Inlet Air Heater

TOP VIEW
Inlet Air Heater Lamp Connector P40 Intake Manifold Air Temperature Sensor

Boost Pressure Sensor

Unit Injector Cylinder #6

Coolant Temperature Sensor 1 2 3 4 5 6

High Pressure Pump Engine Oil Temperature Sensor Injection Actuation Pressure Sensor

Injector Harness Grommet Electronic Control Module (ECM) Timing Calibration Probe Connector J24/P24

Injection Actuation Pressure Control Valve (IAPCV)

1BW1-UP

3126 Truck Engine Electrical System

SENR9628 November 2001

2001 Caterpillar All Rights Reserved

High Pressure Pump
* *

Injection Actuation Pressure Control Valve (IAPCV)

Engine Oil Temperature Sensor

Injection Actuation Pressure Sensor

Intake Manifold Air Temperature Sensor

Injector Harness Grommet

Top Speed/Timing Sensor

Ground Stud

Timing Calibration Probe Connector J24/P24

Bottom Speed/Timing Sensor

Printed in U.S.A.

ECM Ground Strap

Electronic Control Module (ECM) ECM Vehicle Harness Connector J1/P1

LEFT SIDE VIEW

ECM Engine Harness Connector J2/P2

INJECTOR HARNESS GROMMET

A B A701-GY A721-WH A B A702-PU A722-YL

P2 J2 A701-GY A721-WH A702-PU A722-YL A703-BR A723-OR A704-GN A724-WH A705-BU A725-YL A706-GY A726-OR D784-BU D810-PU D811-YL D785-GN D797-PK D798-BK E963-BK E964-WH 6 5 12 11 18 17 22 21 28 27 34 33 40 39 4 10 19 13 1 8 9 37 29 25 15 3 23 24 14 2 32 7 16 26 30 36 38 20 35 31

ELECTRONIC CONTROL MODULE (ECM)

INJECTOR 1 INJECTOR COMMON 1 INJECTOR 2 INJECTOR COMMON 2 INJECTOR 3 INJECTOR COMMON 3 INJECTOR 4 INJECTOR COMMON 4 INJECTOR 5 INJECTOR COMMON 5 INJECTOR 6 INJECTOR COMMON 6 VEHICLE SPEED OUT+ VEH SP IN+/TDC PROBE+ VEH SP IN-/TDC PROBEVEHICLE SPEED OUTINJ ACTUATION PRESS. CONT VALVE IAP CONT VALVE COMMON ENG SP/TMG #1ENG SP/TMG #1+

