2009-05-09_034825_7as48774___3126_schem.pdf

ECM AMP Connectors

SENR9675 May 2002 6 HEUI Injectors

Engine Control Module

PID-FMI

Cab Diagnostic Connector

-

12 V

+

Batteries

ECM Side

ECM Connector P1

Cruise Control On/Off & Set/Resume Switches

Harness Side

Accelerator Pedal Position Sensor

Description

Diagnostic Code Listing Flash PID-FMI Codes

Description

Flash Codes

0-00

No Detected Faults

55

102-04

Boost Press Sensor Short Circuit

1-11

Cylinder 1 Fault

72

102-07

Excessive Boost Pressure

25 25

2-11

Cylinder 2 Fault

72

105-03

Inlet Manifold Air Temp Sensor Open Circuit

38

3-11

Cylinder 3 Fault

73

105-04

Inlet Manifold Air Temp Sensor Short Circuit

38

4-11

Cylinder 4 Fault

73

108-03

Atmospheric Press Sensor Open Circuit

26

5-11

Cylinder 5 Fault

74

108-04

Atmospheric Press Sensor Short Circuit

26

6-11

Cylinder 6 Fault

74

110-00

High Coolant Temp Warning

61

22-13

Check Timing Sensor Calibration

42

110-03

Coolant Temp Sensor Open Circuit

27

30-08

Invalid PTO Throttle Signal

29

110-04

Coolant Temp Sensor Short Circuit

27

30-13

PTO Throttle Sensor Calibration

29

110-11

Very High Coolant Temp

61

41-03

8 Volt Supply Above Normal

21

111-01

Low Coolant Level Warning

62

41-04

8 Volt Supply Below Normal

21

111-02

Coolant Level Sensor Fault

12

Injection Actuation Press

18

111-11

Very Low Coolant Level

62

42-11

Control Valve Driver Fault

Ignition Key Switch

Injection Actuation Pressure Control Valve (IAPCV)

43-02

Ignition Key Switch Fault

71

164-00

Injection Actuation Press Out of Range

17

64-02

Loss of Engine RPM Signal on Engine

34

164-02

Injection Actuation Press Sensor Erratic

15

34

164-03

Injection Actuation Press Open Circuit

15

Speed and Timing Sensor Number 2

Clutch and Service Brake Switches

64-11

No Pattern on Engine Speed and Timing Sensor Number 2

Top Camshaft Speed/Timing Sensor

ECM Connector P2

DT Connector Receptacle

Bottom Camshaft Speed/Timing Sensor

DT Connector Plug

Injection Actuation Pressure Sensor

OEM Installed

Caterpillar Installed

Harness Side

ECM Side

Coolant Level Sensor

Check Engine Lamp

3126E Truck Engine Electrical System

Warning Lamp

Speedometer & Tachometer 45 35

15 55

25

Boost Pressure Sensor

20 65

10

75

15

25

5

5 0

MPH

85

30

RPM X 1000

Receptacle Wedge

DPF1-UP

Plug Wedge

Atmospheric Pressure Sensor

A/C High Pressure Switch

Cooling Fan

70-05

Inlet Air Heater Open Circuit

49

164-04

Injection Actuation Press Short Circuit

15

70-06

Inlet Air Heater Short Circuit

49

164-11

Injection Actuation Press System

39

71-00

Idle Shutdown Override

01

168-02

Intermittent Battery Power to the ECM

51

71-01

Idle Shutdown Occurrence

47

190-00

Engine Overspeed Warning

35

71-14

PTO Shutdown Occurrence

47

190-02

Loss of RPM Signal on Engine Speed

34

and Timing Sensor Number 1 84-00

(Specific Ratings Only)

Plug Wedge

Vehicle Speed Sensor

Oil Pressure Sensor

PTO Accelerator Position Sensor

Receptacle Wedge Plug Wedge

HD Connector Receptacle

(Optional)

Fast Idle Enabled Lamp Or Wait To Start Lamp

HD Connector Plug

PTO Switch On Lamp

Oil Temperature Sensor

(Optional)

Fast Idle Enable Switch

Coolant Temperature Sensor Pin Contact

Socket Contact

PTO On/Off & PTO Set/Resume Switches

Transmission Neutral Switch

Sealing Plug

Interface Relay (Engine Derate)

AT/MT/HT Transmission Relay

Inlet Air Temperature Sensor

Speed/Timing Sensor Connectors

IAPCV Connector Intake Air Heater Relay

Exhaust Brake Exhaust Brake On/Off Switch

150 Series Receptacle

Intake Air Heater

150 Series Plug

Intake Air Heater Lamp

A

© 2002 Caterpillar All Rights Reserved

Printed in U.S.A.

