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• UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE MANUAL FOR TRUCK, TRACTOR, YARD TYPE: 46,662 GVWR, DED, 4 X 2, M878A2
• WARNING SUMMARY
• WARNING SUMMARY-continued
• FOR INFORMATION ON FIRST AID
• WARNING
• WARNING-continued
• WARNING-continued
• WARNING-continued
• WARNING-continued
• WARNING-continued
• WARNING-continued
• TRUCK, TRACTOR, YARD TYPE: 46,662 GVWR, DED, 4 X 2, M878A2 is changed as follows
• LIST OF EFFECTIVE PAGES
• REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
• Table of Contents
• Table of Contents-continued
• Table of Contents-continued
• Table of Contents-continued
• Table of Contents-continued
• HOW TO USE THIS MANUAL
• CONTENTS OF VOLUME I (WORK PACKAGE-FORMATTED MANUAL)
• FEATURES OF VOLUME I (WORK PACKAGE-FORMATTED MANUAL)
• SERVICE, TROUBLESHOOTING, AND REPAIR OF 1090-0800-01 FAN CLUTCH
• INSTALLATION AND SERVICE GUIDE Front Air Fan Drives
• Preventive Maintenance
• Fan Clutch Lining Maintenance
• Troubleshooting Guide
• Fan Clutch Service Parts and Repair
• Rebuild Procedures
• Rebuild Procedures-continued
• Fan and Fan Clutch Torque Specifications
• Figure 1. Normally Closed Fan Clutch Control Circuit
• Specifications 3126E Truck Engine
• Important Safety Information
• Table of Contents
• Engine Design
• Fuel Filter Lines
• Unit Injector
• Valve Mechanism Cover
• Cylinder Head Valves-continued
• Cylinder Head
• Air Inlet Elbow
• Exhaust Elbow
• Engine Oil Filter Base
• Engine Oil Cooler Bypass Valve
• Engine Oil Pan
• Water Pump
• Cylinder Block
• Crankshaft
• Rear Seal Carrier (If Equipped)
• Vibration Damper
• Piston and Rings
• Top Ring and Intermediate Ring
• Piston Cooling Jet
• Front Housing and Covers
• Gear Group (Front)
• Flywheel
• Crankshaft Pulley
• Table 3. Belt Tension Chart
• Belt Tensioner (If Equipped)
• Coolant Temperature Sensor
• Boost Pressure Sensor
• Air Inlet Heater
• Index
• Systems Operation Testing and Adjusting 3126E Truck Engine
• Important Safety Information
• Table of Contents
• Systems Operation Section
• General Information
• Illustration 3 Left side view
• Glossary of Electronic Control Terms
• Desired RPM
• Illustration 4 Example Of Pulse Width Modulation
• Supply Voltage
• Electronic Control System Components
• Illustration 6 Electronic control system components (top view)
• Table 1. Electrical Connectors And Functions
• Table 2. Diagnostic Flash Codes-continued
• Illustration 7. Diagram of Components for the HEUI fuel system
• Component Description
• Unit injector hydraulic pump
• HEUI Fuel System Operation
• The low pressure fuel system
• Injection Actuation System
• Injection Actuation System-continued
• Actuation Oil Pressure Control
• Unit injector hydraulic pump
• Operation of the Injection Actuation Pressure Control Valve
• Valve Operation for ENGINE OFF
• Valve Operation for ENGINE CRANKING
• Oil Flow for ENGINE CRANKING
• Valve Operation for RUNNING ENGINE
• Components of the HEUI Injector
• Illustration 15 Component of the HEUI injector
• Solenoid
• Nozzle Assembly
• Operation of the HEUI Fuel Injector
• Pre-Injection
• Pre-Injection-continued
• Pilot Injection
• Pre-Injection Metering (PRIME)
• Injection Delay
• Injection Delay-continued
• Main Injection
• Main Injection-continued
• End of Injection
• Fuel Heater And Water Separator (If Equipped)
• Air Inlet and Exhaust System
• Turbocharger
• Valve System Components
• Illustration 28 Location Of Components
• Illustration 29 Schematic Of Air Inlet Heater (Typical Example)
• illustration 30 Flow Chart Of Controller Of Air Inlet Heater
• Lubrication System
• Illustration 32 Right Side View Of Engine
• Cooling System
• Illustration 35 Cooling System Schematic
• Coolant For Air Compressor (If Equipped)
• Basic Engine
• Vibration Damper
• Electrical System
• Engine Electrical System