J29 P29

J30 P30 CYL NO.1

A B

A703-BR A723-OR

J31 P31 CYL NO.2

A B

A704-GN A724-WH

J32 P32 CYL NO.3

A B

A705-BU A725-YL

J33 P33 CYL NO.4

A B

A706-GY A726-OR TIMING CALIBRATION PROBE CONNECTOR A D797-PK B D798-BK J36 P36

J34 P34 CYL NO.5

J24 P24 1 2

CYL NO.6 A B P9 A B P4 E965-BU E966-YL E963-BK E964-WH

INJECTION ACTUATION PRESSURE CONTROL VALVE

TOP SPEED/TIMING SENSOR

ENGINE SPEED / TIMING ENGINE SPEED / TIMING + J9

BOTTOM SPEED/TIMING SENSOR

ENGINE SPEED / TIMING ENGINE SPEED / TIMING + J4

E965-BU E966-YL A746-PK D841-GN 995-BU C967-BU E795-YL

ENG SP/TMG #2ENG SP/TMG #2+ BOOST PRESSURE INJ ACTUATION PRESS. COOLANT TEMP INTAKE MANF AIR TEMP OIL TEMP

BOOST PRESSURE SENSOR

BOOST PRESSURE SENSOR COMMON +5V

GN YL OR

C A746-PK B 993-BR A 997-OR P3 J3

993-BR 997-OR

SENSOR COMMON +5V

INJECTION ACTUATION PRESSURE SENSOR

D796-OR INJ ACTUATION PRESS. SENSOR COMMON +5V GN YL OR C B A D841-GN 993-BR 997-OR

INLET AIR HEATER

P35 J35

COOLANT TEMPERATURE SENSOR

COOLANT TEMP SENSOR COMMON +5V

WH BK OR

C B A J10 P10

995-BU 993-BR 997-OR

INTAKE MANIFOLD AIR TEMPERATURE SENSOR

INTAKE MANF AIR TEMP SENSOR COMMON +5V

WH BK OR

C B A J21 P21

C967-BU 993-BR 997-OR

INLET AIR HEATER RELAY J37 P37 D812-RD 1 D796-OR 2 N/O D812-RD D796-OR

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

ENGINE OIL TEMPERATURE SENSOR

ENGINE OIL TEMP SENSOR COMMON +5V

WH BK OR

C B A J51 P51

E795-YL 993-BR 997-OR

INLET AIR HEATER

TO +BATTERY

TO ENGINE CYL HEAD (NOT CYL HEAD GND STUD) INLET AIR HEATER GROUND STRAP

469 468 469 468

LAV B A B A APC

P40 B D796-OR A D812-RD CONNECTED TO LAV HARNESS OR APC HARNESS

ECM GND STRAP TO ECM MOUNTING BOLT

TO POWER PACK INTERFACE

C B K L M N P R S T U V W X Y Z E A A F B C D D E F G H J

C B K L M N P R S T U V W X Y Z E A A F B C D D E F G H J

469 468

LAV INTERFACE HARNESS

570 571 572 573 574 575 89 577 578 586 585 579 581 580 581 580 35 30 37 40 38 14 2 29 22 7 1 18 5 28 4 6 3 8 9 10 11 12 13 15 16 17 19 20 21 23 24 25 26 27 31 32 33 34 36 39 P6 +8V MULTI-FUNCTION SENSOR COMMON THROTTLE POSITION EXHAUST BRAKE XMSN NEUTRAL SW SERVICE BRAKE SW #1 FAST IDLE ENABLE SW SENSOR COMMON CHECK ENGINE LAMP ATA DATA LINK+ (J1587) ATA DATA LINK- (J1587) VEHICLE SPEED IN+ -BATTERY +BATTERY -BATTERY +BATTERY

TO VEHICLE COMPONENTS

FROM (J1) ELECTRONIC CONTROL MODULE (ENGINE)

J2 P1

ENGINE BULKHEAD

TO POWER PACK INTERFACE J1

C B K L M N P R S T U V W X Y Z e A a f b c D d E F G H J

C B K L M N P R S T U V W X Y Z e A a f b c D d E F G H J

469 468

APC INTERFACE HARNESS

570 571 572 573 574 575 576 577 578 142 151 579 581 580 581 580 35 30 37 40 38 14 2 29 22 7 1 18 5 28 4 6 3 8 9 10 11 12 13 15 16 17 19 20 21 23 24 25 26 27 31 32 33 34 36 39 P1 J1 +8V MULTI-FUNCTION SENSOR COMMON THROTTLE POSITION EXHAUST BRAKE XMSN NEUTRAL SW SERVICE BRAKE SW #1 FAST IDLE ENABLE SW SENSOR COMMON CHECK ENGINE LAMP ATA DATA LINK+ (J1587) ATA DATA LINK- (J1587) VEHICLE SPEED IN+ -BATTERY +BATTERY -BATTERY +BATTERY 35 30 37 40 38 14 2 29 22 7 1 18 5 28 4 6 3 8 9 CONNECTED TO 10 LAV HARNESS OR 11 APC HARNESS 12 13 15 16 17 19 20 21 23 24 25 26 27 31 32 33 34 36 39 J1 +8V MULTI-FUNCTION SENSOR COMMON THROTTLE POSITION EXHAUST BRAKE XMSN NEUTRAL SW SERVICE BRAKE SW #1 FAST IDLE ENABLE SW SENSOR COMMON CHECK ENGINE LAMP ATA DATA LINK+ (J1587) ATA DATA LINK- (J1587) VEHICLE SPEED IN+ -BATTERY +BATTERY -BATTERY +BATTERY NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT NOT USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED USED

TO VEHICLE COMPONENTS

FROM (J1) ELECTRONIC CONTROL MODULE (ENGINE)

J1 P1

POWER PACK BULKHEAD

ELECTRONIC CONTROL MODULE (ECM)

