Cat Caterpillar 3126B Marine Engine Workshop Service Repair Manual + Parts Manual

Cat Caterpillar 3126B Marine Engine Workshop Service Repair Manual + Parts Manual

 

Loaded with illustrations, instructions, photos, and diagrams, complete to service and repair your engine. Read and print pages directly from the CD, or copy the entire manual to your hard drive.

 

 

MODEL COVERSTHE FOLLOWING SERIAL NUMBERS:

– BKD1-Up

– G3E1-Up

– DPF1-Up

– 1AJ1-Up

– 8YL1-Up

– CRP1-Up

– CKM1-Up

– 7AS1-Up

– 8SZ1-Up

– 9SZ1-Up

 

 

MANUAL COVERS:

Schematic (3126B Industrial Engine Electrical System)

Schematic (3126B Marine Engine Electrical System)

Schematic (3126B Engine for Claas Combine Applications Electrical System)

Schematic (3126B Industrial Engine Electrical System)

Parts Manual (3126B Industrial Engine)

Troubleshooting (3126B Marine Engines):

Throttle Position Sensor – Calibrate

Engine Speed Timing Sensor – Calibrate

Air Inlet Heater Circuit – Test

Analog Sensor Supply Circuit – Test

CAN Data Link Circuit – Test

Cat Data Link Circuit – Test

Coolant Level Sensor Circuit – Test

Digital Sensor Supply Circuit – Test

Electrical Connectors – Inspect

Electrical Power Supply Circuit – Test

Engine Pressure Sensor Open or Short Circuit – Test

Engine Speed Timing Sensor Circuit – Test

Engine Synchronize Switch Circuit – Test

Engine Temperature Sensor Open or Short Circuit – Test

How To Use the Functional Tests

Indicator Lamp Circuit – Test

Injection Actuation Pressure – Test

Injection Actuation Pressure Control Valve Circuit – Test

Injection Actuation Pressure Sensor – Test

Injector Solenoid Circuit – Test

Switch Circuits – Test

Throttle Position Sensor Circuit – Test

Transmission Oil Temperature Sensor Open or Short Circuit – Test

Component Diagram

Electrical Connectors and Functions

Electronic Service Tools

Engine Wiring Information

Glossary

Replacing the ECM

Self-Diagnostics

Sensors and Electrical Connectors

System Overview

Customer Passwords

Factory Passwords

Factory Passwords Worksheet

Flash Programming

Programming Parameters

Service Information Report

System Configuration Parameters

CID 0001 FMI 11 Cylinder #1 Injector fault

CID 0002 FMI 11 Cylinder #2 Injector fault

CID 0003 FMI 11 Cylinder #3 Injector fault

CID 0004 FMI 11 Cylinder #4 Injector fault

CID 0005 FMI 11 Cylinder #5 Injector fault

CID 0006 FMI 11 Cylinder #6 Injector fault

CID 0041 FMI 03 8 Volt DC Supply short to +batt

CID 0041 FMI 04 8 Volt DC Supply short to ground

CID 0042 FMI 11 Inject Actuation Control Valve open_short

CID 0091 FMI 08 Throttle Position signal abnormal

CID 0091 FMI 13 Throttle Position calibration required

CID 0094 FMI 03 Fuel Pressure open short to +batt

CID 0094 FMI 04 Fuel Pressure short to ground

CID 0100 FMI 03 Engine Oil Pressure open short to +batt

CID 0100 FMI 04 Engine Oil Pressure short to ground

CID 0102 FMI 03 Boost Pressure Sensor short to +batt

CID 0102 FMI 04 Boost Pressure Sensor short to ground

CID 0105 FMI 03 Inlet Manifold Temp Sensor open short to +batt

CID 0105 FMI 04 Inlet Manifold Temp Sensor short to ground

CID 0110 FMI 03 Engine Coolant Temperature open short to +batt

CID 0110 FMI 04 Engine Coolant Temperature short to ground

CID 0127 FMI 03 Transmission Oil Pressure open short to +batt

CID 0127 FMI 04 Transmission Oil Pressure short to groundf

CID 0164 FMI 00 High Injector Actuation Pressure

CID 0164 FMI 02 Injector Actuation Pressure signal erratic

CID 0164 FMI 03 Injector Actuation Pressure voltage high

CID 0164 FMI 04 Injector Actuation Pressure voltage low

CID 0164 FMI 11 Injector Actuation Pressure system fault

CID 0168 FMI 02 System Voltage intermittent erratic

CID 0174 FMI 03 Fuel Temperature open short to +batt

CID 0174 FMI 04 Fuel Temperature short to ground

CID 0175 FMI 03 Engine Oil Temperature open short to +batt

