is shorted to ground. As a result of this fault, the a. Turn the “ECS” switch to the OFF/RESET
Action Alarm does not sound when the Action Alarm position.
should sound.
b. Use the correct service tools to remove
1. Check the Alarm. contact 4 from the engine harness connector
for the Main Display Module.
a. Disconnect the engine harness from the
Action Alarm. c. Reconnect the engine harness connector to
the Main Display Module.
Note: The Action Alarm has a problem if the FMI 06
diagnostic code is not active. The Action Alarm is d. Turn the “ECS” switch to the
not causing the problem if the FMI 06 diagnostic COOLDOWN/STOP position.
code is still active.
Expected Result: FMI 06 should NOT be
b. Measure the resistance across the terminals active.
of the Action Alarm.
Results:
Expected Result: The resistance across the
terminals is 200 ± 100 . • OK - FMI 06 is NOT active. The Main
Display Module is NOT causing the
Results: problem. The problem is intermittent.
The probable cause is a poor electrical
OK - The resistance is correct. If the Action connection at the harness connectors or a
Alarm does not sound, proceed to Step 2. damaged harness. Check the harness for
damage and clean the harness connectors
Not OK - The resistance across the terminals as cleaning is required. STOP.
is not correct. Replace the Action Alarm.
STOP. • Not OK - FMI 06 is still active. The Main
2. Check The Harness. Main Display Module. For more information,
see Testing And Adjusting, “Module -
a. Turn the “ECS” switch to the OFF/RESET Replace”.
position.
b. Disconnect the engine harness from the

Action Alarm.
60
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”.
61
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 b. Use the 7X-1710 Multimeter Probe to
Display Module reads the voltage of contact 34 measure the voltage at the connector of the
below normal or the voltage is shorted to ground. Main Display Module. The voltage should be
Normal supply voltage is 9.0 ± 0.5 DCV. measured from contact 34 to contact 2.
1. Measure The Voltage At The Main Display c. Do not disconnect the harness from the Main
Module. Display Module.
a. Turn the “ECS” switch to the Expected Results: The voltage should be 9.0
COOLDOWN/STOP position. ± 0.5 DCV.
Results:
62
• OK - The voltage is correct. The display

power supply is correct. If the FMI 03
diagnostic code is still active, the Main
Main Display Module. For more information
on this subject, see Testing And Adjusting,
“Module - Replace”.
• 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.

position.
b. Disconnect the engine harness from the Main

Display Module.
c. At the engine harness connector for the Main

connector contact 34 to connector contact
1 (+battery).

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.

information on this subject, see Testing And
63
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 b. Use the 7X-1710 Multimeter Probe to
Display Module reads the voltage of contact 34 measure the voltage at the connector for the
below normal or the voltage is shorted to ground. Main Display Module. The voltage should be
Normal supply voltage is 9.0 ± 0.5 DCV. measured from contact 34 to contact 2.
1. Measure the Voltage at the Main Display c. Do NOT disconnect the harness from the
Module. Main Display Module.
a. Turn the “ECS” switch to the Expected Result: The voltage should
COOLDOWN/STOP position. measure 9.0 ± 0.5.
Results:
64
• OK - The voltage is correct. If the FMI 04 Expected Results: The resistance should be
diagnostic code is still active, the Main greater than 5000 ohms.
Main Display Module. For more information Results:
on this subject, see Testing And Adjusting,
“Module - Replace”. • OK - The resistance of the harness circuit is
correct. The Main Display Module is faulty.
• Not OK - The voltage is not correct. The Replace the Main Display Module. See
Display Power Supply has a problem. Testing And Adjusting, “Module - Replace”.
Proceed to Step 2.
• Not OK - The resistance of the harness
2. Disconnect the Quad Gauge Cluster Modules. circuit is incorrect. The machine harness is
faulty. Repair the harness or replace the
a. Turn the “ECS” switch to the OFF/RESET harness.
position.
i01036642
b. Disconnect the Quad Gauge Cluster Modules.
c. Turn the ECS switch to the COOLDOWN/STOP

Alert Indicator - Troubleshoot
position. SMCS Code: 7400-038-IND; 7451-038-IND
d. At the engine harness connector for the Main
Display Module, measure the voltage from Indicator Lamp Is Always Flashing
connector contact 34 to connector contact 2
(ground). This procedure is for the parameter that has the
indicator lamp that flashes all of the time. The
e. Reconnect the Quad Gauge Cluster Modules “Always Flashing” condition is probably caused by
one at a time. Between reconnecting the an undesired open circuit. Also, the Main Display
Modules, record the voltage of the display Module may cause this problem (unlikely condition).
power supply.
1. Locate The Switch.
Expected Result: The voltage should be 9.0
± 0.5 DCV after each of the Quad Gauge a. Turn the “ECS” switch to the OFF/RESET
Cluster Modules have been reconnected. position.
Results: b. Locate the switch that corresponds to the

parameter that is always flashing the indicator
• OK - The voltage is correct. The Display lamp. If necessary, use the Electrical System
Power Supply is correct. Proceed to Step 3. Schematic in order to assist in locating the
switch.
• Not OK - The voltage is not correct after
reconnecting one of the Quad Gauge c. Check for loose terminal connections or
Cluster Modules. The Quad Gauge Cluster corroded terminal connections to the switch.
Module that affected the voltage has
a problem. Replace the Quad Gauge d. Clean corroded terminals and tighten loose
Cluster Module. For more information on connections.
this subject, see Testing And Adjusting,
“Module - 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 b. Connect a jumper wire from the signal wire to
position. the ground wire. If a ground wire is not near,
connect the signal wire to the battery ground.
b. Disconnect the machine harness from the
main display module. c. Turn the “ECS” switch to the
c. At the machine harness connector for the
Main Display Module, measure the resistance Expected Result: The indicator lamp should
between connector contact 34 and connector stop flashing.
contact 2.
65
Results: a. Turn the “ECS” switch to the OFF/RESET

