Caterpillar 3126B, 3126E Truck Engine Troubleshooting Manual

Covers: Caterpillar 3126B and 3126E truck engines with serial number prefixes:

• BKD
• G3E
• DPF
• 1AJ
• 8YL
• CKM
• CRP
• 7AS
• 8SZ
• 9SZ

Pages: 412
Format: PDF file
File size: 4mb
Compatibility: Windows/Mac computers
Notes: Searchable, printable, instant download

This downloadable troubleshooting manual covers symptom and code-based troubleshooting for Cat 3126B and 3126E on-highway diesel engines with the serial numbers listed. High resolution PDF format.

Topics:

Electronic Troubleshooting

• System Overview
• Electronic Service Tools
• Replacing the ECM
• Sensors and Electrical Connectors
• Programming Parameters
• Customer Passwords
• ECM Date/Time Stamped Information
• ECM Snapshot
• Flash Programming
• Cruise Control Parameters
• Data Link Parameters
• Dedicated PTO Parameters
• Engine/Gear Parameters
• Engine Monitoring Parameters
• Idle Parameters
• Input Selections
• Maintenance Parameters
• Output Selections
• Passwords
• Selected Engine Rating
• Smart Idle Parameters
• Timer Parameters
• Trip Parameters
• Truck Manufacture Parameters
• Vehicle Speed Parameters
• System Configuration Parameters
• System Configuration Parameters

Troubleshooting without a Diagnostic Code

• Can Not Reach Top Engine RPM
• Can Not Reach Vehicle Speed Limit
• Check Engine Lamp or Warning Lamp Is Malfunctioning
• Cruise Control, Idle, or PTO Can Not Be Set
• Driver Questionnaire
• Driver Questionnaire Response
• ECM Will Not Accept Passwords
• Electronic Service Tool Will Not Communicate with ECM
• Elevated Idle
• Engine Cranks but Will Not Start
• Engine Has Early Wear
• Engine Misfires, Runs Rough or Is Unstable
• Engine Vibration
• Engine Will Not Crank
• Excessive Black Smoke
• Excessive Valve Lash
• Excessive White Smoke
• Intermittent Cruise Control, Idle, or PTO Kickout
• Intermittent Engine Shutdown
• Intermittent Low Power or Power Cutout
• Low Power/Poor or No Response to Throttle
• Poor Acceleration or Response

Troubleshooting with a Diagnostic Code

• Diagnostic Codes
• 0001-11 Cylinder #1 Injector current fault (72)
• 0002-11 Cylinder #2 Injector current fault (72)
• 0003-11 Cylinder #3 Injector current fault (73)
• 0004-11 Cylinder #4 Injector current fault (73)
• 0005-11 Cylinder #5 Injector current fault (74)
• 0006-11 Cylinder #6 Injector current fault (74)
• 0022-11 Primary to Secondary Engine Speed Signal Calibration (42)
• 0022-13 Engine Speed Signal Calibration Not Performed (42)
• 0030-08 PTO Throttle signal invalid (29)
• 0030-13 PTO Throttle out of calibration (29)
• 0041-03 8 Volt Supply voltage high (21)
• 0041-04 8 Volt Supply voltage low (21)
• 0042-11 Injection Actuation Pressure output fault
• 0043-02 Key Switch Fault (71)
• 0064-02 Secondary Engine Speed loss of signal
• 0064-11 Secondary Engine Speed no pattern
• 0070-05 Inlet Air Heater current low
• 0070-06 Inlet Air Heater current high
• 0071-00 Idle Shutdown Override (01)
• 0071-01 Idle Shutdown (47)
• 0071-14 PTO Shutdown (47)
• 0084-00 Vehicle Overspeed Warning (41)
• 0084-01 Vehicle Speed loss of signal (31)
• 0084-02 Vehicle Speed signal invalid (36)
• 0084-08 Vehicle Speed signal out of range (36)
• 0084-10 Vehicle Speed signal rate of change
• 0091-08 Throttle Position Invalid (32)
• 0091-13 Throttle Position out of calibration (28)
• 0096-03 Fuel Level voltage high
• 0096-04 Fuel Level voltage low
• 0100-03 Oil Pressure voltage high (24)
• 0100-04 Oil Pressure voltage low (24)
• 0100-11 Very Low Oil Pressure (46)
• 0102-03 Boost Pressure voltage high (25)
• 0102-04 Boost Pressure voltage low (25)
• 0102-07 Boost Pressure not responding
• 0105-00 High Intake Manifold Air Temperature Warning (64)
• 0105-03 Intake Manifold Air Temperature voltage high (38)
• 0105-04 Intake Manifold Air Temperature voltage low
• 0105-11 Very High Intake Manifold Air Temperature
• 0108-03 Barometric Pressure voltage high (26)
• 0108-04 Barometric Pressure voltage low (26)
• 0110-00 High Coolant Temperature Warning
• 0110-03 Coolant Temperature voltage high (27)
• 0110-04 Coolant Temperature voltage low (27)
• 0110-11 Very High Coolant Temperature (61)
• 0111-01 Low Coolant Level Warning (62)
• 0111-02 Coolant Level signal invalid (12)
• 0111-03 Coolant Level voltage high (12)
• 0111-04 Coolant Level voltage low (12)
• 0111-11 Very Low Coolant Level (62)
• 0128-03 Secondary Fuel Level voltage high
• 0128-04 Secondary Fuel Level voltage low
• 0164-00 Excessive Injection Actuation Pressure
• 0164-02 Injection Actuation Pressure Signal Erratic
• 0164-03 Injection Actuation Pressure voltage high
• 0164-04 Injection Actuation Pressure voltage low
• 0164-11 Injection Actuation Pressure system fault
• 0168-02 ECM Battery Power Intermittent (51)
• 0186-14 PTO Engine Shutdown Switch Occurrence
• 0190-00 Engine Overspeed Warning (35)
• 0190-02 Primary Engine Speed Loss of Signal
• 0190-11 Primary Engine Speed no pattern (34)
• 0224-11 Theft Deterrent Active (00)
• 0224-14 Theft Deterrent Active with Engine Cranking
• 0231-02 J1939 Data Incorrect (58)
• 0231-11 J1939 Data Link Fault (58)
• 0231-12 J1939 Device Not Responding
• 0232-03 5 Volt Supply voltage high (21)
• 0232-04 5 Volt Supply voltage low (21)
• 0246-11 Brake Pedal Switch #1 Fault
• 0247-11 Brake Pedal Switch #2 Fault
• 0252-11 Engine Software Incorrect (59)
• 0253-02 Check Customer or System Parameters
• 0253-14 Truck Manufacturer Parameter Not Programmed