CID 0175 FMI 04 Engine Oil Temperature short to ground.pdf

CID 0177 FMI 03 Transmission Oil Temperature open short to +batt

CID 0177 FMI 04 Transmission Oil Temperature short to ground

CID 0253 FMI 02 Personality Module mismatch

CID 0261 FMI 13 Engine Timing Calibration required

CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt

CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground

CID 0268 FMI 02 Check Programmable Parameters

CID 0320 FMI 02 Speed Timing Sensor Loss of Signal

CID 0320 FMI 11 Speed Timing Sensor mechanical failure

CID 0342 FMI 02 Loss of Secondary Engine Speed signal

CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical failure

CID 0617 FMI 05 Air Inlet Heater Relay open current below normal

CID 0617 FMI 06 Air Inlet Heater Relay grounded current above norm

CID 1249 FMI 08 Secondary Throttle Position signal abnormal

CID 1249 FMI 13 Secondary Throttle Position calibration required

Diagnostic Codes

Flash Codes

E015 High Engine Coolant Temperature Derate

E017 High Engine Coolant Temperature Warning

E025 High Inlet Air Temperature Derate

E027 High Inlet Air Temperature Warning

E030 High Transmission Oil Temperature Warning

E039 Low Engine Oil Pressure Derate

E057 Low Engine Coolant Level Derate

E059 Low Engine Coolant Level Warning

E096 High Fuel Pressure

E100 Low Engine Oil Pressure Warning

E113 High Transmission Oil Pressure

E190 Engine Overspeed Warning

E268 Unexpected Engine Shutdown

Event Codes

Battery

Can Not Reach Top Engine RPM

Coolant in Engine Oil

Coolant Temperature Is Too High

ECM Will Not Accept Factory Passwords

ECM Will Not Communicate with Other Systems or Display Modules

Electronic Service Tool Will Not Communicate with ECM

Engine Cranks but Will Not Start

Engine Has Early Wear

Engine Misfires, Runs Rough or Is Unstable

Engine Oil in Cooling System

Engine Oil in Exhaust System

Engine Stalls at Low RPM

Engine Vibration

Engine Will Not Crank

Excessive Black Smoke

Excessive Engine Oil Consumption

Excessive Fuel Consumption

Excessive Valve Lash

Excessive White Smoke

Exhaust Temperature Is Too High

Fuel in Cooling System

Intermittent Engine Shutdown

Intermittent Low Power or Power Cutout

Low Engine Oil Pressure

Low Power Poor or No Response to Throttle

Mechanical Noise (Knock) in Engine

Noise Coming from Cylinder

Poor Acceleration or Response

 

 

Specifications (3126B Marine Engine):

Aftercooler

Alternator and Regulator 1

Alternator and Regulator 2

Auxiliary Water Pump

Belt Tension Chart

Belt Tensioner

Boost Pressure Sensor

Camshaft

Connecting Rod

Connecting Rod Bearing Journal

Coolant Level Sensor – If Equipped

Coolant Temperature Sensor

Crankcase Breather

Crankshaft

Crankshaft Seals

Cylinder Block

Cylinder Block Cover Group

Cylinder Head

Cylinder Head Valves

Electric Starting Motor 1

Electric Starting Motor 2

Electric Starting Motor 3

Electric Starting Motor 4

Engine Design

Engine Oil Cooler Bypass Valve

Engine Oil Filter Base

Engine Oil Pan

Engine Oil Pressure Sensor

Engine Oil Pump

Flywheel

Flywheel Housing

Front Housing and Covers

Fuel Filter Base

Fuel Temperature Sensor – If Equipped

Gear Group (Front)

Injection Actuation Pressure Control Valve

Injection Actuation Pressure Sensor

Inlet Air Temperature Sensor

Magnetic Pickup

Main Bearing Journal

Piston and Rings

Piston Cooling Jet

Rear Seal Carrier – If Equipped

Speed Timing Sensor

Turbocharger

Valve Mechanism Cover

Valve Rocker Arms, Lifters, and Bridges

Vibration Damper

Water Temperature Regulator

 

Systems Operation (3126B Marine Engine):

Air Inlet and Exhaust System

Basic Engine

Cooling System

Electrical System

Electronic Control System Components

Engine Design

Fuel System

General Information

Glossary of Electronic Control Terms

Lubrication System

 

Testing & Adjusting (3126B Marine Engine):

