Receptacle Wedge

Receptacle Wedge
Receptacle Wedge
ECM Side
ECM Side

Pin Contact

150 Series Receptacle

DT Connector Receptacle

HD Connector Receptacle

Speed/Timing Sensor Connectors

ECM Connector P2
ECM Connector P1

Socket Contact
ECM AMP Connectors

Plug Wedge
Plug Wedge
Plug Wedge

Sealing Plug
Harness Side
Harness Side

150 Series Plug

IAPCV Connector
DT Connector Plug

HD Connector Plug
Pump
Hydraulic

(Optional)
(Optional)

Oil Level Switch

Oil Pressure Sensor

Inlet Air Heater Relay

(Specific Ratings Only)
Boost Pressure Sensor
6 HEUI Injectors

2002 Caterpillar
All Rights Reserved
Inlet Air Temperature Sensor
Coolant Temperature Sensor
Atmospheric Pressure Sensor
Hydralic Pump

Injection Actuation Pressure Sensor

Top Camshaft Speed/Timing Sensor

A
IAPCV Intregral to

Bottom Camshaft Speed/Timing Sensor

Ground Strap
Inlet Air Heater
Caterpillar Installed

OEM Installed
Engine Control Module

Fast Idle Enable Switch

or Wait to Start Lamp
Check Engine Lamp

Fast Idle Enabled Lamp

A/C High Pressure Switch
Ignition Key Switch

15
25

5
0
35
45

MPH
55

85
65

AT/MT/HT Transmission Relay

75
5
10
12V

15
Accelerator Pedal Position Sensor
+

20

RPMX100 30
25
Warning Lamp
Set/Resume Switches

Sensor
Cruise Control On/Off &

Switches
Batteries
J1939 Cab

Coolant Level Sensor

Cooling Fan

Exhaust Brake

Inlet Air Heater Lamp

Diagnostic Connector

PTO Switch On Lamp

Vehicle Speed Sensor
Clutch and Service Brake Switches

PTO Accelerator Position

Speedometer & Tachometer

Transmission Neutral Switch

Exhaust Brake On/Off Switch

Printed in U.S.A.
PTO On/Off & PTO Set/Resume

8 Page, JVD
HEP1-UP

SENR9638-00
Electrical System
3126E Truck Engine
June 2002
SENR9638

Diagnostic Code Listing

PID-FMI Description Flash PID-FMI Description Flash
Codes Codes
0-00 No Detected Faults 55 105-04 Inlet Manifold Temperature Sensor Short Circuit 38
1-11 Cylinder 1 Fault 72 105-11 Very High Inlet Manifold Temperature Warning 64
2-11 Cylinder 2 Fault 72 108-03 Atmospheric Pressure Sensor Open Circuit 26
3-11 Cylinder 3 Fault 73 108-04 Atmospheric Pressure Sensor Short Circuit 26
4-11 Cylinder 4 Fault 73 110-00 High Coolant Temperature Warning 61
5-11 Cylinder 5 Fault 74 110-03 Coolant Temperature Sensor Open Circuit 27
6-11 Cylinder 6 Fault 74 110-04 Coolant Temperature Sensor Short Circuit 27
22-13 Check Timing Sensor Calibration 42 110-11 Very High Coolant Temperature Warning 61
30-08 Invalid PTO Throttle Signal 29 111-01 Low Coolant Level Warning 62
