3408E-3412E Engine Controls

3408E/3412E ENGINE CONTROLS

HYDRAULIC ELECTRONIC UNIT INJECTION(HEUI)

©2001 Caterpillar Inc.

PUMPCONTROL

VALVE

OILFILTER

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR

HYDRAULICTEMPERATURE

SENSORCOLD START

OILRESERVOIR OIL PRESSURE

SENSOR

HYDRAULICSUPPLY

PUMPGROUP

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTER

FUELTRANSFER

PUMP

PRIMARYFUEL FILTER

WATERSEPARATOR

LUBE OILPUMP

TO LUBESYSTEM

3408E/3412E HEUI FUEL SYSTEM

FLUID MANIFOLDHYDRAULIC PASSAGE


ECM

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH

TURBO OUTLET PRESS. SENSOR

SECONDARYSPEED/TIMING SENSOR

PRIMARYSPEED/TIMING SENSOR

HYDRAULICPRESSURE SENSOR

24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE

COOLANT TEMP. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

8 OR 12INJECTORS

TDC SERVICEPROBE ACCESS

INSTRUMENTPANEL

AUTO RETARDER CONTROL

EPTC II TRANSMISSION CONTROL

ELECTRONIC SERVICE TOOL

CAT DATA LINK

FAN

FAN SPEED SENSOR

FAN CONTROL VALVE

TURBO INLET PRESSURE SENSOR

THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,AND GROUND LEVEL SHUTDOWN (2) SWITCHES

THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH

3408E/3412E HEUI SYSTEMCOMPONENT DIAGRAM

MACHINEHARNESS

ELECTRONIC CONTROL SYSTEM

HEUI CONTROL LOGIC

ENGINE SPEED

FUEL QUANTITY FUEL RPM

COLD MODE

SELECTTIMING

CONVERTDESIREDTIMING

HYDRAULIC OILTEMPERATURE

TIMING CONTROL

DEGREES BTDC DESIREDTIMINGBTDC

TIMING

FUEL INJECTIONTIMING WAVE FORM

ELECTRONICGOVERNOR

TORQUEMAPS

FRCMAPS

TURBO OUTLET ANDATMOSPHERIC

PRESSURE SENSORS

ENGINECONTROL

LOGIC

THROTTLE

SHUTDOWNS

INJECTIONACTUATIONCONTROL

ENGINE RPM

TDC

87654321

FUELINJECTIONCONTROL

TO PUMPCONTROL VALVE

SIGNALSTO FUEL

INJECTORS

SPEED/TIMINGSIGNAL

ENGINE RPM

SPEED/TIMINGSENSORS

TIMINGWHEEL

ENGINE RPM

ECM

HYDRAULIC OILTEMPERATURE ANDPRESSURE SENSORS

3408E/3412E ELECTRONIC GOVERNOR

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS


INSTRUMENTPANEL




CAT DATA LINK

FANFAN SPEED SENSOR

PROPORTIONAL VALVE


THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH

HEUI SYSTEMCOMPONENT DIAGRAM

MACHINEHARNESS

393229381812

732-PK996-GN998-BR999-WHF723-PKF724-PU

SECONDARY ENGINE SPEED+V TIMINGDIGITAL RETURNPRIMARY ENGINE SPEEDTIMING CAL +TIMING CAL -

ECM(3408E/3412 E)