• Testing and Adjusting Section
• Inspection With The Engine Running
• Engine Speed - Check
• Finding Top Center Position for No. 1 Piston
• Fuel Quality - Test
• Fuel System Pressure - Test
• Illustration 48 1U-5470 Engine Pressure Test Group
• Gear Group (Front) - Time
• Unit Injector - Test-continued
• Air Inlet and Exhaust System
• Exhaust Restriction
• Catalytic Converter/Muffler
• Turbocharger - Inspect
• Inspection of the Turbine Wheel and the Turbine Housing
• Table 8. Amount Of Pressure That Is Required To Check The Wastegate Valve
• Inlet Manifold Pressure - Test
• Exhaust Temperature - Test
• Aftercooler Core Leakage
• Air System Restriction
• Engine Crankcase Pressure (Blowby) - Test
• Compression - Test
• Valve Lash and Valve Bridge Adjustment
• Valve Lash and Valve Bridge Adjustment-continued
• Lubrication System
• Reasons for Low Engine Oil Pressure
• Reason for High Engine Oil Pressure
• Excessive Bearing Wear - Inspect
• Increased Engine Oil Temperature - Inspect
• Cooling System
• Check the fan and/or the fan shroud
• Cooling System - Inspect
• Cooling System - Test
• Illustration 69 4C-6500 Digital Thermometer
• Making the Correct Antifreeze Mixtures
• Testing The Radiator And Cooling System For Leaks
• Test For The Water Temperature Gauge
• Water Pump - Test
• Basic Engine
• Flywheel - Inspect
• Flywheel Housing - Inspect
• Illustration 85 Checking bore runout of the flywheel housing
• Vibration Damper - Check
• Electrical System
• Belt Tension Chart
• Charging System - Test
• Electric Starting System - Test
• Engine Oil Pressure Sensor - Test
• Index
• Index-continued
• Troubleshooting 3126E Truck Engine
• Important Safety Information
• Table of Contents
• Table of Contents-continued
• Troubleshooting Section
• Fuel Injection
• Illustration 3 HEUI Fuel System
• Injection Actuation Pressure Control System
• Caterpillar Engine Monitoring
• Self-Diagnostics
• ECM Lifetime Totals
• Maintenance Indicator Data
• Programmable Parameters
• Glossary
• Camshaft Speed/Timing Sensor
• Diagnostic Lamp
• Fuel Temperature Sensor
• Open Circuit
• Remote Station Operation
• Electronic Service Tools
• Optional Service Tools
• Sensors and Electrical Connectors
• Schematic Drawing
• Illustration 10 Left side engine view
• Illustration 11 Top engine view
• Engine Wiring Harness Diagram
• Programming Parameters
• Replacing the ECM without the Use of the ECM Replacement Feature from Caterpillar Electronic Technician (ET)
• Customer Passwords
• ECM Snapshot
• Snapshot Information that Is Triggered Externally
• Storage of Snapshots in the ECM
• Factory Passwords Worksheet
• Service Information Report
• Customer Specified Parameters
• Customer Specified Parameters Table
• Table 6. Customer Specified Parameter Table-continued
• Table 6. Customer Specified Parameter Table-continued
• Table 6. Customer Specified Parameter Table-continued
• Table 6. Customer Specified Parameter Table-continued
• Customer Specified Parameters Worksheet
• Table 10. Vehicle Speed Parameters
• Table 15. Timer Parameters
• Cruise Control Parameters
• "Engine Brake Mode"
• Data Link Parameters
• "PTO Engine RPM Set Speed Input A"
• "PTO Kickout Vehicle Speed Limit "
• Engine/Gear Parameters
• "Top Engine Limit (TEL)"
• "Fan Pulley Ratio"
• Engine Monitoring Parameters
• Idle Parameters
• "Idle RPM Limit"
• Input Selections
• MAR99 through JUN01 Personality Modules
• OCT01 and newer Personality Modules
• OCT01 and newer Personality Modules
• Maintenance Parameters
• "Fast Idle Enabled Lamp"
• OCT01 and newer Personality Modules
• Passwords
• "Dash - Customer Parameters"
• Truck Manufacture Parameters
• Vehicle Speed Parameters
• "Vehicle Speed Cal (J1939-Trans)"
• "VSL Protection"
• System Configuration Parameters
• Troubleshooting without a Diagnostic Code
• Can Not Reach Vehicle Speed Limit
• Check Cold Mode Operation
