CONTROLES DE MOTOR 3408E/3412

-1-
CONTROLES DE MOTOR 3408E/3412
HYDRAULIC ELECTRONIC UNIT INJECTION
(HEUI)
©1997 Caterpillar Inc.
-2-
-3-
SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E
AL SISTEMA
DE LUBRICACION
HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE
ARRAQUE EN FRIO
FILTRO DE
ACEITE
GRUPO DE
BOMBA DE
SUMINISTRO
DE ACEITE
ENFRIADOR
DE ACEITE
BOMBA DE
LUBRICACION
FLUID MANIFOLD
HYDRAULIC PASSAGE
SENSOR DE
PRESION DE ACEITE
CIRCUITO
COOL DOWN
SENSOR DE
PRESION
DE ACEITE
SENSOR
TEMPERATURA
DE COMBUST.
FLUID MANIFOLD
HYDRAULIC PASSAGE
VALVULA DE
CONTROL
DE BOMBA
BOMBA DE
TRANSFERENCIA
DE COMBUST.
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE
HEUI
ECM
FILTRO
SECUNDARIO
DE COMBUST.
TANQUE DE COMBUSTIBLE
VALVULA
REGULADORA DE
PRESION
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- 13 -
- 14 -
- 15 -
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- 17 -
Material de Estudiante
SISTEMA3408E/3412E HEUI
8 O 12
INYECTORES
DIAGRAMA DE COMPONENTES
HARNESS DE
MOTOR
ADEM II
MODULO DE
CONTROL
ELECTRONICO
PERNO DE
(ECM)
TIERRA
HARNESS DE
MAQUINA
15 AMP
BREAKER
SWITCH DE DESCONEXION
RELE
PRINCIPAL
24 V
KEY
SWITCH
VALVULA DE CONTROL DE LA BOMBA
SENSOR DE
PRESION DE ACEITE
SENSOR PRIMARIO
DE SPEED/TIMING
CONECTOR
DE INTERFACE
A LA MAQUINA
ACCESO AL
SENSOR DE SERVICIO TDC
SENSOR DE
ACELERADOR
PEDAL DE
ACELERADOR
SENSOR SECUNDARIO
DE SPEED/TIMING
SWITCHESS DE ACELERADOR DE RESPALDO, DE HABILITACION DE
BAJA EN VACIO ELEVADO,Y SWITCH DE APAGADO A NIVEL DE PISO
SENSOR DE PRESION INGRESO AL TURBO
SENSOR DE TEMP DE REFRIGERANTE
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 -
- 21 -
- 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
CANTIDAD DE COMB.
TEMPERATURA
ACEITE
SINCRONIZ.
COMB.
GRADOS BTDC
RPM
SELECC.
SINCRONIZ.
MODO FRIO
SINCRONIZ.
DESEADA
BTDC
CONVIERTE A
SINCRONIZ.
DESEADA
FORMA DE ONDA DE LA
SINCRONIZ. DE LA INYECCION
Material del Estudiante
GOBERNADOR ELECTRONICO 3408E/3412E
SHUTDOWNS
SENSORES DE
PRESION Y DE TEMP.
DE ACEITE
A LA VALVULA DE
CONTROL DE BOMBA
ECM
CONTROL DE
ACTUACION
DE INYECCION
8
7
SEÑALES A
LOS INYECTORES 6
DE COMBUSTIBLE 5
4
3
2
1
CONTROL
INYECCION
COMBUST.
SEÑAL DE
SPEED/TIMING
GOBERNADOR
ELECTRONICO
RPM DE MOTOR
MAPAS
FRC
LOGICA DE
CONTROL
DE MOTOR
TDC
RPM DE MOTOR
RPM DE MOTOR
RUEDA DE
SINCRONIZACION
SENSORES DE
SPEED/TIMING
MAPAS
TORQUE
SENSORES DE PRESION
ATMOSFERICA Y DE
SALIDA DEL TURBO
ACELERADOR
Material del Estudiante
SISTEMA3408E/3412E HEUI
8 O 12
INYECTORES
DIAGRAMA DE COMPONENTES
ADEM II
MODULO DE
CONTROL
ELECTRONICO
PERNO DE
(ECM)
TIERRA
HARNESS DE
MOTOR
HARNESS DE
MAQUINA
15 AMP
BREAKER
SWITCH DE DESCONEXION
RELE
PRINCIPAL
24 V
KEY
SWITCH
VALVULA DE CONTROL DE LA BOMBA
SENSOR DE
PRESION DE ACEITE
SENSOR PRIMARIO
DE SPEED/TIMING
CONECTOR
DE INTERFACE
A LA MAQUINA
TDC SERVICE
PROBE ACCESS
SENSOR DE
ACELERADOR
PEDAL DE
ACELERADOR
SENSOR SECUNDARIO
DE SPEED/TIMING
SWITCHESS DE ACELERADOR DE RESPALDO, DE HABILITACION DE
BAJA EN VACIO ELEVADO,Y SWITCH DE APAGADO A NIVEL DE PISO
SENSOR DE PRESION INGRESO AL TURBO
SENSOR DE TEMP DE REFRIGERANTE
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
BK
WH
A
B
C
P2 J2
SENSOR
SPEED/TIMING
PRIMARIO
ECM
(3408E/3412 E)
P20 J20
OR
BK
WH
CONECTOR DE
CALIBRACION DE SINCRONIZACION
