3408E/3412E ENGINE CONTROLS

HYDRAULIC ELECTRONIC UNIT INJECTION

(HEUI)

©1997 Caterpillar Inc.

 3408E/3412E HEUI FUEL SYSTEM
TO LUBE
SYSTEM

HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
 8 OR 12
3408E/3412E HEUI SYSTEM
INJECTORS COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE GROUND DISCONNECT SWITCH
ENGINE (ECM) BOLT
HARNESS
24 V
MAIN KEY
MACHINE POWER RELAY
HARNESS 15 AMP SWITCH
BREAKER
PUMP CONTROL VALVE
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PRIMARY PROBE ACCESS
THROTTLE
SPEED/TIMING SENSOR SENSOR ACCELERATOR
PEDAL
SECONDARY THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
SPEED/TIMING SENSOR AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

FAN CONTROL VALVE

TURBO OUTLET PRESS. SENSOR
FAN SPEED SENSOR
FAN
ATMOSPHERIC PRESS. SENSOR
CAT DATA LINK

OIL PRESSURE SENSOR ELECTRONIC SERVICE TOOL

EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP. SENSOR
AUTO RETARDER CONTROL

FUEL TEMPERATURE SENSOR

INSTRUMENT
PANEL
COOLANT FLOW SWITCH
ELECTRONIC CONTROL SYSTEM
HEUI INJECTOR TESTING
METHODS

INJECTOR SOLENOID TEST

CYLINDER CUT-OUT

AUTOMATIC INJECTOR TEST

 HEUI CONTROL LOGIC

TIMING CONTROL
ENGINE SPEED
TIMING DEGREES BTDC DESIRED
TIMING FUEL INJECTION
FUEL QUANTITY FUEL RPM BTDC
SELECT CONVERT TIMING WAVE FORM
TIMING DESIRED
TIMING
HYDRAULIC OIL
TEMPERATURE COLD MODE
 3408E/3412E ELECTRONIC GOVERNOR

HYDRAULIC OIL
SHUTDOWNS TEMPERATURE AND
PRESSURE SENSORS
TO PUMP
CONTROL VALVE
INJECTION ECM
ACTUATION ELECTRONIC
CONTROL GOVERNOR
8
SIGNALS 7
TO FUEL 6 FUEL FRC TORQUE ENGINE THROTTLE
INJECTORS 5 INJECTION MAPS MAPS CONTROL
ENGINE RPM
4 CONTROL LOGIC
3
2 TDC
1
SPEED/TIMING ENGINE RPM ENGINE RPM
SIGNAL

TURBO OUTLET AND

ATMOSPHERIC
TIMING PRESSURE SENSORS
WHEEL

SPEED/TIMING
SENSORS
 8 OR 12
HEUI SYSTEM
INJECTORS ADEM II
COMPONENT DIAGRAM
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE 15 AMP POWER RELAY SWITCH
HARNESS BREAKER
PUMP CONTROL VALVE
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PRIMARY PROBE ACCESS
THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL
SECONDARY
SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

PROPORTIONAL VALVE
TURBO OUTLET PRESS. SENSOR
FAN SPEED SENSOR
FAN
ATMOSPHERIC PRESS. SENSOR
CAT DATA LINK

OIL PRESSURE SENSOR ELECTRONIC SERVICE TOOL

EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP. SENSOR AUTO RETARDER CONTROL

FUEL TEMPERATURE SENSOR

INSTRUMENT
PANEL
COOLANT FLOW SWITCH
 SPEED/TIMING SENSORS
SECONDARY
SPEED/TIMING
SENSOR P44 J44
OR A
BK B
WH C

P2 J2

PRIMARY ECM
SPEED/TIMING (3408E/3412 E)
SENSOR P20 J20
732-PK 39 SECONDARY ENGINE SPEED
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 PRIMARY ENGINE SPEED
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -
P26 P1 J1
TIMING CALIBRATION 1
CONNECTOR 2
 TIMING WHEEL
TDC REF

SECONDARY REF TDC SINGLE

4
SPEED/TIMING 50/50 TOOTH
SENSOR
TDC CYLINDER No. 1
3 8
REF PRIMARY
SPEED/TIMING
SENSOR
TDC

REF

TIMING
1 CALIBRATION
6 RANGE ± 10°

TDC REF

TIMING WHEEL
ROTATION TDC
REF
5 2

7 REF
TDC
REF TDC
 CRANKING

TIMING GEAR TOOTH TABLE

TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE
A 80 % NONE IDENTIFIED
B 80 %
C 80 %
D 80 %
E 80 %
F 80 %
G 80 %
H 50 %