position.
• No - The engine harness is open or the
Main Display Module has a problem. b. Locate the switch that corresponds to the
Proceed to Step 3. parameter that never flashes the indicator
lamp. If necessary, use the Electrical System
• Yes - The circuit is operating correctly. The Schematic to assist in locating the switch.
switch has a problem. Check the switch or
replace the switch. c. Check for loose connections or corroded
terminal connections to the switch.
d. Clean corroded terminals and tighten the
a. Turn the “ECS” switch to the OFF/RESET loose connections.
position.
b. On the Electrical Schematic, trace the signal
wire from the switch to the Main Display a. Disconnect the signal wire from the switch.
Module.
b. Turn the “ECS” switch to the
c. Determine the signal connector contact COOLDOWN/STOP position.
number at the Main Display Module.
Expected Result: The indicator lamp should
d. Disconnect the engine harness from the Main flash.
Display Module.
Results:
e. At the engine harness connector for the Main
Display Module, measure the resistance that • OK - The indicator lamp flashes. The circuit
is between the signal contact and contact 2 is operating correctly. The switch has a
(ground). problem. Check the switch or replace the
switch.
Note: Jumper wire from Step 2 is still connected.
• Not OK - The indicator lamp does not flash.
Expected Result: The resistance should be The engine harness is open or the Main
less than 5.0 ohms. Display Module has a problem. Proceed
to Step 3.
Results:
• No - The resistance is greater than 5.0
ohms. The engine harness has a problem. a. Turn the “ECS” switch to the OFF/RESET
Repair the engine harness or replace the position.
engine harness.
Note: The signal wire remains disconnected from
• Yes - The resistance is less than 5.0 ohms. the switch. Do Not allow the contact to touch any
The harness resistance is correct. The Main other components.
Main Display Module. For more information b. On the Electrical System Schematic, trace
on this subject, see Testing And Adjusting, the signal wire from the switch to the Main
“Module - Replace”. Display Module.
c. Determine the signal connector contact

Indicator Lamp Never Flashes number at the Main Display Module.
This procedure is for the parameter that occurs
d. Disconnect the engine harness from the Main
when the indicator lamp never flashes. The “Never
Flashes” condition is probably caused by a short to Display Module.
ground. Also, the Main Display Module may cause
this problem (unlikely condition).
Display Module, measure the resistance that
is between signal contact and contact 2
(ground).
66
Expected Result: The resistance should be Alert Indicator Lamp Always

FLASHING
Results:
This procedure is for the coolant level switch with a
continuously flashing alert indicator.
ohms. The harness resistance is correct.
The “ALWAYS FLASHING” condition is probably
caused by an undesired open circuit or a faulty
main display module (unlikely condition).
1. Locate Switch 6 that always flashes the low
coolant level indicator.
ohm. The engine harness has a problem.
There is a short between ground and the
position.
signal wire in the engine harness. Repair
b. Locate the switch that corresponds to the
harness. STOP.
coolant level alarm that always flashes.
If necessary, use the Electrical System
i01145394 Schematic to assist in locating the switch.
Level Switch (Coolant) - c. Check for loose terminal connections or

Troubleshoot corroded terminal connections to the switch.
SMCS Code: 1408-035-ZS; 7422-035-CLT; d. Clean corroded terminals and tighten loose
7451-035-ZS connections.
The main display module is unable to identify 2. Check The Harness.

system errors in simple open switch circuits or close
switch circuits. No information (CID FMI) is available a. Disconnect the signal wire from the switch.
to assist the operator with troubleshooting.
b. Connect a jumper wire from the signal wire to
During normal operation, the possible fault the ground wire. If a ground wire is not near,
conditions for the low coolant level switch are listed connect the signal wire to the battery ground.
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
“Always FLASHING” condition, see Alert Indicator Expected Result: The indicator lamp should
Lamp Always FLASHING. stop flashing.
Results:
• The alert indicator NEVER FLASHES for the
coolant level switch. For the “NEVER FLASHES”
procedure, see Alert Indicator Lamp NEVER • No - The engine harness is open or the
FLASHES. main display module has a problem.
Proceed to 3.
Note: The indicator shows the open condition or the
ground condition of the switch inputs. When the • Yes - The circuit is operating correctly. The
low coolant level switch is open, the alert indicator switch has a problem. Check the switch or
for the low coolant level switch FLASHES. When replace the switch.
the input for the low coolant level is grounded, the
alert indicator for the low coolant level switch is 3. Check The Harness.
OFF. Therefore, in order to check a circuit, while the
service person is watching for the correct result on a. Turn the ECS to the OFF/RESET position.
the alert indicator, the service person is required to
open switch number 6 (pin 32) and ground switch b. On the Electrical System Schematic, trace the
number 6 (pin 32). signal wire from the switch (pin 32) to the
Main Display Module.
67
c. Determine the connector contact number for Expected Result: The indicator lamp should
the signal 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: The jumper wire from 2 is still connected. The engine harness is open or the Main
Display Module has a problem. Proceed
Expected Result: The resistance should be to Step 3.
less than 5.0 ohms.
Results:
a. Turn the ECS to the OFF/RESET position.
• No - The resistance is greater than 5.0
ohms. The engine harness has a problem. Note: The signal wire remains disconnected from
Repair the engine harness or replace the the switch. Do NOT allow the contact to touch any
engine harness. other components.
• Yes - The resistance is less than 5.0 ohms. b. On the Electrical System Schematic, trace
The harness resistance is correct. The Main the signal wire from the switch to the Main
Display Module has a problem. Replace the Display Module.
on the subject, see Testing And Adjusting, c. Determine the number for the signal contact
“Module - Replace”. at the Main Display Module.
d. Disconnect the connector contact for the