A
B
C
P26
1
2
732-PK
996-GN
998-BR
999-WH
F723-PK
F724-PU
39
32
29
38
18
12
P1 J1
VELOCIDAD SECUNDARIA DE MOTOR
+V SINCRONIZACION
RETORNO DIGITAL
VELOCIDAD PRIMARIA DE MOTOR
CAL DE TIMING +
CAL DE TIMING -
- 28 -
- 29 RUEDA DE SINCRONIZACION
REF
TDC
REF
SENSOR
SPEED/TIMING
SECUNDARIO
TDC
4
DIENTE
50/50
TDC CILINDRO No. 1
8
3
SENSOR
SPEED/TIMING
PRIMARIO
REF
TDC
REF
RANGO DE
CALIBRACION DE SINCRONIZACION
RANGO ± 10°
1
6
REF
TDC
ROTACION DE LA
RUEDA DE SINCRONIZACION
TDC
REF
2
5
7
TDC
REF
REF
TDC
- 30 ARRANQUE
TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION
ENTRADA PORCENTAJE
A TABLA
PWM
80 %
80 %
80 %
80 %
80 %
80 %
80 %
50 %
A
B
C
D
E
F
G
H
80/20 %
A
B
80/20 %
C
CILINDRO
DE REFERENCIA
NINGUNO IDENTIFICADO
80/20 %
D
80/20 %
E
80/20 %
F
80/20 %
G
ROTACION DE LA RUEDA DE SINCRONIZACION
50/50%
H
- 31 DESPUES DE RECONOCER EL PATRON
TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION
ENTRADA PORCENTAJE CILINDRO
A TABLA
DE REFERENCIA
PWM
80 %
80 %
80 %
80 %
80 %
80 %
80 %
50 %
A
B
C
D
E
F
G
H
NO
CIL NO. 3
NO
NO
CIL NO. 4
NO
NO
CIL NO. 8
ROTACION DE LA RUEDA DE SINCRONIZACION
A
B
CIL NO. 3
BORDE DE
REFERENCIA
C
D
CIL NO. 3
TDC
E
CIL NO. 4
BORDE DE
REFERENCIA
F
G
CIL NO. 4
TDC
H
CIL NO. 8
BORDE DE
REFERENCIA
- 32 TABLA DE DIENTES DE ENGRANAJE DE SINCRONIZACION
ENTRADA PORCENTAJE CILINDRO
A TABLA
PWM
DE REFERENCIA
80 %
80 %
80 %
80 %
80 %
80 %
80 %
50 %
A
B
C
D
E
F
G
H
ROTACION DE LA
A
B
C
RUEDA DE SINCRONIZACION
D
E
62° BTDC (EEPROM)
CIL NO. 3
(REFERENCIA)
F
G
62° BTDC (EEPROM)
SINC. DESEADA
SINC. DESEADA
DEMORA
OPERACION NORMAL
NO
CIL NO. 3
NO
NO
CIL NO. 4
NO
NO
CIL NO. 8
NO 3
INYECCION
DEMORA
TDC
ASUMIDO
CIL NO. 3
ACTUAL TDC
(CALIBRADO)
CIL NO. 4
(REFERENCIA)
NO. 4
INYECCION
TDC
ASUMIDO
CIL NO. 4
ACTUAL TDC
(CALIBRATO)
H
- 33 -
SENSOR DE CALIBRACION DE SINCRONIZACION
SECONDARY
SPEED/TIMING
SENSOR
P44 J44
OR
BK
WH
A
B
C
P2 J2
PRIMARY
SPEED/TIMING
SENSOR
ECM
(3408E/3412E)
P20 J20
OR
BK
WH
SENSOR DE CALIBRACION
DE SINCRONIZACION
A
B
C
732-PK
996-GN
998-BR
999-WH
F723-PK
F724-PU
39
32
29
38
18
12
P1 J1
P26
1
2
TIMING CALIBRATION
CONNECTOR
SECONDARY ENGINE SPEED
+V TIMING
DIGITAL RETURN
PRIMARY ENGINE SPEED
TIMING CAL +
TIMING CAL -
- 34 -
CALIBRACION DE SINCRONIZACION
RUEDA DE
SINCRONIZACION
DISTANCIA DE BORDE DE REFERENCIA AL TDC
BORDE DE
REFERENCIA
CIL. NO. 1 TDC
ASUMIDO
-10°
SEÑAL DEL SENSOR
DE CALIBRACION DE SINCRONIZACION
+10°
± 10°
MAXIMUM TIMING REFERENCE OFFSET ± 10 DEGREES
CIL. NO. 1 TDC
ACTUAL
TIMING
REFERENCE
OFFSET
- 35 FORMA DE ONDA DE LA CORRIENTE DE INYECCION
CURRENT FLOW
UN CICLO
CORRIENTE PICO DE ACCIONAMIENTO
CORRIENTE PICO DE SOSTENIMIENTO
0
1
2
3
TIEMPO (MILISEGUNDOS)
4
5
- 36 MOVIMIENTO DE LA VALVULA POPPET
CURRENT FLOW
POPPET
LIFT
CORRIENTE
0
1
2
3
TIEMPO (MILISEGUNDOS)
4
5
- 37 FORMA DE ONDA Y CARACTERISTICAS DE RESPUESTA
RAPIDEZ DE
INYECCION
CURRENT FLOW
POPPET
LIFT
CORRIENTE
FIN DE
INYECCION
INICIO DE LA
INYECCION
0
1
DURACION
2
3
TIEMPO (MILISEGUNDOS)
4
5
- 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
ARRANQUE EN FRIO
FILTRO DE
ACEITE
GRUPO DE
BOMBA DE
SUMINISTRO
DE ACEITE
ENFRIADOR
DE ACEITE
BOMBA DE
LUBRICACION
FLUID MANIFOLD
HYDRAULIC PASSAGE
SENSOR DE
PRESION DE ACEITE
CIRCUITO
COOL DOWN
SENSOR DE
PRESION
DE ACEITE
SENSOR
TEMPERATURA
DE COMBUST.
