-1-

CONTROLES DE MOTOR 3408E/3412

HYDRAULIC ELECTRONIC UNIT INJECTION
(HEUI)

©1997 Caterpillar Inc.

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SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E

AL SISTEMA
DE LUBRICACION

HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE FLUID MANIFOLD
ARRAQUE EN FRIO SENSOR DE HYDRAULIC PASSAGE
PRESION DE ACEITE
CIRCUITO SENSOR SENSOR DE
GRUPO DE COOL DOWN TEMPERATURA PRESION
BOMBA DE DE ACEITE
FILTRO DE DE COMBUST.
SUMINISTRO
ACEITE DE ACEITE FLUID MANIFOLD
HYDRAULIC PASSAGE

VALVULA DE
CONTROL HEUI
DE BOMBA ECM
ENFRIADOR
DE ACEITE
BOMBA DE
TRANSFERENCIA
DE COMBUST. FILTRO VALVULA
BOMBA DE SECUNDARIO REGULADORA DE
LUBRICACION DE COMBUST. PRESION
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE TANQUE DE COMBUSTIBLE
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 Material de Estudiante

8 O 12
SISTEMA3408E/3412E HEUI
INYECTORES DIAGRAMA DE COMPONENTES
ADEM II
MODULO DE
CONTROL
ELECTRONICO SWITCH DE DESCONEXION
PERNO DE
HARNESS DE (ECM) TIERRA
MOTOR
24 V
RELE KEY
HARNESS DE PRINCIPAL
MAQUINA 15 AMP SWITCH
BREAKER
VALVULA DE CONTROL DE LA BOMBA
CONECTOR
SENSOR DE DE INTERFACE
PRESION DE ACEITE A LA MAQUINA
ACCESO AL
SENSOR PRIMARIO SENSOR DE SERVICIO TDC
SENSOR DE
DE SPEED/TIMING ACELERADOR PEDAL DE
ACELERADOR
SENSOR SECUNDARIO SWITCHESS DE ACELERADOR DE RESPALDO, DE HABILITACION DE
DE SPEED/TIMING BAJA EN VACIO ELEVADO,Y SWITCH DE APAGADO A NIVEL DE PISO

SENSOR DE TEMP DE REFRIGERANTE SENSOR DE PRESION INGRESO AL TURBO

VALVVULA DE CONTROL DE VENTILADOR

SENSOR DE PRESION A LA SALIDA DEL TURBO
FAN SPEED SENSOR
VENTILADOR
SENSOR DE PRESION ATMOSF.
CAT DATA LINK

SENSOR DE PRESION DE ACEITE HERRAMIENTA DE SERV. ELECTRONICO

CONTROL DE TRANSMISION EPTC II

SENSOR DE TEMPERATURA DE ACEITE
CONTROL DE AUTO RETARDADOR

SENSOR DE TEMP.DE COMBUSTIBLE

PANELDE
INSTRUMENTOS
SWITCH DE FLUJO DE REFRIGERANTE
 - 19 -

SISTEMA DE CONTROL ELECTRONICO

- 20 -
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- 22 -
 - 23 -

METODOS PARA PROBAR INYECTORES

HEUI

• PRUEBA DE SOLENOIDES DE INYECTOR

• CORTE DE CILINDROS

• PRUEBA AUTOMATICA DE INYECTORES

 - 24 -

LOGICA DE CONTROL HEUI

CONTROL DE SINCRONIZACION
VELOCIDAD DE MOTOR
SINCRONIZ. GRADOS BTDC SINCRONIZ.
DESEADA FORMA DE ONDA DE LA
CANTIDAD DE COMB. COMB. RPM
BTDC CONVIERTE A SINCRONIZ. DE LA INYECCION
SELECC.
SINCRONIZ. SINCRONIZ.
DESEADA
TEMPERATURA
ACEITE MODO FRIO
 Material del Estudiante