80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 80/20 % 50/50%

A B C D E F G H

TIMING WHEEL ROTATION

 AFTER PATTERN RECOGNITION

TIMING GEAR TOOTH TABLE

TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE
A 80 % NO
B 80 % CYL NO. 3
C 80 % NO
D 80 % NO
E 80 % CYL NO. 4
F 80 % NO
G 80 % NO
H 50 % CYL NO. 8

TIMING WHEEL ROTATION

A B C D E F G H

CYL NO. 3 CYL NO. 3 CYL NO. 4 CYL NO. 4 CYL NO. 8
REFERENCE TDC REFERENCE TDC REFERENCE
EDGE EDGE EDGE
 TIMING GEAR TOOTH TABLE
TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE
NORMAL OPERATION
A 80 % NO
B 80 % CYL NO. 3
C 80 % NO
D 80 % NO
E 80 % CYL NO. 4
F 80 % NO
G 80 % NO
H 50 % CYL NO. 8

TIMING WHEEL ROTATION

A B C D E F G H

62° BTDC (EEPROM) 62° BTDC (EEPROM)

DES TIMING DES TIMING

DELAY NO. 3 DELAY NO. 4

INJECTION INJECTION
ASSUMED ASSUMED
TDC TDC
CYL NO. 3 CYL NO. 4
CYL NO. 3 ACTUAL TDC CYL NO. 4 ACTUAL TDC
(REFERENCE) (CALIBRATED) (REFERENCE) (CALIBRATED)
 TIMING CALIBRATION SENSOR
SECONDARY
SPEED/TIMING
SENSOR P44 J44

OR A
BK B
WH C

P2 J2

PRIMARY ECM
SPEED/TIMING (3408E/3412E)
SENSOR P20 J20
732-PK 39 SECONDARY ENGINE SPEED
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 PRIMARY ENGINE SPEED
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -

TIMING CALIBRATION P1 J1
SENSOR
P26
1
2

TIMING CALIBRATION
CONNECTOR
 TIMING CALIBRATION

TIMING
WHEEL

REFERENCE EDGE TO TDC DISTANCE

REFERENCE
EDGE ASSUMED ACTUAL
CYL. NO. 1 TDC CYL. NO. 1 TDC

-10° +10° TIMING

REFERENCE
TIMING CALIBRATION ± 10° OFFSET
SENSOR SIGNAL

MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES

 INJECTION CURRENT WAVEFORM
ONE CYCLE
CURRENT FLOW

PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

0 1 2 3 4 5
TIME (MILLISECONDS)
 POPPET VALVE MOVEMENT

POPPET
LIFT
CURRENT FLOW

CURRENT

0 1 2 3 4 5
TIME (MILLISECONDS)
 WAVEFORM AND RESPONSE CHARACTERISTICS

INJECTION
RATE

POPPET
LIFT
CURRENT FLOW

CURRENT

END OF
INJECTION

START OF
DURATION
INJECTION

0 1 2 3 4 5
TIME (MILLISECONDS)
FUEL SYSTEM LIMITS

• Maximum Horsepower
• Maximum Torque
• Fuel Ratio
• Cold Mode Limit
• Cranking Fuel
FUEL SYSTEM COLD MODES

• Speed Control
• Fuel Limiting
• Injection Timing
• Injection Actuation Pressure
• Ether Injection
 FUEL SYSTEM DERATES

• Automatic Altitude Compensation

• Automatic Filter Compensation
• Engine Warning Derate
FUEL INJECTION SYSTEM
3408E/3412E HEUI FUEL SYSTEM

TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
 3408E/3412E HEUI FUEL SYSTEM
LOW PRESSURE OIL (HYDRAULIC) SUPPLY
TO LUBE
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK
 3408E/3412E HEUI FUEL SYSTEM
TO LUBE
HIGH PRESSURE HYDRAULICS
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR

COOL DOWN FUEL HYDRAULIC

HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER SECONDARY
PUMP PRESSURE
FUEL REGULATING
LUBE OIL
FILTER VALVE
PUMP
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK
TO LUBE
SYSTEM 3408E/3412E HEUI FUEL SYSTEM
LOW PRESSURE FUEL SUPPLY
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR

COOL DOWN FUEL HYDRAULIC

HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL FILTER REGULATING
PUMP (2 MICRON) VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK
INJECTOR FLUID FLOW HIGH PRESSURE HYDRAULIC OIL