FLUID MANIFOLD
HYDRAULIC PASSAGE
VALVULA DE
CONTROL
DE BOMBA
BOMBA DE
TRANSFERENCIA
DE COMBUST.
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE
HEUI
ECM
FILTRO
SECUNDARIO
DE COMBUST.
TANQUE DE COMBUSTIBLE
VALVULA
REGULADORA DE
PRESION
- 43 -
- 44 -
- 45 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
ARRANQUE EN FRIO
FILTRO DE
ACEITE
FLUID MANIFOLD
HYDRAULIC PASSAGE
SENSOR DE
PRESION DE ACEITE
COOL DOWN
CIRCUIT
GRUPO DE
BOMBA DE
SUMINISTRO
DE ACEITE
SENSOR
TEMPERATURA
DE COMBUST.
SENSOR DE
PRESION
DE ACEITE
FLUID MANIFOLD
HYDRAULIC PASSAGE
VALVULA DE
CONTROL
DE BOMBA
HEUI
ECM
ENFRIADOR
DE ACEITE
BOMBA DE
LUBRICACION
BOMBA DE
TRANSFERENCIA
DE COMBUST.
FILTRO
SECUNDARIO
DE COMBUST.
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
OIL
SUMP
TANQUE DE COMBUSTIBLE
VALVULA
REGULADORA DE
PRESION
- 46 SISTEMA DE COMBUSTIBLE HEUI 3408E/3412E
AL SISTEMA
DE LUBRICACION
ACEITE A ALTA PRESION
HEUI
SENSOR DE
TEMPERATURA
DE ACEITE
RESERVORIO
DE ACEITE
ARRANQUE EN FRIO
FILTRO DE
ACEITE
GRUPO DE
BOMBA DE
SUMINISTRO
DE ACEITE
FLUID MANIFOLD
HYDRAULIC PASSAGE
SENSOR DE
PRESION DE ACEITE
COOL DOWN
CIRCUIT
SENSOR DE
PRESION
DE ACEITE
SENSOR
TEMPERATURA
DE COMBUST.
FLUID MANIFOLD
HYDRAULIC PASSAGE
VALVULA DE
CONTROL
DE BOMBA
HEUI
ECM
ENFRIADOR
DE ACEITE
BOMBA DE
TRANSFERENCIA
DE COMBUST.
BOMBA DE
LUBRICACION
FILTRO
SECUNDARIO
DE COMBUST.
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE
TANQUE DE COMBUSTIBLE
VALVULA
REGULADORA DE
PRESION
- 47 3408E/3412E HEUI FUEL SYSTEM
AL SISTEMA
SUMINISTRO DE PETROLEO A BAJA PRESION
DE LUBRICACION
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL
RESERVOIR
FILTRO DE
ACEITE
HYDRAULIC
SUPPLY
PUMP
GROUP
FLUID MANIFOLD
HYDRAULIC PASSAGE
OIL PRESSURE
SENSOR
SENSOR DE
PRESION
DE ACEITE
SENSOR
TEMPERATURA
DE COMBUST.
COOL DOWN
CIRCUIT
FLUID MANIFOLD
HYDRAULIC PASSAGE
VALVULA DE
CONTROL
DE BOMBA
HEUI
ECM
ENFRIADOR
DE ACEITE
BOMBA DE
LUBRICACION
BOMBA DE
TRANSFERENCIA
DE COMBUST.