Air in Fuel – Test

Air Inlet and Exhaust System – Inspect

Alternator – Test

Battery – Test

Belt Tension Chart

Charging System – Test

Compression – Test

Connecting Rod Bearings – Inspect

Cooling System – Check – Overheating

Cooling System – Inspect

Cooling System – Test

Cylinder Block – Inspect

Electric Starting System – Test

Engine Crankcase Pressure (Blowby) – Test

Engine Oil Pressure – Test

Engine Oil Pressure Sensor – Test

Engine Oil Pump – Inspect

Engine Speed – Check

Engine Valve Lash – Inspect_Adjust

Excessive Bearing Wear – Inspect

Excessive Engine Oil Consumption – Inspect

Exhaust Temperature – Test

Finding Top Center Position for No. 1 Piston

Flywheel – Inspect

Flywheel Housing – Inspect

Fuel Quality – Test

Fuel System – Inspect

Fuel System – Prime

Fuel System Pressure – Test

Increased Engine Oil Temperature – Inspect

Inlet Manifold Pressure – Test

Main Bearings – Inspect

Pinion Clearance – Adjust

Piston Ring Groove – Inspect

Turbocharger – Inspect

Unit Injector – Test

Vibration Damper – Check

Water Pump – Test

Water Temperature Regulator – Test

 

Disassembly & Assembly (3126B Marine Engine):

Aftercooler – Assemble 1

Aftercooler – Assemble 2

Aftercooler – Disassemble 1

Aftercooler – Disassemble 2

Aftercooler – Install

Aftercooler – Remove

Air Cleaner – Remove and Install

Air Inlet Heater – Remove and Install

Air Inlet Heater Solenoid – Remove and Install

Alternator – Remove and Install

Auxiliary Water Pump – Assemble

Auxiliary Water Pump – Assemble – Type 2

Auxiliary Water Pump – Disassemble

Auxiliary Water Pump – Disassemble – Type 2

Auxiliary Water Pump – Install

Auxiliary Water Pump – Remove

Bearing Clearance – Check

Belt Tensioner – Remove and Install

Camshaft – Install

Camshaft – Remove

Camshaft Bearings – Remove and Install

Camshaft Gear – Remove and Install

Camshaft Idler Gear – Remove and Install

Crankshaft – Install

Crankshaft – Remove

Crankshaft Front Seal – Install

Crankshaft Front Seal – Remove

Crankshaft Gear – Remove and Install

Crankshaft Main Bearings – Install

Crankshaft Main Bearings – Remove

Crankshaft Rear Seal – Install

Crankshaft Rear Seal – Remove

Crankshaft Rear Seal Carrier – Remove and Install

Crankshaft Wear Sleeve (Rear) – Install

Crankshaft Wear Sleeve (Rear) – Remove – If Equipped

Cylinder Head – Install

Cylinder Head – Remove

Electric Starting Motor – Remove and Install

Electronic Control Module – Remove and Install

Engine Oil Cooler – Install

Engine Oil Cooler – Remove

Engine Oil Filter Base – Assemble

Engine Oil Filter Base – Disassemble

Engine Oil Filter Base – Install

Engine Oil Filter Base – Remove

Engine Oil Pan – Remove and Install

Engine Oil Pump – Assemble

Engine Oil Pump – Disassemble

Engine Oil Pump – Install

Engine Oil Pump – Remove

Exhaust Manifold – Remove and Install

Flywheel – Install

Flywheel – Remove

Flywheel Housing – Remove and Install

Front Cover – Install

Front Cover – Remove

Fuel Filter Base – Remove and Install

Fuel Priming Pump – Remove and Install

Fuel Transfer Pump – Install

Fuel Transfer Pump – Remove

Heat Exchanger – Assemble

Heat Exchanger – Disassemble

Heat Exchanger – Install

Heat Exchanger – Remove

Housing (Front) – Install

Housing (Front) – Remove

Injection Actuation Pressure Control Valve – Install

Injection Actuation Pressure Control Valve – Remove

Inlet and Exhaust Valve Guides – Remove and Install

Inlet and Exhaust Valve Seat Inserts – Remove and Install

Inlet and Exhaust Valves – Remove and Install

Lifter Group – Remove and Install

Piston Cooling Jets – Remove and Install

Pistons and Connecting Rods – Assemble

Pistons and Connecting Rods – Disassemble

Pistons and Connecting Rods – Install

Pistons and Connecting Rods – Remove

Rocker Shaft – Assemble

Rocker Shaft – Disassemble

Rocker Shaft and Pushrod – Install

Rocker Shaft and Pushrod – Remove

Turbocharger – Install

Turbocharger – Remove

Unit Injector – Install

Unit Injector – Remove

Unit Injector Hydraulic Pump – Install

Unit Injector Hydraulic Pump – Remove

Unit Injector Sleeve – Install

Unit Injector Sleeve – Remove

Valve Mechanism Cover – Remove and Install

Valve Mechanism Cover Base – Remove and Install

Vibration Damper and Pulley – Remove and Install

Water Pump – Assemble

Water Pump – Disassemble

Water Pump – Install

Water Pump – Remove

Water Temperature Regulator – Remove and Install

 

Operation & Maintenance Manual (3126B Marine Engine):