P2 J2

ABC

ORBKWH

SECONDARYSPEED/TIMING

SENSOR

ABC

ORBKWH

PRIMARYSPEED/TIMING

SENSOR

TIMING CALIBRATIONCONNECTOR

12

SPEED/TIMING SENSORS

P44 J44

P20 J20

P26 P1 J1

4

3

6

5

7

2

1

8

REF

REF

REF

REF

REF

REF

REF

REF

TDCTDC

TDC

TDCTDC

TDC

TDC

SINGLE50/50 TOOTH

TIMING WHEELROTATION

TDC CYLINDER No. 1

TIMINGCALIBRATIONRANGE ± 10°

PRIMARYSPEED/TIMING

SENSOR


SENSOR

TIMING WHEEL

A B C D E F G H

TIMING WHEEL ROTATION

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

TIMING GEAR TOOTH TABLETABLEENTRY

CYLINDERREFERENCE

ABCDEFGH

80 %80 %80 %80 %80 %80 %80 %50 %

NONE IDENTIFIED

PWM DUTYCYCLE

CRANKING

TIMING GEAR TOOTH TABLE

PWM DUTYCYCLE

CYLINDERREFERENCE

80 %80 %80 %80 %80 %80 %80 %50 %

AFTER PATTERNRECOGNITIONNO

CYL NO. 3NONOCYL NO. 4NONOCYL NO. 8

TABLEENTRY


ABCDEFGH

A B C D E F G H

CYL NO. 3REFERENCE

EDGE

CYL NO. 3TDC

CYL NO. 4REFERENCE

EDGE

CYL NO. 4TDC

CYL NO. 8REFERENCE

EDGE

TIMING GEAR TOOTH TABLE

PWM DUTYCYCLE

CYLINDERREFERENCE

80 %80 %80 %80 %80 %80 %80 %50 %

NORMAL OPERATIONNOCYL NO. 3NONOCYL NO. 4NONOCYL NO. 8

CYL NO. 4(REFERENCE)

CYL NO. 4ACTUAL TDC

(CALIBRATED)

62° BTDC (EEPROM)

DES TIMING

NO. 4INJECTION

TABLEENTRY


ABCDEFGH

A B C D E F G H

CYL NO. 3(REFERENCE)

CYL NO. 3ACTUAL TDC

(CALIBRATED)

62° BTDC (EEPROM)

DES TIMING

DELAY NO. 3INJECTION

DELAY

ASSUMEDTDC

ASSUMEDTDC

393229381812

732-PK996-GN998-BR999-WHF723-PKF724-PU


ECM(3408E/3412E)

P2 J2

ABC

ORBKWH


SENSOR

ABC

ORBKWH

PRIMARYSPEED/TIMING

SENSOR

TIMING CALIBRATIONCONNECTOR

P26TIMING CALIBRATION

SENSOR

P44 J44

P20 J20

P1 J1

12

TIMING CALIBRATION SENSOR

REFERENCE EDGE TO TDC DISTANCE

REFERENCEEDGE ASSUMED

CYL. NO. 1 TDCACTUAL

CYL. NO. 1 TDC

TIMINGREFERENCE

OFFSET

MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES

TIMING CALIBRATIONSENSOR SIGNAL

TIMINGWHEEL

+10°± 10°

-10°

TIMING CALIBRATION

INJECTION CURRENT WAVEFORM

0 1 2 3 4

CU

RR

EN

T F

LO

W

TIME (MILLISECONDS)

PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

ONE CYCLE

5

POPPET VALVE MOVEMENT

0 1 2 3 4

CU

RR

EN

T F

LO

W

TIME (MILLISECONDS)

CURRENT

POPPETLIFT

5

WAVEFORM AND RESPONSE CHARACTERISTICS

0 1 2 3 4

CU

RR

EN

T F

LO

W

TIME (MILLISECONDS)