FILTRO PRIMARIO
Y SEPARADOR
DE AGUA
DE PETROLEO
SUMIDERO
DE ACEITE
FILTRO
SECUNDARIO
(2 MICRON)
TANQUE DE COMBUSTIBLE
VALVULA
REGULADORA DE
PRESION
FLUJO DE FLUIDO POR LOS INYECTORES
ADAPTADOR PARA
INYECCION DE ACEITE
ACEITE A ALTA PRESION
ABRAZADERA DEL INYECTOR
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
SUPERIOR DEL INYECTOR
SELLO O´RING
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
SELLO O´RING
INFERIOR DEL INYECTOR
CONTACTO
METAL A METAL
- 50 -
- 51 -
MANIFOLD DE SUMINISTRO DE COMBUSTIBLE
SELLOS DE COMBUSTIBLE
MANGUITO DE
INYECTOR, CULATA
RANURAS DE
PASAJE DE ACEITE DE
PASAJE DE SUMINISTRO
LUBRICACION
DE COMBUSTIBLE A BAJA PRESION EXTRACCION
BASE DE
BALANCIN
PASAJE HIDRAULICO
DE ALTA PRESION
- 52 -
- 53 FORMA DE ONDA DE LA CORRIENTE DE INYECCION
CURRENT FLOW
UN CICLO
CORRIENTE PICO INICIAL
CORRIENTE DE SOSTENIMIENTO
0
1
2
3
TIEMPO (MILSEGUNDOS
4
5
- 54 CARACTERISTICAS DE LA ONDA Y RESPUESTA
INYECCION
RATE
CURRENT FLOW
APERTURA DE
VALVULA
CORRIENTE
DURACION
0
1
INICIO DE
INYECCION
2
3
TIME (MILLISECONDS)
4
5
FIN DE
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
ADAPTER BOLT
POPPET
SPRING SLEEVE SHIM SEAL
SOLENOID
ASSEMBLY
ARMATURE
SPACER
SCREW
SCREW
SEAL
INTENSIFIER PISTON
RETAINER RING
BARREL GROUP
WASHER
NOZZLE GROUP
DOWEL
PLUNGER
SPRING
SEAL
BARREL
BALL
BALL
STOP CHECK
PLATE PLATE
DOWEL
STOP
LIFT
SPACER
DOWEL
STOP SPRING SLEEVE CHECK
PIN
TIP
CASE
ESPACIADOR
MANGUITO
ARMADURA
VALVULA
SOLENOIDE
CUERPO DE VALVULA
LAINA
BARRIL
PISTON
ADAPTADOR
ARANDELA
UNIT INJECTOR
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
BOLTS
INJECTOR CLAMP
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
VALVE SEAT
EXHAUST
VALVE SEAT
POPPET
SPRING
ARMATURE
SCREW
- 61 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
- 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 -
SPACER
SLEEVE
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
FILTER
PIN
SLEEVE
SPACER
NOZZLE CHECK
VALVE
NOZZLE
- 66 EDGE FILTER
FUEL INLET
CHECK VALVE
REVERSE FLOW
CHECK VALVE
FUEL INLET
EDGE FILTER
FUEL INLET
- 67 PRIME INJECTION RATE SHAPING
PRIME = PRE-INJECTION METERING
START OF INJECTION
0
1
INJECTION RATE
DURATION
2
3
TIME (MILLISECONDS)
4
5
- 68 -
BARREL GROUP
OIL FLOW
PRIME RATE SHAPING
BARREL
PLUNGER
PRIME RATE
SHAPING PASSAGE
SPILL
PORT
CROSS SECTION
OF PLUNGER
FUEL TO
NOZZLE GROUP
START OF INJECTION
PRESSURE DROP
FINAL
PRESSURE INCREASE
- 69 -
INTENSIFIER
PISTON
INTENSIFIER
PISTON SEAL
BARREL GROUP
VENTING INTERNAL LEAKS
BARREL
VENTING
CHECK VALVE
- 70 INJECTOR CHECK VALVES
FUEL INLET
CHECK VALVE
BARREL GROUP
NOZZLE GROUP
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
VELOCIDAD DE MOTOR
RATEADO
- 72 -
- 73 -
PUERTO DE CEBADO
VALVULA
COMPENSADORA
BOMBA HEUI
ORIFICIO
AL DRENAJE
RESERVORIO
PLATO BASCULANTE
BASE DE LA VALVULA
BOMBA DE TRANSFERENCIA
- 75 -
- 76 -
- 77 COOL DOWN BYPASS CIRCUIT
TO LUBE
SYSTEM
.020 IN.