30-13 PTO Throttle Sensor Calibration 29 111-02 Coolant Level Sensor Fault 12
41-03 8 Volt Supply Above Normal 21 111-03 Coolant Level Sensor Open Circuit 12
41-04 8 Volt Supply Below Normal 21 111-04 Coolant Level Sensor Short Circuit 12
42-11 Injection Actuation Pressure Control Valve Driver 18 111-11 Very Low Coolant Level 62
43-02 Ignition Key Switch Fault 71 128-03 Secondary Fuel Level Sensor Open Circuit 44
64-02 Loss of Engine RPM Signal #2 34 128-04 Secondary Fuel Level Sensor Short Circuit 44
64-11 No Pattern on RPM Speed Sensor #2 34 164-00 Injection Actuation Pressure Out of Range 17
70-05 Inlet Air Heater Open Circuit 49 164-02 Injection Actuation Pressure Sensor Erratic 15
70-06 Inlet Air Heater Short Circuit 49 164-03 Injection Actuation Pressure Sensor Open Circuit 15
71-00 Idle Shutdown Override 01 164-04 Injection Actuation Pressure Sensor Short Circuit 15
71-01 Idle Shutdown Occurrence 47 164-11 Injection Actuation Pressure System 15
71-14 PTO Shutdown Timer Occurrence 47 168-02 Low or Intermittent Battery 51
84-00 Vehicle Overspeed Warning 41 186-04 PTO Engine Shutdown Switch Short Circuit 00
84-01 Loss of Vehicle Speed Signal 31 186-14 PTO Shutdown Switch Occurrence 47
84-02 Invalid Vehicle Speed Signal 36 190-00 Engine Overspeed Warning 35
84-08 Vehicle Speed Out of Range 36 190-02 Loss of Engine RPM Signal #1 34
84-10 Vehicle Speed Rate of Change 36 190-11 No Pattern on RPM Speed Sensor #1 34
91-08 Invalid Throttle Signal 32 224-11 Theft Deterrent Active 00
91-13 Throttle Sensor Calibration 28 224-14 Engine Cranking with Theft Deterrent Active 00
96-03 Primary Fuel Level Sensor Open Circuit 44 231-02 J1939 Required Data Not Received 58
96-04 Primary Fuel Level Sensor Short Circuit 44 231-12 J1939 Device Not Responding 58
100-03 Oil Pressure Sensor Open Circuit 24 232-03 5 Volt Supply Above Normal 21
100-04 Oil Pressure Sensor Short Circuit 24 232-04 5 Volt Supply Below Normal 21
100-11 Very Low Oil Pressure 46 246-11 Brake Switch #1 Fault 00
102-03 Boost Pressure Sensor Open Circuit 25 247-11 Brake Switch #2 Fault 00
102-04 Boost Pressure Sensor Short Circuit 25 252-11 Incorrect Engine Software 59
102-07 Excessive Boost Pressure 25 253-02 Check Customer or System Parameters 56
105-00 High Inlet Manifold Temperature Warning 64 253-14 Truck Manufacturer Parameter Not Programmed 56
105-03 Inlet Manifold Temperature Sensor Open Circuit 38
 3126E ENGINE HARNESS WIRING DIAGRAM INJECTOR HARNESS GROMMET

