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TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
8 OR 12
3408E/3412E HEUI SYSTEM
INJECTORS COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE GROUND DISCONNECT SWITCH
ENGINE (ECM) BOLT
HARNESS
24 V
MAIN KEY
MACHINE POWER RELAY
HARNESS 15 AMP SWITCH
BREAKER
PUMP CONTROL VALVE
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PRIMARY PROBE ACCESS
THROTTLE
SPEED/TIMING SENSOR SENSOR ACCELERATOR
PEDAL
SECONDARY THROTTLE BACK-UP, ELEVATED LOW IDLE ENABLE,
SPEED/TIMING SENSOR AND GROUND LEVEL SHUTDOWN (2) SWITCHES
P2 J2
PRIMARY ECM
SPEED/TIMING (3408E/3412 E)
SENSOR P20 J20
732-PK 39 SECONDARY ENGINE SPEED
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 PRIMARY ENGINE SPEED
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -
P26 P1 J1
TIMING CALIBRATION 1
CONNECTOR 2
TIMING WHEEL
TDC REF
REF
TIMING
1 CALIBRATION
6 RANGE ± 10°
TDC REF
TIMING WHEEL
ROTATION TDC
REF
5 2
7 REF
TDC
REF TDC
3408E/3412E HEUI FUEL SYSTEM
TO LUBE
SYSTEM
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
3408E/3412E HEUI FUEL SYSTEM
LOW PRESSURE OIL (HYDRAULIC) SUPPLY
TO LUBE
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
PUMP
OIL GROUP
FILTER FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
3408E/3412E HEUI FUEL SYSTEM
TO LUBE
HIGH PRESSURE HYDRAULICS
SYSTEM HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER SECONDARY
PUMP PRESSURE
FUEL REGULATING
LUBE OIL
FILTER VALVE
PUMP
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
TO LUBE
SYSTEM 3408E/3412E HEUI FUEL SYSTEM
LOW PRESSURE FUEL SUPPLY
HEUI
HYDRAULIC
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL FILTER REGULATING
PUMP (2 MICRON) VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
INJECTOR FLUID FLOW HIGH PRESSURE HYDRAULIC OIL
JUMPER TUBE
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
CYLINDER HEAD
INJECTOR SLEEVE
FLUID SUPPLY
MANIFOLD LOWER SLEEVE
O-RING SEAL
LOW PRESSURE
FUEL SUPPLY
CYLINDER
HEAD
METAL-TO- METAL
LOWER INJECTOR CONTACT
O-RING SEAL
FLUID SUPPLY MANIFOLD
0 1 2 3 4 5
TIME (MILLISECONDS)
WAVEFORM AND RESPONSE CHARACTERISTICS
INJECTION
RATE
POPPET
LIFT
CURRENT FLOW
CURRENT
DURATION
0 1 2 3 4 5
START OF TIME (MILLISECONDS) END OF
INJECTION INJECTION
VALVE BODY
GROUP
BARREL GROUP
3 MAIN GROUPS
NOZZLE GROUP
INJECTOR INSTALLATION
ALLEN
SCREWS
JUMPER TUBE
INJECTOR OIL
ADAPTOR VERTICAL
BOLTS
PRIMING PORT COMPENSATOR
VALVE
HEUI PUMP
DRAIN PASSAGE
TRANSFER PUMP
RESERVOIR
SWASHPLATE
COOL DOWN BYPASS CIRCUIT
TO LUBE
.020 IN.