ORIFICE
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
DRAIN
COLD START
OIL
RESERVOIR
OIL
FILTER
FLUID MANIFOLD
HYDRAULIC PASSAGE
OIL PRESSURE
SENSOR
COOL DOWN
CIRCUIT
HYDRAULIC
SUPPLY
PUMP
GROUP
FUEL
TEMPERATURE
SENSOR
HYDRAULIC
PRESSURE
SENSOR
FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL
VALVE
HEUI
ECM
OIL
COOLER
FUEL
TRANSFER
PUMP
LUBE OIL
PUMP
SECONDARY
FUEL
FILTER
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP
FUEL TANK
PRESSURE
REGULATING
VALVE
- 78 -
- 79 -
REVERSE FLOW CHECK VALVE
SEAT
(END VIEW)
FROM
PUMP
TO
INJECTORS
FITTING
VALVE BLOCK
SPRING
CHECK
SEAT
- 80 -
- 81 -
- 82 3408E/3412E HEUI FUEL SYSTEM
HYDRAULIC SYSTEM OPERATION
TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL
RESERVOIR
OIL
FILTER
COOL DOWN
CIRCUIT
HYDRAULIC
SUPPLY
PUMP
GROUP
OIL
COOLER
FLUID MANIFOLD
HYDRAULIC PASSAGE
OIL PRESSURE
SENSOR
HYDRAULIC
PRESSURE
SENSOR
FUEL
TEMPERATURE
SENSOR
FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL
VALVE
FUEL
TRANSFER
PUMP
LUBE OIL
PUMP
HEUI
ECM
SECONDARY
FUEL
FILTER
PRIMARY
FUEL
FILTER
OIL
SUMP
FUEL TANK
PRESSURE
REGULATING
VALVE
SISTEMA DE CONTROL HIDRAULICO HEUI
ARRANQUE
AL SISTEMA
LUBRICACION
DE
RESERVORIO DE
ARRANQUE EN FRIO
PISTON DE CONTROL
DE DESPLAZAMIENTO
AL MANIFOLD
IZQUIERDO
VALVULA CHECK
BOMBA DE SUMINISTRO
SOLENOID
(ENERGIZED)
CARRETE
SENSADO
DE CARGA
SUMIDERO DE ACEITE
VALVULA DE
CONTROL
DE BOMBA
DRENAJE DE
CARCAZA DE BOMBA
AL MANIFOLD
DERECHO
CARRETE
LIMITADOR
DE PRESION
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
TO LUBE
SYSTEM
COLD START
RESERVIOR
TO LEFT OIL
MANIFOLD
DISPLACEMENT
CONTROL PISTON
CHECK VALVE
SUPPLY PUMP
SOLENOID
(DE-ENERGIZED)
OIL SUMP
LOAD
SENSING
SPOOL
PUMP
CONTROL
VALVE
PUMP
CASE DRAIN
TO RIGHT OIL
MANIFOLD
PRESSURE
LIMITER
SPOOL
- 86 -
COMPENSATOR ASSEMBLY
DESTROKE
PUMP
CONTROL VALVE
PRESSURE
LIMITER SPOOL
ORIFICE
LOAD SENSING
SPOOL
CHECK VALVE
DRAIN ORIFICE
TO DISPLACEMENT
CONTROL PISTON
TO CASE DRAIN
- 87 HEUI HYDRAULIC CONTROL SYSTEM
UPSTROKE
TO LUBE
SYSTEM
COLD START
RESERVIOR
DISPLACEMENT
CONTROL PISTON
TO LEFT OIL
MANIFOLD
CHECK VALVE
SUPPLY PUMP
SOLENOID
(ENERGIZED)
LOAD
SENSING
SPOOL
OIL SUMP
PUMP
CONTROL
VALVE
PUMP
CASE DRAIN
TO RIGHT OIL
MANIFOLD
PRESSURE
LIMITER
SPOOL
- 88 -
COMPENSATOR ASSEMBLY
UPSTROKE
PUMP
CONTROL VALVE
PRESSURE
LIMITER SPOOL
ORIFICE
LOAD SENSING
SPOOL
CHECK VALVE
DRAIN ORIFICE
FROM
DISPLACEMENT
CONTROL PISTON
TO CASE DRAIN
- 89 HEUI HYDRAULIC CONTROL SYSTEM
PRESSURE LIMITER OPERATION
TO LUBE
SYSTEM
COLD START
RESERVIOR
TO LEFT OIL
MANIFOLD
DISPLACEMENT
CONTROL PISTON
PRESSURE
LIMITER
SPOOL
SUPPLY PUMP
SOLENOID
(DE-ENERGIZED)
LOAD
SENSING
SPOOL
PLUGGED
ORIFICE
OIL SUMP
PUMP
CONTROL
VALVE
PUMP
CASE DRAIN
TO RIGHT OIL
MANIFOLD
- 90 COMPENSATOR ASSEMBLY
PRESSURE LIMITER OPERATION
PRESSURE LIMITER
SPOOL
PUMP
CONTROL VALVE
ORIFICE
LOAD SENSING
SPOOL
CHECK VALVE
PLUGGED
ORIFICE
DRAIN ORIFICE
TO
DISPLACEMENT
CONTROL PISTON
TO CASE DRAIN
- 91 -
PUMP CONTROL VALVE
NO CURRENT FLOW
COIL
ASSEMBLY
STOP
POPPET
VALVE
ADAPTER SEAL
SEAT CAGE
FROM LOAD
SENSING SPOOL
VALVE
STATOR
EDGE FILTER
SPRING
RETAINER
ARMATURE
SOLENOID
PIN
SHELL
RING
TO
CASE DRAIN
VALVE
BLOCK
- 92 -
VALVULA DE CONTROL DE BOMBA
FLUJO ALTO DE CORRIENTE
CONJUNTO DE
BOBINA
DETENCION
VALVULA
POPPET ADAPTADOR SELLO ASIENTO
DE LA VALVULA
DE SENSADO DE
JAULA CARGA
ESTATOR
FILTRO DE BORDE
RESORTE DE
RETENCION
ARMADURA
SOLENOIDED PIN
CORAZA
O´RING
G CARCAZA
DRENAJE DE