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

a. Turn the ECS to the OFF/RESET position.
Results:
b. Locate the switch that corresponds to the
parameter that never flashes the indicator • OK - The resistance is greater than 5000
lamp. If necessary, use the Electrical System ohms. The harness resistance is correct.
Schematic to assist in locating the switch.
c. Check for loose connections or corroded information on this subject, see Testing And
terminal connections to the switch.
d. Clean corroded terminals and tighten the • Not OK - The resistance is less than 5000
ohms. The engine harness has a problem.
loose connections.
2. Check The Harness. signal wire in the engine harness. Repair
harness. STOP.
a. Disconnect the signal wire from the switch.
b. Turn the ECS to the COOLDOWN/STOP

position.
68
i01036695 • OK - The Display Area alternates between

“LH” values and “RH” values for exhaust
LH/RH Switch - Troubleshoot temperature. The circuit is operating
correctly. The switch has a problem. Check
SMCS Code: 1408-038-ZS; 7332-038-ZS; the switch or replace the switch.
7451-038-ZS
• Not OK - The Display Area does not
This procedure is for the “LH/RH” switch that will alternate between “LH” values and “RH”
not toggle certain values. The values that are listed values for exhaust temperature. The signal
below are not toggled. wire for the engine harness is probably
shorted to ground. Proceed to Step 3.
• Left exhaust temperature value
• Right exhaust temperature value
• Left air inlet restriction value position.
• right air inlet restriction value Note: The signal wire remains disconnected from
the switch. Do not allow the contact to touch any
The “Doesn’t Toggle” condition for the “LH/RH” other components.
switch is probably caused by an open circuit. Also,
the Main Display Module has a problem (unlikely b. On the Electrical System Schematic, trace the
condition). signal wire from the switch to the Main Display
Module. The contact for the signal connector
1. Locate The Switch. is contact 19 at the Main Display Module.
a. Turn the “ECS” switch to the OFF/RESET c. Disconnect the engine harness from the Main
position. Display Module.
b. Locate the “LH/RH” switch. If necessary, use d. At the engine harness connector for the Main
the Electrical System Schematic to assist in Display Module, measure the resistance
locating the switch. between the signal contact and contact 2
(ground).
c. Check for loose connections or corroded
terminal connections to the switch. Expected Result: The resistance should be
d. Clean corroded terminals and tighten loose
connections. Results:
2. Check The Harness. • The resistance is greater than 5000 ohms.
The harness resistance is correct. The Main
a. Disconnect the signal wire from the switch. Display Module has a problem. Replace the
b. Turn the “ECS” switch to the on this subject, see Testing And Adjusting,
COOLDOWN/STOP position. “Module - Replace”.
c. Ground the signal wire. Float the signal wire. • The resistance is less than 5000 ohms. The
Repeat Step 2.c. engine harness has a problem. There is a
short between ground and the signal wire
Expected Result: The Display Area should in the engine harness. Repair the engine
Show the “LH” value and the “RH” value for harness or replace the engine harness.
exhaust temperature and the Display Area
should show the “LH” value and the “RH”
value for air inlet restriction.
Results:
69
i01036785 a. Turn the “ECS” switch to the OFF/RESET

position.
Scroll Switch - Troubleshoot
b. Connect a jumper wire from the signal wire to
SMCS Code: 1408-038-ZS; 7332-038-ZS; the ground wire. If a ground wire is not near,
7451-038-ZS connect the signal wire to battery ground.
The Scroll Switch Does Not Scroll c. On the Electrical System Schematic, trace
the signal wire from the switch to the Main
This procedure is for the “SCROLL” switch that does Display Module. The contact that is used
not scroll parameter values in the Display Area. The for the signal connector at the Main Display
“Does Not Scroll” condition is probably caused by Module is contact 23.
an undesired open circuit. Also, the Main Display
Module may cause the problem (unlikely condition). d. Disconnect the engine harness from the Main
Display Module.
a. Turn the “ECS” switch to the OFF/RESET Display Module, measure the resistance
position. between the signal contact and contact 2
(ground).
b. Locate the “SCROLL” switch. If necessary,
use the Electrical System Schematic to assist Expected Result: The resistance should be
in locating the switch. less than 5 ohms.
c. Check for loose terminal connections or Results:

