3126B INDUSTRIAL ENGINE ELECTRICAL SCHEMATIC

SENR9590-01

July 2001

3126B

Industrial Engine

Electrical System

BEJ1-UP

DCS1-UP

Timing Calibration

Probe Connector

Engine Oil

Pressure Sensor

Atmospheric

Pressure Sensor

Fuel

Pressure Sensor

Engine Oil

Temperature Sensor

6 Electronic

Unit Injectors

J401/P401

J100/P100

P101/J101

J103/P103

J402/P402

P300/J300

P209/J209

P203/J203

J201/P201

J200/P200

P400

J500/P500

P204/J204

Injection Actuation

Pressure Sensor

Battery

Disconnect

Switch

15 Amp

Breaker

15 Amp

Breaker

Keyswitch

Warning Lamp

Diagnostic Lamp

Engine Service

Caterpillar Supplied

Tool Connector

Customer Installed

Service Tool

Connector

Throttle

Position Sensor

Coolant

Level Sensor

Auxiliary

Temperature Sensor

Auxiliary

Pressure Sensor

P220/J220

P800/J800

J403/P403

J66

J63

J61

P61

J1939

Terminating

Resistor

P142/J142

Battery

12 or 24VDC

Maintenance

Due Lamp

Engine Monitoring

System (EMS)

Display Modules

OEM Installed Switches:

PTO Enable

PTO Ramp Up/Down

PTO Interrupt

Remote Shutdown

Starting Aid Override

Overspeed Verify

Intermediate Engine Speed

Maintenance Due Reset

Torque Limit

Inlet Air Shutoff

Solenoid

Inlet Air Heater

Air Inlet

Ground Stud

J1939

Terminating

Resistor

SMMS

NOTE:

Components within

this area are

recommendations

Customer

Connector

Turbo Outlet

(Intake Manifold Air)

Pressure Sensor

Engine Coolant

Temperature Sensor

Intake Manifold Air

Temperature Sensor

Electronic Control Module (ECM)

Injection Actuation

Pressure Control

Valve (IAPCV)

Primary Engine

Speed/Timing Sensor

Secondary Engine

Speed/Timing Sensor

2001 Caterpillar

Printed in U.S.A.

Harness Side

ECM Connector P1

ECM Connector P2

Harness Side

ECMSide

ECM AMP Connectors

Electronics

Ground Stud

Inlet Air Heater Breaker

Inlet Air Heater

Relay

To ECM J2/P2

Inlet Air Shutoff Relay

LEFT SIDE VIEW

Engine Oil

Pressure

Sensor

Engine Oil

Pressure

Sensor

(Optional Location)

Fuel

Pressure

Sensor

(Optional Location)

Intake Manifold

Air Temperature

Sensor

Primary

Speed/Timing

Sensor

Secondary

Speed/Timing

Sensor

Injection

Actuation

Pressure

Control Valve

(IAPCV)

Injector

Harness

Grommet

Atmospheric

Pressure

Sensor

Intake Manifold

Air Temperature

Sensor

Injection

Actuation

Pressure

Sensor

Engine Coolant

Injector

Harness

Connector

P300/J300

Inlet Air

Heater

Relay

Temperature

Sensor

Engine Oil

Temperature

Sensor

ECM

Ground

Strap

Connector

J2/P2

ECM

Connector

J1/P1

Turbo Outlet

Pressure Sensor

(Intake Manifold Air)

Service Tool

Caterpillar Supplied

Connector

J63

Customer

Electronics

Ground

Stud

Fuel

Pressure

Sensor

Connector

J61

Probe

Timing Calibration

Connector

P400

Electronic

Control

Module

(ECM)

DEVICE

120

ABC

(165-0201)

TERMINATION

RESISTOR

(134-2540)

(NOTE B & C)

(NOTE B)

(165-0200)

BABC

ABC

MAX LENGTH 1 METER

(153-2707)

(NOTES B & E)

120

B AC

TERMINATION

RESISTOR

(134-2540)

(NOTE B & C)

J63

(NOTE A)

229/BK

893/GN

892/BR

A234/BK

K990/GN

K900/YL

ELECTRONICS

GROUND STUD

120/YL A

MAX LENGTH 40 METERS

-BAT.