INJECTOR OIL INJECTOR CLAMP

ADAPTER

JUMPER TUBE

ROCKER ARM BASE

INJECTOR
LUBE OIL PASSAGE

HIGH PRESSURE
HYDRAULIC PASSAGE

FLUID SUPPLY
MANIFOLD

CYLINDER HEAD
INJECTOR SLEEVE

CYLINDER HEAD

LOW PRESSURE
FUEL SUPPLY

COOLANT
CYLINDER BLOCK
METAL WASHER
 INJECTOR FUEL SUPPLY

INJECTOR

UPPER INJECTOR UPPER SLEEVE

O-RING SEAL O-RING SEAL

CYLINDER HEAD
INJECTOR SLEEVE

FLUID SUPPLY
MANIFOLD LOWER SLEEVE
O-RING SEAL

LOW PRESSURE
FUEL SUPPLY

CYLINDER
HEAD

METAL-TO- METAL
LOWER INJECTOR CONTACT
O-RING SEAL
 FLUID SUPPLY MANIFOLD

CYLINDER HEAD ROCKER ARM

FUEL SEALS INJECTOR SLEEVE BASE

LOW PRESSURE EXTRACTOR LUBRICATION OIL HIGH PRESSURE

FUEL SUPPLY PASSAGE SPLINES PASSAGE HYDRAULIC PASSAGE
 INJECTION CURRENT WAVEFORM
ONE CYCLE
CURRENT FLOW

PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

0 1 2 3 4 5
TIME (MILLISECONDS)
 WAVEFORM AND RESPONSE CHARACTERISTICS

INJECTION
RATE
POPPET
LIFT
CURRENT FLOW

CURRENT

DURATION

0 1 2 3 4 5
START OF TIME (MILLISECONDS) END OF
INJECTION INJECTION
 VALVE BODY
GROUP

BARREL GROUP

HEUI UNIT INJECTOR

3 MAIN GROUPS

NOZZLE GROUP
 3408E/3412E HEUI INJECTOR
COMPONENTS

VALVE BODY GROUP

BODY SOLENOID
ADAPTER BOLT ARMATURE ASSEMBLY

POPPET SPRING SLEEVE SHIM SEAL SPACER SCREW SCREW

SEAL

INTENSIFIER PISTON

BARREL GROUP
RETAINER RING

WASHER NOZZLE GROUP

LIFT
DOWEL BALL DOWEL SPACER DOWEL TIP CASE

STOP CHECK STOP STOP SPRING SLEEVE CHECK

PLUNGER SPRING SEAL BARREL BALL
PLATE PLATE PIN
 SPACER
SLEEVE
ARMATURE

VALVE

VALVE BODY SOLENOID

SHIM
BARREL
ADAPTER

UNIT INJECTOR
PISTON WASHER COMPONENTS

UPPER FUEL SEAL

PLUNGER

FUEL INLET
CHECK VALVE

PIN
SLEEVE
SPACER

LOWER FUEL SEAL

CHECK
NOZZLE
 INJECTOR INSTALLATION
ALLEN
SCREWS

HORIZONTAL INJECTOR CLAMP

BOLTS

JUMPER TUBE
INJECTOR OIL
ADAPTOR VERTICAL
BOLTS
 VALVE BODY GROUP

SOLENOID DE-ENERGIZED SOLENOID ENERGIZED

POPPET VALVE CLOSED POPPET VALVE OPEN

POPPET VALVE

SOLENOID

ARMATURE

INLET ARMATURE
EXHAUST POPPET
VALVE SEAT SCREW
VALVE SEAT SPRING
 SUPPLY OIL

INTENSIFIER
PISTON

BARREL GROUP
FUEL PRESSURE INCREASE

BARREL

PLUNGER

FUEL INLET
CHECK VALVE
REVERSE FLOW
CHECK VALVE

FUEL TO
FUEL FROM NOZZLE
TRANSFER PUMP
 NOZZLE GROUP

REVERSE FLOW
CHECK VALVE

VIEW OF STOP PLATE &

REVERSE FLOW CHECK VALVE

CHECK VALVE

FUEL
ATOMIZATION
 VALVE BODY GROUP
SOLENOID DE-ENERGIZED

POPPET VALVE

SOLENOID

ARMATURE

INLET
VALVE SEAT

EXHAUST
VALVE SEAT
SLEEVE SPACER

VALVE
ARMATURE

SOLENOID
BODY
SHIM
BARREL
ADAPTER

PISTON WASHER
UNIT INJECTOR
END OF INJECTION

PLUNGER

BALL

PIN
SLEEVE
SPACER

CHECK
NOZZLE
 BARREL

PISTON WASHER

BARREL GROUP
REFILLING THE BARREL

PLUNGER

FUEL INLET
CHECK VALVE

FUEL EDGE PIN

FILTER
SLEEVE
SPACER

NOZZLE CHECK
VALVE
NOZZLE
 EDGE FILTER
FUEL INLET
CHECK VALVE

REVERSE FLOW
CHECK VALVE

FUEL INLET FUEL INLET

EDGE FILTER
 PRIME INJECTION RATE SHAPING

PRIME = PRE-INJECTION METERING INJECTION RATE

START OF INJECTION DURATION

0 1 2 3 4 5
TIME (MILLISECONDS)
 BARREL GROUP
OIL FLOW PRIME RATE SHAPING

BARREL

PLUNGER

PRIME RATE
SHAPING PASSAGE SPILL
PORT

CROSS SECTION
OF PLUNGER
FUEL TO
NOZZLE GROUP
FINAL
START OF INJECTION PRESSURE DROP PRESSURE INCREASE
INTENSIFIER
PISTON