B A

Inlet Air Heater

Inlet Air Heater Relay

Inlet Air Heater Ground Strap

RIGHT SIDE VIEW

SENR9525 November 1999

Electronic Service Tool Will Not Communicate with the ECM

Engine Cranks, But Will Not Start

Connect Electronic Service Tool to the Cab data link, turn ignition key switch ON, engine OFF. Attempt to establish communications with the ECM.
ECM does not communicate ECM Communicates

Engine Pressure Sensor Open or Short Circuit Test

Connect Electronic Service Tool to Cab Data Link and check for ACTIVE 5 Volt Sensor Supply Code. NO ACTIVE Supply Codes Check for ACTIVE Engine Pressure Sensor OPEN or SHORT Circuit Code. If the code is not ACTIVE and the Engine is not running properly, refer to Troubleshooting Without A Diagnostic Code. ACTIVE Open or Short Circuit Code Check Electrical Connectors and Wiring. Active SHORT Circuit Code Turn the ignition key ON, engine OFF. Disconnect the Sensor Connector with the ACTIVE Short Circuit Code in order to create an Open Circuit condition. Code Changes To OPEN Circuit SHORT Circuit Code Remains ACTIVE Supply Code Refer to +5Volt Pressure Sensor Supply Voltage Circuit Test

Engine Temperature Sensor Open or Short Circuit Test

Connect an Electronic Service Tool and check for an ACTIVE Engine Temperature Sensor OPEN or SHORT Circuit Code. If the code is not ACTIVE and the Engine is not running properly, refer to Troubleshooting Without A Diagnostic Code. ACTIVE Open or Short Circuit Code Check Electrical Connectors and Wiring.

Does not crank, refer to engine will not crank.

Try to start the Engine.

Engine starts, but ECM does not communicate with the Service Tool

Does not start

Repair Service Tool

OK

Connect another Service Tool to the ECM, but use the same Service Tool Cables as in the previous step.
No Communications

Ensure after-market engine protection devices (not installed by Caterpillar) are not active, preventing the ECM or Ignition Key Switch from receiving battery power.
OK

NOT OK

Repair Cables

OK

Refer to Inspecting Electrical Connectors

Connect the Service Tool using a completely different set of Service Tool cables.
No Communications

NOT OK

Active SHORT Circuit Code

Active OPEN Circuit Code With the ignition key On and engine OFF, Install a short circuit between terminal-1 and terminal-2 of the Sensor Connector and check for an ACTIVE Short Circuit code. OPEN Circuit Code Active with jumper SHORT Circuit Code Active with jumper

Refer to Inspecting Electrical Connectors

Active OPEN Circuit Code Measure Sensor Supply Voltage with multimeter. Reading should be within 4.5 to 5.5 VDC range. Supply OK NOT OK Refer to +5Volt Engine Pressure Sensor Supply Voltage Circuit Test

With the ignition key ON and engine OFF, Disconnect the Sensor Connector with the ACTIVE Short Circuit Code in order to create an Open Circuit condition. Code Changes To OPEN Circuit SHORT Circuit Code Remains

Disconnect ECM Connector P1 from the ECM. Use the Service Tool Bypass Harness as indicated in the Ignition Key Switch Circuit Test.
ECM and Service Tool Communicate No Communications

Refer to the Ignition Keyswitch Circuit Test

NOT OK

Check ECM power, ground, and keyswitch connections with the ignition key switch ON. Battery voltage at ECM Connector J1/P1 terminal-52, 53 and 70, to terminal-65 and 67 should be 11.0 -13.5 VDC for a 12 Volt system and 22.0 - 27.0 for a 24 Volt system.
OK

If a Short Circuit code was Active before the sensor was disconnected and an Open Circuit code became Active after the sensor was disconnected then thoroughly inspect the connector for signs of moisture. Inspect the seals and connect the sensor. If the code reappears, the sensor or pigtail harness is the problem. Temporarily connect a new sensor but do not install it into the engine. If the code is no longer Active with the new sensor connected, replace the old sensor.