Aftercooler Condensate Drain Valve – Inspect Clean

Aftercooler Core – Clean Test

Alternator – Inspect

Auxiliary Water Pump (Rubber Impeller) – Inspect

Battery – Replace

Battery Electrolyte Level – Check

Battery or Battery Cable – Disconnect

Belts – Inspect Adjust Replace

Coolant – Change

Coolant Extender (ELC) – Add

Coolant Level – Check

Coolant Temperature Regulator – Replace

Cooling System Supplemental Coolant Additive (SCA) – Test Add

Crankshaft Vibration Damper – Inspect

Engine Air Cleaner Element (Single Element) – Inspect Clean Replace

Engine Air Cleaner Service Indicator – Inspect – If Equipped

Engine Crankcase Breather – Clean

Engine Mounts – Inspect

Engine Oil and Filter – Change

Engine Oil Level – Check

Engine Oil Level Gauge – Calibrate

Engine Oil Sample – Obtain

Engine Storage Procedure – Check

Engine Valve Lash – Check

Fluid Recommendations

Fuel System – Prime

Fuel System Primary Filter (Water Separator) Element – Replace

Fuel System Primary Filter Water Separator – Drain

Fuel System Secondary Filter – Replace

Fuel System Water Separator – Check Drain

Fuel Tank Water and Sediment – Drain

Fumes Disposal Filter Element – Replace

Fumes Disposal Filter Service Indicator – Check

Heat Exchanger – Inspect

Hoses and Clamps – Inspect Replace

Maintenance Interval Schedule – Commercial Ratings

Maintenance Interval Schedule – High Performance

Overhaul Considerations

Refill Capacities 1

Refill Capacities 2

Starting Motor – Inspect

Transmission Oil Level – Check

Turbocharger – Inspect

Walk-Around Inspection

Water Pump – Inspect

Zinc Rods – Inspect Replace

After Starting Engine

After Stopping Engine

Before Starting Engine

Cold Weather Starting

Diagnostic Flash Code Retrieval

Diagnostic Lamp

Emergency Stopping

Engine Operation

Engine Operation with Active Diagnostic Codes

Engine Operation with Intermittent Diagnostic Codes

Fault Logging

Fuel and the Effect from Cold Weather

Fuel Conservation Practices

Fuel Related Components in Cold Weather

Gauges and Indicators

Manual Stop Procedure

Marine Power Display

Marine Towing

Monitoring System

Overspeed

Product Lifting

Product Storage

Self-Diagnostics

Sensors and Electrical Components

Starting the Engine

Starting with Jump Start Cables

Declaration of Conformity

Model View Illustrations

Plate Locations and Film Locations

Product Description

Reference Information

Customer Assistance

Engine Performance

Engine Rating Conditions

Engine Rating Definitions

Maintenance Log

Maintenance Records

Marine Classification Society Certification Requirements

Ordering Replacement Parts

Reference Material

Before Starting Engine

Burn Prevention

Crushing Prevention and Cutting Prevention

Electrical System

Engine Electronics

Engine Starting

Engine Stopping

Fire Prevention and Explosion Prevention

General Hazard Information

Mounting and Dismounting

Safety Messages

 

Specifications (3126B Engine for Caterpillar Built Machines):

Air Inlet Elbow

Air Inlet Heater

Alternator and Air Compressor Mounting Group

Alternator and Regulator

Atmospheric Pressure Sensor – If Equipped

Belt Tension Chart

Belt Tensioner – If Equipped

Camshaft

Connecting Rod

Connecting Rod Bearing Journal

Coolant Temperature Sensor

Crankcase Breather

Crankshaft

Crankshaft Seals

Cylinder Block

Cylinder Block Cover Groupf

Cylinder Head

Cylinder Head Valves

Electric Starting Motor

Electronic Control Wiring Group

Engine Design

Engine Oil Filter Base

Engine Oil Level Switch – If Equipped

Engine Oil Pan (1)

Engine Oil Pan (2)

Engine Oil Pressure Sensor – If Equipped

Engine Oil Pump

Engine Oil Temperature Sensor

Exhaust Manifold

Fan Drive

Flywheel

Flywheel Housing (1)

Flywheel Housing (2)

Front Housing and Covers

Fuel Filter and Water Separator

Fuel Filter Base

Fuel Pressure Sensor

Fuel Transfer Pump

Gear Group (Front) (1)

Gear Group (Front) (2)

Injection Actuation Pressure Control Valve

Injection Actuation Pressure Sensor

Inlet Air Temperature Sensor

Inlet Manifold – Internal Mounted Air Inlet Heater

Main Bearing Journal

Piston and Rings (1)

Piston and Rings (2)

Piston Cooling Jet (1)

Piston Cooling Jet (2)