• Check Engine Lamp or Warning Lamp Is Malfunctioning
• Cruise Control, Idle, or PTO Can Not Be Set
• On/Off switch for Cruise Control and Idle Control
• ET Status Screen-continued
• Driver Questionnaire
• Driver Questionnaire Response
• ECM Will Not Accept Factory Passwords
• Electronic Service Tool Will Not Communicate with ECM
• Elevated Idle
• Ignition Key Switch
• Personality Module
• Engine Has Early Wear
• Engine Misfires, Runs Rough or Is Unstable
• Engine Vibration
• Engine Will Not Crank
• Excessive Black Smoke
• Excessive White Smoke
• Intermittent Cruise Control, Idle, or PTO Kickout
• ET Status Screen-continued
• Intermittent Engine Shutdown
• Intermittent Low Power or Power Cutout
• Battery Power or Ground to the ECM
• Low Power/Poor or No Response to Throttle
• Cold Mode Operation
• Power Train Data Link
• Poor Acceleration or Response
• Power Train Data Link
• Troubleshooting with a Diagnostic Code
• 0003-11 Cylinder 3 Fault (73)
• 0005-11 Cylinder 5 Fault (74)
• 0022-13 Check Timing Sensor Calibration (42)
• 0041-03 8 Volt Supply Above Normal (21)
• 0043-02 Ignition Key Switch Fault (71)
• 0070-05 Inlet Air Heater Open Circuit (49)
• 0071-01 Idle Shutdown Occurrence (47)
• 0084-01 Loss of Vehicle Speed Signal (31)
• 0084-10 Vehicle Speed Rate of Change (36)
• 0091-13 Throttle Sensor Calibration (28)
• 0100-03 Oil Pressure Sensor Open Circuit (24)
• Test Step 1. Check for Diagnostic Codes
• 0102-00 Boost Pressure Reading Stuck High (25)
• 0102-07 Excessive Boost Pressure
• Test Step 2. Inspect Electrical Connectors and Wiring
• 0105-03 Inlet Manifold Temp Sensor Open Circuit (38)
• 0105-11 Very High Inlet Manifold Temp (64)
• Test Step 3. Check the Sensor In The Engine
• 0108-03 Atmospheric Pr Sensor Open Circuit (26)
• Test Step 1. Check for Diagnostic Codes
• 0110-03 Coolant Temp Sensor Open Circuit (27)
• 0110-04 Coolant Temp Sensor Short Circuit (27)
• Test Step 1. Check for Diagnostic Codes
• Test Step 5. Compare the Temperature Reading to the Temperature from Another Gauge
• 0111-01 Low Coolant Level Warning (62)
• 0111-02 Coolant Level Sensor Fault (12)
• 0111-03 Coolant Level Sensor Open Circuit (12)
• 0111-11 Very Low Coolant Level (62)
• 0128-03 Secondary Fuel Level Sensor Open Circuit (44)
• 0128-04 Secondary Fuel Level Sensor Short Circuit (44)
• 0164-02 Injection Actuation Pr Sensor Erratic (15)
• 0164-11 Injection Actuation Pressure System (39)
• 0186-14 PTO Shutdown Switch Occurrence (47)
• 0190-11 No Pattern on Speed Sensor #1 (34)
• 0224-14 Engine Cranking with Theft Deterrent Active (00)
• 0231-12 J1939 Device Not Responding
• 0232-04 5 Volt Supply Below Normal (21)
• 0247-11 Brake Switch #2
• 0253-14 Truck Manufacturer Parameter Not Programmed
• Diagnostic Functional Tests
• Illustration 21 Schematic of the +5 V supply for the engine pressure sensor
• Test Step 2. Connect ET and Check for Active Diagnostic Codes
• Test Step 4. Disconnect the +5 V Sensors While Active Diagnostic Codes are Being Monitored
• Test Step 5. Check the Engine Harness
• Accelerator Pedal Position Sensor
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 2. Check for Active Diagnostic Codes
• Test Step 5. Monitor ET while the Accelerator Pedal Position Sensor is Being Disconnected
• Test Step 7. Disconnect the Power Supply Connections for the Accelerator Pedal Position Sensor at the ECM
• Test Step 9. Check the Duty Cycle of the Accelerator Pedal Position Sensor at the ECM
• Illustration 26 Accelerator pedal assembly
• Air Inlet Heater Circuit - Test
• Control of the Air Inlet Heater During Engine Cranking
• Illustration 27 The Diagram for the air inlet heater
• Illustration 30 Connections for the ECM terminals
• Illustration 31 Operational chart for the air inlet heater
• Test Step 1. Inspect Electrical Connectors and Wiring
• Illustration 32 Connections for the Test Lamp