GOBERNADOR ELECTRONICO 3408E/3412E

SENSORES DE
SHUTDOWNS PRESION Y DE TEMP.
DE ACEITE
A LA VALVULA DE
CONTROL DE BOMBA
CONTROL DE ECM
ACTUACION GOBERNADOR
DE INYECCION ELECTRONICO
8
SEÑALES A 7
LOS INYECTORES 6 CONTROL MAPAS MAPAS LOGICA DE ACELERADOR
DE COMBUSTIBLE 5 INYECCION RPM DE MOTOR
FRC TORQUE CONTROL
4 COMBUST. DE MOTOR
3
2 TDC
1
SEÑAL DE RPM DE MOTOR RPM DE MOTOR
SPEED/TIMING
SENSORES DE PRESION
ATMOSFERICA Y DE
RUEDA DE SALIDA DEL TURBO
SINCRONIZACION

SENSORES DE
SPEED/TIMING
 Material del Estudiante

8 O 12
SISTEMA3408E/3412E HEUI
INYECTORES DIAGRAMA DE COMPONENTES
ADEM II
MODULO DE
CONTROL
ELECTRONICO SWITCH DE DESCONEXION
PERNO DE
HARNESS DE (ECM) TIERRA
MOTOR
24 V
RELE KEY
HARNESS DE PRINCIPAL
MAQUINA 15 AMP SWITCH
BREAKER
VALVULA DE CONTROL DE LA BOMBA
CONECTOR
SENSOR DE DE INTERFACE
PRESION DE ACEITE A LA MAQUINA
TDC SERVICE
SENSOR PRIMARIO PROBE ACCESS
SENSOR DE
DE SPEED/TIMING ACELERADOR PEDAL DE
ACELERADOR
SENSOR SECUNDARIO SWITCHESS DE ACELERADOR DE RESPALDO, DE HABILITACION DE
DE SPEED/TIMING BAJA EN VACIO ELEVADO,Y SWITCH DE APAGADO A NIVEL DE PISO

SENSOR DE TEMP DE REFRIGERANTE SENSOR DE PRESION INGRESO AL TURBO

VALVVULA DE CONTROL DE VENTILADOR

SENSOR DE PRESION A LA SALIDA DEL TURBO
FAN SPEED SENSOR
VENTILADOR
SENSOR DE PRESION ATMOSF.
CAT DATA LINK

SENSOR DE PRESION DE ACEITE HERRAMIENTA DE SERV. ELECTRONICO

CONTROL DE TRANSMISION EPTC II

SENSOR DE TEMPERATURA DE ACEITE
CONTROL DE AUTO RETARDADOR

SENSOR DE TEMP.DE COMBUSTIBLE

PANELDE
INSTRUMENTOS
SWITCH DE FLUJO DE REFRIGERANTE
 - 27 -

SENSORES DE SPEED/TIMING
SENSOR
SPEED/TIMING
SECUNDARIO P44 J44
OR A
BK B
WH C

P2 J2

SENSOR ECM
SPEED/TIMING (3408E/3412 E)
PRIMARIO P20 J20
732-PK 39 VELOCIDAD SECUNDARIA DE MOTOR
OR A 996-GN 32 +V SINCRONIZACION
BK B 998-BR 29 RETORNO DIGITAL
WH C 999-WH 38 VELOCIDAD PRIMARIA DE MOTOR
F723-PK 18 CAL DE TIMING +
F724-PU 12 CAL DE TIMING -
P26 P1 J1
CONECTOR DE 1
CALIBRACION DE SINCRONIZACION 2
- 28 -
 - 29 -
RUEDA DE SINCRONIZACION
TDC REF

SENSOR REF TDC DIENTE

4 50/50
SPEED/TIMING
SECUNDARIO
TDC CILINDRO No. 1
3 8
REF SENSOR
SPEED/TIMING
PRIMARIO
TDC

REF

RANGO DE
1 CALIBRACION DE SINCRONIZACION
6 RANGO ± 10°

TDC REF

ROTACION DE LA
RUEDA DE SINCRONIZACION TDC
REF
5 2

7 REF
TDC
REF TDC
 - 30 -

ARRANQUE

TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION

ENTRADA PORCENTAJE CILINDRO
A TABLA PWM DE REFERENCIA
A 80 % NINGUNO IDENTIFICADO
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

ROTACION DE LA RUEDA DE SINCRONIZACION

 - 31 -

DESPUES DE RECONOCER EL PATRON

TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION

ENTRADA PORCENTAJE CILINDRO
A TABLA PWM DE REFERENCIA
A 80 % NO
B 80 % CIL NO. 3
C 80 % NO
D 80 % NO
E 80 % CIL NO. 4
F 80 % NO
G 80 % NO
H 50 % CIL NO. 8