INTENSIFIER
PISTON SEAL
BARREL GROUP
VENTING INTERNAL LEAKS
BARREL

VENTING
CHECK VALVE
 INJECTOR CHECK VALVES

BARREL GROUP NOZZLE GROUP

FUEL INLET
CHECK VALVE
VENTING
CHECK VALVE

REVERSE FLOW
CHECK VALVE

NOZZLE
CHECK VALVE

FUEL
ATOMIZATION
 HYDRAULIC INJECTION PRESSURE CONTROL
INJECTION PRESSURE

HEUI

MECHANICALLY ACTUATED
FUEL SYSTEM

IDLE PEAK TORQUE RATED

ENGINE SPEED
 PRIMING PORT COMPENSATOR
VALVE
HEUI PUMP

ORIFICE VALVE BASE

DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR

SWASHPLATE
 COOL DOWN BYPASS CIRCUIT
TO LUBE
.020 IN.
SYSTEM ORIFICE HEUI
HYDRAULIC
DRAIN TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP
FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER

FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP REGULATING
FUEL
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
 REVERSE FLOW CHECK VALVE

SEAT
(END VIEW)

FROM
TO
PUMP
INJECTORS

FITTING VALVE BLOCK SPRING CHECK SEAT

 3408E/3412E HEUI FUEL SYSTEM
TO LUBE
HYDRAULIC SYSTEM OPERATION
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT PRESSURE
TEMPERATURE
SUPPLY SENSOR
OIL SENSOR
PUMP
FILTER GROUP FLUID MANIFOLD
HYDRAULIC PASSAGE

PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER SECONDARY
PUMP PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL
FILTER
OIL
SUMP FUEL TANK
 HEUI HYDRAULIC CONTROL SYSTEM
START-UP
TO LEFT OIL TO RIGHT OIL
TO LUBE COLD START
RESERVIOR MANIFOLD MANIFOLD
SYSTEM DISPLACEMENT
CONTROL PISTON

CHECK VALVE
PRESSURE
LIMITER
SUPPLY PUMP SPOOL

SOLENOID LOAD
SENSING
(ENERGIZED)
SPOOL

OIL SUMP
PUMP
CONTROL
VALVE

PUMP
CASE DRAIN
 COMPENSATOR ASSEMBLY
START-UP
PRESSURE LIMITER SPOOL

ORIFICE

PUMP CONTROL
VALVE LOAD SENSING SPOOL

CHECK VALVE

FROM DISPLACEMENT
CONTROL PISTON

DRAIN ORIFICE

TO CASE DRAIN
TO
CASE
DRAIN
REVERSE FLOW
CHECK VALVES
 HEUI HYDRAULIC CONTROL SYSTEM
DESTROKE
TO LEFT OIL TO RIGHT OIL
TO LUBE COLD START
RESERVIOR MANIFOLD MANIFOLD
SYSTEM DISPLACEMENT
CONTROL PISTON

CHECK VALVE
PRESSURE
LIMITER
SUPPLY PUMP SPOOL

LOAD
SOLENOID SENSING
(DE-ENERGIZED) SPOOL

OIL SUMP
PUMP
CONTROL
VALVE

PUMP
CASE DRAIN
 COMPENSATOR ASSEMBLY
DESTROKE
PRESSURE
LIMITER SPOOL

ORIFICE
PUMP
CONTROL VALVE

LOAD SENSING
SPOOL

CHECK VALVE

TO DISPLACEMENT
CONTROL PISTON
DRAIN ORIFICE

TO CASE DRAIN
 HEUI HYDRAULIC CONTROL SYSTEM
UPSTROKE
TO LEFT OIL TO RIGHT OIL
TO LUBE COLD START
RESERVIOR MANIFOLD MANIFOLD
SYSTEM DISPLACEMENT
CONTROL PISTON