Diagnostic Functional Tests

• 5 Volt Engine Pressure Sensor Supply Circuit – Test
• Accelerator Pedal (Throttle) Position Sensor Circuit – Test
• Air Inlet Heater Circuit – Test
• ATA (SAE J1587 / J1708) Data Link Circuit – Test
• Change Oil Lamp Circuit – Test
• Check Engine Lamp Circuit – Test
• Clutch Pedal Position Switch Circuit – Test
• Coolant Level Sensor Circuit – Test
• Cooling Fan Circuit and A/C Compressor Clutch
• Circuit – Test
• Cooling Fan Circuit and A/C High Pressure Switch
• Circuit – Test
• Cruise Control Switch Circuit – Test
• ECM Memory – Test
• Electrical Connectors – Inspect
• Engine Pressure Sensor Open or Short Circuit – Test
• Engine Running Output Circuit – Test
• Engine Speed/Timing Sensor Circuit – Test
• Engine Temperature Sensor Open or Short Circuit – Test
• Exhaust Brake Circuit – Test
• Exhaust Particulate Filter Circuit – Test
• Fast Idle Enable Circuit – Test
• Fast Idle Lamp Circuit – Test
• Fuel Level Sensor Circuit – Test
• Idle Shutdown Timer – Test
• Ignition Key Switch Circuit and Battery Supply Circuit
• Ignore Brake/Clutch Switch Circuit – Test
• Injection Actuation Pressure – Test
• Injection Actuation Pressure Control Valve Circuit – Test
• Injection Actuation Pressure Sensor – Test
• Injector Solenoid Circuit – Test
• Input Selection Switch Circuit – Test
• Neutral Switch Circuit – Test
• Powertrain Data Link Circuit – Test
• PTO Engine Shutdown Switch Circuit – Test
• PTO Shutdown Timer – Test
• PTO Switch Circuit – Test
• PTO Switch ON Lamp Circuit – Test
• Remote PTO Accelerator Position Sensor Circuit – Test
• Service Brake Pedal Position (Switch 1) Circuit – Test
• Service Brake Pedal Position (Switch 2) Circuit – Test
• Starting Aid Output Circuit – Test
• Tachometer Circuit – Test
• Transmission (AT/MT/HT) Relay Circuit – Test
• Vehicle Speed and Speedometer Circuit – Test
• Wait To Start Lamp Circuit – Test
• Warning Lamp Circuit – Test

Calibration Procedures

• Engine Speed/Timing Sensor – Calibrate
• Vehicle Speed Circuit – Calibrate

Index

RENR1367-11