SENR9675-00

41

190-11

No Pattern on Engine Speed

34

and Timing Sensor Number 1 84-01

Loss of Vehicle Speed Signal

31

224-11

Theft Deterrent Enabled

84-02

Invalid Vehicle Speed Signal

36

224-14

Engine Cranking / Theft Deterrent Enabled

00

84-08

Vehicle Speed Out of Range

36

231-11

J1939 Data Link Fault

58

84-10

Vehicle Speed Rate of Change

36

232-03

5 Volt Supply Above Normal

21

91-08

Invalid Throttle Signal

32

232-04

5 Volt Supply Below Normal

21

91-13

Throttle Sensor Calibration

28

246-11

Service Brake Switch Number 1 Fault

00

Oil Press Sensor Open Circuit

24

247-11

Service Brake Switch Number 2 Fault

00

100-04

Oil Press Sensor Short Circuit

24

252-11

Incorrect Engine Software

59

100-11

Very Low Oil Press

46

253-02

Check Customer or System Parameters

56

102-03

Boost Press Sensor Open Circuit

25

253-14

Truck Manuf. Parameter Not Programmed

56

100-03

Receptacle Wedge

Vehicle Overspeed Warning

00

3126E ENGINE HARNESS WIRING DIAGRAM

INJECTOR HARNESS GROMMET

L983-WH

12 11 10 9 8 7

L983-WH L984-OR L984-OR L985-YL L985-YL J301

P301

J302

B A

J303

P302

B A

INJECTOR CYLINDER NO.2

INJECTOR CYLINDER NO.1

P303

J304

B A

J305

P304

B A

INJECTOR CYLINDER NO.3

P305

J306

B A

INJECTOR CYLINDER NO.4

P306

A706-GY

P2 J2 L983-WH L984-OR L985-YL A706-GY A705-BU A704-GN A703-BR A702-PU A701-GY

6 5 4 3 2 1

B A

INJECTOR CYLINDER NO.6

INJECTOR CYLINDER NO.5

ENGINE HARNESS CONNECTOR

P300

44 45 46 55 54 39 38 37 36 47 67 68 1 63 64 4 5 61 62 70 40 27 6 7 14 3 2 15 16 17 24 42 41

J300

A705-BU A704-GN A703-BR A702-PU A701-GY A B

INJECTION ACTUATION PRESSURE CONTROL VALVE (IAPCV) GN YL OR

ENGINE BOOST PRESSURE

ENGINE BOOST PRESSURE SENSOR

ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

A746-PK G829-GN G828-WH

C B A

J200

ENGINE INJECTION ACTUATION PRESSURE SENSOR

ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

A747-GY G829-GN G828-WH

994-GY G827-BU G826-BR

J204

GN YL OR

GN YL OR

ENGINE OIL PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V

G883-GN G846-YL 995-BU C967-BU

994-GY G827-BU G826-BR

C B A

P201 J201 NOTE B ENGINE OIL TEMPERATURE SENSOR NOTE A

G833-PK TOP CAMSHAFT ENGINE SPEED/TIMING SENSOR G846-YL G829-GN

1 2

ENGINE OIL TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

J101

ENGINE COOLANT TEMPERATURE SENSOR

A B

E963-BK E964-WH

J401

BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+

995-BU G833-PK

J100

J402

C967-BU G833-PK

J103

P103

G850-BU

28 29 30 31 43 22 23 56 57 65 66 69 20 21 8

P402

K995-OR J501

INPUT SIGNAL WIRES TO ECM

P501 C987-RD G850-BU

1 2

OUTPUT SIGNAL WIRES FROM ECM

SIGNAL PLUS

INTAKE AIR HEATER

COMPONENTS ARE SHOWN WITH THE KEY OFF UNLESS OTHERWISE SPECIFIED: ALL WIRES TO BE 18 AWG OR LARGER SAE J1560 TYPE TXL OR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE J1708.

SIGNAL MINUS (-) BATTERY / SENSOR RETURN

IAP CONTROL VALVE IAP CONTROL VALVE COMMON ENGINE BOOST PRESSURE ENGINE INJECTION ACTUATION PRESSURE

ENGINE ATMOSPHERIC PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

ENGINE OIL PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR

COMMON

ENGINE OIL PRESSURE SENSOR +5V ECM GROUND STRAP TO ECM MOUNTING BOLT

INPUT #16 ENGINE OIL TEMPERATURE ENGINE COOLANT TEMPERATURE INLET AIR TEMPERATURE

ENGINE TEMPERATURE SENSOR COMMON

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+

INTAKE AIR HEATER RELAY

N/O RELAY

TO ENGINE CYLINDER HEAD (NOT CYLINDER HEAD GROUND STUD)