L983-WH 12 ENGINE HARNESS CONNECTOR

L983-WH 11
L984-OR 10
P2 J2
L984-OR 9
L985-YL 8 L983-WH 44 INJECTOR COMMON CYLINDERS 1 & 2
L985-YL 7 L984-OR 45 INJECTOR COMMON CYLINDERS 3 & 4
L985-YL 46 INJECTOR COMMON CYLINDERS 5 & 6
J301 P301 J302 P302 J303 P303 J304 P304 J305 P305 J306 P306 A706-GY 6 A706-GY 55 INJECTOR CYLINDER 6
B B B B B B 5 A705-BU 54 INJECTOR CYLINDER 5
A A A A A A 4 A704-GN 39 INJECTOR CYLINDER 4
3 A703-BR 38 INJECTOR CYLINDER 3
2 A702-PU 37 INJECTOR CYLINDER 2
1 A701-GY 36 INJECTOR CYLINDER 1
INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR INJECTOR 47
P300 J300
CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER CYLINDER 67
NO.1 NO.2 NO.3 NO.4 NO.5 NO.6 68
A705-BU 1
A704-GN 63
A703-BR 64
A702-PU 4
A701-GY 5
INJECTION ACTUATION 2 G854-PK 61 IAP CONTROL VALVE
PRESSURE CONTROL VALVE 1 G855-PU 62 IAP CONTROL VALVE COMMON
(IAPCV) J500 P500 70
ENGINE BOOST
ENGINE BOOST PRESSURE C A746-PK A746-PK 40 ENGINE BOOST PRESSURE
PRESSURE
ENGINE PRESSURE SENSOR COMMON B G829-GN G849-BR 27 ENGINE INJECTION ACTUATION PRESSURE
SENSOR
ENGINE PRESSURE SENSOR +5V A G828-WH 6
183-4760
7
J200 P200
A747-GY 14 ENGINE ATMOSPHERIC PRESSURE
G829-GN 3 ENGINE PRESSURE SENSOR COMMON
ENGINE INJECTION G828-WH 2 ENGINE PRESSURE SENSOR +5V
ACTUATION ENGINE INJECTION ACTUATION PRESS. GN C G849-BR 15
PRESSURE ENGINE PRESSURE SENSOR COMMON YL B G829-GN 16
SENSOR ENGINE PRESSURE SENSOR +5V 0R A G828-WH 17
194-6726 994-GY 24 ENGINE OIL PRESSURE SENSOR
P204 J204
G827-BU 42 ENGINE OIL PRESSURE SENSOR COMMON
ENGINE ATMOSPHERIC G826-BR 41 ENGINE OIL PRESSURE SENSOR +5V
PRESSURE ENGINE ATMOSPHERIC PRESSURE C A747-GY 25
SENSOR ENGINE PRESSURE SENSOR COMMON B G829-GN 51
ECM GROUND STRAP
161-1703 ENGINE PRESSURE SENSOR +5V A G828-WH 52
NOTE A 53
P203 J203 TO ECM
21
G458-GY 33 ENGINE OIL LEVEL SWITCH MOUNTING
ENGINE OIL 995-BU 32 ENGINE COOLANT TEMPERATURE BOLT
PRESSURE C967-BU 35 ENGINE INLET AIR TEMPERATURE
ENGINE OIL PRESSURE SENSOR C 994-GY
SENSOR 9
ENGINE OIL PRESSURE SENSOR COMMON B G827-BU
161-1705
ENGINE OIL PRESSURE SENSOR +5V A G826-BR G846-YL 34 NOT USED
NOTE A
26
P201 J201
G833-PK 18 ENGINE TEMPERATURE SENSOR COMMON
TOP CAMSHAFT ENGINE 10
SPEED/TIMING SENSOR 11
ENGINE OIL LEVEL
SWITCH A G458-GY 12
ENGINE OIL LEVEL
183-5903 TOP CAMSHAFT SPEED/TIMING- A E963-BK 49 TOP CAMSHAFT SPEED/TIMING-
ENGINE OIL LEVEL COMMON B G829-GN
NOTE A TOP CAMSHAFT SPEED/TIMING+ B E964-WH 48 TOP CAMSHAFT SPEED/TIMING+
J802 P802
J401 P401 13
169-3300 50
1 G846-YL 19
NOT
2 G833-PK BOTTOM CAMSHAFT SPEED/TIMING- A E965-BU 59 BOTTOM CAMSHAFT SPEED/TIMING-
USED
J101 BOTTOM CAMSHAFT SPEED/TIMING+ B E966-YL 58 BOTTOM CAMSHAFT SPEED/TIMING+
J402 P402 28
BOTTOM CAMSHAFT ENGINE
29
ENGINE COOLANT SPEED/TIMING SENSOR
30
TEMPERATURE ENGINE COOLANT TEMPERATURE 1 995-BU
31
SENSOR ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK
43
130-9811 J100 P100 22
INLET AIR 23
ENGINE K995-OR HEATER RELAY 56
INLET AIR J501 P501 57
ENGINE INTAKE MANIFOLD AIR TEMPERATURE 1 C967-BU
TEMPERATURE 1 C987-RD 65
ENGINE TEMPERATURE SENSOR COMMON 2 G833-PK
SENSOR 2 G850-BU G850-BU 8 INLET AIR HEATER RELAY