CHECK VALVE
PRESSURE
LIMITER
SUPPLY PUMP SPOOL

LOAD
SOLENOID SENSING
(ENERGIZED) SPOOL

OIL SUMP
PUMP
CONTROL
VALVE

PUMP
CASE DRAIN
 COMPENSATOR ASSEMBLY
UPSTROKE
PRESSURE
LIMITER SPOOL

ORIFICE
PUMP
CONTROL VALVE
LOAD SENSING
SPOOL

CHECK VALVE

FROM
DISPLACEMENT
DRAIN ORIFICE CONTROL PISTON

TO CASE DRAIN
 HEUI HYDRAULIC CONTROL SYSTEM
PRESSURE LIMITER OPERATION
TO LEFT OIL TO RIGHT OIL
TO LUBE COLD START
RESERVIOR MANIFOLD MANIFOLD
SYSTEM DISPLACEMENT
CONTROL PISTON

PRESSURE
LIMITER
SUPPLY PUMP SPOOL

LOAD
SOLENOID SENSING
(DE-ENERGIZED) SPOOL
PLUGGED
ORIFICE

OIL SUMP
PUMP
CONTROL
VALVE

PUMP
CASE DRAIN
 COMPENSATOR ASSEMBLY
PRESSURE LIMITER OPERATION
PRESSURE LIMITER
SPOOL

PUMP
CONTROL VALVE ORIFICE

RESTRICTION
LOAD SENSING
SPOOL

CHECK VALVE

TO
DISPLACEMENT
CONTROL PISTON
DRAIN ORIFICE
TO CASE DRAIN
 PUMP CONTROL VALVE
NO CURRENT FLOW
FROM LOAD
COIL POPPET SENSING SPOOL
ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE

STOP STATOR

EDGE FILTER

SPRING
RETAINER

TO VALVE
ARMATURE SOLENOID PIN SHELL RING CASE DRAIN BLOCK
 PUMP CONTROL VALVE
HIGH CURRENT FLOW
FROM LOAD
COIL POPPET SENSING SPOOL
ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE
EDGE
FILTER

STOP STATOR

VALVE TO SPRING
ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
HEUI SYSTEM POWER SUPPLIES

• ECM: 24 VOLTS

• SPEED/TIMING SENSORS: 12.5 VOLTS

• INJECTORS: 105 VOLTS

• ANALOG SENSORS: 5 VOLTS

• DIGITAL SENSORS: 8 VOLTS

• PUMP CONTROL VALVE: 0 to 24 VOLTS

 3408E/3412E HEUI SYSTEM
8 OR 12
ECM POWER SUPPLY COMPONENTS
INJECTORS
ADEM II
ELECTRONIC
CONTROL
ENGINE MODULE DISCONNECT SWITCH
(ECM) GROUND
HARNESS BOLT

24 V
MAIN KEY
MACHINE 15 AMP POWER RELAY SWITCH
HARNESS BREAKER
PUMP
CONTROL VALVE
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PRIMARY PROBE ACCESS THROTTLE
SPEED/TIMING SENSOR ACCELERATOR
SENSOR PEDAL
SECONDARY
SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

FAN CONTROL VALVE

TURBO OUTLET PRESS. SENSOR
FAN SPEED SENSOR
FAN
ATMOSPHERIC PRESS. SENSOR
CAT DATA LINK

OIL PRESSURE SENSOR ELECTRONIC SERVICE TOOL

EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP. SENSOR
AUTO RETARDER CONTROL

FUEL TEMPERATURE SENSOR

INSTRUMENT
PANEL
COOLANT FLOW SWITCH
 ECM POWER SUPPLY CIRCUIT

DISCONNECT ENGINE BLOCK

SWITCH GROUND BOLT
BATTERY
ECM
P1 J1 (3408E/3412E)
(-)
229-BK-14 05 (-) BATTERY
24 VOLTS DC
229-BK-14 11 (-) BATTERY
(+) 1 150-RD-14 04 (+) BATTERY
15 A
2 150-RD-14 06 (+) BATTERY
CIRCUIT BREAKER
26 113-OR 23 KEY SWITCH ON
113-OR
P3 J3
10 AMP
112-PU
308-YL R

117-RD 200-BK C OFF

S ON
105-RD B ST

KEY SWITCH
 SPEED/TIMING SENSOR POWER SUPPLY
12.5 ± 1 VOLTS
SECONDARY
SPEED/TIMING
SENSOR (LH) P44 J44
OR A
BK B
WH C
P2 J2
PRIMARY ECM
SPEED/TIMING (3408E/3412E)
SENSOR (RH) P20 J20
732-PK 39 SECONDARY ENGINE SPEED
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 PRIMARY ENGINE SPEED
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -

P1 J1
 INJECTOR WIRING SCHEMATIC
ECM
J52/P52 P2 J2 (3408/3412E)
1 A701-GY 16 SOLENOID 1 POWER
SOLENOID 1
2 F726-YL 05 SOLENOID 1/3 RETURN
3 A703-BR 32 SOLENOID 3 POWER
SOLENOID 3
4 F726-YL