• Test Step 5. Check the Voltage at the Lamp for the Air Inlet Heater
• Test Step 8. Check the Battery Voltage to Connector J648 for the Lamp
• Test Step 10. Check Battery Voltage to the Connector P501 for the Air Inlet Heater Relay
• ATA (SAE J1587 / J1708) Data Link Circuit - Test
• Illustration 36 Schematic for ATA Data Link with 6-pin connector
• Test Step 2. Determine The Type Of Problem With The Data Link
• Test Step 3. Check the Battery Voltage Supply to the Cab Data Link Connector
• Test Step 5. Check the Battery Voltage at the ECM
• Test Step 6. Connect the ET Directly to the ECM
• Change Oil Lamp Circuit - Test
• Electrical Connections of the Lamp
• Test Step 2. Check for Normal Operation of the Change Oil Lamp
• Check Engine Lamp Circuit - Test
• Check Engine Lamp
• Illustration 45 Schematic for Lamp
• Test Step 2. Check for Normal Operation of the Lamp
• Test Step 3. Test the Lamp Circuit
• Clutch Pedal Position Switch Circuit - Test
• Clutch Switch
• Cruise Control Pause Switch
• A service brake pedal position
• Table 145. Cruise Control Kickout Status Table
• Table 146. Idle Kickout Status Table
• Table 147. Fast Idle Kickout Status Table
• Table 148. Table For The PTO Kickout Status Screen On The Electronic Service Tool
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 3. Check Clutch Switch Status on the Electronic Service Tool
• "Cruise Control PAUSE Switch"
• Test Step 5. Check the Switch Circuit for the ECM
• Coolant Level Sensor Circuit - Test
• Test Step 1. Use Cat ET to Check for an Active Coolant Level Sensor Fault
• Test Step 2. Inspect Electrical Connectors and Wiring for the 4-Pin Sensor
• Illustration 52 Terminal locations for ECM connector P1 (4-pin sensor)
• Test Step 3. Disconnect the Coolant Level Sensor and Check the Supply Voltage (+5 VDC)
• Test Step 6. Check the Wire Harness for the Coolant Level Low
• Test Step 7. Use a Breakout T to Check the ECM
• Test Step 8. Inspect Electrical Connectors and Wiring for the 2-Wire Float Sensor
• Test Step 9. Disconnect the Coolant Level Sensor and Check the Supply Voltage (+5 VDC)
• Cooling Fan Circuit and A/C Compressor Clutch Circuit - Test
• Cooling Fan Off Conditions
• Illustration 60 Cooling fan circuit
• Illustration 153. The following conditions will turn the Fan ON for Illustration 60
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 2. Check the Programming of the "Fan Control Type" Parameter
• Test Step 5. Check the A/C Compressor Clutch Switch
• Test Step 7. Use the "Cooling Fan Solenoid Special Test" on the Electronic Service Tool to Check the Circuit
• Cooling Fan Circuit and A/C High Pressure Switch Circuit- Test
• Cooling Fan ON Conditions
• Illustration 64. This schematic represents the on/off fan
• Table 154. The following conditions will turn the Fan ON for Illustration 64
• Table 155. The following conditions will turn the Fan ON for Illustration 65
• Table 156. The following conditions will turn the Fan ON for Illustration 66
• Table 157. The following conditions will turn the Fan ON for Illustration 67
• Table 158. The following conditions will turn the Fan ON for Illustration 68
• Table 159. The following conditions will turn the Fan ON for Illustration 69
• Table 160. The following conditions will turn the Fan ON for Illustration 70
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 2. Check the Programming of the "Fan Control Type" Parameter
• Test Step 6. Use a Voltmeter to Check the A/C Pressure Switch
• Test Step 7. Use ET to Check the ECM
• Test Step 9. Use the "Cooling Fan Solenoid Special Test" on ET to Check the Circuit
• Cruise Control Switch Circuit - Test
• Cruise Control On/Off Switch
• Usage of Transmission Style Switches
• The following kickout status parameters
• Table 162. Cruise Control Kickout Status Table
• Table 163. Idle Kickout Status Table
• Table 164. Fast Idle Kickout Status Table