ENGINE CONTROL MODULE

130-9811 J103 P103 69
N/O
20
RELAY
INLET AIR 66
(+) BATTERY SUPPLY WIRES INLET AIR 60
HEATER GROUND
HEATER
STRAP
INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE P648

B G850-BU
SIGNAL PLUS A C987-RD
COMPONENTS ARE SHOWN WITH THE KEY OFF
SIGNAL MINUS UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 18 AWG OR LARGER SAE J1560 TYPE TXL
(-) BATTERY / SENSOR RETURN OR EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE J1708.

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 B
HEATER LAMP A
C987-RD J648

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

CHECK ENGINE
N/O LAMP L994-YL
RELAY
K995-OR

C987-RD

ENGINE CONTROL MODULE

WARNING LAMP
659-PK 659-PK 29 WARNING LAMP
KEY SWITCH FAST IDLE L994-YL 28 CHECK ENGINE LAMP
OFF ENABLED LAMP K998-BU 30 OUTPUT #1
ON OR NOTE A
G880-PK G880-PK 31 OUTPUT #9
START WAIT TO 48
START LAMP 61
E718-PK 10 OUTPUT #2
E991-GY 12 OUTPUT #3
EXHAUST BRAKE FLYBACK NOTE A G836-WH 13 OUTPUT #4
EXHAUST BRAKE ON/OFF SWITCH
SOLENOID DIODE 15
C981-GY 16 EXHAUST BRAKE ON/OFF SWITCH
NOTE A 63
SIGNAL+ C974-PU C974-PU 36 SPEEDOMETER POSITIVE
SPEEDOMETER
ALTERNATOR STARTER C973-GN 37 SPEEDOMETER NEGATIVE
NOTE A
MOTOR SIGNAL- C973-GN NOTE A 27
GROUND (12V) 26
9 PIN CAB 993-BR 3 INPUT SENSOR COMMON #2
CONNECTOR SIGNAL+ 450-YL F713-OR 17 INPUT #14
TACHOMETER
+BAT. B 450-YL 38 TACHOMETER POSITIVE
NOTE A
-BAT. A SIGNAL- 451-BR 451-BR 39 TACHOMETER NEGATIVE
J NOTE A 57
H 43
J1587 - G E793-BU E793-BU 9 J1587 DATA LINK NEGATIVE
- 12V + - 12V + - 12V + J1587 + F E794-YL E794-YL 8 J1587 DATA LINK POSITIVE
J1939 SHIELD E A249-BK A249-BK 42 J1939 DATA LINK SHIELD
NOTE A
J1939 - D K990-GN K990-GN 34 J1939 DATA LINK NEGATIVE
BATTERY 3 BATTERY 2 BATTERY 1
J1939 + C K900-YL K900-YL 50 J1939 DATA LINK POSITIVE
NOTE A 1
14
J906-BR 70 IGNITION KEY SWITCH
NOTE A 25
TO ALLISON AT/MT/HT SHIFT 14 AWG GXL
101-RD 52 UNSWITCHED +BATTERY
MODULATOR FOR AUTOMATIC 14 AWG GXL
101-RD 53 UNSWITCHED +BATTERY
TRANSMISSIONS 20A 14 AWG GXL
229-BK 65 -BATTERY
ENGINE 14 AWG GXL
229-BK 67 -BATTERY
BLOCK
G838-BR 19 OUTPUT #6
NOTE A
G839-BU 20 OUTPUT #7
NOTE A 51
NOTE A C978-BR C978-BR 35 SET
H795-PK
C979-OR C979-OR 44 RESUME
K999-GN 56 INPUT #1 (PTO ON/OFF SWITCH)
SET/RESUME SWITCH FAST IDLE ENABLE SWITCH
K980-PK 58 INPUT #2
NOTE A N/O MOMENTARY SWITCH
H795-PK L902-GN L902-GN 40 INPUT #18
G840-PU 21 OUTPUT #8
NOTE A
H795-PK C975-WH C975-WH 59 CRUISE CONTROL ON/OFF SWITCH
K982-YL 60 INPUT #3
CRUISE CONTROL ON/OFF SWITCH SERVICE BRAKE PEDAL POSITION SWITCH N/C
G841-GN 7 INPUT #4
H795-PK C992-PU C992-PU 45 SERVICE BRAKE PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) 55
SERVICE BRAKE PEDAL POSITION SWITCH #2 N/O
+BAT. G842-GY 47 INPUT #5
(PEDAL RELEASED POSITION)
G882-WH G882-WH 64 INPUT #13
NOTE A G843-OR 6 INPUT #6
CLUTCH PEDAL POSITION SWITCH N/C
L901-GY 18 INPUT SENSOR COMMON #1
NOTE A
H795-PK C977-BU C977-BU 22 CLUTCH PEDAL POSITION SWITCH
(PEDAL RELEASED POSITION) 23
DIAGNOSTIC ENABLE SWITCH
G879-OR 2 +5V
NOTE A
H795-PK G844-PK G844-PK 46 INPUT #7
C983-WH 49 ENGINE COOLANT LEVEL NORMAL
N/O MOMENTARY SWITCH TRANSMISSION NEUTRAL SWITCH N/O
+BAT. C984-YL 54 ENGINE COOLANT LEVEL LOW
(TRANSMISSION IN GEAR)
A/C HIGH PRESSURE SWITCH N/C 409-OR 409-OR 62 INPUT #12
NOTE A
SENR9638-00