ROTACION DE LA RUEDA DE SINCRONIZACION

A B C D E F G H

CIL NO. 3 CIL NO. 3 CIL NO. 4 CIL NO. 4 CIL NO. 8
BORDE DE TDC BORDE DE TDC BORDE DE
REFERENCIA REFERENCIA REFERENCIA
 - 32 -

TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION

ENTRADA PORCENTAJE CILINDRO
A TABLA PWM DE REFERENCIA
OPERACION NORMAL
A 80 % NO
B 80 % CIL NO. 3
C 80 % NO
D 80 % NO
E 80 % CIL NO. 4
F 80 % NO
G 80 % NO
H 50 % CIL NO. 8

ROTACION DE LA RUEDA DE SINCRONIZACION

A B C D E F G H

62° BTDC (EEPROM) 62° BTDC (EEPROM)

SINC. DESEADA SINC. DESEADA

DEMORA NO 3 DEMORA NO. 4

INYECCION INYECCION
TDC TDC
ASUMIDO ASUMIDO
CIL NO. 3 CIL NO. 4
CIL NO. 3 ACTUAL TDC CIL NO. 4 ACTUAL TDC
(REFERENCIA) (CALIBRADO) (REFERENCIA) (CALIBRATO)
 - 33 -

SENSOR DE CALIBRACION DE SINCRONIZACION

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 -

SENSOR DE CALIBRACION P1 J1
DE SINCRONIZACION
P26
1
2

TIMING CALIBRATION
CONNECTOR
 - 34 -

CALIBRACION DE SINCRONIZACION

RUEDA DE
SINCRONIZACION

DISTANCIA DE BORDE DE REFERENCIA AL TDC

BORDE DE
REFERENCIA CIL. NO. 1 TDC CIL. NO. 1 TDC
ASUMIDO ACTUAL

-10° +10° TIMING

REFERENCE
SEÑAL DEL SENSOR ± 10° OFFSET
DE CALIBRACION DE SINCRONIZACION

MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES

 - 35 -
FORMA DE ONDA DE LA CORRIENTE DE INYECCION
UN CICLO
CURRENT FLOW

CORRIENTE PICO DE ACCIONAMIENTO

CORRIENTE PICO DE SOSTENIMIENTO

0 1 2 3 4 5
TIEMPO (MILISEGUNDOS)
 - 36 -
MOVIMIENTO DE LA VALVULA POPPET

POPPET
LIFT
CURRENT FLOW

CORRIENTE

0 1 2 3 4 5
TIEMPO (MILISEGUNDOS)
 - 37 -
FORMA DE ONDA Y CARACTERISTICAS DE RESPUESTA

RAPIDEZ DE
INYECCION

POPPET
LIFT
CURRENT FLOW

CORRIENTE

FIN DE
INYECCION

INICIO DE LA
DURACION
INYECCION

0 1 2 3 4 5
TIEMPO (MILISEGUNDOS)
 - 38 -

LIMITES DEL SISTEMA DE COMBUSTIBLE

• Potencia Maxima
• MaximoTorque
• Relacion aire/combustible
• Limite de modo en frio
• Combustible en el arranque
 - 39 -

MODOS EN FRIO DEL SISTEMA DE COMBUSTIBLE

• Control de velocidad
• Limitacion de combustible
• Sincronizacion de la inyeccion
• Presion de actuacion de inyeccion
• Inyeccion de eter
 - 40 -

DERATEOS DEL SISTEMA DE COMBUSTIBLE

• Compensacion automatica por altura

• Compensacion automatica por filtro
• Advertencia de derateo de motor
 - 41 -

SISTEMA DE INYECCION DE COMBUSTIBLE

 -42-

SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E

AL SISTEMA
DE LUBRICACION

HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE FLUID MANIFOLD
ARRANQUE EN FRIO SENSOR DE HYDRAULIC PASSAGE
PRESION DE ACEITE
CIRCUITO SENSOR SENSOR DE
GRUPO DE COOL DOWN TEMPERATURA PRESION
BOMBA DE DE ACEITE
FILTRO DE DE COMBUST.
SUMINISTRO
ACEITE DE ACEITE FLUID MANIFOLD
HYDRAULIC PASSAGE

