3408E-3412E Engine Controls

3408E/3412E ENGINE CONTROLS
HYDRAULIC ELECTRONIC UNIT INJECTION (HEUI)
2001 Caterpillar Inc.
3408E/3412E HEUI FUEL SYSTEM

TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR HYDRAULIC SUPPLY PUMP GROUP OIL PRESSURE SENSOR COOL DOWN CIRCUIT
FLUID MANIFOLD HYDRAULIC PASSAGE
OIL FILTER
FUEL TEMPERATURE SENSOR
HYDRAULIC PRESSURE SENSOR
OIL COOLER
PUMP CONTROL VALVE FUEL TRANSFER PUMP PRIMARY FUEL FILTER WATER SEPARATOR OIL SUMP
ECM
HEUI
LUBE OIL PUMP
SECONDARY FUEL FILTER
PRESSURE REGULATING VALVE
FUEL TANK
8 OR 12 INJECTORS
3408E/3412E HEUI SYSTEM

ADEM II ELECTRONIC CONTROL MODULE (ECM)
COMPONENT DIAGRAM
GROUND BOLT 15 AMP BREAKER DISCONNECT SWITCH 24 V
ENGINE HARNESS
MACHINE HARNESS PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR COOLANT TEMP. SENSOR MACHINE INTERFACE CONNECTOR TDC SERVICE PROBE ACCESS THROTTLE SENSOR
MAIN KEY POWER RELAY SWITCH
ACCELERATOR PEDAL THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES TURBO INLET PRESSURE SENSOR FAN CONTROL VALVE
TURBO OUTLET PRESS. SENSOR ATMOSPHERIC PRESS. SENSOR
FAN SPEED SENSOR FAN 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 CONTROL LOGIC

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

SHUTDOWNS TO PUMP CONTROL VALVE HYDRAULIC OIL TEMPERATURE AND PRESSURE SENSORS ECM ELECTRONIC GOVERNOR FRC MAPS TORQUE MAPS
INJECTION ACTUATION CONTROL
8 7 SIGNALS 6 TO FUEL 5 INJECTORS 4 3 2 1 SPEED/TIMING SIGNAL
FUEL INJECTION CONTROL
ENGINE RPM TDC
ENGINE CONTROL LOGIC
THROTTLE
ENGINE RPM TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS
ENGINE RPM
TIMING WHEEL SPEED/TIMING SENSORS
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
GROUND DISCONNECT SWITCH BOLT MAIN KEY 15 AMP POWER RELAY SWITCH BREAKER
24 V
ENGINE HARNESS
MACHINE HARNESS PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR COOLANT TEMP. SENSOR TDC SERVICE PROBE ACCESS MACHINE INTERFACE CONNECTOR THROTTLE SENSOR
ACCELERATOR PEDAL
TURBO INLET PRESSURE SENSOR PROPORTIONAL VALVE
TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR ATMOSPHERIC PRESS. SENSOR CAT DATA LINK OIL PRESSURE SENSOR HYDRAULIC TEMP. SENSOR FUEL TEMPERATURE SENSOR COOLANT FLOW SWITCH INSTRUMENT PANEL ELECTRONIC SERVICE TOOL EPTC II TRANSMISSION CONTROL AUTO RETARDER CONTROL FAN
SECONDARY SPEED/TIMING SENSOR
SPEED/TIMING SENSORS
P44 J44 OR BK WH A B C P2 J2
PRIMARY SPEED/TIMING SENSOR
ECM (3408E/3412 E) P20 J20 A OR B BK C WH 732-PK 996-GN 998-BR 999-WH F723-PK F724-PU 39 32 29 38 18 12 P1 J1 SECONDARY ENGINE SPEED +V TIMING DIGITAL RETURN PRIMARY ENGINE SPEED TIMING CAL + TIMING CAL -
TIMING CALIBRATION CONNECTOR
P26 1 2
TIMING WHEEL
TDC SECONDARY SPEED/TIMING SENSOR REF 4 REF TDC SINGLE 50/50 TOOTH TDC CYLINDER No. 1 3 8 REF TDC REF TIMING CALIBRATION RANGE 10 REF PRIMARY SPEED/TIMING SENSOR
1 6
TDC TIMING WHEEL ROTATION
REF 5 2
TDC
TDC REF
7 TDC
REF
CRANKING
TIMING GEAR TOOTH TABLE
TABLE PWM DUTY CYLINDER CYCLE ENTRY REFERENCE A B C D E F G H 80/20 % 80 % 80 % 80 % 80 % 80 % 80 % 80 % 50 % 80/20 % NONE IDENTIFIED
80/20 %
80/20 %
80/20 %
80/20 %
50/50%
TIMING WHEEL ROTATION

