B

Title

CYLINDER
INJECTOR
#1
P301

160-7689

155-2269
153-9693

3E-3369

Electrical Troubleshooting Guide

SENR9819

Systems Operation Testing and Adjusting

SENR9818

CYLINDER
INJECTOR
#2
P302

INJECTOR HARNESS
GROMMET

INJECTOR HARNESS
CONNECTOR
P300

P1

B
3E-5179

116-6158
1

P648

12

Related Electrical Service Manuals

CYLINDER
INJECTOR
#3
P303

2002 Caterpillar
All Rights Reserved

11

CYLINDER
INJECTOR
#4
P304

J300

12 11 10

10

4
5
6

B
9
8
7

155-2252

9
8

3126E Truck Engine

Electrical System

P300
7

Form Number

LEF1-UP

CYLINDER
INJECTOR
#6
P306

CYLINDER
INJECTOR
#5
P305

INJECTOR HARNESS
CONNECTOR LOCATIONS

Printed in U.S.A.

RENR7898-00

164-02
164-03
164-04
164-11
168-02
175-03
175-04
186-04
186-14
190-00
190-02
190-11
224-11
224-14
231-02
231-12
232-03
232-04
246-11
247-11
252-11
253-02
253-14

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
Oil Temperature Sensor Open Circuit
Oil Temperature Sensor Short Circuit
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

High Inlet Manifold Temperature Warning

Inlet Manifold Temperature Sensor Open Circuit
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
Secondary Fuel Level Sensor Open Circuit
Secondary Fuel Level Sensor Short Circuit
Injection Actuation Pressure Out of Range

169-8670

71
34
34
49
49
01
47
47
41
31
36
36
36
32
28
44
44
24
24
46
25
25
25

P301
P302
P303
P304
P305
P306

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

P200

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

111-2416

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

J203
J204
B

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

P100
P101
P103
P400
P500
P501
A

15
15
15
15
51
24
24
47
47
35
34
34
00
00
58
58
21
21
00
00
59
56
56

Flash
Codes
64
38
38
64
26
26
61
27
27
61
44
44
17

P201

Description

P402
B

RENR7898
December 2002

Diagnostic Codes
Flash
PID-FMI
Codes
55
105-00
72
105-03
72
105-04
73
105-11
73
108-03
74
108-04
74
110-00
42
110-03
29
110-04
29
110-11
21
128-03
21
128-04
18
164-00

160-7690

Description

P401
155-2267

PID-FMI

100-3320

P2

ENGINE HARNESS WIRING DIAGRAM

A701 GY-16
A702 PU-16
A703 BR-16
A704 GN-16

P306
1539693

P304
1539693

STAINLESS STEEL
BRAIDED SHIELD

INJECTOR
HARNESS
CONNECTOR
INJECTOR HARNESS
GROMMET
A701
A702
A703
A704
A705
A706
L985
L985
L984
L984
L983
L983

B
A

B
A

B
A

A705 BU-16
CYLINDER
INJECTOR
#6
222-5966

CYLINDER
INJECTOR
#5
222-5966

B
A

CYLINDER
INJECTOR
#4
222-5966

P303
1539693

P302
1539693

B
A

P301
1539693

CYLINDER
INJECTOR
#3
222-5966

P305
1539693

CYLINDER
INJECTOR
#2
222-5966

B
A

CYLINDER
INJECTOR
#1
222-5966

A706 GY-16
L985 YL-16

L985 YL-16
L984 OR-16
L984 OR-16
L983 WH-16
L983 WH-16

P300
1552252
GY-16
PU-16
BR-16
GN-16
BU-16
GY-16
YL-16
YL-16
OR-16
OR-16
WH-16
WH-16

A701 GY-18
A702 PU-18
A703 BR-18
A704 GN-18
A705 BU-18
A706 GY-18
L983 WH-18
L983 WH-18
L984 OR-18
L984 OR-18
L985 YL-18
L985 YL-18
E963 BK-18
E964 WH-18
E965 BU-18
E966 YL-18