VALVULA DE
CONTROL HEUI
DE BOMBA ECM
ENFRIADOR
DE ACEITE
BOMBA DE
TRANSFERENCIA
DE COMBUST. FILTRO VALVULA
BOMBA DE SECUNDARIO REGULADORA DE
LUBRICACION DE COMBUST. PRESION
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE TANQUE DE COMBUSTIBLE
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SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E

SUMINISTRO DE BAJA PRESION DE ACEITE
AL SISTEMA
DE LUBRICACION HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE FLUID MANIFOLD
ARRANQUE EN FRIO SENSOR DE HYDRAULIC PASSAGE
PRESION DE ACEITE
COOL DOWN SENSOR SENSOR DE
GRUPO DE CIRCUIT TEMPERATURA PRESION
BOMBA DE DE COMBUST. DE ACEITE
SUMINISTRO
FILTRO DE DE ACEITE
ACEITE FLUID MANIFOLD
HYDRAULIC PASSAGE

VALVULA DE
CONTROL HEUI
DE BOMBA ECM
ENFRIADOR
DE ACEITE

BOMBA DE
TRANSFERENCIA FILTRO VALVULA
BOMBA DE DE COMBUST. SECUNDARIO REGULADORA DE
LUBRICACION DE COMBUST. PRESION
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO

OIL
SUMP TANQUE DE COMBUSTIBLE
 - 46 -

SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E

AL SISTEMA
ACEITE A ALTA PRESION
DE LUBRICACION HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE FLUID MANIFOLD
ARRANQUE EN FRIO SENSOR DE HYDRAULIC PASSAGE
PRESION DE ACEITE

COOL DOWN SENSOR SENSOR DE

GRUPO DE CIRCUIT TEMPERATURA PRESION
BOMBA DE DE COMBUST. DE ACEITE
SUMINISTRO
FILTRO DE DE ACEITE
ACEITE FLUID MANIFOLD
HYDRAULIC PASSAGE

VALVULA DE
CONTROL HEUI
DE BOMBA ECM
ENFRIADOR
DE ACEITE

BOMBA DE
TRANSFERENCIA
FILTRO VALVULA
DE COMBUST.
SECUNDARIO REGULADORA DE
BOMBA DE
LUBRICACION DE COMBUST. PRESION
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO

SUMIDERO
DE ACEITE TANQUE DE COMBUSTIBLE
 - 47 -

3408E/3412E HEUI FUEL SYSTEM

AL SISTEMA SUMINISTRO DE PETROLEO A BAJA PRESION
DE LUBRICACION HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR

COOL DOWN SENSOR SENSOR DE

HYDRAULIC CIRCUIT TEMPERATURA PRESION
SUPPLY DE COMBUST. DE ACEITE
PUMP
FILTRO DE GROUP
ACEITE FLUID MANIFOLD
HYDRAULIC PASSAGE

VALVULA DE
CONTROL HEUI
DE BOMBA ECM
ENFRIADOR
DE ACEITE

BOMBA DE
TRANSFERENCIA
DE COMBUST. FILTRO VALVULA
BOMBA DE SECUNDARIO REGULADORA DE
LUBRICACION (2 MICRON) PRESION
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO

SUMIDERO
DE ACEITE TANQUE DE COMBUSTIBLE
FLUJO DE FLUIDO POR LOS INYECTORES ACEITE A ALTA PRESION

ADAPTADOR PARA ABRAZADERA DEL INYECTOR

INYECCION DE ACEITE

JUMPER

ROCKER ARM BASE

INYECTOR
PASAJE DE ACEITE DE LUBRICACION

PASAJE DE ACEITE
A ALTA PRESION

MANIFOLD DE
SUMINISTRO DE FLUIDO

MANGUITO DE INYECTOR
EN LA CULATA

CULATA

SUMINISTRO DE
COMBUSTIBLE A BAJA PRESION

REFRIGERANTE
BLOQUE DE CILINDROS
ARANDELA DE METAL
 - 49 -

SUMINISTRO DE COMBUSTIBLE AL INYECTOR

INYECTOR

SELLO O´RING SELLO O´RING

SUPERIOR DEL INYECTOR SUPERIOR DEL MANGUITO

CAMISETA DEL INYECTOR

LADO DE CULATA

MANIFOLD DE
SUMINISTRO DE FLUIDO SELLO O´RING
INFERIOR DE MANGUITO

SUMINISTRO DE COMBUSTIBLE
A BAJA PRESION

CULATA

CONTACTO
SELLO O´RING METAL A METAL
INFERIOR DEL INYECTOR
- 50 -
 - 51 -

MANIFOLD DE SUMINISTRO DE COMBUSTIBLE

MANGUITO DE BASE DE
SELLOS DE COMBUSTIBLE INYECTOR, CULATA BALANCIN

PASAJE DE SUMINISTRO RANURAS DE PASAJE DE ACEITE DE PASAJE HIDRAULICO

DE COMBUSTIBLE A BAJA PRESION EXTRACCION LUBRICACION DE ALTA PRESION
- 52 -
 - 53 -
FORMA DE ONDA DE LA CORRIENTE DE INYECCION
UN CICLO
CURRENT FLOW

CORRIENTE PICO INICIAL

CORRIENTE DE SOSTENIMIENTO

0 1 2 3 4 5
TIEMPO (MILSEGUNDOS
 - 54 -
CARACTERISTICAS DE LA ONDA Y RESPUESTA

INYECCION
RATE
APERTURA DE
VALVULA
CURRENT FLOW

CORRIENTE

DURACION

0 1 2 3 4 5
INICIO DE TIME (MILLISECONDS) FIN DE
INYECCION INYECCION
- 55 -
 -

GRUPO DE CUERPO
DE VALVULA

GRUPO DE BARRIL

UNIDAD INYECTORA HEUI

3 GRUPOS PRINCIPALES

GRUPO DE BOQUILLA
 - 57 -

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 PIN
PLATE PLATE
 -
ESPACIADOR
MANGUITO
ARMADURA

VALVULA

CUERPO DE VALVULA SOLENOIDE

LAINA
BARRIL
ADAPTADOR

UNIT INJECTOR
PISTON ARANDELA COMPONENTS

SELLO SUPERIOR DE COMBUSTIBLE

VARILLA (PLUNGER)

VALVULA CHECK DE
INGRESO DE COMBUSTIBLE

PIN
MANGUITO
ESPACIADOR

SELLO INFERIOR DE COMBUSTIBLE

CHECK
BOQUILLA
 - 59 -

INJECTOR INSTALLATION
ALLEN
SCREWS

HORIZONTAL INJECTOR CLAMP

BOLTS

JUMPER TUBE
INJECTOR OIL
ADAPTOR VERTICAL
BOLTS
 - 60 -

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
 - 61 -
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
 - 62 -