corroded terminal connections to the switch.
• OK - The resistance is less than 5 ohms.
d. Clean the corroded terminals and tighten the The harness resistance is correct. The Main
loose connections. Display Module has a problem. Replace the
2. Check The Harness. on this subject, see Testing And Adjusting,
“Module - Replace”.
a. Disconnect the signal wire from the switch.
• Not OK - The resistance should be greater
b. Turn the “ECS” switch to the than 5 ohms. The engine harness has a
COOLDOWN/STOP position. problem. There is an open circuit between
ground and the signal wire in the engine
c. Alternately, ground the signal wire and float harness. Repair the engine harness or
the signal wire. replace the engine harness.
Expected Result: The Display Area should The Scroll Switch Continually
scroll from one parameter value to the next
parameter value. Scrolls
Results: This procedure is for the “SCROLL” switch that
continually scrolls parameter values in the Display
• OK - The Display Area scrolls from one Area. The “Continually Scrolls” condition is probably
parameter value to the next parameter caused by a short to ground. Also, the Main Display
value. The circuit is operating correctly. The Module may cause this problem (unlikely condition).
switch has a problem. Check the switch or
replace the switch. 1. Locate The Switch.
• Not OK - The Display Area does not scroll a. Turn the “ECS” switch to the OFF/RESET
from one parameter value to the next position.
parameter value. The signal wire for the
engine harness probably has an open b. Locate the “SCROLL” switch. If necessary,
circuit. Proceed to Step 3. use the Electrical System Schematic to assist
in locating the switch.
c. Check for loose terminal connections or
corroded terminal connections to the switch.
70
d. Clean corroded terminals and tighten loose • Not OK - The resistance is less than 5000
connections. ohms. The engine harness has a problem.
a. Disconnect the signal wire from the “SCROLL” harness.
switch.
i01037665
b. Turn the ECS to the COOLDOWN/STOP
position. Clear/Mode Switch -
Expected Result: The Display Area should Troubleshoot
NOT scroll from one parameter value to the
next parameter value. SMCS Code: 1408-038-ZS; 7332-038-ZS;
7451-038-ZS
Results:
The “CLEAR/MODE” Switch Does
• OK - The Display Area does NOT scroll from
one parameter to the next parameter. The NOT Clear Logged Diagnostic
circuit is operating correctly. The switch has Codes and Tattletale Values or
a problem. Check or replace the switch.
Does NOT Initiate Mode Changes
• Not OK - The Display Area scrolls from
one parameter to the next parameter. The This procedure is for the “CLEAR/MODE” switch
engine harness is shorted to ground or that will not clear logged diagnostic codes and
the Main Display Module has a problem. the “CLEAR/MODE” switch that will not clear
Proceed to Step 3. “tattletale values”. Also, this procedure is for the
“CLEAR/MODE” switch that does NOT initiate mode
3. Check The Harness. changes on the Display Area. The “Does NOT
Clear” Logged Diagnostic Codes and Tattletale
a. Turn the “ECS” switch to the OFF/RESET Values or “Does Not Initiate Mode Changes”
position. condition is probably caused by an undesired open
circuit. Also, the Main Display Module can be the
Note: The signal wire remains disconnected from cause of the problem (unlikely condition).
the switch. Do Not allow the contact to touch any
other components. 1. Locate The Switch.
b. On the Electrical System Schematic, trace a. Turn the “ECS” switch to the OFF/RESET
the signal wire from the switch to the Main position.
Display Module. The Signal Contact at the
Main Display Module is 23. b. Locate the “CLEAR/MODE” switch. If
necessary, use the Electrical System
c. Disconnect the engine harness from the Main Schematic to assist in locating the switch.
Display Module.
d. At the engine harness connector for the Main corroded terminal connections.
Display Module, measure the resistance
between Signal Contact 23 and contact 2 d. Clean corroded terminals and tighten loose
(ground). connections.
Expected Result: The resistance should be 2. Check The Harness.

greater than 5000 ohms .
a. Disconnect the “CLEAR” signal wire from the
Results: “CLEAR/MODE” switch.
• OK - The resistance is greater than 5000 b. Turn the “ECS” switch to the
ohms. The harness resistance is correct. COOLDOWN/STOP position.
Replace the Main Display Module. For more c. Alternately, ground the “CLEAR” signal wire
information on this subject, see Testing And and float the “CLEAR” signal wire.
71
Expected Result: The Display Area should The “CLEAR/MODE” Switch

clear the diagnostic codes or tattletale values.
Automatically Clears Logged
Results: Diagnostic Codes and Tattletale
Values or Does Not Initiate Mode
• OK - The Display Area clears the diagnostic
codes or the tattletale values. The circuit Changes
is operating correctly. The switch has a
problem. Check the switch or replace the This procedure is for the “CLEAR/MODE” switch
switch. that “Automatically Logged” Diagnostic Codes and
Tattletale Values on the Display Area. The “Does
• Not OK - The Display Area Does Not Not Clear Logged Diagnostic Codes” and Tattletale
clear logged diagnostic codes or tattletale values or “Does Not Initiate Mode Changes” is
values. The signal wire in the engine probably caused by an undesired open circuit.
harness probably has an open circuit. Also, the Main Display Module may cause the
Proceed to Step 3. problem (unlikely condition).
3. Check The Harness. 1. Locate The Switch.
a. Turn the “ECS” switch to the OFF/RESET a. Turn the “ECS” switch to the OFF/RESET
position. position.
b. Connect a jumper wire from the “CLEAR” b. Locate the “CLEAR/MODE” switch. If
signal wire to the ground wire. If a ground necessary, use the Electrical System
wire is not near, connect the “CLEAR” signal Schematic to assist in locating the switch.
wire to battery ground.
c. On the Electrical System Schematic, trace the corroded terminal connections to the switch.
“CLEAR” signal wire from the switch to the
Main Display Module. d. Clean corroded terminals and tighten loose
connections.
d. The “CLEAR” signal is contact 33 at the Main
Display Module. 2. Check The Harness.
e. Disconnect the engine harness from the Main a. Disconnect the “CLEAR” signal wire from the
Display Module. “CLEAR/MODE” switch.
f. At the engine harness connector for the Main b. Turn the “ECS” switch to the
Display Module, measure the resistance COOLDOWN/STOP position.
between the “CLEAR” Signal Contact and
Contact 2 (ground). Expected Result: The Display Area should
NOT clear diagnostic codes or tattletale
Expected Results: The resistance should be values.
less than 5 ohms.
Results:
Results:
• OK - The Display Area does NOT clear
• OK - The resistance is less than 5 ohms. diagnostic codes or tattletale values. The
The harness resistance is correct. The Main circuit is operating correctly. The switch has
Display Module has a problem. There is an a problem. Check the switch or replace
open between ground and the “CLEAR” the switch.
signal wire in the engine harness.
• Not OK - The Display Area continues to
• Not OK - The resistance is greater than 5 clear logged diagnostic codes or tattletale
ohms. The engine harness has a problem. values. The engine harness is shorted to
There is an open between ground and the ground or the Main Display Module has a
“CLEAR” signal wire in the engine harness. problem. Proceed to Step 3.
Repair the engine harness or replace the
engine harness. 3. Check The Harness.
72
a. Turn the “ECS” switch to the OFF/RESET a. Turn the “ECS” switch to the OFF/RESET
position. position.
Note: The “CLEAR” signal wire remains b. Locate the Alarm Silence Switch. If necessary,
disconnected from the switch. Do Not allow the use the Electrical System Schematic to assist
contact to touch any components. in locating the switch.
b. On the Electrical System Schematic, trace the c. Check for loose terminals or corroded terminal
“CLEAR” signal wire from the switch to the connections to the switch.
Main Display Module. The “CLEAR” signal
contact is number 33 at the Main Display d. Clean corroded terminals and tighten loose
Module. connections.
c. Disconnect the engine harness from the Main 2. Check The Harness.
Display Module.
a. Disconnect the signal wire from the Alarm
d. At the engine harness connector for the Main Silence switch.
Display Module, measure the resistance that
is between the “CLEAR” Signal Contact 33 b. Turn the “ECS” switch to the OFF/RESET
and Contact 2 (ground). position.
Expected Result: The resistance should be c. Ground the signal wire from the Alarm Silence
greater than 5000 ohms. switch.
Results: Expected Result: The Alarm should become