BLOQUE 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
ECM POWER SUPPLY COMPONENTS
8 OR 12
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
MACHINE
HARNESS
DISCONNECT SWITCH
GROUND
BOLT
15 AMP
BREAKER
MAIN
KEY
POWER RELAY SWITCH
24 V
PUMP
CONTROL VALVE
MACHINE
INTERFACE
CONNECTOR
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
THROTTLE
SENSOR
ACCELERATOR
PEDAL
SECONDARY
SPEED/TIMING SENSOR
THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES
TURBO INLET PRESSURE SENSOR
COOLANT TEMP. 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
COOLANT FLOW SWITCH
INSTRUMENT
PANEL
CIRCUITO DE SUMINISTRO DE ENERGIA AL ECM
SWITCH DE
DESCONEXION
PERNO A TIERRA
EN EL MOTOR
BATTERIA
P1 J1
(-)
24 VOLTIOS DC
(+)
15 A
CIRCUIT BREAKER
113-OR
1
2
26
229-BK-14
229-BK-14
150-RD-14
150-RD-14
113-OR
05
11
04
06
23
ECM
(3408E/3412E)
(-) BATTERIA
(-) BATTERIA
(+) BATTERIA
(+) BATTERIA
KEY SWITCH ON
P3 J3
10 AMP
112-PU
308-YL
117-RD
105-RD
200-BK
R
C OFF
S ON
B ST
SWITCH DE ARRANQUE
SUMINISTRO DEPOTENCIA A LOS SENSORES DE VELOCIDAD
12.5 ± 1 VOLTS
SENSOR
SPEED/TIMING
SECUNDARIO (LH)
P44 J44
OR
BK
WH
A
B
C
P2 J2
SENSOR
SPEED/TIMING
PRIMARIO (RH)
ECM
(3408E/3412E)
P20 J20
OR
BK
WH
A
B
C
732-PK
996-GN
998-BR
999-WH
F723-PK
F724-PU
39
32
29
38
18
12
P1 J1
VELOC. SEC. DE MOTOR
+V TIMING
DIGITAL RETURN
VELOC.PRIM DE MOTOR
TIMING CAL +
TIMING CAL -
- 97 INJECTOR WIRING SCHEMATIC
J52/P52
SOLENOID 1
SOLENOID 3
1
2
3
4
P2 J2
ECM
(3408/3412E)
A701-GY
F726-YL
A703-BR
F726-YL
16
05
32
SOLENOID 1 POWER
SOLENOID 1/3 RETURN
SOLENOID 3 POWER
A702-PU
F727-BU
A704-GN
F727-BU
40
11
34
SOLENOID 2 POWER
SOLENOID 2/4 RETURN
SOLENOID 4 POWER
A705-BU
F728-BR
A707-PU
F728-BR
32
17
38
SOLENOID 5 POWER
SOLENOID 5/7 RETURN
SOLENOID 7 POWER
A706-GY
F729-GN
A708-BR
F729-GN
28
21
22
SOLENOID 6 POWER
SOLENOID 6/8 RETURN
SOLENOID 8 POWER
A709-OR
F730-GY
A711-PU
F730-GY
37
27
31
SOLENOID 9 POWER
SOLENOID 9/11 RETURN
SOLENOID 11 POWER
A710-GY
F731-OR
A712-BR
F731-OR
18
33
12
SOLENOID 10 POWER
SOLENOID 10/12 RETURN
SOLENOID 12 POWER
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
J21 P21
+V ANALOG
SENSOR DE TEMPERATURA ANALOG RETURN
REFRIGERANTE DE MOTOR SIGNAL
A
B
C
+V ANALOG
SENSOR DE PRESION ANALOG RETURN
SIGNAL
ACEITE DE MOTOR
P22 J22
A
B
C
+V ANALOG
ANALOG RETURN
SIGNAL
P23 J23
A
B
C
SENSOR DE PRESION
SALIDA DEL TURBO
P25 J25
SENSOR DE PRESION
ENTRADA DEL TURBO
+V ANALOG
ANALOG RETURN
SIGNAL
+V ANALOG
SENSOR DE
ANALOG RETURN
PRESION ATMOSFERICA SIGNAL
A
B
C
P27 J27
A
B
C
+V ANALOG
ANALOG RETURN
SIGNAL
P45 J45
A
B
C
ANALOG
SENSOR DE TEMPERATURA +V
ANALOG RETURN
COMBUSTIBLE
SIGNAL
P43 J43
A
B
C
SENSOR DE PRESION
DE ACEITE
P51 J51
SENSOR DE TEMPERATURA +V ANALOG
ANALOG RETURN
DE ACEITE
SIGNAL
A
B
C
P1 J1
36
30
ECM (3408E/3412E HEUI)
+V ANALOG SUPPLY
ANALOG RETURN
SUMINBISTRO DE ENERGIA
SENSORES ANALOGOS
5 ± 0.2 VOLTS
- 99 -
THROTTLE
POSITION SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL
FAN
SPEED 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
DIGITAL SENSOR
POWER SUPPLY
P84 J84
A
B
C
8 ± 0.5 VOLTS
- 100
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
- 101
ELECTRONIC SENSORS AND SYSTEMS
- 102
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
MACHINE
INTERFACE
CONNECTOR
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
- 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
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
- 105
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