CAT DATA LINK +

CAT DATA LINK -

J1939 SHIELD

J1939 DATA -

J1939 DATA +

+BAT.

CAT SUPPLIED

ENGINE SERVICE TOOL

CONNECTOR

OPTIONAL REMOTE

TACHOMETER MODULE OR

QUAD GAUGE MODULE

(NOTES G & B)

G850/BUINLET AIR HEATER

C987/RD

IAH RELAY RETURN

INLET AIR

HEATER

INLET AIR

HEATER

RELAY

G850/BU

C987/RD

G850/BU

C987/RD

QUAD GAUGE MODULE

(NOTE G)

OPTIONAL EMS DISPLAY MODULES

RPM X100

TACHOMETER MODULE

(NOTE G)

MAIN EMS MODULE

(NOTE G)

(NOTE F)

+24V

MODULE DATA

+V MODULE

MODULE CLOCK

MODULE LOAD

-BAT

US/METRIC

SCROLL FORWARD

CAT DATA LINK -

AUXILIARY CKT

WARNING LAMP

WARNING

SCROLL BACKWARD

BACKLIGHT LAMP PWR

MODULE DATA

+V MODULE

MODULE CLOCK

MODULE LOAD

-BAT

CAT DATA LINK +

AIR INLET

GROUND STUD

GROUND

STRAP

INJECTOR

CYLINDER

NO.1

P301/J301

INJECTOR

CYLINDER

NO.2

P302/J302

INJECTOR

CYLINDER

NO.3

P303/J303

INJECTOR

CYLINDER

NO.4

P304/J304

INJECTOR

CYLINDER

NO.5

P305/J305

INJECTOR

CYLINDER

NO.6

P306/J306

PRIMARY

SPEED/TIMING SENSOR

TURBO OUTLET

PRESSURE SENSOR

(INTAKE MANIFOLD AIR)

(161-9928)

ENGINE COOLANT

TEMPERATURE SENSOR

(130-9811)

SECONDARY

SPEED/TIMING SENSOR

1E963/BK

P401/J401

+5V

E965/BU

E966/YL

E964/WH

G828/WH

A746/PK

G829/GN

995/BU

G833/PK

P200/J200

P100/J100

P402/J402

SIGNAL

RETURN

SIGNAL

COMMON

SIGNAL -

SIGNAL +

SIGNAL -

SIGNAL +

ENGINE OIL PRESSURE

SENSOR

(161-1705)

ATMOSPHERIC PRESSURE

SENSOR

(161-9925 NOTE S)

(163-8530 NOTE T)

ENGINE OIL

TEMPERATURE SENSOR

(191-6587)

INTAKE MANIFOLD AIR

TEMPERATURE SENSOR

(130-9811)

FUEL PRESSURE SENSOR

(161-9931)

+5V

AG828/WH

994/GY

G828/WH

A747/GY

G829/GN

1401/BU

G833/PK

G828/WH

G829/GN B

J209/P209

J101/P101

P201/J201

J203/P203

413/BR

G829/GN

C967/BU

G833/PK

P103/J103

SIGNAL

RETURN

SIGNAL

RETURN

SIGNAL

RETURN

SIGNAL

COMMON

SIGNAL

COMMON

L983/WH

L984/OR

L985/YL

A706/GY

A705/BU

J300/P300

INJECTOR HARNESS

GROMMET

A704/GN

A703/BR

A702/PU

A701/GY

TIMING

CALIBRATION

PROBE

CONNECTOR

G857/YL

G856/WH

P400

J2/P2

INJECTOR COMMON 1 & 2

INJECTOR COMMON 3 & 4

INJECTOR COMMON 5 & 6

INJECTOR 6

INJECTOR 5

INJECTOR 4

INJECTOR 3

INJECTOR 2

INJECTOR 1

TIMING CALIBRATION PROBE -

TIMING CALIBRATION PROBE +

PRIMARY SP/TMG SIG -

UNUSED

PRIMARY SP/TMG SIG +

SECONDARY SP/TMG SIG -

SECONDARY SP/TMG SIG +

COOL. TEMP. SNSR

PASSIVE SNSR COMMON

ANALOG SNSR POWER (+5V)