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

TABLE ENTRY A B C D E F G H PWM DUTY CYCLE 80 % 80 % 80 % 80 % 80 % 80 % 80 % 50 % CYLINDER REFERENCE NO CYL NO. 3 NO NO CYL NO. 4 NO NO CYL NO. 8
NORMAL OPERATION
62 BTDC (EEPROM) DES TIMING DELAY NO. 3 INJECTION
62 BTDC (EEPROM) DES TIMING DELAY ASSUMED TDC CYL NO. 4 (REFERENCE) NO. 4 INJECTION
ASSUMED TDC
CYL NO. 3 (REFERENCE)
CYL NO. 3 ACTUAL TDC (CALIBRATED)
CYL NO. 4 ACTUAL TDC (CALIBRATED)
TIMING CALIBRATION SENSOR

SECONDARY SPEED/TIMING SENSOR P44 J44 OR A BK B WH C P2 J2 PRIMARY SPEED/TIMING SENSOR ECM (3408E/3412E) P20 OR BK WH J20 A B C 732-PK 996-GN 998-BR 999-WH F723-PK F724-PU 39 32 29 38 18 12 P1 J1 SECONDARY ENGINE SPEED +V TIMING DIGITAL RETURN PRIMARY ENGINE SPEED TIMING CAL + TIMING CAL -
TIMING CALIBRATION SENSOR
P26 1 2
TIMING CALIBRATION CONNECTOR
TIMING CALIBRATION
TIMING WHEEL
REFERENCE EDGE TO TDC DISTANCE REFERENCE EDGE ASSUMED CYL. NO. 1 TDC
ACTUAL CYL. NO. 1 TDC
-10 TIMING CALIBRATION SENSOR SIGNAL 10
+10
TIMING REFERENCE OFFSET
MAXIMUM TIMING REFERENCE OFFSET 10 DEGREES
INJECTION CURRENT WAVEFORM

ONE CYCLE
CURRENT FLOW
PULL-IN PEAK CURRENT
HOLD-IN PEAK CURRENT
TIME (MILLISECONDS)
POPPET VALVE MOVEMENT
POPPET LIFT CURRENT FLOW
CURRENT
TIME (MILLISECONDS)
WAVEFORM AND RESPONSE CHARACTERISTICS

POPPET LIFT INJECTION RATE
CURRENT FLOW
CURRENT
DURATION
1
START OF INJECTION
5
END OF INJECTION
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

TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR HYDRAULIC SUPPLY PUMP GROUP
OIL PRESSURE SENSOR COOL DOWN CIRCUIT
OIL FILTER
OIL COOLER
ECM
HEUI
LUBE OIL PUMP
FUEL TANK

TO LUBE SYSTEM
LOW PRESSURE HYDRAULICS

HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR FLUID MANIFOLD HYDRAULIC PASSAGE FUEL TEMPERATURE SENSOR HYDRAULIC PRESSURE SENSOR
OIL FILTER
HYDRAULIC SUPPLY PUMP GROUP
PUMP CONTROL VALVE OIL COOLER FUEL TRANSFER PUMP PRIMARY FUEL FILTER WATER SEPARATOR OIL SUMP
HEUI ECM
LUBE OIL PUMP
FUEL TANK

TO LUBE SYSTEM
HIGH PRESSURE HYDRAULICS

OIL FILTER
HEUI ECM
LUBE OIL PUMP
FUEL TANK

LOW PRESSURE FUEL SUPPLY
TO LUBE SYSTEM HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR FLUID MANIFOLD HYDRAULIC PASSAGE FUEL TEMPERATURE SENSOR HYDRAULIC PRESSURE SENSOR HEUI
OIL FILTER
PUMP CONTROL VALVE OIL COOLER FUEL TRANSFER PUMP
HEUI ECM
LUBE OIL PUMP
PRIMARY FUEL FILTER WATER SEPARATOR OIL SUMP FUEL TANK
INJECTOR FLUID FLOW