quiet.
ohms. The harness resistance is correct. Result:
Replace the Main Display Module. For more • OK - The Alarm becomes quiet. The circuit
information on this subject, see Testing And is operating correctly. The switch has a
Adjusting, “Module - Replace”. problem. Check the switch or replace the
switch.
ohms. The engine harness has a problem. • Not OK - The Alarm does not become
There is an open between ground and the quiet. The signal wire in the engine harness
“CLEAR” signal wire in the engine harness. probably has an open circuit. Proceed to
Repair the engine harness or replace the Step 3.
engine harness.
i01037861
Alarm Silence Switch - position.
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
The Alarm Silence Switch Does Not signal wire from the switch to the Main Display
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 d. At the engine harness connector for the Main
the problem (unlikely condition). Display Module, measure the resistance that
is between the Signal Contact 29 and contact
1. Locate The Switch. 2 (ground).
73
Expected Result: The resistance should • Not OK - The Alarm does not sound. The
measure less than 5 ohms. engine harness is shorted to ground or
the Main Display Module has a problem.
Results: Proceed to Step 3.
• OK - The resistance measures less than 5 3. Check The Harness.

ohms. The harness resistance is correct.
The Main Display Module has a problem. a. Turn the “ECS” switch to the OFF/RESET
Replace the Main Display Module. position.
• Not OK - The resistance is greater than 5 Note: The Signal Wire remains disconnected from
ohms. The engine harness has a problem. the switch. Do Not allow the contact to touch any
There is an open between ground and the components.
signal wire in the engine harness. Repair
the engine harness or replace the engine b. On the Electrical System Schematic, trace
harness. the Signal Wire from the switch to the Main
Display Module. The Signal Contact at the
Main Display Module is number 29.
The Alarm Silence Switch
Continually Silences The Alarm c. Disconnect the engine harness from the Main
Display Module.
This procedure is for the Alarm Silence switch that
continuously silences the Alarm. The “Continually d. At the engine harness connector for the Main
Silences” condition is probably caused by an Display Module, measure the resistance
undesired open circuit. Also, the Main Display between Signal Contact 29 and Contact 2
Module may cause the problem (unlikely condition). (ground).
1. Locate The Switch. Expected Result: The resistance should be

position. Results:
b. Locate the Alarm Silence switch. If necessary, • OK - The resistance is greater than 5000
use the Electrical System Schematic to assist ohms. The harness resistance is correct.
in locating the switch. The Main Display Module has a problem.
c. Check for loose terminal connections or information on this subject, see Testing And
corroded terminal connections to the switch. Adjusting, “Module - Replace”.
d. Clean corroded terminals and tighten loose • Not OK - The resistance is less than 5000
connections. ohms. The engine harness has a problem.
a. Disconnect the Signal Wire from the Alarm harness.
Silence switch.
b. Turn the “ECS” switch to the i01129925

COOLDOWN/STOP position. Harness Code - Troubleshoot
Expected Result: The Alarm should sound.
SMCS Code: 1408-038; 7451-038
Results:
The harness code for the Caterpillar Monitoring
System must match the application in order to
• OK - The Alarm sounds. The circuit is function properly. If the harness code does not
operating correctly. Check the switch or
match the application, the following problems may
replace the switch.
occur:
• loss of event notification

• incorrect data displays
74
• incorrect gauge needle positions 3. For 155-8653 Engine Monitoring Control

(Caterpillar Monitoring System) and newer
• activation of diagnostic codes modules, turn the Engine Control Switch (ECS) to
the COOLDOWN/STOP position.
Generally, once an engine is put into service there
is no reason to change the harness code. During 4. In order to check the harness code, use Harness
installation, the customer may decide to install Code Mode 5. For more information about
optional sensors or optional gauges that were not Harness Code Mode 5, see Systems Operation,
initially ordered with the engine. Changing these “Harness Code Mode”. STOP.
components may require a different harness code.
5. For the 153-1929 Engine Monitoring Control
Check the current selection for the harness code and earlier Caterpillar Monitoring Systems, use
and compare the current harness code with the a multimeter to check for continuity between the
description in Systems Operation, “Quad Gauge pins for the harness code and Terminal Block 2
Module”. Determine if the harness code is correct (TB-2). Do NOT rely on a visual inspection.
for the application.
6. The pins that determine the harness code are
There are six pins on the back of the Caterpillar located on the back of the Caterpillar Monitoring
Monitoring System that are used to select the System. The harness code is identified by certain
harness code. The pins are grounded or the pins of the 40 pin connector. pin 31, pin 3, pin
pins are left open in various combinations for 21, pin 22, pin 16, and pin 6.
each application. The pins that are grounded
are connected to the negative battery terminal 7. If a 7x-1708 Multimeter Probe (Red) or a
block (“TB-2”). The negative battery terminal block 7x-1709 Multimeter Probe (Black) is available,
(“TB-2”) is located on the inside of the Instrument the continuity check can be made without
Panel. On the wiring schematic, the negative battery removing the wires from the 40 pin connector.
terminal block is labelled as “TB-2”.
8. If the probe adapters are not available, use a
Because of the large number of wires that are 121-9587 Wire Removal Tool to remove the
located on the inside of the Electronic Instrument harness code wire from the connector.
Panel, determining the pins that are connected to
the ground becomes difficult to do visually. There 9. Record each measurement as the measurements
are two accurate methods for determining the are taken. An example is given below.
harness code.
• Harness Code Mode 5 Display (not available on

