Receptacle Wedge Receptacle Wedge Receptacle Wedge

ECM Side

ECM Side

Pin Contact

DT Connector Receptacle

HD Connector Receptacle

Speed/Timing Sensor Connectors

150 Series Receptacle

ECM Connector P2 ECM Connector P1

ECM AMP Connectors

Socket Contact Plug Wedge Plug Wedge Plug Wedge

Harness Side

Harness Side

Sealing Plug

DT Connector Plug

HD Connector Plug

IAPCV Connector

150 Series Plug

(Optional) (Optional) Oil Level Switch Oil Pressure Sensor Inlet Air Heater Relay (Specific Ratings Only) Boost Pressure Sensor OEM Installed Caterpillar Installed

Hydraulic Pump 6 HEUI Injectors

2002 Caterpillar All Rights Reserved

Inlet Air Temperature Sensor Coolant Temperature Sensor
A

Atmospheric Pressure Sensor

Injection Actuation Pressure Sensor

Top Camshaft Speed/Timing Sensor

IAPCV Intregral to Hydralic Pump

Bottom Camshaft Speed/Timing Sensor

Inlet Air Heater Ground Strap Fast Idle Enable Switch Fast Idle Enabled Lamp or Wait to Start Lamp A/C High Pressure Switch AT/MT/HT Transmission Relay Cooling Fan Exhaust Brake Inlet Air Heater Lamp PTO Switch On Lamp Vehicle Speed Sensor PTO Accelerator Position Sensor Transmission Neutral Switch Exhaust Brake On/Off Switch PTO On/Off & PTO Set/Resume Switches

Engine Control Module

Check Engine Lamp

Ignition Key Switch

1 5 5 0 MP H 85 75 5 RP MX100 30 25

Accelerator Pedal Position Sensor

25 35 45 55 65

12V

Cruise Control On/Off & Set/Resume Switches

Warning Lamp

Coolant Level Sensor

Clutch and Service Brake Switches

10 15 20

J1939 Cab Diagnostic Connector

Batteries

Speedometer & Tachometer

Printed in U.S.A.

SENR9638-00
8 Page, JVD

HEP1-UP

3126E Truck Engine Electrical System

SENR9638 June 2002

PID-FMI 0-00 1-11 2-11 3-11 4-11 5-11 6-11 22-13 30-08 30-13 41-03 41-04 42-11 43-02 64-02 64-11 70-05 70-06 71-00 71-01 71-14 84-00 84-01 84-02 84-08 84-10 91-08 91-13 96-03 96-04 100-03 100-04 100-11 102-03 102-04 102-07 105-00 105-03

Description No Detected Faults Cylinder 1 Fault Cylinder 2 Fault Cylinder 3 Fault Cylinder 4 Fault Cylinder 5 Fault Cylinder 6 Fault Check Timing Sensor Calibration Invalid PTO Throttle Signal PTO Throttle Sensor Calibration 8 Volt Supply Above Normal 8 Volt Supply Below Normal Injection Actuation Pressure Control Valve Driver Ignition Key Switch Fault Loss of Engine RPM Signal #2 No Pattern on RPM Speed Sensor #2 Inlet Air Heater Open Circuit Inlet Air Heater Short Circuit Idle Shutdown Override Idle Shutdown Occurrence PTO Shutdown Timer Occurrence Vehicle Overspeed Warning Loss of Vehicle Speed Signal Invalid Vehicle Speed Signal Vehicle Speed Out of Range Vehicle Speed Rate of Change Invalid Throttle Signal Throttle Sensor Calibration Primary Fuel Level Sensor Open Circuit Primary Fuel Level Sensor Short Circuit Oil Pressure Sensor Open Circuit Oil Pressure Sensor Short Circuit Very Low Oil Pressure Boost Pressure Sensor Open Circuit Boost Pressure Sensor Short Circuit Excessive Boost Pressure High Inlet Manifold Temperature Warning Inlet Manifold Temperature Sensor Open Circuit