Install a short circuit between terminal-B and terminal-C of the Sensor Connector and check for an ACTIVE Short Circuit code. OPEN Circuit Code Active with jumper SHORT Circuit Code Active with jumper

If a Short Circuit code was Active before the sensor was disconnected and an Open Circuit code became Active after the sensor was disconnected then thoroughly inspect the connector for signs of moisture. Inspect the seals and connect the sensor. If the code reappears, the sensor is the problem. Temporarily connect a new sensor but do not install it into the engine. If the code is no longer Active with the new sensor connected, replace the old sensor.

If a SHORT Circuit Code appears, temporarily connect the suspect sensor. If an OPEN Circuit code returns, replace the sensor and verify the diagnostic code does not return.

3126B Truck Engine Electrical System

6PZ1-UP 7JZ1-UP

Either the vehicle wiring or another device on the vehicle is causing the communication problem. Connect a test ECM. Turn the Ignition Key ON, engine OFF. If the new ECM communicates and the old ECM does not, reconnect the old ECM and verify the problem returns. If the new ECM communicates and the old ECM does not, replace the ECM. If the new ECM does not communicate, there is a problem with the cables or the battery.

NOT OK Refer to the ECM Memory Test

A new ECM has an unprogrammed Personality Module. The engine will not start or communicate until the Personality Module in the ECM is Flash Programmed.
Not a New ECM

Check the Ignition Key Switch status on the Service Tool. With the Ignition Key Switch ON, the status should display ON. If the status displays OFF, check for voltage from the battery. Battery voltage at ECM Connector J1/P1 terminal-70 to terminal-65 and 67 should be 11.0 -13.5 VDC for a 12 Volt system and 22.0 - 27.0 for a 24 Volt system.
OK NOT Refer OK to the ECM Memory Test NOT OK NOT OK Refer to the Ignition Keyswitch Circuit Test

If the Personality Module has been recently replaced/updated , connect and check for an active 252-11 Incorrect Engine Software.
OK

If a SHORT Circuit Code appears, temporarily connect the suspect sensor. If an OPEN Circuit code returns, replace the sensor and verify the diagnostic code does not return.

Disconnect the ECM Connector J2/P2 and check for Active diagnostic codes. The OPEN Circuit code should be Active with the harness disconnected. Install a jumper (short) between the ECM Connector J2 signal terminal and terminal-18. A SHORT Circuit code should be Active with the jumper installed. OK Remove the sensor signal wire from ECM connector P2 and the sensor connector. Bypass the signal wiring by connecting a wire directly from ECM connector P2 to the sensor connector signal terminal. If the Diagnostic Code disappears with the bypass wire installed, repair or replace the harness. Otherwise, restart the test procedure. NOT OK If the OPEN Circuit code is NOT Active with the harness disconnected, or the SHORT Circuit code is NOT Active with the jumper (short) installed, temporarily install a test ECM. If the test ECM resolves the problem, install the old and verify problem returns. If the test ECM works and the original ECM does not, replace the ECM.

Refer to the Engine Speed/Timing Circuit Test

Observe engine rpm from Electronic Service Tool while cranking the engine. An rpm value should be displayed on the Service Tool.
OK

Disconnect the ECM Connector J2/P2 and check for Active diagnostic codes. The OPEN Circuit code should be Active with the harness disconnected. Install a jumper (short) between the ECM Connector J2 signal terminal and terminal-3. A SHORT Circuit code should be Active with the jumper installed. OK Remove the sensor signal wire from ECM connector P2 and the sensor connector. Bypass the signal wiring by connecting a jumper wire directly from ECM connector P2 to the sensor connector signal terminal. If the Diagnostic Code disappears with the bypass wire installed, repair or replace the harness. Otherwise, restart the test procedure. NOT OK If the OPEN Circuit code is NOT Active with the harness disconnected, or the SHORT Circuit code is NOT Active with the jumper (short) installed, temporarily install a test ECM. If the test ECM resolves the problem, install the old and verify problem returns. If the test ECM works and the original ECM does not, replace the ECM.

If the Truck is equipped with a CAT ID , ensure Theft Deterrent is not Active . Turn the Ignition Key Switch ON, engine OFF, the CAT ID will indicate Theft Deterrent Active.
OK

Monitor the exhaust stack while cranking - if no smoke is present there may be a fuel supply or quality problem. Check fuel pressure, priming, and filters.
OK

NOTE: Refer to the Electronic Troubleshooting Guide for detailed information.