all versions of the Caterpillar Monitoring System)
• A multimeter may be used to check the harness

code that is located on the Caterpillar Monitoring
Systems without Mode 5.
Note: If a ground wire is connected to “pin A”, the

harness code pin is not necessarily grounded. The
other end of the wire may be tied to the harness
and the wire may not be connected to “TB-2”. This
procedure is done so that the same wiring harness
can be used during manufacturing regardless of
the harness code.
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.
75
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, Note: One or more of the pins for the Harness Code
compare the verified harness code with the may need to be grounded in order to change the
Table that is given in Systems Operation, “Quad harness code. Also, one or more of the pins may
Gauge Module”. require grounding to change the harness code. An
example is given below.
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.
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.
76
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
c. Assume that the current harness code is Note: The new harness code will not take effect
harness code 5 “Generator Engine With Prime until power to the Caterpillar Monitoring System is
Panel” and that the desired harness code cycled.
is harness code 7 “Generator Engine With
Premium Panel And JWAC”. Pin 3 should be 3. Verify That The Harness Code Was Changed
ungrounded in order to change from harness Successfully.
code 5 to harness code 7.
a. Check the harness code by using the
2. Turn the Engine Control Switch (ECS) to the Procedure For Checking The Harness Code.
OFF/RESET position.
i01046910
a. In order to change the Harness Code, wires
must be grounded or ungrounded. System Self Test
Note: Pins are grounded by connecting the pins SMCS Code: 1408-038; 7451-038
to the “-Battery” terminal block that is located on
the inside of the instrument panel. On the wiring The Self-Test verifies that the Main Display Module
schematic, the terminal block is labelled “TB-2”. and the Gauge Cluster Modules are operating
Refer to 64. A pin for the harness code is not always properly. The Main Display Module performs an
grounded if a ground wire is connected to the pin. automatic Self-Test each time that the “ECS”
The other end of the wire may be tied in the harness switch is turned from the OFF/RESET position to
and the wire may not be connected to TB-2. The the AUTO position, MAN/START position or the
wire is tied so that the same wiring harness can COOLDOWN/STOP position.
be used during manufacturing regardless of the
harness code. Note: When the “ECS” switch is in the AUTO
position, the Main Display Module receives power
b. Grounding A Harness Code Pin. For this only when the Remote START/STOP switch is in
step, refer to item 4 in 64. If the wires are not the MAN/START position or the COOLDOWN/STOP
connected to TB-2,the wires can be tied back position.
to this location. The wire can be identified
by the printed label at the end of the wire. The internal circuits and the outputs are
The label follows the format “EMS (number) automatically checked. The operator must observe
TB-2”. “Number” represents the pin number of the outputs in order to determine whether the
the harness code. The wire terminates at the modules and the outputs are operating properly.
pin. After locating the wire that needs to be The Indicator Lamps and the Display Area are
grounded, remove the heat shrink insulation tested for approximately one second.
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 as being connected to the pin of the
Caterpillar Monitoring System that should be
ungrounded. 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.
77
The Main Display Module will then go into the

Normal Mode (Mode 0) of operation.
If a module does not perform the Self-Test, proceed

to Testing And Adjusting, “Module - Replace”.
i01038053
Module - Replace
SMCS Code: 7451-510
Prior to the replacement of a module, ensure that

the replacement is absolutely necessary. A module
Illustration 65 g00543852 is seldom the cause of a problem. Always check
that the harness code is correct for the Main Display
Typical View Of Indicator Lamps
Module and that power is available to the Main
Display Module. For information about a Harness
Code, see Systems Operation, “Quad Gauge
Module”.
1. Turn the “ECS” switch to the OFF/RESET position.

Disconnect the engine harness from the Main
Display Module.
g00543853
Illustration 66 2. Make sure that the Replacement Module has the
Display Area With All Segments Shown correct part number.
Gauge Cluster Modules are tested for approximately 3. Remove the old module and install the
three seconds. Replacement Module.
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
Adjusting, “System Self Test”.
6. Set the display to English units or Metric units.

See Systems Operation, “Units Mode” for more
information.
g00532834
Illustration 67
The needles for the Gauge Cluster Modules will

jump to half scale. The needles will go back to
zero, then the needles will sweep to full scale.
After reaching full scale, the needles will return to
showing the current conditions.
The Action Alarm will sound once.