Description Inlet Manifold Temperature Sensor Short Circuit Very High Inlet Manifold Temperature Warning Atmospheric Pressure Sensor Open Circuit Atmospheric Pressure Sensor Short Circuit High Coolant Temperature Warning Coolant Temperature Sensor Open Circuit Coolant Temperature Sensor Short Circuit Very High Coolant Temperature Warning Low Coolant Level Warning Coolant Level Sensor Fault Coolant Level Sensor Open Circuit Coolant Level Sensor Short Circuit Very Low Coolant Level Secondary Fuel Level Sensor Open Circuit Secondary Fuel Level Sensor Short Circuit Injection Actuation Pressure Out of Range Injection Actuation Pressure Sensor Erratic Injection Actuation Pressure Sensor Open Circuit Injection Actuation Pressure Sensor Short Circuit Injection Actuation Pressure System Low or Intermittent Battery PTO Engine Shutdown Switch Short Circuit PTO Shutdown Switch Occurrence Engine Overspeed Warning Loss of Engine RPM Signal #1 No Pattern on RPM Speed Sensor #1 Theft Deterrent Active Engine Cranking with Theft Deterrent Active J1939 Required Data Not Received J1939 Device Not Responding 5 Volt Supply Above Normal 5 Volt Supply Below Normal Brake Switch #1 Fault Brake Switch #2 Fault Incorrect Engine Software Check Customer or System Parameters Truck Manufacturer Parameter Not Programmed

Diagnostic Code Listing Flash PID-FMI Codes 55 105-04 72 105-11 72 108-03 73 108-04 73 110-00 74 110-03 74 110-04 42 110-11 29 111-01 29 111-02 21 111-03 21 111-04 18 111-11 71 128-03 34 128-04 34 164-00 49 164-02 49 164-03 01 164-04 47 164-11 47 168-02 41 186-04 31 186-14 36 190-00 36 190-02 36 190-11 32 224-11 28 224-14 44 231-02 44 231-12 24 232-03 24 232-04 46 246-11 25 247-11 25 252-11 25 253-02 64 253-14 38

Flash Codes 38 64 26 26 61 27 27 61 62 12 12 12 62 44 44 17 15 15 15 15 51 00 47 35 34 34 00 00 58 58 21 21 00 00 59 56 56

3126E ENGINE HARNESS WIRING DIAGRAM

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

INJECTOR HARNESS GROMMET 12 11 10 9 8 7 6 5 4 3 2 1 P300 J300

ENGINE HARNESS CONNECTOR P2 J2 L983-WH L984-OR L985-YL A706-GY A705-BU A704-GN A703-BR A702-PU A701-GY 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 25 51 52 53 21 33 32 35 9 34 26 18 10 11 12 49 48 13 50 19 59 58 28 29 30 31 43 22 23 56 57 65 8 69 20 66 60 INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR COMMON CYLINDERS 1 & 2 COMMON CYLINDERS 3 & 4 COMMON CYLINDERS 5 & 6 CYLINDER 6 CYLINDER 5 CYLINDER 4 CYLINDER 3 CYLINDER 2 CYLINDER 1

L985-YL J301 P301 J302 P302 J303 P303 J304 P304 J305 P305 J306 P306 A706-GY

B A

B A

B A

B A

B A

B A

INJECTOR CYLINDER NO.1

INJECTOR CYLINDER NO.2

INJECTOR CYLINDER NO.3

INJECTOR CYLINDER NO.4 A704-GN A703-BR

INJECTOR CYLINDER NO.5 A705-BU

INJECTOR CYLINDER NO.6

A702-PU A701-GY INJECTION ACTUATION PRESSURE CONTROL VALVE (IAPCV) ENGINE BOOST PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V C B A J200 ENGINE INJECTION ACTUATION PRESSURE SENSOR 194-6726 ENGINE ATMOSPHERIC PRESSURE SENSOR 161-1703 NOTE A A746-PK G829-GN G828-WH P200 2 1 J500 P500 G854-PK G855-PU A746-PK G849-BR