Check for combustion problems, mechanical problems or extreme temperatures.

NOTE: Refer to the Electronic Troubleshooting Guide for detailed information.

NOTE: Refer to the Electronic Troubleshooting Guide for detailed information.

NOTE: Refer to the Electronic Troubleshooting Guide for detailed information.

1999 Caterpillar All Rights Reserved

Printed in U.S.A.

SENR9525-00
8 Page, JVD

3126B ENGINE HARNESS WIRING DIAGRAM

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

INTAKE MANIFOLD 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 50 52 53 60 9 32 35 33 34 26 18 10 11 12 49 48 13 19 20 21 28 29 30 59 58 31 43 51 22 23 56 57 65 66 69 8 INJECTOR COMMON CYLINDERS 1 & 2 INJECTOR COMMON CYLINDERS 3 & 4 INJECTOR COMMON CYLINDERS 5 & 6 INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 INJECTOR CYLINDER 4 INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 INJECTOR CYLINDER 1

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

INJECTOR CYLINDER NO.1

INJECTOR CYLINDER NO.2

INJECTOR CYLINDER NO.3

INJECTOR CYLINDER NO.4

INJECTOR CYLINDER NO.5 A705-BU A704-GN

INJECTOR CYLINDER NO.6

A703-BR A702-PU A701-GY INJECTION ACTUATION PRESSURE CONTROL VALVE ENGINE BOOST PRESSURE ENGINE PRESSURE SENSOR COMMON ENGINE PRESSURE SENSOR +5V GN YL OR C B A A746-PK G829-GN G828-WH A B J500 P500 ENGINE BOOST PRESSURE SENSOR A746-PK G849-BR G854-PK G855-PU

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

J200 P200

A747-GY G829-GN G828-WH

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

ENGINE INJECTION ACTUATION PRESSURE SENSOR

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

GN YL 0R

C B A

G849-BR G829-GN G828-WH 994-GY G827-BU G826-BR A747-GY G829-GN G828-WH

P204 J204

ENGINE OIL PRESSURE SENSOR ENGINE OIL PRESSURE SENSOR COMMON ENGINE OIL PRESSURE SENSOR +5V ECM GROUND STRAP

ENGINE ATMOSPHERIC PRESSURE SENSOR NOTE A

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

GN YL OR

C B A

P203 J203 995-BU C967-BU G846-YL G833-PK TOP CAMSHAFT ENGINE SPEED/TIMING SENSOR

ENGINE OIL PRESSURE SENSOR NOTE A

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

GN YL OR

C B A

994-GY G827-BU G826-BR

TO ECM ENGINE COOLANT TEMPERATURE MOUNTING ENGINE INTAKE MANIFOLD AIR TEMPERATURE BOLT ENGINE OIL TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

P201 J201

ENGINE COOLANT TEMPERATURE SENSOR

ENGINE COOLANT TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

1 2

995-BU G833-PK

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

A B J401 P401

E963-BK E964-WH

TOP CAMSHAFT SPEED/TIMINGTOP CAMSHAFT SPEED/TIMING+

J100 P100

ENGINE INTAKE MANIFOLD AIR TEMPERATURE SENSOR

ENGINE INTAKE MANIFOLD AIR TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

1 2

C967-BU G833-PK

BOTTOM CAMSHAFT ENGINE SPEED/TIMING SENSOR BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+ A B J402 P402 E965-BU E966-YL

J103 P103

BOTTOM CAMSHAFT SPEED/TIMINGBOTTOM CAMSHAFT SPEED/TIMING+

ENGINE OIL TEMPERATURE SENSOR

ENGINE OIL TEMPERATURE ENGINE TEMPERATURE SENSOR COMMON

1 2

G846-YL G833-PK

J101 P101

ENGINE TIMING CALIBRATION PROBE+ ENGINE TIMING CALIBRATION PROBETO INTAKE AIR HEATER CIRCUIT FUSIBLE PROTECTION

A B J400 P400

G856-WH G857-YL

ENGINE TIMING CALIBRATION PROBE+ ENGINE TIMING CALIBRATION PROBE-

(+) 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 SAE J1708 TO ENGINE CYLINDER HEAD (NOT CYLINDER HEAD GROUND STUD) INTAKE AIR HEATER TO CONNECTOR J648 B A N/O RELAY K995-OR

J501 P501 C987-RD 1 G850-BU 2

G850-BU

INTAKE AIR HEATER RELAY

P1 J1 P648 G850-BU C987-RD VEHICLE HARNESS CONNECTOR NOTE A: A DASHED LINE SPECIFIES AN OPTIONAL FEATURE, NOT AVAILABLE ON ALL SYSTEMS.