SYSTEM ORIFICE HEUI
HYDRAULIC
DRAIN TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE HYDRAULIC PASSAGE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT TEMPERATURE PRESSURE
SUPPLY SENSOR SENSOR
OIL PUMP
FILTER GROUP
FLUID MANIFOLD
HYDRAULIC PASSAGE
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER SECONDARY PRESSURE
LUBE OIL PUMP REGULATING
FUEL
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK
REVERSE FLOW CHECK VALVE
SEAT
(END VIEW)
FROM
TO
PUMP
INJECTORS
STOP STATOR
EDGE FILTER
SPRING
RETAINER
TO VALVE
ARMATURE SOLENOID PIN SHELL RING CASE DRAIN BLOCK
PUMP CONTROL VALVE
HIGH CURRENT FLOW
FROM LOAD
COIL POPPET SENSING SPOOL
ASSEMBLY VALVE ADAPTER SEAL SEAT CAGE VALVE
EDGE
FILTER
STOP STATOR
VALVE TO SPRING
ARMATURE SOLENOID PIN SHELL RING BLOCK CASE DRAIN RETAINER
HEUI SYSTEM POWER SUPPLIES
• ECM: 24 VOLTS
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
KEY SWITCH
SPEED/TIMING SENSOR POWER SUPPLY
12.5 ± 1 VOLTS
SECONDARY
SPEED/TIMING
SENSOR (LH) P44 J44
OR A
BK B
WH C
P2 J2
PRIMARY ECM
SPEED/TIMING (3408E/3412E)
SENSOR (RH) P20 J20
732-PK 39 SECONDARY ENGINE SPEED
OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 PRIMARY ENGINE SPEED
F723-PK 18 TIMING CAL +
F724-PU 12 TIMING CAL -
P1 J1
INJECTOR WIRING SCHEMATIC
ECM
J52/P52 P2 J2 (3408/3412E)
1 A701-GY 16 SOLENOID 1 POWER
SOLENOID 1
2 F726-YL 05 SOLENOID 1/3 RETURN
3 A703-BR 32 SOLENOID 3 POWER
SOLENOID 3
4 F726-YL
J56/P56
1 A702-PU 40 SOLENOID 2 POWER
SOLENOID 2
2 F727-BU 11 SOLENOID 2/4 RETURN
3 A704-GN 34 SOLENOID 4 POWER
SOLENOID 4
4 F727-BU
J53/P53
1 A705-BU 32 SOLENOID 5 POWER
SOLENOID 5
2 F728-BR 17 SOLENOID 5/7 RETURN
3 A707-PU 38 SOLENOID 7 POWER
SOLENOID 7
4 F728-BR
J57/P57
1 A706-GY 28 SOLENOID 6 POWER
SOLENOID 6
2 F729-GN 21 SOLENOID 6/8 RETURN
3 A708-BR 22 SOLENOID 8 POWER
SOLENOID 8
4 F729-GN
J54/P54
1 A709-OR 37 SOLENOID 9 POWER
SOLENOID 9
2 F730-GY 27 SOLENOID 9/11 RETURN
3 A711-PU 31 SOLENOID 11 POWER
SOLENOID 11
4 F730-GY
J58/P58
1 A710-GY 18 SOLENOID 10 POWER
SOLENOID 10
2 F731-OR 33 SOLENOID 10/12 RETURN
3 A712-BR 12 SOLENOID 12 POWER
SOLENOID 12
4 F731-OR
J21 P21 P1 J1 ECM (3408E/3412E HEUI)
+V ANALOG A 36 +V ANALOG SUPPLY
ENGINE COOLANT ANALOG RETURN B 30 ANALOG RETURN
TEMPERATURE SENSOR SIGNAL C
P22 J22
+V ANALOG A
ENGINE OIL ANALOG RETURN B
PRESSURE SENSOR SIGNAL C
P23 J23
+V ANALOG A
TURBO OUTLET ANALOG RETURN B
PRESSURE SENSOR SIGNAL C
P45 J45
+V ANALOG A
HYDRAULIC B
ANALOG RETURN
PRESSURE SENSOR SIGNAL C
P43 J43
+V ANALOG A
FUEL TEMPERATURE ANALOG RETURN B
SENSOR SIGNAL C
P51 J51
DIGITAL SENSOR
FAN
POWER SUPPLY
SPEED SENSOR
P84 J84 8 ± 0.5 VOLTS
+V DIGITAL A
DIGITAL RETURN B
SIGNAL C
PUMP CONTROL VALVE
POWER SUPPLY
0 to 24 VOLTS PWM
0 to 800 mAmps
PUMP CONTROL