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

ENGINE BOOST PRESSURE SENSOR 183-4760

A747-GY G829-GN G828-WH G849-BR G829-GN G828-WH

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

ENGINE INJECTION ACTUATION PRESS. ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V

GN YL 0R P204

C B A

J204

994-GY G827-BU G826-BR

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

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

C B A P203

A747-GY G829-GN G828-WH J203 G458-GY 995-BU C967-BU G846-YL G833-PK TOP CAMSHAFT ENGINE SPEED/TIMING SENSOR

ENGINE OIL PRESSURE SENSOR 161-1705 NOTE A

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

C B A P201

994-GY G827-BU G826-BR J201

ENGINE OIL LEVEL SWITCH ENGINE COOLANT TEMPERATURE ENGINE INLET AIR TEMPERATURE NOT USED ENGINE TEMPERATURE SENSOR COMMON

ENGINE OIL LEVEL SWITCH 183-5903 NOTE A

ENGINE OIL LEVEL ENGINE OIL LEVEL COMMON

A B J802 1 2 J101

G458-GY G829-GN P802 169-3300 G846-YL G833-PK

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

A B J401 P401

E963-BK E964-WH

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

NOT USED

BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+ BOTTOM CAMSHAFT ENGINE SPEED/TIMING SENSOR

A B J402 P402

E965-BU E966-YL

BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+

ENGINE COOLANT TEMPERATURE SENSOR 130-9811 ENGINE INLET AIR TEMPERATURE SENSOR 130-9811

ENGINE COOLANT TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

1 2 J100

995-BU G833-PK P100

K995-OR ENGINE INTAKE MANIFOLD AIR TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON 1 2 J103 C967-BU G833-PK P103 INLET AIR HEATER GROUND STRAP INLET AIR HEATER

INLET AIR HEATER RELAY J501 P501 1 2 N/O RELAY C987-RD G850-BU G850-BU

INLET AIR HEATER RELAY

ENGINE CONTROL MODULE

(+) BATTERY SUPPLY WIRES INPUT SIGNAL WIRES TO ECM OUTPUT SIGNAL WIRES FROM ECM SENSOR SUPPLY VOLTAGE SIGNAL PLUS SIGNAL MINUS (-) BATTERY / SENSOR RETURN
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.

B A

P648 G850-BU C987-RD

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

3126E OEM VEHICLE HARNESS WIRING DIAGRAM

100A WITH 130A PEAK AT 11V INTAKE AIR HEATER LAMP C987-RD B A J648

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS N/O RELAY CHECK ENGINE LAMP K995-OR C987-RD L994-YL ENGINE CONTROL MODULE

WARNING LAMP 659-PK FAST IDLE ENABLED LAMP OR WAIT TO START LAMP NOTE A 659-PK L994-YL K998-BU G880-PK 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 7 45 55 47 64 6 18 22 23 2 46 49 54 62 24 41 69 32 33 68 5 4 66 11 P1 J1 VEHICLE HARNESS CONNECTOR WARNING LAMP CHECK ENGINE LAMP OUTPUT #1 OUTPUT #9

KEY SWITCH OFF ON START

G880-PK

EXHAUST BRAKE SOLENOID

FLYBACK DIODE

NOTE A

EXHAUST BRAKE ON/OFF SWITCH NOTE A

E718-PK E991-GY G836-WH C981-GY

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

ALTERNATOR GROUND

STARTER MOTOR (12V)

SPEEDOMETER NOTE A 9 PIN CAB CONNECTOR +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