3126B VEHICLE HARNESS WIRING DIAGRAM

100A WITH 130A PEAK AT 11V

TO INTAKE AIR HEATER RELAY (CONTACT SIDE)

INTAKE AIR HEATER LAMP

B A J648

TO CONNECTOR P648

C987-RD

ENGINE HARNESS CONNECTOR

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS K995-OR C987-RD N/O RELAY CHECK ENGINE LAMP L994-YL P2 J2 WARNING LAMP FAST IDLE ENABLED LAMP

659-PK NOTE A EXHAUST BRAKE ON/OFF SWITCH

OFF ON START

G880-PK

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

KEY SWITCH

EXHAUST BRAKE SOLENOID

FLYBACK DIODE

NOTE A

E718-PK E991-GY G836-WH

SPEEDOMETER NOTE A ALTERNATOR GROUND STARTER MOTOR (12V) CAB DIAGNOSTIC CONNECTOR C E D F J1587 DATA LINK NEGATIVE B E793-BU J1587 DATA LINK POSITIVE A E794-YL TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR TO J1939 DATA LINK CONNECTOR +BAT. -BAT. TACHOMETER NOTE A

SIGNAL+ SIGNAL-

C974-PU C973-GN NOTE A 993-BR F713-OR 450-YL 451-BR NOTE A E793-BU E794-YL A249-BK K990-GN K900-YL C974-PU C973-GN

SIGNAL+ SIGNAL-

450-YL 451-BR

- 12V +

- 12V +

- 12V +

NOTE A

BATTERY 3

BATTERY 2

BATTERY 1

NOTE A

TO ALLISON AT/MT SHIFT MODULATOR FOR MECHANICAL TRANSMISSION 20A

J906-BR 14 AWG GXL 14 AWG GXL 14 AWG GXL 14 AWG GXL NOTE A C978-BR C979-OR FAST IDLE ENABLE SWITCH H795-PK L902-GN N/O MOMENTARY SWITCH 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 G808-BU G809-GN 1 2 G808-BU G809-GN G845-PU H795-PK C985-BU C986-BR G837-YL

ENGINE BLOCK

H795-PK

SET/RESUME NOTE A H795-PK C975-WH SERVICE BRAKE PEDAL POSITION N/C H795-PK (PEDAL RELEASED POSITION) C992-PU

CRUISE CONT ON/OFF

SERVICE BRAKE PEDAL POSITION #2 N/O +BAT. G882-WH NOTE A (PEDAL RELEASED POSITION) NOTE A

CLUTCH PEDAL POSITION N/C H795-PK (PEDAL RELEASED POSITION) C977-BU NOTE A

DIAGNOSTIC ENABLE SWITCH H795-PK G844-PK +BAT. TRANSMISSION NEUTRAL N/O 409-OR (TRANSMISSION IN GEAR) NOTE A

A/C HIGH PRESS. SWITCH N/C NOTE A H795-PK E971-GN

N/O MOMENTARY SWITCH

COMPONENTS WITHIN THIS AREA ARE CATERPILLAR PROVIDED ACCELERATOR PEDAL SENSOR/SWITCH SENSOR COMMON +8 V ACCELERATOR PEDAL POSITION SENSOR ACCELERATOR PEDAL POSITION BK RD WH B A C H795-PK C985-BU C986-BR

J403 P403

COOLING FAN SOLENOID NOTE A

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

WARNING LAMP CHECK ENGINE LAMP OUTPUT #1 OUTPUT #9

OUTPUT #2 OUTPUT #3 OUTPUT #4

SPEEDOMETER POSITIVE SPEEDOMETER NEGATIVE

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

J1587 DATA LINK NEGATIVE J1587 DATA LINK POSITIVE J1939 DATA LINK SHIELD J1939 DATA LINK NEGATIVE J1939 DATA LINK POSITIVE