• Table 165. Table For The PTO Kickout Status Screen On ET
• Idle Parameters
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 3. Check the Cruise Control Switch Status on ET
• "Bad Vehicle Speed"
• Test Step 5. Check the Switch Circuit
• Test Step 6. Insert a Jumper at the Suspect Switch
• Test Step 7. Insert a Jumper at the Bulkhead Connector
• Microprocessor
• Test Step 2. Check for Diagnostic Codes
• Electrical Connectors - Inspect
• Illustration 77 ECM connectors (AMP)
• Illustration 78 Deutsch connector receptacles and plugs
• Illustration 79 Routing of the Harness and insertion of the plug
• Test Step 3. Perform a Pull Test on Each Wire Terminal Connection
• Test Step 6. Check Connectors for Moisture or Corrosion
• Test Step 7. Inspect the Connector Terminals
• Engine Pressure Sensor Open or Short Circuit - Test
• The following background information
• 102-03 Boost Pressure Sensor Open Circuit (25)
• Results
• Test Step 3. Inspect Electrical Connectors and Wiring
• Test Step 5. Disconnect the Sensor in order to Create an Open Circuit
• Terminals at the Engine Harness Connector
• Illustration 86 Engine harness connector P2
• Test Step 10. Bypass the Harness Wiring Between the ECM and the Sensor Connector
• Illustration 87 Engine Running Output Circuit
• Test Step 1. Inspect Electrical Connectors and Wiring
• Engine Speed/Timing Sensor Circuit - Test
• Illustration 91 Circuit schematic for the speed/timing sensors
• Test Step 2. Check the Installation of the Sensors and the Bracket
• Test Step 3. Measure the Sensor Resistance Through the Engine Harness
• Test Step 4. Measure the Resistance of the Sensor at the Sensor
• Test Step 5. Install the Bypass Harness for the Engine Speed/Timing Sensors
• Engine Temperature Sensor Open or Short Circuit - Test
• Test Step 1. Verify All Active Diagnostic Codes
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 4. Disconnect the Sensor in order to Create an Open Circuit
• Illustration 97 Engine harness connector
• Exhaust Brake Circuit - Test
• Exhaust Brake On/Off Switch
• Illustration 98 Schematic for the exhaust brake that is powered by a relay circuit
• Illustration 99 Schematic for the on/off switch that is connected to terminal 16
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Connect ET and Check the Solenoids and the Relays
• Exhaust Particulate Filter Circuit - Test
• Test Step 1. Inspect Electrical Connectors and Wiring
• Fast Idle Enable Circuit - Test
• A second programmable parameter "Fast Idle RPM #2"
• Test Step 1. Check The Electrical Connectors and The Wiring
• Test Step 4. Insert a Jumper Wire at the Switch
• Fast Idle Lamp Circuit - Test
• Test Step 2. Check for Normal Operation of the Fast Idle Lamp
• Test Step 4. Check ECM Operation of the Fast Idle Lamp
• Fuel Level Sensor Circuit - Test
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Disconnect the Sensor in order to Create an Open Circuit
• Test Step 7. Check the Operation of the ECM by Creating Open and Short Circuits at the ECM Connector
• Idle Shutdown Timer - Test
• Test Step 1. Verify Activation of the Idle Shutdown Timer
• Test Step 2. Verify the Driver Alert Function for Idle Shutdown and the Override Function for Idle Shutdown
• Ignition Key Switch Circuit and Battery Supply Circuit - Test
• Ignition Key Switch Circuit and Battery Supply Circuit - Test-continued
• Illustration 118 Schematic for ECM battery circuit
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 4. Check the Batteries
• Test Step 5. Use the Bypass Harness for ET to Bypass the Vehicle Wiring
• Illustration 121 Bypass harness
• Ignore Brake/Clutch Switch Circuit - Test
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Check the Switch Circuit at the ECM
• Test Step 4. Insert a Jumper Wire at the Switch
• Injection Actuation Pressure - Test