Speed Sensor

SpeedTiming Sensor

Turbocharger

Turbocharger Inlet Pressure Sensor

Turbocharger Outlet Pressure Sensor

Unit Injector

Unit Injector Hydraulic Pump

Valve Mechanism Cover

Valve Rocker Arms, Lifters, and Bridges

Vibration Damper and Pulley

Water Pump (1)

Water Pump (2)

Water Temperature Regulator

 

Systems Operation (3126B Engines for CaterpillarBuilt Machines):

Air Inlet and Exhaust System

Basic Engine

Cooling System

Electrical System

Electronic Control System Components

Fuel System

General Information

Lubrication System

Testing & Adjusting (3126B Engines for CaterpillarBuilt Machines):

Aftercooler – Test

Air in Fuel – Test

Air Inlet and Exhaust System – Inspect

Battery – Test

Charging System – Test

Compression – Test

Connecting Rod Bearings – Inspect

Cooling System – Check – Overheating

Cooling System – Inspect

Cooling System – Test

Cylinder Block – Inspect

Electric Starting System – Test

Engine Crankcase Pressure (Blowby) – Test

Engine Oil Pressure – Test

Engine Oil Pump – Inspect

Engine Speed – Check

Engine Valve Lash – Inspect Adjust

Excessive Bearing Wear – Inspect

Excessive Engine Oil Consumption – Inspect

Exhaust Temperature – Test

Finding Top Center Position for No. 1 Piston

Flywheel – Inspect

Flywheel Housing – Inspect

Fuel Quality – Test

Fuel System – Inspect

Fuel System – Prime (1)

Fuel System – Prime (2)

Fuel System Pressure – Test

Gear Group (Front) – Time

Increased Engine Oil Temperature – Inspect

Inlet Manifold Pressure – Test

Main Bearings – Inspect

Pinion Clearance – Adjust

Piston Ring Groove – Inspect

Turbocharger – Inspect

Unit Injector – Test

Vibration Damper – Check

Water Pump – Test

Water Temperature Regulator – Test

 

Disassembly & Assembly (3126B Engines for Caterpillar Built Machines):

Air Inlet Cover – Remove and Install

Air Inlet Elbow – Remove and Install

Air Inlet Heater Solenoid – Remove and Install

Alternator – Remove and Install

Bearing Clearance – Check

Belt Tensioner – Remove and Install

Camshaft – Install

Camshaft – Remove

Camshaft Bearings – Remove and Install

Camshaft Gear – Remove and Install

Camshaft Idler Gear – Remove and Install

Crankshaft – Install

Crankshaft – Remove

Crankshaft Front Seal – Install

Crankshaft Front Seal – Remove

Crankshaft Gear – Remove and Install

Crankshaft Main Bearings – Install

Crankshaft Main Bearings – Remove

Crankshaft Rear Seal – Install

Crankshaft Rear Seal – Remove

Crankshaft Rear Seal Carrier – Remove and Install

Crankshaft Wear Sleeve (Rear) – Install

Crankshaft Wear Sleeve (Rear) – Remove – If Equipped

Cylinder Head – Install

Cylinder Head – Remove

Electric Starting Motor – Remove and Install

Electronic Control Module – Remove and Install

Engine Oil Cooler – Install

Engine Oil Cooler – Remove

Engine Oil Filter Base – Assemble

Engine Oil Filter Base – Disassemble

Engine Oil Filter Base – Install

Engine Oil Filter Base – Remove

Engine Oil Pan – Remove and Install

Engine Oil Pump – Assemble

Engine Oil Pump – Disassemble

Engine Oil Pump – Install

Engine Oil Pump – Remove

Exhaust Manifold – Remove and Install

Flywheel – Remove and Install

Flywheel Housing – Remove and Install

Front Cover – Install

Front Cover – Remove

Fuel Pressure Regulator – Remove and Install.

Fuel Transfer Pump – Install – If Equipped

Fuel Transfer Pump – Remove – If Equipped

Housing (Front) – Install

Housing (Front) – Remove

Idler Pulley – Remove and Install

Injection Actuation Pressure Control Valve – Remove and Install

Inlet and Exhaust Valve Guides – Remove and Install

Inlet and Exhaust Valve Seat Inserts – Remove and Install

Inlet and Exhaust Valves – Remove and Install

Lifter Group – Remove and Install

Piston Cooling Jets – Remove and Install

Pistons and Connecting Rods – Assemble

Pistons and Connecting Rods – Disassemble

Pistons and Connecting Rods – Install

Pistons and Connecting Rods – Remove

Rocker Shaft – Assemble

Rocker Shaft – Disassemble

Rocker Shaft and Pushrod – Install

Rocker Shaft and Pushrod – Remove

Turbocharger – Assemble

Turbocharger – Disassemble

Turbocharger – Install

Turbocharger – Remove

Unit Injector – Install

Unit Injector – Remove

Unit Injector Hydraulic Pump – Install

Unit Injector Hydraulic Pump – Remove

Unit Injector Sleeve – Install

Unit Injector Sleeve – Remove

Valve Mechanism Cover – Remove and Install

Valve Mechanism Cover Base – Remove and Install

Vibration Damper and Pulley – Remove and Install

Water Pump – Assemble

Water Pump – Disassemble

Water Pump – Install

Water Pump – Remove

Water Temperature Regulator – Remove and Install

Water Temperature Regulator Housing – Remove and Install

Specifications (3126B Industrial Engine):