J300
3E5179
A701 GY-18
A702 PU-18
A703 BR-18
A704 GN-18
A705 BU-18
A706 GY-18
L985 YL-18
L985 YL-18
L984 OR-18
L984 OR-18
L983 WH-18
L983 WH-18

1
2
3
4
5
6
7
8
9
10
11
12

P401
1003320

ENGINE SPEED/TIMING SENSORS

169-3300

(+) BATTERY SUPPLY WIRES

INPUT SIGNAL WIRES TO ECM

P500
1552269

SENSOR SUPPLY VOLTAGE

INJECTION ACTUATION
PRESSURE CONTROL VALVE

SIGNAL PLUS
SIGNAL MINUS

INJECTION ACTUATION PRESSURE SENSOR

194-6726

OR-18
YL-18
GN-18

G828 WH-18
G829 GN-18
G849 BR-18

A
B
C

G829 GN-18
G829 GN-18
G829 GN-18
G829 GN-18
G827 BU -18

P201
1552267
+5V
GROUND
SIGNAL

ENGINE OIL PRESSURE SENSOR

194-6725

G826 BR-18
G827 BU-18
994 GY-18

A
B
C

G833
G833
G833
G833

J203
3E3369
+5V
GROUND
SIGNAL

ATMOSPHERIC PRESSURE SENSOR

194-6722

OR-18
YL-18
GN-18

P101
1552269
ENGINE OIL TEMPERATURE SENSOR
130-9811

SIGNAL
GROUND

+5V
GROUND
SIGNAL

OR-18
YL-18
GN-18

G828 WH-18
G829 GN-18
A746 PK-18

A
B
C

G846 YL-18
C967 BU -18
A701 GY-18
A702 PU-18
A703 BR-18
A704 GN-18
A746 PK-18
G826 BR-18
G827 BU-18

L983 WH-18
L984 OR-18
L985 YL-18
E964 WH-18
E963 BK-18

A705 BU-18
A706 GY-18

STAINLESS STEEL
BRAIDED SHIELD

P200
1698670
BOOST PRESSURE SENSOR
194-6723

PK-18
PK-18
PK-18
PK-18

995 BU -18

G856 WH-18
G857 YL-18
G850 BU-18

G846 YL-18
G833 PK-18

1
2

G849 BR-18

C967 BU -18
G849 BR-18
995 BU -18
994 GY -18

G828 WH-18
G829 GN-18
A747 GY-18

A
B
C

G856 WH-18
G857 YL-18
994 GY-18

G828 WH-18
G828 WH-18
G828 WH-18
G828 WH-18
G826 BR -18

J204
3E3369
+5V
GROUND
SIGNAL

G833 PK-18

A746 PK-18
A747 GY-18
G846 YL-18

G854 PK-18
G855 PU-18

1
2

(-) BATTERY / SENSOR RETURN

G850 BU-18

STAINLESS STEEL
BRAIDED SHIELD
ECM
MOUNTING
BOLT

E965 BU-18
E966 YL-18

A
B

SECONDARY(BOTTOM)

OUTPUT SIGNAL WIRES FROM ECM

A747 GY-18

P402
1112416

ECM
MOUNTING
BOLT

E966 YL-18
E965 BU-18

P103
1552269
INLET AIR TEMPERATURE SENSOR
130-9811

K995-OR
INLET AIR
HEATER RELAY
175-2324

BK-18
BK-18

1
2

SIGNAL
GROUND

P100
1552269

P501
1552269
C987 RD-18
G850 BU-18

ENGINE COOLANT TEMPERATURE SENSOR

130-9811

G850 BU-18

SIGNAL
GROUND

B
A

995 BU -18
G833 PK-18

1
2

P648
1166158

INLET AIR
HEATER

G854 PK-18
G855 PU-18

C967 BU-18
G833 PK-18

1
2

ENGINE CONTROL MODULE

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70

G828 WH-18
G829 GN-18

G854 PK-18
G855 PU-18

E963 BK-18
E964 WH-18

A
B

PRIMARY(TOP)