ANALOG SNSR COMMON

TURBO OUTLET PRESS. SNSR

ATMOSPHERIC PRESS. SNSR

ENG OIL PRESS. SNSR

UNUSED

FUEL PRESS. SNSR

INTAKE MANIF. AIR TEMP. SNSR

UNUSED

L983/WH

L984/OR

L985/YL

A706/GY

A705/BU

A704/GN

A703/BR

A702/PU

A701/GY

G857/YL

G856/WH

E963/BK

E964/WH

E965/BU

E966/YL

995/BU

G833/PK

G828/WH

G829/GN

A746/PK

A747/GY

994/GY

413/BR

C967/BU

UNUSED

No. Function Wire Ident

1 +Bat. (Unswitched) 150/OR

2 Torque Limit Switch M909/GN

3 N/C¹ T936/GN

4 Inlet Air Shutoff Solenoid Relay G971/BR

5 Solenoid Common G969/YL

6 Cat Data Link - 892/BR

7 Cat Data Link + 893/GN

8 Digital Sensor Power (+8V) 167/OR

9 Digital Sensor Return A274/BK

10 Throttle Position Sensor A307/GY

11 Auxiliary Temperature Sensor G488/GN

12 Maintenance Due Reset Switch F426/BU

13 Maintenance Due Lamp F424/YL

14 Analog Sensor Power (+5V) 125/OR

15 Analog Sensor Return T993/BR

16 J1939 Shield A234/BK

17 J1939 Data + K900/YL

18 J1939 Data - K990/GN

19 PTO Interrupt Switch M904/OR

20 N/C¹ 450/YL

21 N/C¹ 451/BR

382/PK

22 N/C¹

23 N/C¹ J983/YL

24 Diagnostic Lamp F404/RD

25 Warning Lamp F420/GN

26 +Bat. (Switched) 120/YL

27 Remote Shutdown Switch F716/WH

28 Intermediate Engine Speed Switch G968/WH

29 PTO Enable Switch 381/PU

30 PTO Ramp Up/Set Switch G955/GN

31 +Bat. (Unswitched) 150/OR

32 +Bat. (Unswitched) 150/OR

33 Auxiliary Pressure Sensor G469/BU

34 N/C¹ H407/YL

35 N/C¹ E798/PK

36 Coolant Level Sensor E452/WH

37 N/C¹ H405/BU

38 Starting Aid Override Switch M910/OR

39 PTO Ramp Down/Resume Switch G967/WH

40 75% Overspeed Verify Switch 387/PK

J61 Customer Pin Out

ENGINE OIL TEMP. SNSR 34

IAP CONTROL VALVE - 62

IAP CONTROL VALVE + 61

INJ. ACTUATION PRESS. SNSR 27

INJECTOR ACTUATION

PRESSURE SENSOR

(167-1708)

+5V

G828/WH

J204/P204

G849/BR

G829/GN

SIGNAL

RETURN

P800/J800

P142/J142

P220/J220

J403/P403

INJECTOR ACTUATION

PRESSURE CONTROL VALVE

(IAPCV)

1G854/PK

G855/PU

P500/J500

SIGNAL +

SIGNAL -

J501/P501

G849/BR

G854/PK

G855/PU

401/BU

(169-3300)

¹ This terminal is for future expansion. Install an 8T-8737 Seal Plug.

3 4 5 6 7 8 9 10

11 12 13 14 15 16 17 18 19 20

26 27 28 29 30

36 37 38 39

Customer Connector J61

Terminal Side

Customer Connector P61

123456789

11121314151617181920

2627282930

36373839

DT Connector Receptacle DT Connector Plug

Plug Wedge

Receptacle Wedge

HD Connector Receptacle

HD Connector Plug

Pin Contact

Sealing Plug

Socket Contact

Speed/Timing Sensor Connectors

150 Series Receptacle

IAPCV Connector

150 Series Plug

ELECTRONIC CONTROL MODULE (ECM)

-BAT.