J56/P56
1 A702-PU 40 SOLENOID 2 POWER
SOLENOID 2
2 F727-BU 11 SOLENOID 2/4 RETURN
3 A704-GN 34 SOLENOID 4 POWER
SOLENOID 4
4 F727-BU

J53/P53
1 A705-BU 32 SOLENOID 5 POWER
SOLENOID 5
2 F728-BR 17 SOLENOID 5/7 RETURN
3 A707-PU 38 SOLENOID 7 POWER
SOLENOID 7
4 F728-BR

J57/P57
1 A706-GY 28 SOLENOID 6 POWER
SOLENOID 6
2 F729-GN 21 SOLENOID 6/8 RETURN
3 A708-BR 22 SOLENOID 8 POWER
SOLENOID 8
4 F729-GN

J54/P54
1 A709-OR 37 SOLENOID 9 POWER
SOLENOID 9
2 F730-GY 27 SOLENOID 9/11 RETURN
3 A711-PU 31 SOLENOID 11 POWER
SOLENOID 11
4 F730-GY

J58/P58
1 A710-GY 18 SOLENOID 10 POWER
SOLENOID 10
2 F731-OR 33 SOLENOID 10/12 RETURN
3 A712-BR 12 SOLENOID 12 POWER
SOLENOID 12
4 F731-OR
 J21 P21 P1 J1 ECM (3408E/3412E HEUI)
+V ANALOG A 36 +V ANALOG SUPPLY
ENGINE COOLANT ANALOG RETURN B 30 ANALOG RETURN
TEMPERATURE SENSOR SIGNAL C

P22 J22
+V ANALOG A
ENGINE OIL ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P23 J23
+V ANALOG A
TURBO OUTLET ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P25 J25 ANALOG SENSOR

+V ANALOG A
TURBO INLET
ANALOG RETURN
SIGNAL
B
C
POWER SUPPLY
PRESSURE SENSOR
P27 J27 5 ± 0.2 VOLTS
+V ANALOG A
ATMOSPHERIC ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P45 J45
+V ANALOG A
HYDRAULIC B
ANALOG RETURN
PRESSURE SENSOR SIGNAL C

P43 J43
+V ANALOG A
FUEL TEMPERATURE ANALOG RETURN B
SENSOR SIGNAL C

P51 J51

HYDRAULIC OIL +V ANALOG A

ANALOG RETURN B
TEMPERATURE SENSOR SIGNAL C
 THROTTLE
POSITION SENSOR J35 P35 P1 J1 ECM (3408E/3412E HEUI)
+V DIGITAL A 29 + V DIGITAL SUPPLY
DIGITAL RETURN B 35 - V DIGITAL RETURN
SIGNAL C

DIGITAL SENSOR
FAN
POWER SUPPLY
SPEED SENSOR
P84 J84 8 ± 0.5 VOLTS
+V DIGITAL A
DIGITAL RETURN B
SIGNAL C
 PUMP CONTROL VALVE
POWER SUPPLY
0 to 24 VOLTS PWM
0 to 800 mAmps

PUMP CONTROL
VALVE J46 P46 P2 J2 ECM (3408E/3412E HEUI)
SUPPLY A 29 + SUPPLY
RETURN B 35 - RETURN
ELECTRONIC SENSORS AND SYSTEMS
 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE POWER RELAY
HARNESS 15 AMP SWITCH
BREAKER

MACHINE
INTERFACE
TDC SERVICE CONNECTOR
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR
 ANALOG SENSORS
• Hydraulic pressure
• Coolant temperature
• Atmospheric pressure
• Turbocharger i n l e t pressure
• Turbocharger outlet pressure
• Lubrication oi l pressure
• Hydraulic temperature
• Fu e l temperature
 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR
 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR

 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR

ATMOSPHERIC PRESS. SENSOR

 ENGINE POWER DERATING MAP
ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500
PERCENT OF FULL LOAD POWER

98% 8,210

96% 8,920

94% 9,630

10,340

ALTITUDE IN FEET
92%

90% 11,050

88% 11,760

86% 12,470

84% 13,180

82% 13,890

80% 14,600

78% 15,310

76% 16,020

74% 16,730

72% 17,440

77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53

ATMOSPHERIC PRESSURE IN kPa

 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE POWER RELAY
HARNESS 15 AMP SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

ATMOSPHERIC PRESS. SENSOR

 AUTOMATIC AIR FILTER COMPENSATION

TURBOCHARGER ATMOSPHERIC
INLET PRESSURE PRESSURE
SENSOR SENSOR

CAT

Filter differential pressure calculated with formula:

Atmospheric sensor pressure - Turbo sensor pressure = ∆P
Fuel limited 2% per 4 inches H20 to max 20%
 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