HIGH PRESSURE HYDRAULIC OIL INJECTOR OIL ADAPTER INJECTOR CLAMP 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 O-RING SEAL UPPER SLEEVE O-RING SEAL CYLINDER HEAD INJECTOR SLEEVE
FLUID SUPPLY MANIFOLD
LOWER SLEEVE O-RING SEAL
LOW PRESSURE FUEL SUPPLY
CYLINDER HEAD METAL-TO- METAL CONTACT
LOWER INJECTOR O-RING SEAL
FLUID SUPPLY MANIFOLD

CYLINDER HEAD INJECTOR SLEEVE ROCKER ARM BASE
FUEL SEALS
LOW PRESSURE FUEL SUPPLY PASSAGE
EXTRACTOR SPLINES
LUBRICATION OIL PASSAGE
HIGH PRESSURE HYDRAULIC PASSAGE
INJECTION CURRENT WAVEFORM

ONE CYCLE
CURRENT FLOW
PULL-IN PEAK CURRENT
HOLD-IN PEAK CURRENT
TIME (MILLISECONDS)
WAVEFORM AND RESPONSE CHARACTERISTICS

INJECTION RATE POPPET LIFT CURRENT FLOW
CURRENT
DURATION
1
START OF INJECTION
5
END OF INJECTION
TIME (MILLISECONDS)
VALVE BODY GROUP
BARREL GROUP
HEUI UNIT INJECTOR

3 MAIN GROUPS
NOZZLE GROUP
3408E/3412E HEUI INJECTOR

COMPONENTS
BODY
VALVE BODY GROUP

ADAPTER BOLT ARMATURE
SOLENOID ASSEMBLY
POPPET SEAL
SPRING SLEEVE SHIM SEAL
SPACER
SCREW
SCREW
INTENSIFIER PISTON RETAINER RING WASHER DOWEL BALL
BARREL GROUP NOZZLE GROUP

DOWEL LIFT SPACER DOWEL TIP CASE
PLUNGER
SPRING
SEAL
BARREL
BALL
STOP CHECK PLATE PLATE
STOP
STOP SPRING SLEEVE PIN
CHECK
SLEEVE VALVE VALVE BODY
SPACER ARMATURE
SOLENOID SHIM
BARREL
ADAPTER
PISTON
WASHER UPPER FUEL SEAL
UNIT INJECTOR
COMPONENTS
PLUNGER FUEL INLET CHECK VALVE PIN SLEEVE SPACER LOWER FUEL SEAL CHECK NOZZLE
INJECTOR INSTALLATION
ALLEN SCREWS HORIZONTAL BOLTS INJECTOR CLAMP
JUMPER TUBE INJECTOR OIL ADAPTOR VERTICAL BOLTS
VALVE BODY GROUP

SOLENOID DE-ENERGIZED
POPPET VALVE CLOSED
SOLENOID ENERGIZED
POPPET VALVE OPEN
POPPET VALVE
SOLENOID
ARMATURE
INLET VALVE SEAT
EXHAUST VALVE SEAT
POPPET SPRING
ARMATURE SCREW
SUPPLY OIL
INTENSIFIER PISTON
BARREL GROUP
FUEL PRESSURE INCREASE
BARREL
PLUNGER
FUEL INLET CHECK VALVE REVERSE FLOW CHECK VALVE
FUEL FROM TRANSFER PUMP
FUEL TO NOZZLE
NOZZLE GROUP
REVERSE FLOW CHECK VALVE
VIEW OF STOP PLATE AND 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 VALVE
SPACER
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 FILTER SPACER
PIN SLEEVE
NOZZLE CHECK VALVE
NOZZLE
FUEL INLET CHECK VALVE
EDGE FILTER
FUEL INLET
FUEL INLET
EDGE FILTER
PRIME INJECTION RATE SHAPING

PRIME = PRE-INJECTION METERING
INJECTION RATE
DURATION START OF INJECTION
TIME (MILLISECONDS)
BARREL GROUP
PRIME RATE SHAPING
OIL FLOW
BARREL
PLUNGER
PRIME RATE SHAPING PASSAGE
SPILL PORT
CROSS SECTION OF PLUNGER