- 106
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
ATMOSPHERIC PRESS. SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
- 107
ENGINE POWER DERATING MAP
100%
7,500
98%
8,210
96%
8,920
94%
9,630
92%
10,340
ALTITUDE IN FEET
PERCENT OF FULL LOAD POWER
ACCORDING TO ATMOSPHERIC PRESSURE
90%
88%
86%
84%
82%
80%
11,050
11,760
12,470
13,180
13,890
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
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
ATMOSPHERIC PRESS. SENSOR
TURBO INLET PRESSURE SENSOR
- 109
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%
- 110
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
TURBO INLET PRESSURE SENSOR
- 111
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
TURBO INLET PRESSURE SENSOR
- 112
340
49.3
320
46.4
300
43.5
280
40.6
OIL PRESSURE IN PSI
OIL PRESSURE IN kPa
OIL PRESSURE MAP
260
240
220
200
180
160
140
120
37.7
34.8
31.9
29
26.1
23.2
20.3
17.4
100
14.5
80
11.6
60
600
700
800
900
1000
1100
1200
1300
1400
ENGINE RPM
kPa x 0.145 = PSI
1500
1600
1700
1800
1900
8.7
2000
- 113
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET (BOOST)
PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
TURBO INLET PRESSURE SENSOR
- 114
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY CAM
SPEED/TIMING SENSOR
BACKUP CAM
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP SENSOR
FUEL TEMPERATURE SENSOR
TURBO INLET PRESSURE SENSOR
- 115
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
FUEL TEMPERATURE SENSOR
COOLANT FLOW SWITCH
TURBO INLET PRESSURE SENSOR
- 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)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
MACHINE
INTERFACE
CONNECTOR
THROTTLE
SENSOR
ACCELERATOR
PEDAL
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
FUEL TEMPERATURE SENSOR
COOLANT FLOW SWITCH
TURBO INLET PRESSURE SENSOR
- 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)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
THROTTLE
SENSOR
ACCELERATOR
PEDAL
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
FUEL TEMPERATURE SENSOR
COOLANT FLOW SWITCH
TURBO INLET PRESSURE SENSOR
- 120
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
ATMOSPHERIC PRESS. SENSOR
OIL PRESSURE SENSOR
HYDRAULIC TEMP. SENSOR
FUEL TEMPERATURE SENSOR
COOLANT FLOW SWITCH
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
- 121
USER DEFINED SHUTDOWN
J3
USER SHUTDOWN
DEVICE
12
P2 J2
1
ECM (3408E/3412E HEUI)
USER SHUTDOWN
- 122
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
THROTTLE
SENSOR
SECONDARY
SPEED/TIMING SENSOR
ACCELERATOR
PEDAL
THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES
TURBO INLET PRESSURE SENSOR
COOLANT TEMP. 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
ETHER SWITCH
J3
23
9
39
21
ECM
(3408E/E3412E)
P1 J1
P3
F708-YL
998-BR
721-GY
710-BR
28
29
19
40
ETHER SW LAMP
DIGITAL RETURN
ETHER REQUEST
ETHER CONTROL
200-BK
200-BK
+
+24V
308-YL
310-PK
RELAY
P37 J37
1
2
ETHER
START VALVE
FROM
CYLINDER
TO ENGINE
- 124
SERVICE
TOOL
CONNECTOR
CAT DATA LINK
LAPTOP
COMPUTER
CONTROL
SERVICE TOOL
CAT
ELECTRONIC TECHNICIAN
7X1701
COMMUNICATION
VIMS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
MAIN MODULE
ADAPTER
VIMS DISPLAY MODULES
- 125
988F/990 CAT DATA LINK CIRCUIT
POWERTRAIN CONTROL
MODULE
Cat Data Link +
Cat Data Link -
SERVICE TOOL
CONNECTOR
CMS
8
9
J42
D
E
H
J
23
24
P3 J3
7
6
31
32
Cat Data Link +
Cat Data Link -
893-GN
892-BR
E794-YL
E-793-BU