VALVE J46 P46 P2 J2 ECM (3408E/3412E HEUI)
SUPPLY A 29 + SUPPLY
RETURN B 35 - RETURN
ELECTRONIC SENSORS AND SYSTEMS
HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE POWER RELAY
HARNESS 15 AMP SWITCH
BREAKER
MACHINE
INTERFACE
TDC SERVICE CONNECTOR
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
ANALOG SENSORS
• Hydraulic pressure
• Coolant temperature
• Atmospheric pressure
• Turbocharger i n l e t pressure
• Turbocharger outlet pressure
• Lubrication oi l pressure
• Hydraulic temperature
• Fu e l temperature
HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
98% 8,210
96% 8,920
94% 9,630
10,340
ALTITUDE IN FEET
92%
90% 11,050
88% 11,760
86% 12,470
84% 13,180
82% 13,890
80% 14,600
78% 15,310
76% 16,020
74% 16,730
72% 17,440
77 76 75 74 73 72 71 70 69 68 67 66 65 64 63 62 61 60 59 58 57 56 55 54 53
TURBOCHARGER ATMOSPHERIC
INLET PRESSURE PRESSURE
SENSOR SENSOR
CAT
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
320 46.4
300 43.5
280 40.6
OIL PRESSURE IN kPa
240 34.8
220 31.9
200 29
180 26.1
160 23.2
140 20.3
120 17.4
100 14.5
80 11.6
60 8.7
600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000
ENGINE RPM
kPa x 0.145 = PSI
HEUI SYSTEM
8 OR 12
INJECTORS
COMPONENT DIAGRAM
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN KEY
MACHINE
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY CAM
SPEED/TIMING SENSOR
BACKUP CAM
SPEED/TIMING SENSOR
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY
SPEED/TIMING SENSOR
SECONDARY
SPEED/TIMING SENSOR
• Throttle Position
• Exhaust Temperature
HEUI SYSTEM
8 OR 12 COMPONENT DIAGRAM
INJECTORS
ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM) GROUND DISCONNECT SWITCH
ENGINE BOLT
HARNESS
24 V
MAIN
MACHINE KEY
HARNESS 15 AMP POWER RELAY SWITCH
BREAKER
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL
SECONDARY
SPEED/TIMING SENSOR
DUTY = 10%
CYCLE
OFF
50%
ON
DUTY = 50%
CYCLE
OFF
1 CYCLE
90%
ON
DUTY
= 90%
CYCLE
OFF
MACHINE
HYDRAULIC INTERFACE
PRESSURE SENSOR CONNECTOR
TDC SERVICE
PROBE ACCESS
PRIMARY THROTTLE ACCELERATOR
SPEED/TIMING SENSOR SENSOR PEDAL
SECONDARY
SPEED/TIMING SENSOR
LAPTOP
COMPUTER
CONTROL SERVICE TOOL
CAT
ELECTRONIC TECHNICIAN
7X1701
COMMUNICATION
ADAPTER
ADEM II
ELECTRONIC
MAIN MODULE
CONTROL
MODULE
(ECM)
VIMS
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
3408E/3412E HEUI FUEL SYSTEM
TO LUBE
SYSTEM
HEUI
HYDRAULIC OIL
TEMPERATURE
SENSOR
COLD START
OIL FLUID MANIFOLD
RESERVOIR OIL PRESSURE
SENSOR
COOL DOWN FUEL HYDRAULIC
HYDRAULIC CIRCUIT PRESSURE
TEMPERATURE
SUPPLY SENSOR
SENSOR
PUMP
GROUP
FLUID MANIFOLD
OIL
FILTER
PUMP
CONTROL HEUI
VALVE ECM
OIL
COOLER
FUEL
TRANSFER
PUMP SECONDARY PRESSURE
LUBE OIL FUEL REGULATING
PUMP FILTER VALVE
PRIMARY
FUEL FILTER
WATER
SEPARATOR
OIL
SUMP FUEL TANK