FUEL TO NOZZLE GROUP
START OF INJECTION
PRESSURE DROP
FINAL PRESSURE INCREASE
INTENSIFIER PISTON INTENSIFIER PISTON SEAL BARREL
BARREL GROUP
VENTING INTERNAL LEAKS
VENTING CHECK VALVE
INJECTOR CHECK VALVES

FUEL INLET CHECK VALVE
BARREL GROUP
VENTING CHECK VALVE
NOZZLE GROUP
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 DRAIN PASSAGE RESERVOIR
VALVE BASE TRANSFER PUMP
SWASHPLATE
COOL DOWN BYPASS CIRCUIT

TO LUBE SYSTEM HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR FLUID MANIFOLD HYDRAULIC PASSAGE FUEL TEMPERATURE SENSOR HYDRAULIC PRESSURE SENSOR HEUI
OIL FILTER
HEUI ECM
LUBE OIL PUMP
FUEL TANK
SEAT
(END VIEW)
TO INJECTORS
FROM PUMP
FITTING
VALVE BLOCK SPRING
CHECK
SEAT

TO LUBE SYSTEM
HYDRAULIC SYSTEM OPERATION

OIL FILTER
HEUI ECM
LUBE OIL PUMP
FUEL TANK
HEUI HYDRAULIC CONTROL SYSTEM

START-UP
TO LUBE SYSTEM COLD START RESERVOIR TO LEFT OIL MANIFOLD TO RIGHT OIL MANIFOLD
CHECK VALVE DISPLACEMENT CONTROL PISTON LOAD SENSING SPOOL SOLENOID (ENERGIZED) OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
PRESSURE LIMITER SPOOL
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

DESTROKE
TO LUBE SYSTEM COLD START RESERVOIR TO LEFT OIL MANIFOLD DISPLACEMENT CONTROL PISTON TO RIGHT OIL MANIFOLD
CHECK VALVE SUPPLY PUMP LOAD SENSING SPOOL
SOLENOID (DE-ENERGIZED)
OIL SUMP
PUMP CONTROL VALVE PUMP CASE DRAIN
DESTROKE
PUMP CONTROL VALVE
ORIFICE
LOAD SENSING SPOOL CHECK VALVE
DRAIN ORIFICE TO CASE DRAIN
TO DISPLACEMENT CONTROL PISTON

UPSTROKE
TO LUBE SYSTEM COLD START RESERVOIR DISPLACEMENT CONTROL PISTON TO LEFT OIL MANIFOLD TO RIGHT OIL MANIFOLD
CHECK VALVE SUPPLY PUMP LOAD SENSING SPOOL
SOLENOID (ENERGIZED)
OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
UPSTROKE
ORIFICE PUMP CONTROL VALVE
LOAD SENSING SPOOL
CHECK VALVE
DRAIN ORIFICE
FROM DISPLACEMENT CONTROL PISTON TO CASE DRAIN

PRESSURE LIMITER OPERATION
TO LUBE SYSTEM COLD START RESERVOIR TO LEFT OIL MANIFOLD DISPLACEMENT CONTROL PISTON TO RIGHT OIL MANIFOLD
SUPPLY PUMP SOLENOID (DE-ENERGIZED) PLUGGED ORIFICE LOAD SENSING SPOOL
OIL SUMP PUMP CONTROL VALVE PUMP CASE DRAIN
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
COIL ASSEMBLY POPPET VALVE ADAPTER SEAL FROM LOAD SENSING SPOOL SEAT CAGE VALVE EDGE FILTER
STOP
STATOR
ARMATURE
SOLENOID
PIN
SHELL
RING
VALVE BLOCK
TO CASE DRAIN
SPRING RETAINER
PUMP CONTROL VALVE

HIGH CURRENT FLOW
COIL ASSEMBLY POPPET VALVE ADAPTER SEAL FROM LOAD SENSING SPOOL SEAT CAGE VALVE EDGE FILTER
STOP
STATOR
ARMATURE
SOLENOID
PIN
SHELL
RING
VALVE BLOCK
TO CASE DRAIN
SPRING 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 INJECTORS
ECM POWER SUPPLY COMPONENTS