CURRENT

POPPETLIFT

INJECTIONRATE

START OFINJECTION

DURATION

5END OF

INJECTION

FUEL SYSTEM LIMITS

• Maximum Horsepower• Maximum Torque• Fuel Ratio

• Cranking Fuel• Cold Mode Limit

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

PUMPCONTROL

VALVE

OILFILTER

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSORCOLD START


SENSOR

HYDRAULICSUPPLY

PUMPGROUP

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTER

FUELTRANSFER

PUMP

PRIMARYFUEL FILTER

WATERSEPARATOR

LUBE OILPUMP

TO LUBESYSTEM




ECM

TO LUBESYSTEM

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER


OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSOR

OIL PRESSURESENSOR

ECM

COOL DOWNCIRCUIT

LOW PRESSURE HYDRAULICS

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLY

PUMPGROUP



TO LUBESYSTEM

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER


OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSOR

OIL PRESSURESENSOR

ECM

COOL DOWNCIRCUIT

HIGH PRESSURE HYDRAULICS

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLY

PUMPGROUP



TO LUBESYSTEM

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER


OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSOR

OIL PRESSURESENSOR

ECM

COOL DOWNCIRCUIT

LOW PRESSURE FUEL SUPPLY

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTER

PRIMARYFUEL FILTER

WATERSEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLYPUMP

GROUP



LOW PRESSUREFUEL SUPPLY

CYLINDER HEADINJECTOR SLEEVE

FLUID SUPPLYMANIFOLD

INJECTOR

INJECTOR OILADAPTER

JUMPER TUBE

INJECTOR CLAMP

HIGH PRESSUREHYDRAULIC PASSAGE

CYLINDER HEAD

ROCKER ARM BASE

LUBE OIL PASSAGE

CYLINDER BLOCKCOOLANT

METAL WASHER

HIGH PRESSUREHYDRAULIC OIL

INJECTOR FLUID FLOW

FLUID SUPPLYMANIFOLD

INJECTOR

CYLINDERHEAD

LOWER INJECTORO-RING SEAL

UPPER INJECTORO-RING SEAL

METAL-TO- METALCONTACT

LOW PRESSUREFUEL SUPPLY


UPPER SLEEVEO-RING SEAL

LOWER SLEEVEO-RING SEAL

INJECTOR FUEL SUPPLY

LOW PRESSUREFUEL SUPPLY PASSAGE


HIGH PRESSUREHYDRAULIC PASSAGE

ROCKER ARMBASE

LUBRICATION OILPASSAGE

EXTRACTORSPLINES

FUEL SEALS

FLUID SUPPLY MANIFOLD

INJECTION CURRENT WAVEFORMONE CYCLE

0 1 2 3 4

CU

RR

EN

T F

LO

W

TIME (MILLISECONDS)

HOLD-IN PEAK CURRENT

5

PULL-IN PEAK CURRENT

WAVEFORM AND RESPONSE CHARACTERISTICS

0 1 2 3 4

CU

RR

EN

T F

LO

W

TIME (MILLISECONDS)

CURRENT

POPPETLIFT

INJECTIONRATE

START OFINJECTION

DURATION

5END OF

INJECTION

HEUI UNIT INJECTOR3 MAIN GROUPS

VALVE BODYGROUP

BARREL GROUP

NOZZLE GROUP

STOPPINPLUNGER SPRING SEAL BARREL BALL

DOWEL

SEAL

INTENSIFIER PISTON

RETAINER RING

WASHER

STOPPLATE

CHECKPLATE

BALL

STOP

DOWEL

SPRING

LIFTSPACER

SLEEVE

DOWEL

CHECK

TIP CASE

POPPET SPRING SLEEVE SHIM SEAL

ADAPTER BOLT

SPACER

ARMATURE

SCREW

SOLENOIDASSEMBLY

SCREW

BODYVALVE BODY GROUP

BARREL GROUP

NOZZLE GROUP

3408E/3412E HEUI INJECTORCOMPONENTS

SHIMBARREL

PISTON

VALVE

FUEL INLETCHECK VALVE

PIN

SPACER

ADAPTER

SPACER

ARMATURE

SOLENOID

WASHER

PLUNGER

SLEEVE

SLEEVE

UNIT INJECTOR COMPONENTS

LOWER FUEL SEAL

VALVE BODY

UPPER FUEL SEAL

NOZZLE

CHECK

HORIZONTAL BOLTS

JUMPER TUBE

INJECTOR CLAMP

VERTICAL BOLTS

ALLEN SCREWS

INJECTOR OILADAPTOR

INJECTOR INSTALLATION

SOLENOID DE-ENERGIZED SOLENOID ENERGIZEDPOPPET VALVE CLOSED POPPET VALVE OPEN

ARMATURESCREWPOPPET

SPRINGINLET

VALVE SEAT

SOLENOID

POPPET VALVE

ARMATURE

EXHAUSTVALVE SEAT

VALVE BODY GROUP


INTENSIFIERPISTON

PLUNGER

FUEL TONOZZLE

BARREL

BARREL GROUPFUEL PRESSURE INCREASE

REVERSE FLOWCHECK VALVE

FUEL FROMTRANSFER PUMP

SUPPLY OIL

VIEW OF STOP PLATE AND REVERSE FLOW CHECK VALVE


FUEL ATOMIZATION

NOZZLE GROUP

CHECK VALVE

INLETVALVE SEAT

SOLENOID

POPPET VALVE

ARMATURE

EXHAUSTVALVE SEAT

SOLENOID DE-ENERGIZEDVALVE BODY GROUP

SHIM

BARREL

PISTON

VALVE

BALL

PIN

SPACER

ADAPTER

SPACER

ARMATURE

SOLENOID

WASHER

PLUNGER

SLEEVE

SLEEVE

NOZZLE

BODY

UNIT INJECTOREND OF INJECTION

CHECK

BARREL GROUPREFILLING THE BARREL

BARREL

PISTON


PIN

SPACER

WASHER

PLUNGER

SLEEVE

NOZZLENOZZLE CHECK

VALVE

FUEL EDGEFILTER


EDGE FILTER

EDGE FILTER


FUEL INLET FUEL INLET

PRIME INJECTION RATE SHAPING

0 1 2 3 4TIME (MILLISECONDS)