Air Compressor – Bendix Tu-Flo Air Compressors

Air Inlet Elbow

Air Inlet Heater

Alternator and Regulator

Atmospheric Pressure Sensor – If Equipped

Belt Tension Chart

Belt Tensioner

Camshaft

Connecting Rod

Connecting Rod Bearing Journal

Coolant Temperature Sensor

Crankcase Breather

Crankshaft

Crankshaft Seals

Cylinder Block

Cylinder Block Cover Group

Cylinder Head 1

Cylinder Head 2

Cylinder Head Valves

Electric Starting Motor

Electronic Control Wiring Group

Engine Design

Engine Oil Cooler Bypass Valve

Engine Oil Filter Base

Engine Oil Pan

Engine Oil Pressure

Engine Oil Pressure Sensor – If Equipped

Engine Oil Pump

Engine Oil Temperature Sensor

Engine to Transmission Adapter

Exhaust Elbow

Exhaust Manifold

Fan Drive

Flywheel

Flywheel Housing

Front Housing and Covers

Fuel Filter and Water Separator

Fuel Filter Base

Fuel Filter Lines

Fuel Pressure Sensor

Fuel Transfer Pump

Gear Group (Front)

Injection Actuation Pressure Control Valve

Injection Actuation Pressure Sensor

Inlet Air Temperature Sensor

Magnetic Switch

Main Bearing Journal

Piston and Rings 1

Piston and Rings 2

Piston Cooling Jet 1

Piston Cooling Jet 2

Rear Seal Carrier – If Equipped

Refrigerant Compressor

Speed_Timing Sensor

Tachometer Calibration Chart

Turbocharger

Turbocharger Outlet Pressure Sensor

Unit Injector

Unit Injector Hydraulic Pump

Valve Mechanism Cover

Valve Rocker Arms, Lifters, and Bridges

Vibration Damper

Water Pump

Water Temperature Regulator 1

Water Temperature Regulator 2

 

System Operation (3126B Industrial Engine):

Air Inlet and Exhaust System

Basic Engine

Cooling System

Electrical System

Electronic Control System Components

Engine Design

Fuel System

General Information

Glossary of Electronic Control Terms

Lubrication System

 

Testing & Adjusting (3126B Industrial Engine):

Aftercooler – Test

Air in Fuel – Test

Battery – Test

Belt Tension Chart

Charging System – Test

Compression – Test

Connecting Rod Bearings – Inspect

Coolant Temperature Switch – Test

Cooling System – Check – Overheating

Cooling System – Inspect

Cooling System – Test

Cylinder Block – Inspect

Electric Starting System – Test

Engine Crankcase Pressure (Blowby) – Test

Engine Oil Pressure – Test

Engine Oil Pressure Sensor – Test

Engine Oil Pump – Inspect

Engine Speed – Check

Engine Valve Lash – Inspect Adjust

Excessive Bearing Wear – Inspect

Excessive Engine Oil Consumption – Inspect

Exhaust Temperature – Test

Finding Top Center Position for No. 1 Piston

Flywheel – Inspect

Flywheel Housing – Inspect

Fuel Quality – Test

Fuel System – Inspect

Fuel System – Prime

Fuel System Pressure – Test

Increased Engine Oil Temperature – Inspect

Inlet Manifold Pressure – Test

Main Bearings – Inspect

Pinion Clearance – Adjust 1

Pinion Clearance – Adjust 2

Piston Ring Groove – Inspect

Turbocharger – Inspect

Unit Injector – Test

Vibration Damper – Check

Water Pump – Test

Water Temperature Regulator – Test 1

Water Temperature Regulator – Test 2

 

Disassembly & Assembly (3126B Industrial Engine):