• Test Step 3. Engine Cranks but Will not Start
• Test Step 8. Check the High Pressure Oil System for Leaks
• Test Step 10. Evaluate the Quality of the Oil
• Test Step 12. Perform the "Injection Actuation Pressure Test" at both Low Idle and at High Idle
• Injection Actuation Pressure Control Valve Circuit - Test
• Illustration 126. Location of the injection actuation pressure control valve
• Test Step 1. Use the Electronic service Tool to Check for Active Diagnostic Codes
• Test Step 3. Measure the Solenoid Resistance of the Injection Actuation Pressure Control Valve
• Test Step 6. Perform "Injection Actuation Pressure Test"
• Injection Actuation Pressure Sensor - Test
• Illustration 130 Schematic for the injection actuation pressure sensor
• Test Step 3. Inspect Electrical Connectors and Wiring
• Injector Solenoid Circuit - Test
• 6-11 Cylinder 6 Fault (74)
• Illustration 133 Circuit schematic for the injectors
• Test Step 2. Use ET to Check for Logged Diagnostic Codes
• Test Step 4. Use the Injector Solenoid Test to Test the Injector Solenoids
• Test Step 6. Check the Injector Harness from P2 to J300 for an Open Circuit
• Test Step 8. Use the "Injector Solenoid Test" to Check for Short Circuits in the ECM and in the Harness
• Input Selection Switch Circuit - Test
• Input 4 (Torque Limit Switch)
• OCT01 Software
• Illustration 136 Schematic for Torque Limit Switch
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Check the Switch Circuit for the ECM
• Neutral Switch Circuit - Test
• Automatic Transmission Neutral Switch
• Set/Resume Switch
• A Service Brake Pedal Position (Switch 1)
• Table 175. Cruise Control Kickout Status Table
• Table 176. Idle Kickout Status Table
• Table 177. Fast Idle Kickout Status Table
• Table 178. Table For The PTO Kickout Status Screen On ET
• Expected Result
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 3. Check Neutral Switch Status on ET
• Test Step 5. Check the Switch Circuit for the ECM
• Test Step 6. Insert a Jumper at the Neutral Switch
• Powertrain Data Link Circuit - Test
• Anti-Lock Brake Systems (ABS)
• Illustration 145 Schematic for Power train data link
• Illustration 146 ECM pin locations
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Use the Special Test on an Electronic Service Tool to Check the Devices on the J1939 Data Link
• Test Step 4. Check the Power Train Status Screen on an Electronic Service Tool
• Table 183. Powertrain Status Parameter Group Definition Table-continued
• PTO Engine Shutdown Switch Circuit - Test
• Illustration 149. Circuit schematic for the PTO Engine Shutdown Switch
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Check the Switch Circuit for the ECM
• Test Step 5. Insert a Jumper Wire at the Bulkhead Connector
• Test Step 2. Use Cat ET to Verify the Driver Alert Function of the PTO Shutdown
• PTO Switch Circuit - Test
• The PTO Configuration Is Set To Cab Switches
• Table 184. Table For The PTO Kickout Status Screen On ET
• Test Step 1. Check the Programming of the Dedicated PTO Customer Parameter
• Test Step 2. Determine the PTO Installation Setup
• Test Step 3. Inspect Electrical Connectors and Wiring
• Test Step 4. Check the PTO On/Off Switch Circuit with ET
• Test Step 6. Check the Status of the PTO On/Off Switch on ET
• Test Step 7. Check the Status of the Cruise Control Set/Resume Switch on ET
• Illustration 158 ECM Breakout T-connector
• PTO Switch ON Lamp Circuit - Test
• Illustration 159 Schematic for PTO Switch ON Lamp
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Test the PTO Switch ON Lamp Circuit
• Test Step 4. Check ECM Operation of the PTO Switch On Lamp
• Remote PTO Accelerator Position Sensor Circuit - Test
• Illustration 164 Schematic for remote accelerator pedal position sensor
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 2. Check for Active Diagnostic Codes