5

PRIME = PRE-INJECTION METERING INJECTION RATE

DURATIONSTART OF INJECTION

CROSS SECTIONOF PLUNGER

PRIME RATESHAPING PASSAGE

PLUNGER

BARREL

SPILLPORT

FUEL TONOZZLE GROUP

START OF INJECTION PRESSURE DROPFINAL

PRESSURE INCREASE

OIL FLOW

BARREL GROUPPRIME RATE SHAPING

BARREL GROUPVENTING INTERNAL LEAKS

INTENSIFIERPISTON SEAL

BARREL

INTENSIFIERPISTON

VENTINGCHECK VALVE

BARREL GROUP NOZZLE GROUPFUEL INLETCHECK VALVE

NOZZLECHECK VALVE

FUELATOMIZATION

VENTINGCHECK VALVE


INJECTOR CHECK VALVES

IDLE PEAK TORQUE RATED

INJE

CT

ION

PR

ES

SU

RE

MECHANICALLY ACTUATEDFUEL SYSTEM

HEUI

ENGINE SPEED

HYDRAULIC INJECTION PRESSURE CONTROL

PRIMING PORT

ORIFICE

RESERVOIR

SWASHPLATE

TRANSFER PUMP

COMPENSATORVALVE

HEUI PUMP

VALVE BASE

DRAIN PASSAGE

TO LUBESYSTEM

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER

COOL DOWN BYPASS CIRCUIT

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSOR

OIL PRESSURESENSOR

ECM

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLY

PUMPGROUP



CHECKFITTING SPRINGVALVE BLOCK SEAT

REVERSE FLOW CHECK VALVE

FROMPUMP

TOINJECTORS

SEAT(END VIEW)

TO LUBESYSTEM

FUELTRANSFER

PUMP

PUMPCONTROL

VALVE

OILFILTER


OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSOR

OIL PRESSURESENSOR

ECM

COOL DOWNCIRCUIT

HYDRAULIC SYSTEM OPERATION

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTERPRIMARY

FUEL FILTERWATER

SEPARATOR

LUBE OILPUMP

COLD STARTOIL

RESERVOIR

HYDRAULICSUPPLY

PUMPGROUP



TO LUBESYSTEM

TO RIGHT OILMANIFOLD

TO LEFT OILMANIFOLD

COLD STARTRESERVOIR

OIL SUMPPUMP

CONTROLVALVE

LOADSENSINGSPOOL

PRESSURELIMITERSPOOL

PUMPCASE DRAIN

SOLENOID(ENERGIZED)

DISPLACEMENTCONTROL PISTON

HEUI HYDRAULIC CONTROL SYSTEMSTART-UP

CHECK VALVE

PRESSURE LIMITER SPOOL

CHECK VALVE

PUMP CONTROLVALVE

DRAIN ORIFICE

ORIFICE

TOCASEDRAIN

LOAD SENSING SPOOL

FROM DISPLACEMENTCONTROL PISTON

REVERSE FLOWCHECK VALVES

TO CASE DRAIN

START-UPCOMPENSATOR ASSEMBLY

TO LUBESYSTEM


TO LEFT OILMANIFOLD

COLD STARTRESERVOIR

OIL SUMPPUMP

CONTROLVALVE

LOADSENSINGSPOOL


PUMPCASE DRAIN

SOLENOID(DE-ENERGIZED)