ADEM II ELECTRONIC CONTROL MODULE (ECM) MACHINE HARNESS
ENGINE HARNESS
GROUND BOLT 15 AMP BREAKER
DISCONNECT SWITCH 24 V
MAIN KEY POWER RELAY SWITCH
PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR COOLANT TEMP. SENSOR TDC SERVICE PROBE ACCESS MACHINE INTERFACE CONNECTOR THROTTLE SENSOR ACCELERATOR PEDAL THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES TURBO INLET PRESSURE SENSOR FAN CONTROL VALVE TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR ATMOSPHERIC PRESS. SENSOR CAT DATA LINK OIL PRESSURE SENSOR HYDRAULIC TEMP. SENSOR ELECTRONIC SERVICE TOOL EPTC II TRANSMISSION CONTROL AUTO RETARDER CONTROL FAN
FUEL TEMPERATURE SENSOR COOLANT FLOW SWITCH INSTRUMENT PANEL
ECM POWER SUPPLY CIRCUIT

DISCONNECT SWITCH ENGINE BLOCK GROUND BOLT
BATTERY (-) 24 VOLTS DC (+)
15 A CIRCUIT BREAKER 113-OR 10 AMP 112-PU
1 2 26
P3 J3
229-BK-14 229-BK-14 150-RD-14 150-RD-14 113-OR
ECM P1 J1 (3408E/3412E) (-) BATTERY 05 (-) BATTERY 11 (+) BATTERY 04 (+) BATTERY 06 KEY SWITCH ON 23
308-YL 117-RD 105-RD 200-BK
R C OFF S ON B ST KEY SWITCH
SPEED/TIMING SENSOR POWER SUPPLY

12.5 1 VOLTS
SECONDARY SPEED/TIMING SENSOR (LH) P44 J44 OR BK WH A B C P2 J2 PRIMARY SPEED/TIMING SENSOR (RH) ECM (3408E/3412 E) P20 J20 A OR B BK C WH 732-PK 996-GN 998-BR 999-WH F723-PK F724-PU 39 32 29 38 18 12 P1 J1 SECONDARY ENGINE SPEED +V TIMING DIGITAL RETURN PRIMARY ENGINE SPEED TIMING CAL + TIMING CAL -
INJECTOR WIRING SCHEMATIC

J52/P52 SOLENOID 1 SOLENOID 3 1 2 3 4 J56/P56 SOLENOID 2 SOLENOID 4 1 2 3 4 J53/P53 SOLENOID 5 SOLENOID 7 1 2 3 4 J57/P57 SOLENOID 6 SOLENOID 8 1 2 3 4 J54/P54 SOLENOID 9 SOLENOID 11 1 2 3 4 J58/P58 SOLENOID 10 SOLENOID 12 1 2 3 4 A710-GY F731-OR A712-BR F731-OR 18 33 12 SOLENOID 10 POWER SOLENOID 10/12 RETURN SOLENOID 12 POWER A709-OR F730-GY A711-PU F730-GY 37 27 31 SOLENOID 9 POWER SOLENOID 9/11 RETURN SOLENOID 11 POWER A706-GY F729-GN A708-BR F729-GN 28 21 22 SOLENOID 6 POWER SOLENOID 6/8 RETURN SOLENOID 8 POWER A705-BU F728-BR A707-PU F728-BR 32 17 38 SOLENOID 5 POWER SOLENOID 5/7 RETURN SOLENOID 7 POWER A702-PU F727-BU A704-GN F727-BU 40 11 34 SOLENOID 2 POWER SOLENOID 2/4 RETURN SOLENOID 4 POWER A701-GY F726-YL A703-BR F726-YL P2 J2 16 05 26 ECM (3408/3412E) SOLENOID 1 POWER SOLENOID 1/3 RETURN SOLENOID 3 POWER
J21 P21
P1 J1 36 30
ENGINE COOLANT TEMPERATURE SENSOR
+V ANALOG ANALOG RETURN SIGNAL
A B C P22 J22
ECM (3408E/3412E HEUI) +V ANALOG SUPPLY ANALOG RETURN
ENGINE OIL PRESSURE SENSOR
A B C P23 J23
TURBO OUTLET PRESSURE SENSOR
A B C P25 J25
TURBO INLET PRESSURE SENSOR ATMOSPHERIC PRESSURE SENSOR
A B C P27 J27
ANALOG SENSOR POWER SUPPLY