ABBREVIATION

WIRE CODE

ALT ALTERNATOR

CB CIRCUIT BREAKER

CIS CUSTOMER IGNITION SWITCH

DIG DIGITAL

ECM ELECTRONIC CONTROL MODULE

N/C NO CONNECTION

PWM PULSE WIDTH MODULATION

SM STARTING MOTOR

SMMS START MOTOR MAG SWITCH

ATA AMERICAN TRUCKING ASSOCIATION

CUSTOMER SUPPLIED WIRING

NOTE B: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL

NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST

HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS

CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL

NOTE C: MAXIMUM LENGTH OF DATA BUS (TERMINATION RESISTOR

TO TERMINATION RESISTOR) IS 40 METERS

INSTALLATION DETAILS

NOTE L: 12 VOLT BATTERY SYSTEMS MUST USE THE DC/DC CONVERTER

FOR THE EMS TO OPERATE PROPERLY. 24 VOLT SYSTEMS

SHOULD CONNECT SWITCHED BATTERY DIRECT TO PINS

1 & 2 ON THE 12 PIN EMS HARNESS CUSTOMER CONNECTOR

NOTE K: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY (-)

THE ECM DISABLES THE FUEL INJECTION SIGNAL. THIS

ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE LEAVING

THE ECM POWERED TO MONITOR ENGINE DIAGNOSTICS

NOTE H: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.

IF METRIC UNITS ARE REQUIRED NO CONNECTION IS NEEDED.

IF U.S. UNITS ARE REQUIRED, A PERMANENT CONNECTION TO

BATTERY (-) IS REQUIRED

NOTE G: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED MONITORING

STATION. THE TACHOMETER AND/OR QUAD GAUGE UNITS ARE

OPTIONAL AND WILL NOT OPERATE WITHOUT CONNECTION TO

A MAIN EMS MODULE

NOTE F: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR

MUST BE CONNECTED TO BATTERY (-) FOR PROPER OPERATION

NOTE E: USE RECOMMENDED CABLE OR EQUIVALENT PER SAE J1939

SPECIFICATIONS FOR ALL J1939 DATA LINK CONNECTIONS

NOTE D: PLACE APPROPRIATE CIRCUIT PROTECTION

OTHER THAN UNDERGROUND MINING

NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY WIRES

WITHOUT CATERPILLAR ENGINEERING APPROVAL

UNLESS OTHERWISE SPECIFIED:

ALL WIRES TO BE 16 AWG OR LARGER SAE J1128 TYPE SXL OR

EQUIVALENT. FOR TWISTED PAIR SPECIFICATION SEE SAE J1708

ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE CERTAIN

ENGINE FEATURES. CONTACT CATERPILLAR ENGINEERING WHEN

CONSIDERING COMPONENT REMOVAL

NOTE T: USE THIS SENSOR FOR UNDERGROUND MINING APPLICATIONS ONLY

NOTE S: USE THIS SENSOR FOR ALL INDUSTRIAL APPLICATIONS

AUXILIARY

TEMPERATURE

SENSOR

(131-0427)

AUXILIARY

PRESSURE

SENSOR

(161-9932)

THROTTLE

POSITION

SENSOR

(161-8906)

+8V

SIGNAL

RETURN

SIG

+ BAT.

- BAT.

RETURN

+5V

SIGNAL

RETURN

SIGNAL

COOLANT LEVEL

SENSOR

(165-6634)

OFF ENGINE

REMOTE SHUTDOWN SW (NOTE K)

TORQUE LIMIT SW

MAINTENANCE DUE RESET SW

STARTING AID OVERRIDE SW

PTO RAMP

UP/DOWN SWITCH

MAINTENANCE

DUE LAMP

PTO ENABLE SW

PTO INTERRUPT SW

OVERSPEED VERIFY SW

INTERMEDIATE ENGINE SPEED SW

4 AWG

(NOTE B)

14 AWG

(NOTE B)

14 AWG

(NOTE B)

OFF

KEYSWITCH

ALTERNATOR

SMMS

GND

BAT

15A

100A WITH 130A PEAK AT 11V

14 AWG

MTR

BATTERY

STARTING

MOTOR

10 AWG

J1/P1

UNUSED

(NOTE D)

J61/P61

+BAT. (UNSWITCHED)

AIR SHUTOFF SOLENOID RELAY

SOLENOID COMMON

AUXILIARY TEMP SNSR

COOLANT LEVEL SNSR

DIG SNSR PWR (+8V)

DIG SNSR RETURN

AUXILIARY PRESS. SNSR

THROTTLE POSITION SNSR

ANLG SNSR PWR (+5V)