Air Compressor – Remove and Install

Air Compressor Drive Gear – Remove and Install

Air Inlet Heater – Remove and Install

Air Inlet Heater Solenoid – Remove and Install

Bearing Clearance – Check

Belt Tightener – Assemble

Belt Tightener – Disassemble

Belt Tightener – Install

Belt Tightener – Remove

Camshaft – Install

Camshaft – Remove

Camshaft Bearings – Remove and Install

Camshaft Gear – Remove and Install

Camshaft Idler Gear – Remove and Install

Crankshaft – Install

Crankshaft – Remove

Crankshaft Front Seal – Install

Crankshaft Front Seal – Remove

Crankshaft Gear – Remove and Install

Crankshaft Main Bearings – Install

Crankshaft Main Bearings – Remove

Crankshaft Rear Seal – Install

Crankshaft Rear Seal – Remove

Crankshaft Rear Seal Carrier – Remove and Install

Cylinder Head – Install

Cylinder Head – Remove

Electric Starting Motor – Remove and Install

Electronic Control Module – Remove and Install

Engine Oil Cooler – Install

Engine Oil Cooler – Remove

Engine Oil Filter Base – Assemble

Engine Oil Filter Base – Disassemble

Engine Oil Filter Base – Install

Engine Oil Filter Base – Remove

Engine Oil Pan – Remove and Install

Engine Oil Pump – Assemble

Engine Oil Pump – Disassemble

Engine Oil Pump – Install

Engine Oil Pump – Remove

Exhaust Manifold – Remove and Install

Flywheel – Remove and Install

Flywheel Housing – Remove and Install

Fuel Filter Base – Remove and Install

Fuel Pressure Regulator – Remove and Install

Fuel Transfer Pump – Install

Fuel Transfer Pump – Remove

Housing (Front) – Install

Housing (Front) – Remove

Idler Pulley – Remove and Install

Injection Actuation Pressure Control Valve – Remove and Install

Inlet and Exhaust Valve Guides – Remove and Install

Inlet and Exhaust Valve Seat Inserts – Remove and Install

Inlet and Exhaust Valves – Remove and Install

Lifter Group – Remove and Install

Piston Cooling Jets – Remove and Install

Pistons and Connecting Rods – Assemble

Pistons and Connecting Rods – Disassemble

Pistons and Connecting Rods – Install

Pistons and Connecting Rods – Remove

Rocker Shaft – Assemble

Rocker Shaft – Disassemble

Rocker Shaft and Pushrod – Install

Rocker Shaft and Pushrod – Remove

Turbocharger – Assemble

Turbocharger – Disassemble

Turbocharger – Install

Turbocharger – Remove

Unit Injector – Install

Unit Injector – Remove

Unit Injector Hydraulic Pump – Install

Unit Injector Hydraulic Pump – Remove

Unit Injector Sleeve – Install

Unit Injector Sleeve – Remove

Valve Mechanism Cover – Remove and Install

Valve Mechanism Cover Base – Remove and Install

Vibration Damper and Pulley – Remove and Install

Water Pump – Assemble

Water Pump – Disassemble

Water Pump – Install

Water Pump – Remove

Water Temperature Regulator – Remove and Install

Water Temperature Regulator Housing – Remove and Install

 

Troubleshooting (3126B Industrial Engine):