HEUI HYDRAULIC CONTROL SYSTEMDESTROKE

CHECK VALVE


SUPPLY PUMP

PUMPCONTROL VALVE

DRAIN ORIFICE

TO DISPLACEMENT CONTROL PISTON

TO CASE DRAIN

PRESSURELIMITER SPOOL

CHECK VALVE

ORIFICE

LOAD SENSINGSPOOL

DESTROKECOMPENSATOR ASSEMBLY

TO LUBESYSTEM


TO LEFT OILMANIFOLD

COLD STARTRESERVOIR

OIL SUMPPUMP

CONTROLVALVE

LOADSENSINGSPOOL


PUMPCASE DRAIN

SOLENOID(ENERGIZED)

HEUI HYDRAULIC CONTROL SYSTEMUPSTROKE

CHECK VALVE


SUPPLY PUMP

PRESSURELIMITER SPOOL

CHECK VALVE

ORIFICE

LOAD SENSINGSPOOL

PUMPCONTROL VALVE

DRAIN ORIFICE

FROMDISPLACEMENT

CONTROL PISTON

TO CASE DRAIN

UPSTROKECOMPENSATOR ASSEMBLY

TO LUBESYSTEM


TO LEFT OILMANIFOLD

COLD STARTRESERVOIR

OIL SUMPPUMP

CONTROLVALVE

LOADSENSINGSPOOL


PUMPCASE DRAIN

SOLENOID(DE-ENERGIZED)

HEUI HYDRAULIC CONTROL SYSTEMPRESSURE LIMITER OPERATION


SUPPLY PUMP

PLUGGEDORIFICE

PRESSURE LIMITERSPOOL

CHECK VALVE

ORIFICE

LOAD SENSINGSPOOL

PUMPCONTROL VALVE

DRAIN ORIFICE

TODISPLACEMENT

CONTROL PISTON

TO CASE DRAIN

RESTRICTION

PRESSURE LIMITER OPERATIONCOMPENSATOR ASSEMBLY

ADAPTER CAGE

RINGSHELLPIN

STATOR

SEAL SEATPOPPETVALVE

SOLENOIDARMATURE

STOP

TOCASE DRAIN

FROM LOADSENSING SPOOL

VALVE

COILASSEMBLY

EDGEFILTER

SPRINGRETAINER

VALVEBLOCK

NO CURRENT FLOWPUMP CONTROL VALVE

ADAPTER CAGE

RINGSHELLPIN

STATOR

SEAL SEATPOPPETVALVE

SOLENOIDARMATURE

STOP

COILASSEMBLY

EDGEFILTER

SPRINGRETAINER

FROM LOADSENSING SPOOL

VALVE

VALVEBLOCK

TOCASE DRAIN

HIGH CURRENT FLOWPUMP CONTROL VALVE

HEUI SYSTEM POWER SUPPLIES

• ECM: 24 VOLTS

• INJECTORS: 105 VOLTS

• ANALOG SENSORS: 5 VOLTS

• SPEED/TIMING SENSORS: 12.5 VOLTS

• DIGITAL SENSORS: 8 VOLTS

• PUMP CONTROL VALVE: 0 to 24 VOLTS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM)GROUND

BOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMPCONTROL VALVE



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS


INSTRUMENTPANEL




CAT DATA LINK

FAN

FAN SPEED SENSOR

FAN CONTROL VALVE



THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH

3408E/3412E HEUI SYSTEMECM POWER SUPPLY COMPONENTS

MACHINEHARNESS

0511040623

ECM(3408E/3412E)(-) BATTERY(-) BATTERY(+) BATTERY(+) BATTERYKEY SWITCH ON

229-BK-14229-BK-14150-RD-14150-RD-14113-OR

12

26

24 VOLTS DC

(+)

(-)

ENGINE BLOCKGROUND BOLT

CIRCUIT BREAKER

BATTERY

R

CSB ST

OFFON

308-YL

200-BK

105-RD

KEY SWITCH

112-PU

117-RD

113-OR

15 A

10 AMPP3 J3

P1 J1

DISCONNECTSWITCH

ECM POWER SUPPLY CIRCUIT

393229381812

732-PK996-GN998-BR999-WHF723-PKF724-PU


ECM(3408E/3412 E)

P2 J2

ABC

ORBKWH

SECONDARYSPEED/TIMINGSENSOR (LH)

ABC

ORBKWH

PRIMARYSPEED/TIMINGSENSOR (RH)