NOZZLE GROUP

REVERSE FLOW
CHECK VALVE

VIEW OF STOP PLATE &

REVERSE FLOW CHECK VALVE

CHECK VALVE

FUEL
ATOMIZATION
 - 63 -
VALVE BODY GROUP
SOLENOID DE-ENERGIZED

POPPET VALVE

SOLENOID

ARMATURE

INLET
VALVE SEAT

EXHAUST
VALVE SEAT
 - 64 -

SLEEVE SPACER

VALVE
ARMATURE

SOLENOID
BODY
SHIM
BARREL
ADAPTER

PISTON WASHER
UNIT INJECTOR
END OF INJECTION

PLUNGER

BALL

PIN
SLEEVE
SPACER

CHECK
NOZZLE
 - 65 -

BARREL

PISTON WASHER

BARREL GROUP
REFILLING THE BARREL

PLUNGER

FUEL INLET
CHECK VALVE

FUEL EDGE PIN

FILTER
SLEEVE
SPACER

NOZZLE CHECK
VALVE
NOZZLE
 - 66 -

EDGE FILTER
FUEL INLET
CHECK VALVE

REVERSE FLOW
CHECK VALVE

FUEL INLET FUEL INLET

EDGE FILTER
 - 67 -
PRIME INJECTION RATE SHAPING

PRIME = PRE-INJECTION METERING INJECTION RATE

START OF INJECTION DURATION

0 1 2 3 4 5
TIME (MILLISECONDS)
 - 68 -

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
 - 69 -

INTENSIFIER
PISTON

INTENSIFIER
PISTON SEAL
BARREL GROUP
VENTING INTERNAL LEAKS
BARREL

VENTING
CHECK VALVE
 - 70 -

INJECTOR CHECK VALVES

BARREL GROUP NOZZLE GROUP

FUEL INLET
CHECK VALVE
VENTING
CHECK VALVE

REVERSE FLOW
CHECK VALVE

NOZZLE
CHECK VALVE

FUEL
ATOMIZATION
INJECTION PRESSURE
CONTROL DE PRESION HIDRAULICA DE INYECCION

HEUI

SISTEMA DE COMBUSTIBLE
ACCIONADO MECANICAMENTE

VACIO TORQUE PICO RATEADO

VELOCIDAD DE MOTOR
- 72 -
- 73 -
 VALVULA
PUERTO DE CEBADO
COMPENSADORA
BOMBA HEUI

ORIFICIO BASE DE LA VALVULA

AL DRENAJE
BOMBA DE TRANSFERENCIA
RESERVORIO

PLATO BASCULANTE
- 75 -
- 76 -
 - 77 -

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 FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
- 78 -
 - 79 -

REVERSE FLOW CHECK VALVE

SEAT
(END VIEW)

FROM
TO
PUMP
INJECTORS

FITTING VALVE BLOCK SPRING CHECK SEAT

- 80 -
- 81 -
 - 82 -

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 TEMPERATURE PRESSURE
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
 SISTEMA DE CONTROL HIDRAULICO HEUI
ARRANQUE

RESERVORIO DE AL MANIFOLD AL MANIFOLD

AL SISTEMA DE
ARRANQUE EN FRIO IZQUIERDO DERECHO
LUBRICACION PISTON DE CONTROL
DE DESPLAZAMIENTO

VALVULA CHECK
CARRETE
LIMITADOR
BOMBA DE SUMINISTRO DE PRESION

SOLENOID CARRETE
SENSADO
(ENERGIZED)
DE CARGA

SUMIDERO DE ACEITE
VALVULA DE
CONTROL
DE BOMBA

DRENAJE DE
CARCAZA DE BOMBA
 CONJUNTO DE COMPENSADOR
ARRANQUE
CARRETE LIMITADOR DE PRESION

ORIFICIO

VALVULA DE CONTROL
DE BOMBA CARRETE DE SENSADO DE CARGA

VALVULA CHECK

DEL PISTON DE CONTROL DE

DESPLAZAMIENTO

ORIFICIO DE DRENAJE

AL DRENAJE DE LA CARCAZA
AL
DRENAJE DE
CARCAZA
VALVULAS CHECK
DE FLUJO EN REVERSA
 - 85 -

HEUI HYDRAULIC CONTROL SYSTEM

DESTROKE

COLD START TO LEFT OIL TO RIGHT OIL

TO LUBE
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
 - 86 -
COMPENSATOR ASSEMBLY
DESTROKE PRESSURE
LIMITER SPOOL

PUMP ORIFICE
CONTROL VALVE

LOAD SENSING
SPOOL

CHECK VALVE

TO DISPLACEMENT
DRAIN ORIFICE CONTROL PISTON

TO CASE DRAIN
 - 87 -
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
 - 88 -
COMPENSATOR ASSEMBLY
UPSTROKE PRESSURE
LIMITER SPOOL

PUMP ORIFICE
CONTROL VALVE

LOAD SENSING
SPOOL

CHECK VALVE

FROM
DISPLACEMENT
CONTROL PISTON
DRAIN ORIFICE
TO CASE DRAIN
 - 89 -

HEUI HYDRAULIC CONTROL SYSTEM

PRESSURE LIMITER OPERATION

COLD START TO LEFT OIL TO RIGHT OIL

TO LUBE
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
 - 90 -

COMPENSATOR ASSEMBLY
PRESSURE LIMITER OPERATION
PRESSURE LIMITER
SPOOL
PUMP
CONTROL VALVE ORIFICE

LOAD SENSING
SPOOL

CHECK VALVE

TO
PLUGGED DISPLACEMENT
ORIFICE CONTROL PISTON

DRAIN ORIFICE TO CASE DRAIN

 - 91 -

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
 - 92 -

VALVULA DE CONTROL DE BOMBA

FLUJO ALTO DE CORRIENTE
DE LA VALVULA
CONJUNTO DE VALVULA DE SENSADO DE
BOBINA POPPET ADAPTADOR SELLO ASIENTO JAULA CARGA