SIGNAL+ SIGNAL-

C974-PU C973-GN NOTE A

C974-PU C973-GN

TACHOMETER NOTE A

SIGNAL+ SIGNAL-

450-YL 451-BR NOTE A

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

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

- 12V + BATTERY 3

- 12V + BATTERY 2

- 12V + BATTERY 1

NOTE A

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

J1587 J1587 J1939 J1939 J1939

DATA DATA DATA DATA DATA

LINK LINK LINK LINK LINK

NEGATIVE POSITIVE SHIELD NEGATIVE POSITIVE

J906-BR NOTE A TO ALLISON AT/MT/HT SHIFT MODULATOR FOR AUTOMATIC TRANSMISSIONS 14 14 14 14 NOTE A NOTE A NOTE A C978-BR C979-OR FAST IDLE ENABLE SWITCH H795-PK H795-PK C975-WH SERVICE BRAKE PEDAL POSITION SWITCH N/C C992-PU SERVICE BRAKE PEDAL POSITION SWITCH #2 N/O +BAT. CLUTCH PEDAL POSITION SWITCH N/C NOTE A (PEDAL RELEASED POSITION) NOTE A H795-PK C977-BU DIAGNOSTIC ENABLE SWITCH H795-PK G844-PK +BAT. TRANSMISSION NEUTRAL SWITCH N/O 409-OR (TRANSMISSION IN GEAR) NOTE A G882-WH (PEDAL RELEASED POSITION) NOTE A L902-GN N/O MOMENTARY SWITCH AWG AWG AWG AWG GXL GXL GXL GXL 101-RD 101-RD 229-BK 229-BK G838-BR G839-BU C978-BR C979-OR K999-GN K980-PK L902-GN G840-PU C975-WH K982-YL G841-GN C992-PU G842-GY G882-WH G843-OR L901-GY C977-BU G879-OR G844-PK C983-WH C984-YL 409-OR E971-GN PASSIVE MAGNETIC VEHICLE SPEED SENSOR BK RD WH B A C J403 H795-PK C985-BU C986-BR P403 COOLING FAN SOLENOID NOTE A ARC SUPPRESSOR G808-BU G809-GN 1 2 G808-BU G809-GN G845-PU H795-PK C985-BU C986-BR G837-YL

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 INPUT #4 SERVICE BRAKE PEDAL POSITION SWITCH INPUT #5 INPUT #13 INPUT #6 INPUT SENSOR COMMON #1 CLUTCH PEDAL POSITION SWITCH +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

ENGINE BLOCK

20A

H795-PK

SET/RESUME SWITCH NOTE A NOTE A

CRUISE CONTROL ON/OFF SWITCH

H795-PK (PEDAL RELEASED POSITION)

N/O MOMENTARY SWITCH A/C HIGH PRESSURE SWITCH N/C NOTE A H795-PK E971-GN

SENR9638-00

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

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

8 Page, JVD

SOME VEHICLES MAY USE A DIODE FOR ARC SUPPRESSION

TOP VIEW

6 UNIT INJECTOR #6

INJECTOR HARNESS GROMMET

ATMOSPHERIC PRESSURE SENSOR NOTE A

INJECTION ACTUATION PRESSURE SENSOR

INJECTION ACTUATION PRESSURE CONTROL VALVE (INTEGRAL TO PUMP) BOOST PRESSURE SENSOR

INLET AIR HEATER GROUND STRAP

INLET AIR HEATER RELAY

INLET AIR TEMPERATURE SENSOR

INLET AIR HEATER

INLET AIR HEATER LAMP CONNECTOR

INJECTOR HARNESS GROMMET INJECTION ACTUATION PRESSURE CONTROL VALVE (INTEGRAL TO PUMP)

ENGINE GROUND STUD CONNECTION

COOLANT TEMPERATURE SENSOR

SPEED / TIMING SENSORS

VEHICLE HARNESS CONNECTOR J1/P1

OIL PRESSURE SENSOR NOTE A

ENGINE HARNESS CONNECTOR J2/P2

ENGINE CONTROL MODULE

OIL LEVEL SWITCH NOTE A

LEFT SIDE VIEW