 OIL PRESSURE MAP
340 49.3

320 46.4

300 43.5

280 40.6
OIL PRESSURE IN kPa

OIL PRESSURE IN PSI

260 37.7

240 34.8

220 31.9

200 29

180 26.1

160 23.2

140 20.3

120 17.4

100 14.5

80 11.6

60 8.7
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000

ENGINE RPM
kPa x 0.145 = PSI
 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET (BOOST)

PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY CAM
SPEED/TIMING SENSOR

BACKUP CAM
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP SENSOR

FUEL TEMPERATURE SENSOR

 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

DIGITAL SENSORS AND CIRCUITS

• Throttle Position

• Pump Control Valve Signal

• Exhaust Temperature
 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN
MACHINE KEY
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

 PULSE WIDTH MODULATED SIGNALS
10%
ON

DUTY = 10%
CYCLE

OFF

50%
ON

DUTY = 50%
CYCLE

OFF
1 CYCLE
90%
ON

DUTY
= 90%
CYCLE

OFF

DUTY CYCLE = PERCENT OF TIME ON VS PERCENT OF TIME OFF

 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN
MACHINE KEY
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
PUMP CONTROL VALVE

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL

SECONDARY
SPEED/TIMING SENSOR

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
PUMP CONTROL VALVE

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL

SECONDARY
SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

TURBO OUTLET PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

 USER DEFINED SHUTDOWN

J3 P2 J2
ECM (3408E/3412E HEUI)
USER SHUTDOWN 12 1 USER SHUTDOWN
DEVICE
 HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
PUMP CONTROL VALVE

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL

SECONDARY
SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

FAN CONTROL VALVE

TURBO OUTLET PRESS. SENSOR
FAN SPEED SENSOR
FAN
ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

 ETHER INJECTION SYSTEM
P2 J2
ECM
(3408E/E3412E)

ETHER SWITCH J3 P3 P1 J1
23 F708-YL 28 ETHER SW LAMP
9 998-BR 29 DIGITAL RETURN
39 721-GY 19 ETHER REQUEST
21 710-BR 40 ETHER CONTROL
200-BK

200-BK FROM
P37 J37
+ CYLINDER
308-YL 310-PK 1
2

+24V
RELAY ETHER
START VALVE TO ENGINE
 SERVICE
TOOL
CONNECTOR CAT DATA LINK

LAPTOP
COMPUTER
CONTROL SERVICE TOOL

CAT
ELECTRONIC TECHNICIAN

7X1701

COMMUNICATION
ADAPTER

ADEM II
ELECTRONIC
MAIN MODULE

CONTROL
MODULE
(ECM)
VIMS

VIMS DISPLAY MODULES

 988F/990 CAT DATA LINK CIRCUIT

POWERTRAIN CONTROL CMS

MODULE
Cat Data Link + 8 23 Cat Data Link +
Cat Data Link - 9 24 Cat Data Link -

J42 P3 J3 P1 J1 ECM
D 7 893-GN 9 Cat Data Link +
SERVICE TOOL E 6 892-BR 3 Cat Data Link -
CONNECTOR H 31 E794-YL 7 ATA Data Link +
J 32 E-793-BU 1 ATA Data Link -
MACHINE INTERFACE
CONNECTOR
 LOGGED EVENTS
• High coolant temperature
• Loss of coolant flow
• Low (lube) oil pressure
• Abnormal hydraulic pressure
• Hydraulic system pressure fault
• User defined shutdown
• Air inlet restriction
• Engine overspeed
• Low fuel pressure
 HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
PUMP CONTROL VALVE

MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL

SECONDARY
SPEED/TIMING SENSOR THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES

COOLANT TEMP. SENSOR TURBO INLET PRESSURE SENSOR

FAN CONTROL VALVE

TURBO OUTLET PRESS. SENSOR
FAN SPEED SENSOR
FAN
ATMOSPHERIC PRESS. SENSOR
CAT DATA LINK

OIL PRESSURE SENSOR SERVICE TOOL CONNECTOR

EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP SENSOR
AUTO RETARDER CONTROL

FUEL TEMPERATURE SENSOR

INSTRUMENT
PANEL
COOLANT FLOW SWITCH
MACHINE APPLICATIONS
 DECELERATION POSITION SENSOR CIRCUIT

P2 J2
ECM
(3408E/3412E)

F702-GN 24 DECEL POSITION

DECELERATION
POSITION SENSOR
P38 J38 P1 J1
+V DIGITAL A A700-OR 35 +V DIGITAL SUPPLY
DIGITAL RETURN B 998-BR 29 DIGITAL RETURN
SIGNAL C
 THROTTLE SWITCH CIRCUIT