SPEED/TIMING SENSOR POWER SUPPLY12.5 ± 1 VOLTS

P44 J44

P20 J20

P1 J1

160526

A701-GYF726-YLA703-BRF726-YL

P2 J2

INJECTOR WIRING SCHEMATIC

SOLENOID 1 POWERSOLENOID 1/3 RETURNSOLENOID 3 POWER

ECM(3408/3412E)

401134

A702-PUF727-BUA704-GNF727-BU


321738

A705-BUF728-BRA707-PUF728-BR


282122

A706-GYF729-GNA708-BRF729-GN


372731

A709-ORF730-GYA711-PUF730-GY


183312

A710-GYF731-ORA712-BRF731-OR


1234

SOLENOID 1

SOLENOID 3

J52/P52

1234

SOLENOID 2

SOLENOID 4

J56/P56

1234

SOLENOID 5

SOLENOID 7

J53/P53

1234

SOLENOID 6

SOLENOID 8

J57/P57

1234

SOLENOID 9

SOLENOID 11

J54/P54

1234

SOLENOID 10

SOLENOID 12

J58/P58

P22 J22

ENGINE COOLANTTEMPERATURE SENSOR

ENGINE OILPRESSURE SENSOR

+V ANALOGANALOG RETURNSIGNAL


P23 J23

TURBO OUTLETPRESSURE SENSOR


P25 J25



P27 J27

ATMOSPHERICPRESSURE SENSOR


P45 J45



3630

ANALOG SENSORPOWER SUPPLY

P1 J1

P43 J43+V ANALOGANALOG RETURNSIGNAL


P51 J51


HYDRAULIC OILTEMPERATURE SENSOR

ABC

ABC

ABC

ABC

ABC

ABC

ABC

ABC

J21 P21

5 ± 0.2 VOLTS

ECM (3408E/3412E HEUI)+V ANALOG SUPPLYANALOG RETURN

ECM (3408E/3412E HEUI)+ V DIGITAL SUPPLY- V DIGITAL RETURN

2935

DIGITAL SENSORPOWER SUPPLY

P1 J1

ABC

J35 P35

ABC

P84 J84+V DIGITAL

DIGITAL RETURNSIGNAL

FAN SPEED SENSOR

THROTTLEPOSITION SENSOR

+V DIGITALDIGITAL RETURN

SIGNAL

8 ± 0.5 VOLTS

ECM (3408E/3412E HEUI)+ SUPPLY- RETURN

2935

P2 J2

AB

J46 P46

PUMP CONTROLVALVE

SUPPLY RETURN

PUMP CONTROL VALVEPOWER SUPPLY0 to 24 VOLTS PWM

0 to 800 mAmps

ELECTRONIC SENSORSAND

SYSTEMS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH



24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

8 OR 12INJECTORS


DISCONNECT SWITCH


MACHINEHARNESS

ANALOG SENSORS

• Fuel temperature

• Hydraulic temperature

• Lubrication oil pressure

• Turbocharger outlet pressure

• Turbocharger inlet pressure

• Atmospheric pressure

• Coolant temperature

• Hydraulic pressure

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH




24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

8 OR 12INJECTORS


DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH




24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS


8 OR 12INJECTORS


DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH




24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



8 OR 12INJECTORS


DISCONNECT SWITCH


MACHINEHARNESS

100%

98%

96%

94%

92%

90%

88%

86%

84%

82%

80%

78%

76%

74%

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

8,210

8,920

9,630

10,340

11,050

11,760

12,470

13,890

14,600

15,310

16,020

16,730

17,440

13,180

7,500

72%

ENGINE POWER DERATING MAPACCORDING TO ATMOSPHERIC PRESSURE

ATMOSPHERIC PRESSURE IN kPa

PE

RC

EN

T O

F F

UL

L L

OA

D P

OW

ER

AL

TIT

UD

E IN

FE

ET

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH




24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

CAT

AUTOMATIC AIR FILTER COMPENSATION

TURBOCHARGERINLET PRESSURE

SENSOR

ATMOSPHERICPRESSURE

SENSOR

Filter differential pressure calculated with formula:

Atmospheric sensor pressure - Turbo sensor pressure = ∆P

Fuel limited 2% per 4 inches H20 to max 20%

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR

8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR

8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

OIL

PR

ES

SU

RE

IN k

Pa

600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 180060

80

100

120

140

160

180

200

220

240

260

280

300

ENGINE RPM

OIL PRESSURE MAP

1900

320

340

8.7

11.6

14.5

17.4

20.3

23.2

26.1

29

31.9

34.8

37.7

40.6

43.5

46.4

49.3

OIL

PR

ES

SU

RE

IN P

SI

kPa x 0.145 = PSI

2000

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH

TURBO OUTLET (BOOST) PRESS. SENSOR



HYDRAULIC OILPRESSURE SENSOR

24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR

HYDRAULIC OIL TEMP. SENSOR

8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR



8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS



DISCONNECT SWITCH


MACHINEHARNESS

a

• Throttle Position

• Pump Control Valve Signal

• Exhaust Temperature

DIGITAL SENSORS AND CIRCUITS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS



THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH


MACHINEHARNESS

90%

ON

OFF

ON

OFF

ON

OFF

10%

50%

DUTYCYCLE

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

1 CYCLE

= 90%

DUTYCYCLE

= 50%

DUTYCYCLE

= 10%

PULSE WIDTH MODULATED SIGNALS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM)GROUND

BOLT

15 AMPBREAKER

MAINPOWER RELAY KEY

SWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS



THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH


MACHINEHARNESS

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS




THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH


MACHINEHARNESS

ECM (3408E/3412E HEUI)USER SHUTDOWN1

P2 J2

USER DEFINED SHUTDOWN

12

J3

USER SHUTDOWNDEVICE

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR



COOLANT FLOW SWITCH

8 OR 12INJECTORS


FANFAN SPEED SENSOR

FAN CONTROL VALVE



THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH


MACHINEHARNESS

28291940

ECM(3408E/E3412E)

ETHER SWITCH

308-YL

200-BK

P1 J1

ETHER INJECTION SYSTEM

ETHER SW LAMPDIGITAL RETURNETHER REQUESTETHER CONTROL

P2 J2

F708-YL998-BR721-GY710-BR

J3 P323 93921

RELAY

12

+24V

+310-PK

200-BK P37 J37

ETHERSTART VALVE TO ENGINE

FROMCYLINDER

VIMS DISPLAY MODULES

SERVICE TOOLCONNECTOR

CAT DATA LINK

VIM

SM

AIN

MO

DU

LE

ADEM IIELECTRONIC

CONTROLMODULE

(ECM)

LAPTOPCOMPUTER

CATELECTRONIC TECHNICIAN

COMMUNICATIONADAPTER

988F/990 CAT DATA LINK CIRCUIT

89

POWERTRAIN CONTROLMODULE

Cat Data Link +Cat Data Link -

2324

CATERPILLARMONITORING SYSTEM

Cat Data Link +Cat Data Link -

DEHJ

76

3132

9371

893-GN892-BRE794-YLE-793-BU

J42 P3 J3 P1 J1 ECM

Cat Data Link +Cat Data Link -ATA Data Link +ATA Data Link -

SERVICE TOOLCONNECTOR

MACHINE INTERFACECONNECTOR

LOGGED EVENTS

• Engine overspeed

• Air inlet restriction

• User defined shutdown

• Hydraulic system pressure fault

• Abnormal hydraulic pressure

• Low (lube) oil pressure

• Loss of coolant flow

• Low fuel pressure

• High coolant temperature

ADEM IIELECTRONIC

CONTROLMODULE

(ECM) GROUNDBOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR

HYDRAULIC TEMP SENSOR


COOLANT FLOW SWITCH

8 OR 12INJECTORS


INSTRUMENTPANEL



SERVICE TOOL CONNECTOR

CAT DATA LINK

FANFAN SPEED SENSOR

FAN CONTROL VALVE



THROTTLESENSOR

ACCELERATORPEDAL

DISCONNECT SWITCH


MACHINEHARNESS

MACHINE APPLICATIONS

3529

ECM(3408E/3412E)

DECELERATIONPOSITION SENSOR

P1 J1

DECELERATION POSITION SENSOR CIRCUIT

+V DIGITAL SUPPLYDIGITAL RETURN

P2 J2

24 DECEL POSITION

A700-OR998-BR

P38 J38

ABC


SIGNAL

F702-GN

2208

1429

ECM(3408E/3412E)