24
NOTE A
H795-PK E971-GN E971-GN 41 INPUT #11
69
PASSIVE MAGNETIC
G808-BU 1 G808-BU 32 VEHICLE SPEED IN POSITIVE
VEHICLE SPEED
G809-GN 2 G809-GN 33 VEHICLE SPEED IN NEGATIVE
COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED SENSOR
G845-PU 68 INPUT #8 (REMOTE ACCELERATOR)
ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON BK B H795-PK H795-PK 5 AP SENSOR/SWITCH SENSOR COMMON
+8 V RD A C985-BU C985-BU 4 +8V
ACCELERATOR PEDAL POSITION WH C C986-BR C986-BR 66 ACCELERATOR PEDAL POSITION
J403 P403 COOLING FAN SOLENOID G837-YL 11 OUTPUT #5
SENSOR ACCELERATOR ARC
PEDAL POSITION NOTE A P1 J1
SUPPRESSOR
VEHICLE HARNESS CONNECTOR

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

1 2 3 4 5 6
UNIT
INJECTOR #6

ATMOSPHERIC
PRESSURE
INJECTOR HARNESS SENSOR
GROMMET NOTE A

INJECTION ACTUATION
PRESSURE SENSOR

INJECTION ACTUATION
PRESSURE CONTROL VALVE INLET AIR
(INTEGRAL TO PUMP) HEATER
GROUND STRAP
BOOST
PRESSURE
SENSOR

INLET AIR HEATER INLET AIR INLET AIR HEATER

RELAY TEMPERATURE
SENSOR

INLET AIR HEATER

LAMP CONNECTOR

INJECTOR HARNESS
GROMMET

INJECTION ACTUATION
PRESSURE CONTROL VALVE
(INTEGRAL TO PUMP)
ENGINE GROUND
STUD CONNECTION

COOLANT TEMPERATURE
SENSOR

VEHICLE HARNESS
SPEED / TIMING CONNECTOR
SENSORS J1/P1

OIL PRESSURE
SENSOR ENGINE HARNESS
NOTE A CONNECTOR
J2/P2

ENGINE CONTROL
MODULE

OIL LEVEL
SWITCH
NOTE A

LEFT SIDE VIEW