SENSOR SUPPLY VOLTAGE

COMMON CYLINDERS 1 & 2 COMMON CYLINDERS 3 & 4 COMMON CYLINDERS 5 & 6 CYLINDER 6 CYLINDER 5 CYLINDER 4 CYLINDER 3 CYLINDER 2 CYLINDER 1

ENGINE CONTROL MODULE

(+) BATTERY SUPPLY WIRES

E965-BU E966-YL

49 48 13 50 19 59 58

P401

A B

BOTTOM CAMSHAFT ENGINE SPEED/TIMING SENSOR

P100

1 2

INLET AIR TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

P101

1 2

ENGINE COOLANT TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

INLET AIR TEMPERATURE SENSOR

25 51 52 53 60 34 32 35 9 33 26 18 10 11 12

A747-GY G829-GN G828-WH

C B A

P203 J203 NOTE B ENGINE OIL PRESSURE SENSOR NOTE A

A746-PK G849-BR

G849-BR G829-GN G828-WH

C B A

P204

ENGINE ATMOSPHERIC PRESSURE SENSOR NOTE A

P500

P200

GN YL 0R

ENGINE INJECTION ACTUATION PRESS.

G854-PK G855-PU

J500

INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR

P648 B A

G850-BU C987-RD

NOTE A: THIS IS AN OPTIONAL FEATURE NOT INSTALLED ON ALL VEHICLES. NOTE B: CONNECTOR GENDER MAY BE REVERSED ON SOME VEHICLES.

3126E OEM VEHICLE HARNESS WIRING DIAGRAM 100A WITH 130A PEAK AT 11V INTAKE AIR HEATER LAMP

B A

C987-RD

J648

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

K995-OR

L994-YL

WARNING LAMP 659-PK L994-YL K998-BU G880-PK

659-PK

KEY SWITCH

FAST IDLE ENABLED LAMP OR WAIT TO START LAMP

OFF ON START

NOTE A

G880-PK

FLYBACK DIODE

EXHAUST BRAKE SOLENOID

NOTE A

E718-PK E991-GY G836-WH

EXHAUST BRAKE ON/OFF SWITCH

C981-GY

NOTE A

GROUND

9 PIN CAB CONNECTOR

- 12V +

- 12V +

- 12V +

BATTERY 3

BATTERY 2

BATTERY 1

+BAT. B -BAT. A J H J1587 - G E793-BU J1587 + F E794-YL A249-BK J1939 SHIELD E J1939 - D K990-GN J1939 + C K900-YL NOTE A

C974-PU C973-GN NOTE A

C973-GN

SIGNAL-

993-BR F713-OR 450-YL 451-BR

450-YL

SIGNAL+

TACHOMETER NOTE A

C974-PU

SIGNAL+

SPEEDOMETER NOTE A

STARTER MOTOR (12V)

ALTERNATOR

451-BR

SIGNAL-

NOTE A

NOTE A

E793-BU E794-YL A249-BK K990-GN K900-YL

J906-BR NOTE A

TO ALLISON AT/MT/HT SHIFT MODULATOR FOR AUTOMATIC TRANSMISSIONS

14 14 14 14

20A

ENGINE BLOCK

AWG AWG AWG AWG

GXL GXL GXL GXL

NOTE A NOTE A NOTE A

C978-BR C979-OR

H795-PK

SET/RESUME SWITCH

FAST IDLE ENABLE SWITCH

NOTE A NOTE A

H795-PK H795-PK

SERVICE BRAKE PEDAL POSITION SWITCH N/C

H795-PK (PEDAL RELEASED POSITION)

C992-PU

G882-WH

(PEDAL RELEASED POSITION) NOTE A

CLUTCH PEDAL POSITION SWITCH N/C (PEDAL RELEASED POSITION)

H795-PK

DIAGNOSTIC ENABLE SWITCH H795-PK

G842-GY G882-WH G843-OR

G879-OR

G844-PK

N/O MOMENTARY SWITCH

+BAT.

TRANSMISSION NEUTRAL SWITCH N/O (TRANSMISSION IN GEAR) NOTE A

409-OR

A/C HIGH PRESSURE SWITCH N/C

SENR9675-00

E971-GN

H795-PK

C978-BR C979-OR K999-GN K980-PK L902-GN G840-PU C975-WH K982-YL

C977-BU

C977-BU

NOTE A

NOTE A

101-RD 101-RD 229-BK 229-BK G838-BR G839-BU

C992-PU SERVICE BRAKE PEDAL POSITION SWITCH #2 N/O +BAT.