IGNITION KEY SWITCH UNSWITCHED +BATTERY UNSWITCHED +BATTERY -BATTERY -BATTERY OUTPUT #6 OUTPUT #7 SET RESUME INPUT #1 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 AP SENSOR/SWITCH SENSOR COMMON +8V ACCELERATOR PEDAL POSITION OUTPUT #5

SENR9525-00

8 Page, Color 2, JVD

FLYBACK DIODE

VEHICLE HARNESS CONNECTOR NOTE A: A DASHED LINE SPECIFIES AN OPTIONAL FEATURE, NOT AVAIL ABLE ON ALL SYSTEMS.

ECM AMP Connectors

1 2 3 4 5 6 8 9 10 11 12 13

13 23 31 39 47 57 70

1 14 24 32 40 48 58
14 24

>PEI<

23 31 36

40 48

47 57

58 59 60 61 62 63

65 66 67 68 69 70

ECM Side

Vehicle Harness Connector P1

Harness Side

9 10 11 12 13

13 23 31 39 47 57 70

1 14 24 32 40 48 58
14 24 36 40 48 47 57 >PEI< 23 31

58 59 60 61 62 63

65 66 67 68 69 70

ECM Side

Engine Harness Connector P2

Harness Side

Deutsch DT Connector Receptacle

Deutsch DT Connector Plug

Pressure Sensor Connectors

Temperature Sensor Connectors

123456 654321 Injector Harness Connectors 12 11 10 9 8 7

Diagnostic Code Listing Flash PID-FMI Codes 72 102-07 72 105-03 73 105-04 73 108-03 74 108-04 74 110-00 42 110-03 29 110-04 29 110-11 21 111-01 21 111-02 18 111-11 71 34 34 49 49 01 47 47 41 31 36 36 36 32 28 24 24 46 25 25 164-00 164-02 164-03 164-04 164-11 168-02 175-03 175-04 190-00 190-02 190-11 224-11 224-14 231-11 232-03 232-04 246-11 247-11 252-11 253-02

7 8 9 10 11 12

PID-FMI 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 91-13 100-03 100-04 100-11 102-03 102-04

Description 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 Press Control Valve Driver Fault Ignition Key Switch Fault Loss of Engine RPM Signal on Engine Speed and Timing Sensor Number 2 No Pattern on Engine Speed and Timing Sensor Number 2 Inlet Air Heater Open Circuit Inlet Air Heater Short Circuit Idle Shutdown Override Idle Shutdown Occurrence PTO Shutdown 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 Oil Press Sensor Open Circuit Oil Press Sensor Short Circuit Very Low Oil Press Boost Press Sensor Open Circuit Boost Press Sensor Short Circuit

Description Excessive Boost Pressure Inlet Manifold Air Temp Sensor Open Circuit Inlet Manifold Air Temp Sensor Short Circuit Atmospheric Press Sensor Open Circuit Atmospheric Press Sensor Short Circuit High Coolant Temp Warning Coolant Temp Sensor Open Circuit Coolant Temp Sensor Short Circuit Very High Coolant Temp Low Coolant Level Warning Coolant Level Sensor Fault Very Low Coolant Level Injection Actuation Press Out of Range Injection Actuation Press Sensor Erratic Injection Actuation Press Open Circuit Injection Actuation Press Short Circuit Injection Actuation Press System Intermittent Battery Power to the ECM Oil Temp Sensor Open Circuit Oil Temp Sensor Short Circuit Engine Overspeed Warning Loss of RPM Signal on Engine Speed and Timing Sensor Number 1 No Pattern on Engine Speed and Timing Sensor Number 1 Theft Deterrent Enabled Engine Cranking / Theft Deterrent Enabled J1939 Data Link Fault 5 Volt Supply Above Normal 5 Volt Supply Below Normal Service Brake Switch Number 1 Fault Service Brake Switch Number 2 Fault Incorrect Engine Software Check Customer or System Parameters

Flash Codes 25 38 38 26 26 61 27 27 61 62 12 62 17 15 15 15 39 51 24 24 35 34 34 00 00 58 21 21 00 00 59 59