ANLG SNSR RETURN

STARTING AID OVERRIDE SW

MAINTENANCE DUE RESET SW

TORQUE LIMIT SW

REMOTE SHUTDOWN SW

INTERMEDIATE ENGINE SPEED SW

75% OVERSPEED VERIFY SW

PTO INTERRUPT SW

PTO ENABLE SW

PTO RAMP UP/SET SW

PTO RAMP DOWN/RESUME SW

MAINTENANCE DUE LAMP

DIAGNOSTIC LAMP

WARNING LAMP

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

CAT DATA LINK -

CAT DATA LINK +

451/BR

150/OR

125/OR

167/OR

T993/BR

382/PK

M910/OR

F426/BU

E798/PK

G971/BR

G969/YL

G488/GN

E452/WH

A274/BK

G469/BU

A307/GY

387/PK

381/PU

120/YL

892/BR

893/GN

450/YL

M909/GN

F716/WH

G968/WH

M904/OR

T936/GN

G955/GN

G967/WH

F424/YL

F404/RD

F420/GN

15A

CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS

ANLG SNSR RETURN

STARTING AID OVERRIDE SW

MAINTENANCE DUE RESET SW

TORQUE LIMIT SW

REMOTE SHUTDOWN SW

INTERMEDIATE ENG. SPEED SW

OVERSPEED VERIFY SW

PTO INTERRUPT SW

PTO ENABLE SW

1.5A DIGITAL OUT 4 HS

PTO RAMP UP SW

PTO RAMP DOWN SW

MAINTENANCE DUE LAMP

DIAGNOSTIC LAMP

WARNING LAMP

TACHOMETER +

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

PWM OUTPUT 3

TACHOMETER -

+BAT.(UNSWITCHED)

AIR SHUTOFF SOLENOID

SOLENOID COMMON

AUXILIARY TEMP SNSR

COOLANT LEVEL SNSR

DIG SNSR PWR (+8V)

DIG SNSR RETURN

AUXILIARY PRESS. SNSR

THROTTLE POSITION SNSR

ANLG SNSR PWR (+5V)

A + BAT.

DIAGNOSTIC LAMP

WARNING LAMP

CAT DATA LINK -

CAT DATA LINK +

- BAT.B

(J66)

CUST. SUPPLIED ENG

SERVICE TOOL CONN

OPTIONAL

+BAT. (UNSWITCHED)

J1939 SHIELD

J1939 DATA +

J1939 DATA -

150/OR

229/BK

J983/YL

H407/YL

H406/GY

H405/BU

A234/BK

K900/YL

K990/GN

PASSIVE/ACTIVE ANLG 8

+BAT.(UNSWITCHED)

SWITCH INPUT 5

SWITCH INPUT 11

SWITCH INPUT 10

J1939 SHIELD

J1939 DATA +

J1939 DATA -

MAX LENGTH 30 METERS

21 NC229/BK-BAT.

-BAT.

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

-BAT.

+BAT. (SWITCHED)

CAT DATA LINK -

CAT DATA LINK +

-BAT.

(NOTE H)

+24V

- BAT.

US/METRIC

SCROLL FORWARD

CAT DATA LINK -

+V OUT

+V IN

-V OUT

-V IN

DC/DC CONVERTER

(127-8853)

(NOTES B & L)

UNUSED

WARNING LAMP

WARNING

SCROLL BACKWARD

(NOTE B)

BACKLIGHT LAMP PWR

CAT DATA LINK + 6

INPUT SIGNAL WIRES TO ECM

OUTPUT SIGNAL WIRES FROM ECM

SENSOR SUPPLY VOLTAGE

(+) BATTERY SUPPLY WIRES

SIGNAL PLUS

(-) BATTERY / SENSOR RETURN

SIGNAL MINUS

ECM

GROUND

STRAP

ECM

MOUNTING

BOLT

INLET AIR SHUTOFF

SOLENOID RELAY

(NOTE V)

BATTERY

DISCONNECT

SWITCH

INLET AIR SHUTOFF

SOLENOID (NOTE V)

NOTE V: ARC SUPPRESSION DIODES ARE REQUIRED

ON RELAY COILS AND SOLENOID COILS.