NOTE A

N/O MOMENTARY SWITCH

L902-GN

C975-WH

CRUISE CONTROL ON/OFF SWITCH

G844-PK C983-WH C984-YL 409-OR E971-GN

PASSIVE MAGNETIC VEHICLE SPEED SENSOR

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION

BK RD WH

B A C J403

SENSOR ACCELERATOR PEDAL POSITION

ENGINE CONTROL MODULE

C987-RD

CHECK ENGINE LAMP

N/O RELAY

G808-BU G809-GN

1 2

H795-PK C985-BU C986-BR P403

COOLING FAN SOLENOID NOTE A

FLYBACK DIODE

NOTE A: THIS IS AN OPTIONAL FEATURE NOT INSTALLED ON ALL VEHICLES.

G808-BU G809-GN G845-PU H795-PK C985-BU C986-BR G837-YL G841-GN L901-GY

29 28 30 31 48 61 10 12 13 15 16 63 36 37 27 26 3 17 38 39 57 43 9 8 42 34 50 1 14 70 25 52 53 65 67 19 20 51 35 44 56 58 40 21 59 60

WARNING LAMP CHECK ENGINE LAMP OUTPUT #1 OUTPUT #9

OUTPUT #2 OUTPUT #3 OUTPUT #4 EXHAUST BRAKE ON/OFF SWITCH SPEEDOMETER POSITIVE SPEEDOMETER NEGATIVE

INPUT SENSOR COMMON #2 INPUT #14 TACHOMETER POSITIVE TACHOMETER NEGATIVE

J1587 J1587 J1939 J1939 J1939

DATA DATA DATA DATA DATA

LINK LINK LINK LINK LINK

NEGATIVE POSITIVE SHIELD NEGATIVE POSITIVE

IGNITION KEY SWITCH UNSWITCHED +BATTERY UNSWITCHED +BATTERY -BATTERY -BATTERY OUTPUT #6 OUTPUT #7 SET RESUME INPUT #1 (PTO ON/OFF SWITCH) INPUT #2 INPUT #18 OUTPUT #8 CRUISE CONTROL ON/OFF SWITCH INPUT #3

45 55 47 64 6

SERVICE BRAKE PEDAL POSITION SWITCH

22 23 2 46 49 54 62 24 41 69 32 33 68 5 4 66 11 7 18

CLUTCH PEDAL POSITION SWITCH

INPUT #5 INPUT #13 INPUT #6

+5V INPUT #7 ENGINE COOLANT LEVEL NORMAL ENGINE COOLANT LEVEL LOW INPUT #12 INPUT #11 VEHICLE SPEED IN POSITIVE VEHICLE SPEED IN NEGATIVE INPUT #8 (REMOTE ACCELERATOR) AP SENSOR/SWITCH SENSOR COMMON +8V ACCELERATOR PEDAL POSITION OUTPUT #5 INPUT #4 INPUT SENSOR COMMON #1

P1 J1 VEHICLE HARNESS CONNECTOR

TEMPERATURE SENSOR

+BATTERY SWITCHED

1 2 3 4

TS1

LAMP FLASHER

AMBER LAMP

RED LAMP 4 3 2 1 +BATTERY UNSWITCHED

TS2

CRT TM DIAGNOSTIC MODULE s System Statu Alarm Over-Pressure Over-Temp Alarm em System Probl

Ser Com ial m Por Data t

Al ar m

INLET AIR TEMPERATURE SENSOR

INJECTION ACTUATION PRESSURE SENSOR

BOOST PRESSURE SENSOR

TYPICAL CRT TM DIAGNOSTIC MODULE

ENGINE GROUND STUD CONNECTION

INJECTION ACTUATION PRESSURE CONTROL VALVE

INLET AIR HEATER RELAY

INLET AIR HEATER

INLET AIR TEMPERATURE SENSOR

ATMOSPHERIC PRESSURE SENSOR (SELECT RATINGS ONLY)

BOOST PRESSURE SENSOR

ENGINE HARNESS CONNECTOR J2/P2

INJECTOR HARNESS GROMMET ENGINE GROUND STUD CONNECTION

VEHICLE HARNESS CONNECTOR J1/P1

INJECTION ACTUATION PRESSURE CONTROL VALVE (IAPCV)

ENGINE SPEED/TIMING SENSORS

OIL PRESSURE SENSOR (OPTIONAL)

t pu In Max re Hg) su 20" es I ( Pr 10 PS

ATMOSPHERIC PRESSURE SENSOR

INJECTOR HARNESS GROMMET

COOLANT TEMPERATURE SENSOR

se t

TOP VIEW

INLET AIR HEATER

INJECTION ACTUATION PRESSURE SENSOR

Re

OIL LEVEL SWITCH (OPTIONAL)

LEFT SIDE VIEW

ENGINE CONTROL MODULE