ECM
THROTTLE
(3408E/3412E)
SWITCH

P1 J1
F715-PU 2 THROTTLE - LOW IDLE
F718-BU 20 THROTTLE - H.I. PARITY
F716-WH 8 THROTTLE - L.I. PARITY
F717-YL 14 THROTTLE - HIGH IDLE
998-BR 29 DIGITAL RETURN
 CRANK WITHOUT INJECTION PLUG CIRCUIT

ECM
(3408E/3412E)
CRANK WITHOUT
INJECTION PLUG

PLUG "HHH" J24 P24 P1 J1

3 720-GN 25 CRANK W/O INJECT (NO)
BK 2 719-BR 24 CRANK W/O INJECT (NC)
1 998-BR 29 DIGITAL RETURN

PLUG "JJJ"
BK
 MECHANICAL ENGINE FAN CONTROL CIRCUIT

ENGINE FAN
SOLENOID VALVE ECM
P41 J41 P2 J2 (3408E/E3412E)
B F700-BU 19 VARIABLE FAN CLUTCH
C E799-BR 7 PWM DR AND SOL RETURN
F703-GY 25 ENGINE FAN SPEED

ENGINE FAN
SPEED SENSOR J84 P84 P1 J1
+V DIGITAL A A700-OR 35 +V DIGITAL SUPPLY
DIGITAL RETURN B 998-BR 29 DIGITAL RETURN
SIGNAL C 13 A/C ON (INPUT FROM
COMPRESSOR SWITCH)
 THROTTLE LOCK CIRCUIT

RIGHT BRAKE PEDAL SWITCH ECM

P1 J1
998-BR F722-OR 13 Throttle Lock RH Brake (NO)
F721-GY 19 Throttle Lock RH Brake (NC)
998-BR 998-BR 29 Digital Return
J3 P3 F706-PU 27 Throttle Lock ON Lamp
14 Throttle Lock Set/Declerate
THROTTLE F717-YL
2 20 Throttle Lock Resume/Accelerate
LOCK LAMP F718-BU
113-OR BATT+ 24 Throttle Lock ON/OFF
F719-BR
998-BR
THROTTLE LOCK
SET/DECLERATION SW
998-BR
THROTTLE LOCK
RESUME/ACCLERATION SW

998-BR
THROTTLE LOCK SW
 HYDRAULIC ENGINE FAN CONTROL CIRCUIT

HYDRAULIC FAN
SOLENOID VALVE ECM
P2 J2 (3408E/E3412E)
P86 J86
2 F700-BU 19 HYDRAULIC FAN
1 E799-BR 07 PWM DRIVE AND SOL RETURN
 CATERPILLAR MONITORING SYSTEM

P
15 AUT

10 20

5
25
X100
R
24 V
0 MPH 30 44
km/h
 INDUSTRIAL
8 OR 12
INJECTORS 3408E/3412E HEUI SYSTEM
ADEM II COMPONENT DIAGRAM
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
BOLT

24 V
MAIN KEY
15 AMP POWER RELAY SWITCH
BREAKER
PUMP CONTROL VALVE

MACHINE
HYDRAULIC INTERFACE
CONNECTOR
PRESSURE SENSOR TDC SERVICE
PROBE ACCESS
PTO ENABLE/PTO UP/DOWN SWITCHES
PRIMARY ENGINE SHUTDOWN SWITCH
SPEED/TIMING SENSOR ENGINE
HARNESS ETHER ENABLE/OVERRIDE SWITCH
EMERGENCY STOP/VERIFY SWITCH
SECONDARY USER DEFINED SHUTDOWN
SPEED/TIMING SENSOR THROTTLE POSITION SENSOR

COOLANT TEMP. SENSOR FUEL PRESS. SENSOR

TURBO OUTLET PRESS. SENSOR COOLANT LEVEL SWITCH

MACHINE
HARNESS
INLET AIR TEMP. SENSOR
ATMOSPHERIC PRESS. SENSOR
TO AIR SHUTOFF SOLENOID
OIL PRESSURE SENSOR
TO ETHER SOLENOID RELAY

HYDRAULIC TEMP. SENSOR ALARM /WARNING LAMP

DIAGNOSTIC LAMP
FUEL TEMPERATURE SENSOR
MAINTENANCE INDICATOR LAMP

EMS
PANEL
SERVICE TOOL CONNECTOR
DATA LINK
3408E/3412E HEUI FUEL SYSTEM

TO LUBE
SYSTEM
HEUI
HYDRAULIC OIL
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT PRESSURE
TEMPERATURE
SUPPLY SENSOR
SENSOR
PUMP
GROUP
FLUID MANIFOLD
OIL
FILTER
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR

OIL
SUMP FUEL TANK