• Test Step 6. Check the Duty Cycle of the Remote Accelerator Position Sensor at the Sensor
• Test Step 8. Remove the Remote Accelerator Position Sensor From the Accelerator Pedal Assembly
• Test Step 9. Route the Supply Bypass Wires to the Remote Accelerator Pedal Position Sensor
• Service Brake Pedal Position (Switch 1) Circuit - Test
• Cruise Control On/Off Switch
• Operate the vehicle in Cruise/Idle/PTO mode
• The following Kickout Status parameters
• Table 186. Cruise Control Kickout Status Table
• Table 187. Idle Kickout Status Table
• Table 188. Fast Idle Kickout Status Table
• Test Step 1. Determine the Type of Problem
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 3. Check the Service Brake Switch Status on ET
• Test Step 5. Check the Switch Circuit
• Test Step 6. Insert a Jumper at the Service Brake Pedal Position (Switch 1)
• Service Brake Pedal Position (Switch 2) Circuit - Test
• Service Brake Pedal Position (Switch 2)
• Usage of Transmission Style Switches
• Operate the vehicle in Cruise/Idle/PTO mode
• Table 195. Table For The Cruise Control Kickout Status Screen On The Electronic Service Tool
• Table 196. Table For The Idle Kickout Status Screen On The Electronic Service Tool
• Table 197. Fast Idle Kickout Status Table
• Test Step 1. Determine the Type of Problem
• Test Step 2. Inspect Electrical Connectors and Wiring
• Test Step 4. Operate the Vehicle and Check the Kickout Status Parameter
• Test Step 5. Check the Switch Circuit
• Test Step 6. Insert a Jumper at the Service Brake Pedal Position (Switch 2)
• Starting Aid Output Circuit - Test
• Test Step 1. Inspect Electrical Connectors and Wiring
• Tachometer Circuit - Test
• Illustration 174 Schematic No. 1 for tachometer
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Use an Electronic Service Tool to Check the ECM Tachometer Signal
• Test Step 4. Check the ECM Tachometer Signal
• Test Step 6. Check the ECM Connection to the Tachometer
• Transmission (AT/MT/HT) Relay Circuit - Test
• Illustration 178 Schematic for the AT/MT/HT Transmission Relay
• Test Step 2. Use ET to Check the Accelerator Pedal Position Sensor
• Vehicle Speed and Speedometer Circuit - Test
• Speedometer Connection
• Illustration 181 Schematic for a single coil speed sensor and an ECM driven speedometer
• Illustration 182 Schematic for a single coil speed sensor and a second single coil sensor for a speedometer
• Illustration 185 Schematic for an Electronic vehicle speed source and a speedometer
• Test Step 2. Determine the Type of Vehicle Speed Problem
• Test Step 3. Use ET to Check the Speedometer
• Test Step 5. Measure Vehicle Speed Sensor Resistance at the Sensor
• Test Step 7. Test ECM Vehicle Speed Inputs by Using the Speedometer Special Test
• Wait To Start Lamp Circuit - Test
• OCT01 Software
• Test Step 2. Check for Normal Operation of the Wait to Start Lamp
• Test Step 4. Check ECM Operation of Wait to Start Lamp
• Warning Lamp Circuit - Test
• Test Step 1. Inspect Electrical Connectors and Wiring
• Test Step 3. Test the Lamp Circuit
• Expected Result
• Calibration Procedures
• Test Step 4. Connect Cat ET
• Vehicle Speed Circuit - Calibrate
• Test Step 2. Calculate the Revolutions Per Kilometer (Mile) of the Transmission Output Shaft
• Test Step 4. Inspect the Speedometer Calibration
• Index
• Index-continued
• Index-continued
• Index-continued
• Index-continued
• Disassembly and Assembly 3126E Truck Engine
• Important Safety Information
• Table of Contents
• Table of Contents-continued
• Disassembly and Assembly Section
• Fuel Filter Base - Install
• Fuel Transfer Pump - Install
• Fuel Pressure Regulator - Remove and Install
• Unit Injector - Remove
• Removal Of The Injector
• Steps For Cleaning The Carbon Deposits
• Unit Injector - Install
• Illustration 26 This is an illustration of the 154-8016 Fuel Injector Seals