THROTTLESWITCH

P1 J1

THROTTLE SWITCH CIRCUIT

THROTTLE - LOW IDLETHROTTLE - H.I. PARITYTHROTTLE - L.I. PARITYTHROTTLE - HIGH IDLEDIGITAL RETURN

F715-PUF718-BUF716-WHF717-YL998-BR

252429

ECM(3408E/3412E)

CRANK WITHOUTINJECTION PLUG

P1 J1

CRANK WITHOUT INJECTION PLUG CIRCUIT

CRANK W/O INJECT (NO)720-GN719-BR

J24 P24

998-BR

321

CRANK W/O INJECT (NC)DIGITAL RETURN

BK

PLUG "HHH"

PLUG "JJJ"

BK

352913

ECM(3408E/E3412E)

ENGINE FANSPEED SENSOR

P1 J1

+V DIGITAL SUPPLYDIGITAL RETURN

P2 J2

197

25

VARIABLE FAN CLUTCHPWM DR AND SOL RETURNENGINE FAN SPEED

A700-OR998-BR

J84 P84

ABC


SIGNAL

F703-GY

P41 J41

BC

ENGINE FANSOLENOID VALVE

E799-BRF700-BU

A/C ON (INPUT FROMCOMPRESSOR SWITCH)

MECHANICAL ENGINE FAN CONTROL CIRCUIT

F706-PU

ECMP1 J1

13192927142024

Throttle Lock RH Brake (NO)Throttle Lock RH Brake (NC)Digital ReturnThrottle Lock ON LampThrottle Lock Set/DeclerateThrottle Lock Resume/AccelerateThrottle Lock ON/OFF

998-BR

RIGHT BRAKE PEDAL SWITCH

F721-GYF722-OR

THROTTLELOCK LAMP

J3 P3

2113-OR BATT+

F717-YLF718-BUF719-BR

998-BR

998-BR

998-BR

998-BR

998-BR

THROTTLE LOCKSET/DECLERATION SW

THROTTLE LOCKRESUME/ACCLERATION SW

THROTTLE LOCK SW

THROTTLE LOCK CIRCUIT

ECM(3408E/E3412E)P2 J2

1907

HYDRAULIC FANPWM DRIVE AND SOL RETURN

P86 J86

21

HYDRAULIC FANSOLENOID VALVE

E799-BRF700-BU

HYDRAULIC ENGINE FAN CONTROL CIRCUIT

R0

5

1015

20

25

30

P

X100

24 V MPHkm/h

44

AUT

CATERPILLAR MONITORING SYSTEM

INLET AIR TEMP. SENSOR

SERVICE TOOL CONNECTORDATA LINK

EMSPANEL

DIAGNOSTIC LAMP

ALARM /WARNING LAMP

TO AIR SHUTOFF SOLENOID

TO ETHER SOLENOID RELAY

ADEM IIELECTRONIC

CONTROLMODULE

(ECM)GROUND

BOLT

15 AMPBREAKER

MAINPOWER RELAY

KEYSWITCH





24 V

MACHINEINTERFACE

CONNECTOR

ENGINEHARNESS

PUMP CONTROL VALVE



OIL PRESSURE SENSOR



8 OR 12INJECTORS


PTO ENABLE/PTO UP/DOWN SWITCHESENGINE SHUTDOWN SWITCH

ETHER ENABLE/OVERRIDE SWITCHEMERGENCY STOP/VERIFY SWITCH

USER DEFINED SHUTDOWNTHROTTLE POSITION SENSOR

DISCONNECT SWITCH

INDUSTRIAL3408E/3412E HEUI SYSTEM

COMPONENT DIAGRAM

MACHINEHARNESS

FUEL PRESS. SENSOR

COOLANT LEVEL SWITCH

MAINTENANCE INDICATOR LAMP

PUMPCONTROL

VALVE

OILFILTER

OILCOOLER

HEUI

HEUI

OILSUMP

HYDRAULICPRESSURE

SENSOR


SENSORCOLD START


SENSOR

HYDRAULICSUPPLY

PUMPGROUP

COOL DOWNCIRCUIT

FUEL TANK

FUELTEMPERATURE

SENSOR

PRESSUREREGULATING

VALVE

SECONDARYFUEL

FILTER

FUELTRANSFER

PUMP

PRIMARYFUEL FILTER

WATERSEPARATOR

LUBE OILPUMP

TO LUBESYSTEM




ECM

Documents

3408E-3412E Engine Controls