5 0.2 VOLTS
A B C P45 J45 A B C P43 J43
A B C P51 J51
HYDRAULIC OIL TEMPERATURE SENSOR
A B C
THROTTLE POSITION SENSOR

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

DIGITAL SENSOR POWER SUPPLY

P84 J84 A B C
8 0.5 VOLTS
PUMP CONTROL VALVE POWER SUPPLY

0 to 24 VOLTS PWM 0 to 800 mAmps
PUMP CONTROL VALVE
SUPPLY RETURN J46 P46 A B
P2 J2 29 35
ECM (3408E/3412E HEUI) + SUPPLY - RETURN
ELECTRONIC SENSORS AND SYSTEMS
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
MAIN KEY 15 AMP POWER RELAY SWITCH BREAKER
TDC SERVICE PROBE ACCESS PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR
MACHINE INTERFACE CONNECTOR
ANALOG SENSORS

Hydraulic pressure Coolant temperature Atmospheric pressure Turbocharger inlet pressure Turbocharger outlet pressure Lubrication oil pressure Hydraulic temperature Fuel temperature
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
MAIN 15 AMP POWER RELAY BREAKER
KEY SWITCH
HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR
TDC SERVICE PROBE ACCESS
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
COOLANT TEMP. SENSOR
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
ATMOSPHERIC PRESS. SENSOR
ENGINE POWER DERATING MAP

ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500 8,210 8,920 9,630 10,340 11,050 11,760 12,470 13,180 13,890 14,600 15,310 16,020 16,730 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
PERCENT OF FULL LOAD POWER
98% 96% 94% 92% 90% 88% 86% 84% 82% 80% 78% 76% 74% 72%
ATMOSPHERIC PRESSURE IN kPa
ALTITUDE IN FEET
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
TURBO INLET PRESSURE SENSOR
AUTOMATIC AIR FILTER COMPENSATION

TURBOCHARGER INLET PRESSURE SENSOR ATMOSPHERIC PRESSURE 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%
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
TURBO OUTLET PRESS. SENSOR
OIL PRESSURE SENSOR
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
OIL PRESSURE SENSOR
OIL PRESSURE MAP

340 320 300 280 49.3 46.4 43.5 40.6 37.7 34.8 31.9 29 26.1 23.2 20.3 17.4 14.5 11.6 8.7 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
OIL PRESSURE IN kPa
260 240 220 200 180 160 140 120 100 80 60
ENGINE RPM
kPa x 0.145 = PSI
OIL PRESSURE IN PSI
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
MAIN 15 AMP POWER RELAY BREAKER
KEY SWITCH
HYDRAULIC OIL PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR
TURBO OUTLET (BOOST) PRESS. SENSOR ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC OIL TEMP. SENSOR
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
OIL PRESSURE SENSOR
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH a
24 V
MACHINE HARNESS
OIL PRESSURE SENSOR
COOLANT FLOW SWITCH
DIGITAL SENSORS AND CIRCUITS Throttle Position Pump Control Valve Signal Exhaust Temperature
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS
MACHINE INTERFACE CONNECTOR THROTTLE SENSOR ACCELERATOR PEDAL
OIL PRESSURE 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
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ADEM II ELECTRONIC CONTROL MODULE (ECM) GROUND BOLT DISCONNECT SWITCH
ENGINE HARNESS
MACHINE HARNESS PUMP CONTROL VALVE MACHINE INTERFACE CONNECTOR TDC SERVICE PROBE ACCESS THROTTLE SENSOR
24 V
ACCELERATOR PEDAL
OIL PRESSURE SENSOR
COOLANT FLOW SWITCH
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS PUMP CONTROL VALVE MACHINE INTERFACE CONNECTOR THROTTLE SENSOR
ACCELERATOR PEDAL THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE, AND GROUND LEVEL SHUTDOWN (2) SWITCHES TURBO INLET PRESSURE SENSOR
OIL PRESSURE SENSOR
COOLANT FLOW SWITCH
USER DEFINED SHUTDOWN
J3 USER SHUTDOWN DEVICE 12
P2 J2 1 ECM (3408E/3412E HEUI) USER SHUTDOWN
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS PUMP CONTROL VALVE MACHINE INTERFACE CONNECTOR THROTTLE SENSOR
TURBO OUTLET PRESS. SENSOR FAN SPEED SENSOR FAN ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
COOLANT FLOW SWITCH
ETHER INJECTION SYSTEM