MACHINE INTERFACE
CONNECTOR
ECM
P1 J1
9
Cat Data Link +
3
Cat Data Link 7
ATA Data Link +
1
ATA Data Link -
- 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
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
ENGINE
HARNESS
GROUND
BOLT
DISCONNECT SWITCH
24 V
MACHINE
HARNESS
MAIN
15 AMP POWER RELAY
BREAKER
KEY
SWITCH
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
TDC SERVICE
PROBE ACCESS
MACHINE
INTERFACE
CONNECTOR
THROTTLE
SENSOR
ACCELERATOR
PEDAL
SECONDARY
SPEED/TIMING SENSOR
THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
AND GROUND LEVEL SHUTDOWN (2) SWITCHES
TURBO INLET PRESSURE SENSOR
COOLANT TEMP. 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
F702-GN
DECELERATION
POSITION SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL
P38 J38
A
B
C
P2 J2
ECM
(3408E/3412E)
24
DECEL POSITION
P1 J1
A700-OR
998-BR
35
29
+V DIGITAL SUPPLY
DIGITAL RETURN
- 130
THROTTLE SWITCH CIRCUIT
ECM
(3408E/3412E)
THROTTLE
SWITCH
P1 J1
F715-PU
F718-BU
F716-WH
F717-YL
998-BR
2
20
8
14
29
THROTTLE - LOW IDLE
THROTTLE - H.I. PARITY
THROTTLE - L.I. PARITY
THROTTLE - HIGH IDLE
DIGITAL RETURN
- 131
CRANK WITHOUT INJECTION PLUG CIRCUIT
ECM
(3408E/3412E)
CRANK WITHOUT
INJECTION PLUG
PLUG "HHH" J24 P24
BK
PLUG "JJJ"
BK
3
2
1
P1 J1
720-GN
719-BR
998-BR
25
24
29
CRANK W/O INJECT (NO)
CRANK W/O INJECT (NC)
DIGITAL RETURN
- 132
MECHANICAL ENGINE FAN CONTROL CIRCUIT
ENGINE FAN
SOLENOID VALVE
P41 J41
B
C
F700-BU
E799-BR
F703-GY
ENGINE FAN
SPEED SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL
J84 P84
A
B
C
P2 J2
ECM
(3408E/E3412E)
19
7
25
VARIABLE FAN CLUTCH
PWM DR AND SOL RETURN
ENGINE FAN SPEED
P1 J1
A700-OR
998-BR
35
29
13
+V DIGITAL SUPPLY
DIGITAL RETURN
A/C ON (INPUT FROM
COMPRESSOR SWITCH)
- 133
THROTTLE LOCK CIRCUIT
RIGHT BRAKE PEDAL SWITCH
P1 J1
998-BR
F722-OR
F721-GY
998-BR
J3 P3
THROTTLE
LOCK LAMP
2
113-OR BATT+
998-BR
THROTTLE LOCK
SET/DECLERATION SW
998-BR
THROTTLE LOCK
RESUME/ACCLERATION SW
998-BR
THROTTLE LOCK SW
998-BR
F706-PU
F717-YL
F718-BU
F719-BR
13
19
29
27
14
20
24
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
- 134
HYDRAULIC ENGINE FAN CONTROL CIRCUIT
HYDRAULIC FAN
SOLENOID VALVE
P2 J2
P86 J86
2
1
F700-BU
E799-BR
19
07
ECM
(3408E/E3412E)
HYDRAULIC FAN
PWM DRIVE AND SOL RETURN
SISTEMA DE MONITOREO CATERPILLAR
P
15
10
5
25
X100
R
24 V
AUT
20
0
MPH
km/h
30
44
- 136
- 137
8 OR 12
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)
INDUSTRIAL
3408E/3412E HEUI SYSTEM
COMPONENT DIAGRAM
GROUND
BOLT
DISCONNECT SWITCH
15 AMP
BREAKER
MAIN
POWER RELAY
24 V
KEY
SWITCH
PUMP CONTROL VALVE
HYDRAULIC
PRESSURE SENSOR
PRIMARY
SPEED/TIMING SENSOR
MACHINE
INTERFACE
CONNECTOR
TDC SERVICE
PROBE ACCESS
PTO ENABLE/PTO UP/DOWN SWITCHES
ENGINE SHUTDOWN SWITCH
ETHER ENABLE/OVERRIDE SWITCH
EMERGENCY STOP/VERIFY SWITCH
USER DEFINED SHUTDOWN
ENGINE
HARNESS
SECONDARY
SPEED/TIMING SENSOR
THROTTLE POSITION SENSOR
COOLANT TEMP. SENSOR
TURBO OUTLET PRESS. SENSOR
FUEL 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
ALARM /WARNING LAMP
HYDRAULIC TEMP. SENSOR
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
RESERVOIR
OIL
FILTER
COOL DOWN
CIRCUIT
HYDRAULIC
SUPPLY
PUMP
GROUP
OIL
COOLER
FLUID MANIFOLD
OIL PRESSURE
SENSOR
HYDRAULIC
PRESSURE
SENSOR
FUEL
TEMPERATURE
SENSOR
FLUID MANIFOLD
PUMP
CONTROL
VALVE
FUEL
TRANSFER
PUMP
LUBE OIL
PUMP
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP
HEUI
ECM
SECONDARY
FUEL
FILTER
FUEL TANK
PRESSURE
REGULATING
VALVE