P2
1607690

PRESSURE SENSOR +5V

PRESSURE SENSOR COMMON

INLET AIR HEATER RELAY

ATMOSPHERIC PRESSURE

TEMPERATURE SENSOR COMMON

TIMING CALIBRATION(-)
TIMING CALIBRATION(+)
ENGINE OIL PRESSURE

INJECTION ACT. PRESSURE

COOLANT TEMPERATURE
ENGINE OIL TEMPERATURE
INLET AIR TEMPERATURE
INJECTOR CYL 1
INJECTOR CYL 2
INJECTOR CYL 3
INJECTOR CYL 4
BOOST PRESSURE
ENGINE OIL PRESSURE (+5V)
ENGINE OIL PRESSURE COMMON
INJECTOR COMMON CYL 1&2
INJECTOR COMMON CYL 3&4
INJECTOR COMMON CYL 5&6
SPEED/TIMING TOP(+)
SPEED/TIMING TOP(-)

INJECTOR CYL 5
INJECTOR CYL 6

SPEED/TIMING BOTTOM(+)
SPEED/TIMING BOTTOM(-)
IAP CONTROL VALVE(+)
IAP CONTROL VALVE(-)

ECM GND STRAP

P400
1552269

G850 BU-18
C987 RD-18

TIMING CALIBRATION
(TC) PROBE CONNECTOR

G856 WH-18
G857 YL-18

1
2

INLET AIR
HEATER GROUND
STRAP

TO ECM
MOUNTING
BOLT

G850 BU-18

J648
B
A
C987-RD

INLET AIR
HEATER LAMP

TYPICAL VEHICLE HARNESS WIRING DIAGRAM

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

K995-OR

C987-RD

CHECK ENGINE
LAMP

N/O
RELAY

ENGINE CONTROL MODULE

L994-YL

P1
1607689
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

G880-PK

FLYBACK
DIODE

EXHAUST BRAKE
SOLENOID

E718-PK
E991-GY
G836-WH

EXHAUST BRAKE ON/OFF SWITCH

C981-GY

SPEEDOMETER
ALTERNATOR

C974-PU

SIGNAL+

C973-GN

STARTER
MOTOR

C973-GN

SIGNAL-

GROUND

9 PIN CAB
CONNECTOR

- 24V +

- 24V +

- 24V +

BATTERY 3

BATTERY 2

BATTERY 1

+BAT. B
-BAT. A
J
H
J1587 - G
J1587 + F
J1939 SHIELD E
J1939 - D
J1939 + C

TACHOMETER

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

450-YL

SIGNAL+

451-BR

SIGNAL-

C974-PU

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

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

J906-BR
TO ALLISON AT/MT/HT SHIFT
MODULATOR FOR AUTOMATIC
TRANSMISSIONS

14
14
14
14

20A

ENGINE
BLOCK

GXL
GXL
GXL
GXL

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

C978-BR
C979-OR

H795-PK

SET/RESUME SWITCH

FAST IDLE ENABLE SWITCH

H795-PK

H795-PK

AWG
AWG
AWG
AWG

N/O MOMENTARY SWITCH

L902-GN

C975-WH

CRUISE CONTROL ON/OFF SWITCH

SERVICE BRAKE PEDAL POSITION SWITCH N/C

H795-PK
(PEDAL RELEASED POSITION)

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

G842-GY
G882-WH
G843-OR
L901-GY
C977-BU

(PEDAL RELEASED POSITION)

G882-WH
CLUTCH PEDAL POSITION SWITCH N/C
H795-PK

C978-BR
C979-OR
K999-GN
K980-PK
L902-GN
G840-PU
C975-WH
K982-YL
G841-GN
C992-PU

C977-BU

(PEDAL RELEASED POSITION)

DIAGNOSTIC ENABLE SWITCH
H795-PK

G879-OR

G844-PK

N/O MOMENTARY SWITCH

TRANSMISSION NEUTRAL SWITCH N/O

+BAT.