DETENCION ESTATOR

FILTRO DE BORDE

RESORTE DE
RETENCION

BLOQUE DE
ARMADURA SOLENOIDED PIN CORAZA O´RING G CARCAZA
DRENAJE DE VALVULA
 - 93 -

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

 - 94 -

3408E/3412E HEUI SYSTEM

8 OR 12
ECM POWER SUPPLY COMPONENTS
INJECTORS
ADEM II
ELECTRONIC
CONTROL
ENGINE MODULE GROUND DISCONNECT SWITCH
HARNESS (ECM)
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
 CIRCUITO DE SUMINISTRO DE ENERGIA AL ECM

SWITCH DE PERNO A TIERRA

DESCONEXION EN EL MOTOR
BATTERIA
ECM
P1 J1 (3408E/3412E)
(-)
229-BK-14 05 (-) BATTERIA
24 VOLTIOS DC
229-BK-14 11 (-) BATTERIA
(+) 15 A
1 150-RD-14 04 (+) BATTERIA
2 150-RD-14 06 (+) BATTERIA
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

SWITCH DE ARRANQUE
 SUMINISTRO DEPOTENCIA A LOS SENSORES DE VELOCIDAD

12.5 ± 1 VOLTS

SENSOR
SPEED/TIMING
SECUNDARIO (LH) P44 J44
OR A
BK B
WH C

P2 J2
SENSOR ECM
SPEED/TIMING (3408E/3412E)
PRIMARIO (RH) P20 J20
732-PK 39 VELOC. SEC. DE MOTOR
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 VELOC.PRIM DE MOTOR
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -

P1 J1
 - 97 -
INJECTOR WIRING SCHEMATIC
ECM
J52/P52 P2 J2 (3408/3412E)
SOLENOID 1 1 A701-GY 16 SOLENOID 1 POWER
2 F726-YL 05 SOLENOID 1/3 RETURN
SOLENOID 3 3 A703-BR 32 SOLENOID 3 POWER
4 F726-YL

J56/P56

SOLENOID 2 1 A702-PU 40 SOLENOID 2 POWER

2 F727-BU 11 SOLENOID 2/4 RETURN
SOLENOID 4 3 A704-GN 34 SOLENOID 4 POWER
4 F727-BU

J53/P53

SOLENOID 5 1 A705-BU 32 SOLENOID 5 POWER

2 F728-BR 17 SOLENOID 5/7 RETURN
SOLENOID 7 3 A707-PU 38 SOLENOID 7 POWER
4 F728-BR

J57/P57

SOLENOID 6 1 A706-GY 28 SOLENOID 6 POWER

2 F729-GN 21 SOLENOID 6/8 RETURN
SOLENOID 8 3 A708-BR 22 SOLENOID 8 POWER
4 F729-GN

J54/P54

SOLENOID 9 1 A709-OR 37 SOLENOID 9 POWER

2 F730-GY 27 SOLENOID 9/11 RETURN
SOLENOID 11 3 A711-PU 31 SOLENOID 11 POWER
4 F730-GY

J58/P58

SOLENOID 10 1 A710-GY 18 SOLENOID 10 POWER

2 F731-OR 33 SOLENOID 10/12 RETURN
SOLENOID 12 3 A712-BR 12 SOLENOID 12 POWER
4 F731-OR
 J21 P21 P1 J1 ECM (3408E/3412E HEUI)
+V ANALOG A 36 +V ANALOG SUPPLY
SENSOR DE TEMPERATURA ANALOG RETURN B 30 ANALOG RETURN
REFRIGERANTE DE MOTOR SIGNAL C