• Illustration 27 149-2955 Seal Protector
• Check the Fuel System for Leaks
• Unit Injector Sleeve - Remove
• Unit Injector Sleeve - Install
• Injection Actuation Pressure Control Valve - Disassemble
• Injection Actuation Pressure Control Valve - Install
• Illustration 43 (Type I) 151-0858 Tube
• Unit Injector Hydraulic Pump - Install
• Illustration 49
• Turbocharger - Remove
• Turbocharger - Install
• Installation Procedure
• Exhaust Particulate Filter - Disassemble
• Illustration 64 Typical example Orientation of the DPF module
• Exhaust Particulate Filter - Assemble
• Air Inlet Heater - Remove and Install
• Air Inlet Heater Solenoid - Remove and Install
• Inlet and Exhaust Valves - Remove and Install
• Inlet and Exhaust Valve Guides - Remove and Install
• Table 15. Required Tools
• Inlet and Exhaust Valve Seat Inserts - Remove and Install
• Engine Oil Filter Base - Remove
• Engine Oil Filter Base - Disassemble
• Engine Oil Filter Base - Assemble
• Engine Oil Pump - Remove
• NOTICE
• Engine Oil Pump - Assemble
• Engine Oil Pump - Install
• Water Pump - Remove
• Water Pump - Disassemble
• Water Pump - Assemble
• Water Pump - Install
• Water Temperature Regulator - Remove and Install
• Flywheel - Remove
• Flywheel - Install
• Crankshaft Rear Seal - Remove
• Illustration 131 Typical example
• Crankshaft Wear Sleeve (Rear) - Remove (If Equipped)
• Crankshaft Rear Seal Carrier - Remove and Install
• Flywheel Housing - Remove and Install
• Installation Procedure
• Rear Power Take-Off (RPTO) - Disassemble
• Illustration 142 Schematic Drawing
• Illustration 143 Schematic Drawing
• Rear Power Take-Off (RPTO) - Assemble
• Illustration 146 Schematic Drawing
• Illustration 147 Schematic Drawing
• Illustration 149 Schematic Drawing
• Vibration Damper and Pulley - Remove and Install
• Crankshaft Front Seal - Remove
• Front Cover - Remove
• Housing (Front) - Remove
• Housing (Front) - Install
• Installation Procedure
• Valve Mechanism Cover - Remove and Install
• Installation Procedure
• Valve Mechanism Cover Base - Remove and Install
• Rocker Shaft and Pushrod - Remove
• Rocker Shaft - Disassemble
• Rocker Shaft - Assemble
• Cylinder Head - Remove
• Cylinder Head - Install
• Lifter Group - Remove and Install
• Installation Procedure
• Camshaft - Remove
• Camshaft - Install
• Camshaft Gear - Remove and Install
• Engine Oil Pan - Remove and Install
• Piston Cooling Jets - Remove and Install
• Pistons and Connecting Rods - Remove
• Pistons and Connecting Rods - Disassemble
• Pistons and Connecting Rods - Assemble
• Illustration 216 Schematic Drawing
• Pistons and Connecting Rods - Install
• Illustration 222 Schematic Drawing
• Crankshaft Main Bearings - Remove
• Crankshaft Main Bearings - Install
• Crankshaft - Remove
• NOTICE
• Crankshaft Gear - Remove and Install
• Bearing Clearance - Check
• Atmospheric Pressure Sensor - Remove and Install
• Engine Oil Pressure Sensor - Remove and Install
• Engine Oil Temperature Sensor - Remove and Install
• Injection Actuation Pressure Sensor - Remove and Install
• Speed/Timing Sensor - Remove and Install
• Boost Pressure Sensor - Remove and Install
• Inlet Air Temperature Sensor - Remove and Install
• Idler Pulley - Remove
• Idler Pulley - Assemble
• Belt Tensioner - Remove and Install
• Belt Tightener - Disassemble
• Belt Tightener - Install
• Two-Piece Fan Drive Mounting (If Equipped)
• Fan Drive - Remove
• Engine Control Module - Remove and Install
• Electric Starting Motor - Remove and Install
• Air Compressor - Remove and Install
• Installation Procedure
• Illustration 287 Schematic Drawing
• Air Compressor Drive Gear - Remove
• Air Compressor Drive Gear - Install
• Index
• Index-continued
• Index-continued
• Schematic 3126E Truck Engine Electrical System
• ENGINE HARNESS WIRING DIAGRAM
• THE METRIC SYSTEM AND EQUIVALENTS
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