(TRANSMISSION IN GEAR)

409-OR

A/C HIGH PRESSURE SWITCH N/C

E971-GN

H795-PK

E971-GN

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED

BK
RD
WH

B
A
C
J403

SENSOR ACCELERATOR
PEDAL POSITION

G808-BU
G809-GN

1
2

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

H795-PK
C985-BU
C986-BR
COOLING FAN SOLENOID

P403

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
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

ARC
SUPPRESSOR

SOME VEHICLES MAY USE

A DIODE FOR ARC SUPPRESSION

INJECTION ACTUATION
PRESSURE SENSOR
ENGINE OIL
TEMPERATURE
SENSOR

INLET AIR HEATER

RELAY

INLET AIR
TEMPERATURE
SENSOR

INLET AIR HEATER

ATMOSPHERIC
PRESSURE
SENSOR

BOOST
PRESSURE
SENSOR

INLET AIR HEATER

LAMP CONNECTOR

INLET AIR HEATER

GROUND STRAP

TIMING CALIBRATION
(TC) PROBE
CONNECTOR

INJECTOR HARNESS
GROMMET

INJECTION ACTUATION
PRESSURE CONTROL VALVE

ENGINE GROUND
STUD CONNECTION

COOLANT TEMPERATURE
SENSOR

PRIMARY(TOP)
SPEED/TIMING
SENSOR
VEHICLE HARNESS
CONNECTOR
J1/P1

SECONDARY(BOTTOM)
SPEED/TIMING
SENSOR

ENGINE HARNESS
CONNECTOR
J2/P2

ENGINE
OIL PRESSURE
SENSOR

ENGINE CONTROL
MODULE

LEFT SIDE VIEW

INJECTION ACTUATION
PRESSURE SENSOR
J204
ENGINE OIL
TEMPERATURE
SENSOR
P101

INLET AIR
TEMPERATURE
SENSOR
P103

ENGINE HARNESS
CONNECTOR AND SPLICE LOCATIONS

INLET AIR HEATER

RELAY COIL
P501

INLET AIR HEATER

LAMP CONNECTOR
P648
B

ENGINE
OIL PRESSURE
SENSOR
P201

INJECTOR HARNESS
CONNECTOR
J300

TIMING
CALIBRATION
(TC) PROBE
CONNECTOR
P400

BOOST
PRESSURE
SENSOR
P200
SPLICE
G828

SPLICE
G833
SPLICE
G850

SPLICE
G829

COOLANT TEMPERATURE
SENSOR
P100

ATMOSPHERIC
PRESSURE
SENSOR
J203

SPLICE
L983

SPLICE
L984

INJECTION ACTUATION
PRESSURE CONTROL VALVE
P500

RENR7898-00

PASSIVE MAGNETIC
VEHICLE SPEED
SENSOR

ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON

+8 V
ACCELERATOR PEDAL POSITION

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

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

SPLICE
L985

PRIMARY(TOP)
SPEED/TIMING
SENSOR
P401

SECONDARY(BOTTOM)
SPEED/TIMING
SENSOR
P402

STAINLESS STEEL
BRAIDED SHIELD
TERMINATION

STAINLESS STEEL
BRAIDED SHIELD
TERMINATION

ENGINE HARNESS
CONNECTOR
P2

THIS SCHEMATIC IS FOR THE 3126E TRUCK ENGINE (S/N: LEF)

HARNESS
CHG
190-7421 01 (J2 / ENGINE)
153-8920 02 (INJECTOR)