Engine Speed Timing Sensor – Calibrate

Throttle Position Sensor – Calibrate

Air Inlet Heater Circuit – Test

Air Shutoff System – Test

Analog Sensor Open or Short Circuit – Test

Analog Sensor Supply Circuit – Test

Auxiliary Temperature Sensor Circuit – Test

CAN Data Link Circuit – Test

Cat Data Link Circuit – Test

Coolant Level Sensor Circuit – Test

Diagnostic Lamp Circuit – Test

Digital Sensor Supply Circuit – Test

ECM_Personality Module – Test

Electrical Connectors – Inspect

Electrical Power Supply Circuit – Test

Engine Speed Timing Sensor Circuit – Test

Engine Temperature Sensor Open or Short Circuit – Test

Injection Actuation Pressure – Test

Injection Actuation Pressure Control Valve Circuit – Test

Injection Actuation Pressure Sensor – Test

Injector Solenoid Circuit – Test

Maintenance Due Lamp Circuit – Test

PTO Ramp Up Down Switch Circuit – Test

Switch Circuits – Test

Throttle Position Sensor Circuit – Test

Warning Lamp Circuit – Test

Component Diagram

Electrical Connectors and Functions

Electronic Service Tools

Engine Wiring Information

Replacing the ECM

Self-Diagnostics

Sensors and Electrical Connectorf

System Overview

Customer Passwords

Factory Passwords

Factory Passwords Worksheet

Flash Programming

Programming Parameters

Service Information Report

System Configuration Parameters

CID 0001 FMI 11 Cylinder #1 Injector fault

CID 0002 FMI 11 Cylinder #2 Injector fault

CID 0003 FMI 11 Cylinder #3 Injector fault

CID 0004 FMI 11 Cylinder #4 Injector fault

CID 0005 FMI 11 Cylinder #5 Injector fault

CID 0006 FMI 11 Cylinder #6 Injector fault

CID 0042 FMI 11 Inject Actuation Control Valve open short

CID 0091 FMI 08 Throttle Position signal abnormal

CID 0091 FMI 13 Throttle Position calibration required

CID 0094 FMI 03 Fuel Pressure open short to +batt

CID 0094 FMI 04 Fuel Pressure short to ground

CID 0100 FMI 03 Engine Oil Pressure open short to +batt

CID 0100 FMI 04 Engine Oil Pressure short to ground

CID 0110 FMI 03 Engine Coolant Temperature open short to +batt

CID 0110 FMI 04 Engine Coolant Temperature short to ground

CID 0164 FMI 00 High Injector Actuation Pressure

CID 0164 FMI 02 Injector Actuation Pressure signal erratic

CID 0164 FMI 03 Injector Actuation Pressure voltage high

CID 0164 FMI 04 Injector Actuation Pressure voltage low

CID 0164 FMI 11 Injector Actuation Pressure system fault

CID 0168 FMI 02 System Voltage intermittent erratic

CID 0172 FMI 03 Intake Manifold Air Temp open short to +batt

CID 0172 FMI 04 Intake Manifold Air Temp short to ground

CID 0175 FMI 03 Engine Oil Temperature open short to +batt

CID 0175 FMI 04 Engine Oil Temperature short to ground

CID 0247 FMI 09 J1939 Data Link communications

CID 0253 FMI 02 Personality Module mismatch

CID 0254 FMI 12 Electronic Control Module Error

CID 0261 FMI 13 Engine Timing Calibration required

CID 0262 FMI 03 5 Volt Sensor DC Power Supply short to +batt

CID 0262 FMI 04 5 Volt Sensor DC Power Supply short to ground

CID 0263 FMI 03 Digital Sensor Supply short to +batt

CID 0263 FMI 04 Digital Sensor Supply short to ground

CID 0268 FMI 02 Check Programmable Parameters

CID 0273 FMI 03 Turbo Outlet Pressure open short to +batt

CID 0273 FMI 04 Turbo Outlet Pressure short to ground

CID 0274 FMI 03 Atmospheric Pressure open short to +batt

CID 0274 FMI 04 Atmospheric Pressure short to ground

CID 0320 FMI 02 Speed Timing Sensor Loss of Signal

CID 0320 FMI 11 Speed Timing Sensor mechanical failure

CID 0342 FMI 02 Loss of Secondary Engine Speed signal

CID 0342 FMI 11 Secondary Engine Speed Sensor mechanical failure

CID 0617 FMI 05 Air Inlet Heater Relay open current below normal

CID 0617 FMI 06 Air Inlet Heater Relay grounded current above norm

Diagnostic Codes

Flash Codes

E004 Engine Overspeed Shutdown

E005 Fuel Filter Restriction Derate

E006 Fuel Filter Restriction Shutdown

E015 High Engine Coolant Temperature Derate

E016 High Engine Coolant Temperature Shutdown

E017 High Engine Coolant Temperature Warning

E025 High Inlet Air Temperature Derate

E027 High Inlet Air Temperature Warning

E039 Low Engine Oil Pressure Derate

E040 Low Engine Oil Pressure Shutdown

E057 Low Engine Coolant Level Derate

E058 Low Engine Coolant Level Shutdown

E059 Low Engine Coolant Level Warning

E095 Fuel Filter Restriction Warning

E096 High Fuel Pressure

E100 Low Engine Oil Pressure Warning

E190 Engine Overspeed Warning

E443 High Auxiliary Pressure

E445 High Auxiliary Temperature

Event Codes

Alternator – Charging Problem

Battery

Can Not Reach Top Engine RPM

Coolant in Engine Oil

Coolant Temperature Is Too High

ECM Will Not Accept Factory Passwords

Electronic Service Tool Will Not Communicate with ECM

Engine Cranks but Will Not Start

Engine Has Early Wear

Engine Misfires, Runs Rough or Is Unstable

Engine Stalls at Low RPM

Engine Vibration

Engine Will Not Crank

Excessive Black Smoke

Excessive Engine Oil Consumption

Excessive White Smoke

Exhaust Temperature Is Too High

Fuel Dilution of Engine Oil

Fuel in Cooling System

Intermittent Engine Shutdown

Intermittent Low Power or Power Cutout

Low Engine Oil Pressure

Low Power Poor or No Response to Throttle

Noise Coming from Cylinder

Poor Acceleration or Response

 

Bonus Material:

Battery Cross Ref

Battery Specs

Cooling System (3126B & 3126E)

DSTC

Fuel System (3126B & 3126E)

Intake, Exhaust & Turbocharger (3126B & 3126E)

Lubrication (3126B & 3126E)

Mechanical (3126B & 3126E)

One Safe Source

Shop Supplies &Tools

Troubleshooting (3126B & 3126E)

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 

Language: English 
Format: PDF

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 10, WINDOWS 8, WINDOWS 7, VISTA 32 and 64, XP, ME, 98, NT, 2000 ETC.) 

Windows/Mac/Tablet/Phone Friendly