78
i01038123 3. Use black electrical tape to secure the removed

socket or the removed wire to the harness
Main Display Module bundle. Make sure that the contact does not
Initialization - Adjust touch any metallic components. Reconnect the
engine harness to the Main Display Module.
SMCS Code: 7451-025
4. Turn the “ECS” switch to the COOLDOWN/STOP
The Main Display Module Initialization is an internal position.
process that occurs within the Main Display Module.
During the Main Display Module Initialization, the 5. Various indicators in the Display Area illuminate.
Main Display Module monitors the CAT Data Link. Wait for ten seconds.
Also, the Main Display Module monitors the inputs
for the harness code. During the Main Display 6. Turn the “ECS” switch to the OFF/RESET position.
Module Initialization, the Main Display Module Reinstall the socket or reinstall the wire that was
learns about the engine that is being monitored. removed in Step 2 into the original position on
the connector for the Main Display Module.
The Main Display Module Initialization typically
occurs when the Main Display Module is replaced. 7. Turn the “ECS” switch to the COOLDOWN/STOP
The harness code is new when the Main position. Make sure that the Main Display Module
Display Module is replaced. However, when a successfully completes the Self Test. For more
previously used Main Display Module is used as information on this subject, see Testing And
a replacement, the procedure of initialization is Adjusting, “System Self Test”. Check the harness
necessary. Unexplained diagnostics with the CAT code for accuracy. For a list of valid harness
Data Link can occur if the Main Display Module is codes, see Systems Operation, “Gauge Cluster
not initialized correctly. The service person must Modules”.
activate the process for the Main Display Module
Initialization when the following condition exists or i01046881
the condition is suspected.
Glossary of Terms
The Main Display Module that will be installed was
taken out of service from an application that had SMCS Code: 7451
the same harness code as the Main Display Module
that will be removed. +Battery – This term refers to the harness wiring
that is part of the circuit that connects to the battery
Perform the Main Display Module Initialization if positive post. System Battery Voltage is also used
the preceding condition exists or this condition in place of +Battery.
is expected.
+V – +V is a constant voltage that is supplied to a
This procedure causes the process of the Main component in order to provide electrical power for
Display Module Initialization to occur on any Main the operation of a component. +V is provided by an
Display Module. In order to perform the Main electronic control module or the battery.
Display Module Initialization, the Main Display
Module must be powered up with a valid harness Abnormal – This word refers to an engine condition
code. The harness code must be different from the that is not normal or a signal that is not normal. The
previous harness code that was used to power presence of an abnormal condition or signal means
down the Main Display Module. For a list of valid that a problem exists. The operator is notified when
harness codes, see Systems Operation, “Quad the warning operation is activated.
Gauge Modules”.
CID (Component Identifier) – A diagnostic code
1. Turn the “ECS” switch to the OFF/RESET position. identifies a component that is having a problem.
A CID may also identify a system that is having
2. Disconnect the engine harness from the Main a problem. Examples of components that may
Display Module. Remove the socket or remove be identified are the engine speed sensor, the oil
the wire from one of the following holes. The pressure sensor or the exhaust temperature sensor.
holes for the connectors are 3, 6, 12, 16, 22 or The CID is a four digit or three digit code that is
31. shown on the Display Area when the Main Display
Module is in Service Mode (Mode 2).
79
Clear – When diagnostic information is removed Hold or “On-Hold” – On-Hold refers to holding a
from the memory of the Main Display Module, the set of diagnostic information that is shown in the
memory is cleared. Before clearing the information, Display Area when the Main Display Module is
the information must be “on-hold”. in Service Mode or Numeric Readout Mode. It is
necessary to hold the set of diagnostic information
Connector Contact – A connector contact is the before troubleshooting or clearing.
component of a harness connector that makes the
electrical connection. Connector contacts are either Indicator Lamp – An indicator lamp is a red LED or
pins or sockets. a yellow LED that is located in the upper section of
the Main Display Module. The Indicator Lamps flash
Detected Diagnostic – A detected diagnostic fault when a problem exists. The associated pictograph
is a diagnostic fault that has been discovered by symbol identifies the abnormal engine condition.
the Main Display Module. Examples of detected
diagnostic faults are an open harness or a shorted Indicator Lamp Problem – A problem occurs with an
harness. Also detected diagnostic faults may be indicator lamp when the operation of an indicator
problems with a switch, problems with a sensor or lamp does not correspond to a known engine
problems with an electronic module. The diagnostic condition.
fault is recorded and the diagnostic fault is shown
on the Display Area when the Main Display Module Jumper Wire – A jumper wire is a piece of wire that
is in Service Mode (Mode 2). is used to make an electrical connection during
troubleshooting.
Diagnostic – Showing information that is not normal
is referred to as diagnostics. Also, monitoring MID (Module Identifier) – An MID is a diagnostic
information or recording information that is not code that tells the service person which electronic
normal is known as diagnostics. Diagnostic module has diagnosed the problem. Examples of
information is available when the Main Display the modules are the Main Display Module, engine
Module is in Service Mode, Normal Mode, Tattletale control module (ECM) and other modules. The MID
Mode or Numeric Mode. is a three digit code that is shown in the Display
Area when the Main Display Module is in Service
Display – The gauges, indicators, or the display Mode (Mode 2).
area is referred to as the display of the Caterpillar
Monitoring System. Problem – A problem refers to the presence of an
abnormal engine condition such as low engine oil
Floating – Floating is the state of a module input pressure. When a problem exists, warning operation
that is not connected to a reference. The reference is activated and the message center notifies the
may be a positive reference, a negative reference operator.
or any other reference.
SCROLL – The process of showing (within the
FMI (Failure Mode Identifier) – A diagnostic code Display Area) all the available sets of diagnostic
that tells describes the type of problem that has information, one set at a time. A set of diagnostic
occurred. For example, Voltage Above Normal information is shown briefly. Then, the display
would be a problem. The FMI is a code with automatically advances to the next set. After all sets
two-digits that is preceded by a decimal point or the are shown, the sets are repeated.
letter “F” that is shown on the Display Area when the
Main Display Module is in Service Mode (Mode 2). Show – Show refers to the information that is
located within the Display Area of the Caterpillar
Harness Code – The grounded condition or the Monitoring System that is viewed by the operator
open condition of the harness code input is known or service person.
as the Harness Code. The contacts for the harness
code input are given below. contact 3, contact 6, Signal Wire – The signal wire is the harness wire
contact 12, contact 16, contact 22, and contact 31. which connects the sensor or the switch to the Main
The harness code describes the characteristics Display Module.
of the electronic system to the Main Display
Module. The Caterpillar Monitoring System is used Switch Input – A switch input is any input of the
on various Caterpillar products. The Caterpillar Main Display Module which is expecting only an
Monitoring System must know the characteristics open (floating) or grounded signal.
of the electronic system that is being monitored. If
the Harness Code Mode (Mode 5) is an available System Voltage – The actual voltage that exists
mode, the decimal representation of the harness between the positive battery post and the negative
code is shown in the Display Area when the Main battery post is the system voltage. System voltage
Display Module is in Harness Code Mode (Mode 5). is also referred to as +battery voltage.
80
Unnassigned/Unprogrammed – The unused inputs

of the Main Display Module and the unused outputs
of the Main Display Module are not defined by the
software. Therefore, the inputs and the outputs are
unavailable to the end user.
i01038129
Connector Contact Description

of Main Display Module
SMCS Code: 1408-546-CY; 7451-546-CY
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)
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)
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
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
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)
(continued)
81
(Table 18, contd)