P2 J2
ECM (3408E/E3412E)
ETHER SWITCH
J3
P3 F708-YL 998-BR 721-GY 710-BR
P1 J1
23 9 39 21
200-BK 200-BK + 308-YL 310-PK
28 29 19 40
ETHER SW LAMP DIGITAL RETURN ETHER REQUEST ETHER CONTROL
P37 J37 1 2
FROM CYLINDER
+24V
RELAY
ETHER START VALVE
TO ENGINE
CAT DATA LINK

SERVICE TOOL CONNECTOR COMMUNICATION ADAPTER
CAT ELECTRONIC TECHNICIAN
LAPTOP COMPUTER
VIMS
MAIN MODULE
VIMS DISPLAY MODULES
988F/990 CAT DATA LINK CIRCUIT

POWERTRAIN CONTROL MODULE Cat Data Link + Cat Data Link 8 9 23 24 CATERPILLAR MONITORING SYSTEM Cat Data Link + Cat Data Link -
J42 SERVICE TOOL CONNECTOR D E H J
P3 J3 7 6 31 32
893-GN 892-BR E794-YL E-793-BU
ECM P1 J1 9 Cat Data Link + 3 Cat Data Link 7 ATA Data Link + 1 ATA Data Link -
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
8 OR 12 INJECTORS
HEUI SYSTEM
COMPONENT DIAGRAM
ENGINE HARNESS
GROUND BOLT
DISCONNECT SWITCH
24 V
MACHINE HARNESS PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR MACHINE INTERFACE CONNECTOR THROTTLE SENSOR
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)
DECEL POSITION
F702-GN
24
P1 J1
DECELERATION POSITION SENSOR

P38 J38
A B C
A700-OR 998-BR
35 29
+V DIGITAL SUPPLY DIGITAL RETURN
THROTTLE SWITCH CIRCUIT
THROTTLE SWITCH
P1 J1 F715-PU F718-BU F716-WH F717-YL 998-BR 2 20 8 14 29
ECM (3408E/3412E)
THROTTLE - LOW IDLE THROTTLE - H.I. PARITY THROTTLE - L.I. PARITY THROTTLE - HIGH IDLE DIGITAL RETURN
CRANK WITHOUT INJECTION PLUG CIRCUIT

ECM (3408E/3412E) CRANK WITHOUT INJECTION PLUG PLUG "HHH" J24 P24 BK 3 2 1 720-GN 719-BR 998-BR
P1 J1
25 24 29
CRANK W/O INJECT (NO) CRANK W/O INJECT (NC) DIGITAL RETURN
PLUG "JJJ" BK
MECHANICAL ENGINE FAN CONTROL CIRCUIT

ENGINE FAN SOLENOID VALVE
P41 J41 P2 J2
ECM (3408E/E3412E)
VARIABLE FAN CLUTCH PWM DR AND SOL RETURN ENGINE FAN SPEED
B C ENGINE FAN SPEED SENSOR

F700-BU E799-BR F703-GY
19 7 25
J84 P84
P1 J1
A B C
A700-OR 998-BR
35 29 13
+V DIGITAL SUPPLY DIGITAL RETURN A/C ON (INPUT FROM COMPRESSOR SWITCH)
THROTTLE LOCK CIRCUIT

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

P86 J86 2 1 F700-BU E799-BR P2 J2 19 07
ECM (3408E/E3412E)
HYDRAULIC FAN PWM DRIVE AND SOL RETURN
CATERPILLAR MONITORING SYSTEM
15 10 5 20 25 X100 0 MPH km/h 30
P
AUT
R
24 V
44
8 OR 12 INJECTORS
INDUSTRIAL 3408E/3412E HEUI SYSTEM