P22 J22
+V ANALOG A
SENSOR DE PRESION ANALOG RETURN B
ACEITE DE MOTOR SIGNAL C

P23 J23
+V ANALOG A
SENSOR DE PRESION ANALOG RETURN B
SALIDA DEL TURBO SIGNAL C

P25 J25 SUMINBISTRO DE ENERGIA

+V ANALOG A
SENSOR DE PRESION
ANALOG RETURN
SIGNAL
B
C
SENSORES ANALOGOS
ENTRADA DEL TURBO
P27 J27 5 ± 0.2 VOLTS
+V ANALOG A
SENSOR DE ANALOG RETURN B
PRESION ATMOSFERICA SIGNAL C

P45 J45
+V ANALOG A
SENSOR DE PRESION ANALOG RETURN B
DE ACEITE SIGNAL C

P43 J43

SENSOR DE TEMPERATURA +V ANALOG

ANALOG RETURN
A
B
COMBUSTIBLE SIGNAL C

P51 J51

SENSOR DE TEMPERATURA +V ANALOG A

ANALOG RETURN B
DE ACEITE SIGNAL C
 - 99 -

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
 - 100

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
 - 101

ELECTRONIC SENSORS AND SYSTEMS

 - 102

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
INTERFACE
TDC SERVICE CONNECTOR
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR

SECONDARY
SPEED/TIMING SENSOR
 - 103

ANALOG SENSORS
• Hydraulic pressure
• Coolant temperature
• Atmospheric pressure
• Turbocharger inlet pressure
• Turbocharger outlet pressure
• Lubrication oil pressure
• Hydraulic temperature
• Fuel temperature
 - 104

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
 - 105

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

 - 106

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

 - 107

ENGINE POWER DERATING MAP

ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500

98% 8,210
PERCENT OF FULL LOAD POWER

96% 8,920

94% 9,630

92% 10,340

ALTITUDE IN FEET
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

 - 108

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

ATMOSPHERIC PRESS. SENSOR

 - 109

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%
 - 110

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

 - 111

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

 - 112

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
 - 113

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 (BOOST)

PRESS. SENSOR

ATMOSPHERIC PRESS. SENSOR

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

 - 114

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 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

 - 115
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

 - 116

DIGITAL SENSORS AND CIRCUITS

• Throttle Position
• Pump Control Valve Signal

• Exhaust Temperature
 - 117
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
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

 - 118

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

 - 119
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
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

 - 120
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

 - 121

USER DEFINED SHUTDOWN

J3 P2 J2
ECM (3408E/3412E HEUI)
USER SHUTDOWN 12 1 USER SHUTDOWN
DEVICE
 - 122
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

OIL PRESSURE SENSOR

HYDRAULIC TEMP. SENSOR

FUEL TEMPERATURE SENSOR

COOLANT FLOW SWITCH

 - 123

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
 - 124
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

 - 125

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
 - 126

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
 - 127

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
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 SERVICE TOOL CONNECTOR

EPTC II TRANSMISSION CONTROL

HYDRAULIC TEMP SENSOR
AUTO RETARDER CONTROL

FUEL TEMPERATURE SENSOR

INSTRUMENT
PANEL
COOLANT FLOW SWITCH
 - 128

MACHINE APPLICATIONS
 - 129

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
 - 130

THROTTLE SWITCH CIRCUIT

THROTTLE ECM
SWITCH (3408E/3412E)

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
 - 131

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
 - 132

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)
 - 133

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 F718-BU 20 Throttle Lock Resume/Accelerate
LOCK LAMP 24 Throttle Lock ON/OFF
113-OR BATT+ F719-BR
998-BR
THROTTLE LOCK
SET/DECLERATION SW
998-BR
THROTTLE LOCK
RESUME/ACCLERATION SW

998-BR
THROTTLE LOCK SW
 - 134

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
 SISTEMA DE MONITOREO CATERPILLAR

P
15 AUT

10 20

5
25
X100
R
24 V
0 MPH 30 44
km/h
- 136
 - 137

INDUSTRIAL
8 OR 12
INJECTORS 3408E/3412E HEUI SYSTEM
ADEM II COMPONENT DIAGRAM
ELECTRONIC
CONTROL
MODULE GROUND
(ECM) 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
 - 138

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
OIL SENSOR
PUMP
FILTER GROUP
FLUID MANIFOLD

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