Generator Set - Description Of Main Module Connector
Number
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)
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)
38 Sensor 8/Switch 18/Sender 4 Sensor, Switch or Sender 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
Number
3 Harness Code 1 Main Module Configuration Programming Pulled Low Or Floating
7 Sensor 1/Switch 11 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
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
18 Switch 9/Sender 2 Switch Or Sender Input Fuel Level
(continued)
82
(Table 19, contd)

Marine - Description Of Main Module Connector
Number
23 Service Switch Input SCROLL switch
25 Display Module Clock Gauge Module Driver Output Driver For Gauge Sequencing
26 Frequency 1 Digital Sensor 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
32 Switch 6 Switch Input Coolant Level
34 Display Module Power Gauge Module Supply Output 9 DCV
35 Display Module Data Gauge Module Data Output Data For Gauge Information
38 Sensor 8/Switch 18/Sender 4 Sensor, Switch or Sender Input Transmission Oil Pressure
Table 20
Locomotive - Description Of Main Display Module Connector
Number
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
(continued)
83
(Table 20, contd)

Locomotive - Description Of Main Display Module Connector
Number
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
18 Switch 9/Sender 2 Sensor Or Sender Input Unassigned/Unprogrammed
20 Switch 4 Switch Input Spare Switch Connection
23 Service Switch Input Scroll Switch
25 Display Module Clock Gauge Module Driver Output Driver For Gauge
Sequencing
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
34 Display Module Power Gauge Module Supply Output +9 DCV
35 Display Module Data Gauge Module Data Output Data For Gauge Information
38 Sensor 8/Switch 18/Sender 3 Sensor, Switch Or Sender Input Unassigned/Unprogrammed
i01046908
System Schematic
SMCS Code: 1400; 7451; 7566
84
g00574693
Illustration 68
85
System Schematic For 3500B Electronic Instrument Panel -

Marine Engines.
86
g00574696
Illustration 69
87

Generator Set Engines.
88
g00574698
Illustration 70
89

Locomotive Engines
90
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 ........................................................ 73
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 ....................................................... 44
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 .. 53 Circuit Breakers, Relays, and Wiring ................. 13
CID 0263 FMI 03 Sensor Power Supply Voltage Switches............................................................. 12
Above Normal - Test ............................................ 55
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 ....................................................... 57 Indicator Lamp Never Flashes ........................... 67
CID 0271 FMI 06 Alarm (Action) Current Above LH/RH Switch - Troubleshoot ................................ 68
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 ............ 78
CID 0821 FMI 04 Display Power Supply Voltage Modes Of Operation .............................................. 29
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 ........................................ 30
or Does NOT Initiate Mode Changes ............... 70
Connector Contact Description of Main Display
Module ................................................................. 80
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 Module.. 7 Units Mode ............................................................ 38
Customer Connector “C”.................................... 8
Customer Connector “D”.................................... 10
Customer Connector “G”.................................... 11 W
Emergency Stop Push Button............................ 7
Engine Control Switch........................................ 7 Warning Operation ................................................ 39
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 .................................. 69

The Scroll Switch Continually Scrolls................. 69
The Scroll Switch Does Not Scroll ..................... 69
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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SENR6587-02

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents CID 0819 FMI 02 Display Data Link Incorrect -

Testing and Adjusting Section

Systems Operation Section

• Engine Control Switch (ECS) (Not on Locomotive

• Dimmer (Locomotive Engines only)

• Alarm Silence Switch • Inlet air pressure (boost)

Engine Control Switch Emergency Stop Push Button

4. If the engine is programmed for cooldown mode,

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

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

37 - 39 Speed Adjust Potentiometer 16 Unassigned

23 Sensor Supply Voltage (Transmission

Customer Connector “D” Table 4

1 - 16 Unassigned Unassigned 13 - 14 Throttle −Battery

Locomotive Power Connector “F”

The ECM must be powered by isolated power only.

Note: The Locomotive OEM is responsive for

Connector “F” (37) provides 24 DCV to the junction

• General alarm relay 15 Shutdown Notify (COM)

• Feedback for the load 19 Load Feedback

i01024778 The MANUAL START CRANK SWITCH (2) permits

The Engine Protection Override Switch is a

When the Engine Protection Override Switch is in

When the Engine Protection Override Switch is • ECM circuit

Circuit Breakers, Relays, and • “DeNOx” (non-marine Generator Set only)

Instrument Modules for

• An alarm The display window on the main display module

Instrument Modules for Marine

Instrument Modules for

The display area on the main module indicates the

Alert Indicator Description

• sender inputs Low System Voltage - red

• engine ECM This lamp indicates that the DC Voltage of the

Overcrank - red High Aftercooler Coolant Temperature - amber

Not In AUTO - red Low Oil Pressure - amber

Engine System Status - red Low Coolant Temperature - amber

Low Coolant Level - amber

This lamp illuminates when the engine coolant

Low Fuel Level - amber

This lamp illuminates when the contacts for the fuel

Quad Gauge Module

The Quad Gauge Electronic Modules show the

Harness Codes are used by the Main Display

A panel is provided that gives the technician

Engine Oil Pressure (1) Quad Gauge Module For Prime

When the needle is pointing straight up, the value

The information is received from the engine ECM

Engine Coolant Temperature (2)

This engine coolant temperature gauge displays

When the needle is pointing straight up, the value

This gauge displays battery voltage or charging g00530412