COMPONENT DIAGRAM
GROUND BOLT DISCONNECT SWITCH 24 V KEY SWITCH
15 AMP BREAKER PUMP CONTROL VALVE HYDRAULIC PRESSURE SENSOR PRIMARY SPEED/TIMING SENSOR SECONDARY SPEED/TIMING SENSOR COOLANT TEMP. SENSOR ENGINE HARNESS
MAIN POWER RELAY
PTO ENABLE/PTO UP/DOWN SWITCHES ENGINE SHUTDOWN SWITCH ETHER ENABLE/OVERRIDE SWITCH EMERGENCY STOP/VERIFY SWITCH USER DEFINED SHUTDOWN THROTTLE POSITION SENSOR FUEL PRESS. SENSOR COOLANT LEVEL SWITCH INLET AIR TEMP. SENSOR
MACHINE HARNESS
ATMOSPHERIC PRESS. SENSOR TO AIR SHUTOFF SOLENOID OIL PRESSURE SENSOR TO ETHER SOLENOID RELAY ALARM /WARNING LAMP DIAGNOSTIC LAMP FUEL TEMPERATURE SENSOR MAINTENANCE INDICATOR LAMP EMS PANEL SERVICE TOOL CONNECTOR DATA LINK

TO LUBE SYSTEM HEUI HYDRAULIC TEMPERATURE SENSOR COLD START OIL RESERVOIR HYDRAULIC SUPPLY PUMP GROUP OIL PRESSURE SENSOR COOL DOWN CIRCUIT
OIL FILTER
OIL COOLER
ECM
HEUI
LUBE OIL PUMP
FUEL TANK

3408E-3412E Engine Controls

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3408E-3412E Engine Controls

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3408E/3412E ENGINE CONTROLS

HYDRAULIC ELECTRONIC UNIT INJECTION (HEUI)

2001 Caterpillar Inc.

3408E/3412E HEUI FUEL SYSTEM

FUEL TEMPERATURE SENSOR

HYDRAULIC PRESSURE SENSOR

FLUID MANIFOLD HYDRAULIC PASSAGE

LUBE OIL PUMP

SECONDARY FUEL FILTER

PRESSURE REGULATING VALVE

3408E/3412E HEUI SYSTEM

MAIN KEY POWER RELAY SWITCH

TURBO OUTLET PRESS. SENSOR ATMOSPHERIC PRESS. SENSOR

FAN SPEED SENSOR FAN 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 CONTROL LOGIC

CONVERT DESIRED TIMING

FUEL INJECTION TIMING WAVE FORM

HYDRAULIC OIL TEMPERATURE

3408E/3412E ELECTRONIC GOVERNOR

INJECTION ACTUATION CONTROL

8 7 SIGNALS 6 TO FUEL 5 INJECTORS 4 3 2 1 SPEED/TIMING SIGNAL

FUEL INJECTION CONTROL

ENGINE RPM TDC

ENGINE CONTROL LOGIC

ENGINE RPM TURBO OUTLET AND ATMOSPHERIC PRESSURE SENSORS

TIMING WHEEL SPEED/TIMING SENSORS

TURBO INLET PRESSURE SENSOR PROPORTIONAL VALVE

SECONDARY SPEED/TIMING SENSOR

PRIMARY SPEED/TIMING SENSOR

TIMING CALIBRATION CONNECTOR

TDC TIMING WHEEL ROTATION

TIMING WHEEL ROTATION

TIMING GEAR TOOTH TABLE

AFTER PATTERN RECOGNITION

TIMING WHEEL ROTATION

CYL NO. 3 REFERENCE EDGE

CYL NO. 3 CYL NO. 4 TDC REFERENCE EDGE

CYL NO. 4 TDC

CYL NO. 8 REFERENCE EDGE

TIMING GEAR TOOTH TABLE

TIMING WHEEL ROTATION

62 BTDC (EEPROM) DES TIMING DELAY NO. 3 INJECTION

CYL NO. 3 (REFERENCE)

CYL NO. 3 ACTUAL TDC (CALIBRATED)

CYL NO. 4 ACTUAL TDC (CALIBRATED)

TIMING CALIBRATION SENSOR

TIMING CALIBRATION SENSOR

TIMING CALIBRATION CONNECTOR

ACTUAL CYL. NO. 1 TDC

-10 TIMING CALIBRATION SENSOR SIGNAL 10

TIMING REFERENCE OFFSET

MAXIMUM TIMING REFERENCE OFFSET 10 DEGREES

INJECTION CURRENT WAVEFORM

PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

POPPET VALVE MOVEMENT

POPPET LIFT CURRENT FLOW