3500B ENGINE CONTROLS

ELECTRONIC UNIT INJECTION (EUI)

©2002 Caterpillar Inc.

 3516B FUEL SUPPLY CIRCUIT (793C)
FUEL
PRESSURE
REGULATOR
OIL RENEWAL CYLINDER
HEAD
INJECTOR
ENGINE
BLOCK
PRIMING PUMP SUPPLY

FUEL TANK FUEL

SECONDARY
DIFFERENTIAL
FUEL FILTERS
PRESSURE
(2 MICRON)
SWITCH

PRIMARY ECM
FUEL FUEL
FILTER TRANSFER
FUEL PUMP
HEATER
 BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM
P26 T/C CONNECTOR ECM
DISCONNECT
J4/P4 THROUGH
GROUND SWITCH BATTERY
J19/P19
BOLT
J2

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL THROTTLE LEVEL
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH
+ BATTERY
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE CYLINDER
STARTING RELAY
SWITCH SENSOR
AID SWITCH ENGINE
FUEL FILTER J106/P106 J28/P28 LEFT
TURBOCHARGER ETHER START VALVE
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE USER DEFINED SHUTDOWN
+ BATTERY
SENSOR
COOLANT J47/P47 J25/P25 RIGHT TO ELECTRONIC SERVICE
FLOW TURBOCHARGER PRELUBRICATION TOOL CONNECTOR
SWITCH INLET PRESSURE PUMP TO VIMS, EPTC II OR
SENSOR
P30/J30 J23/P23 MONITORING SYSTEM
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR ENGINE FAN
TEMPERATURE J29/P29 CRANKCASE P41/J41 CONTROL
SENSOR PRESSURE SOLENOID
SENSOR
RIGHT P31/J31 J103/P103
TURBOCHARGER WASTEGATE
EXHAUST CONTROL SOLENOID
P84/J84
J113/P113 A/C ON
TEMPERATURE OIL RENEWAL
SENSOR CONTROL SOLENOID SWITCH
FAN SPEED SENSOR
OTHER SYSTEMS CONTROLLED BY THE ECM
• Oil Renewal
• Exhaust Wastegate Control
• Engine Oil Prelube
• Variable Speed Fan Control
• Ether Injection System
 BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM
P26 T/C CONNECTOR ECM
DISCONNECT
J4/P4 THROUGH
GROUND SWITCH BATTERY
J19/P19
BOLT
J2

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL THROTTLE LEVEL
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH
+ BATTERY
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE CYLINDER
STARTING RELAY
SWITCH SENSOR
AID SWITCH ENGINE
FUEL FILTER J106/P106 J28/P28 LEFT
TURBOCHARGER ETHER START VALVE
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE USER DEFINED SHUTDOWN
+ BATTERY
SENSOR
COOLANT J47/P47 J25/P25 RIGHT TO ELECTRONIC SERVICE
FLOW TURBOCHARGER PRELUBRICATION TOOL CONNECTOR
SWITCH INLET PRESSURE PUMP TO VIMS, EPTC II OR
SENSOR
P30/J30 J23/P23 MONITORING SYSTEM
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR ENGINE FAN
TEMPERATURE J29/P29 CRANKCASE P41/J41 CONTROL
SENSOR PRESSURE SOLENOID
SENSOR
RIGHT P31/J31 J103/P103
TURBOCHARGER WASTEGATE
EXHAUST CONTROL SOLENOID
P84/J84
J113/P113 A/C ON
TEMPERATURE OIL RENEWAL
SENSOR CONTROL SOLENOID SWITCH
FAN SPEED SENSOR
 ELECTRONIC
CONTROL SYSTEM
EUI INJECTOR TESTING
METHODS

• INJECTOR SOLENOID TEST

• CYLINDER CUT-OUT

• AUTOMATIC INJECTOR TEST

 EUI CONTROL LOGIC

TIMING CONTROL
ENGINE SPEED TIMING DEGREES BTDC DESIRED
TIMING FUEL INJECTION
FUEL QUANTITY FUEL RPM
SELECT BTDC CONVERT TIMING WAVE FORM
TIMING DESIRED
TIMING
COOLANT COLD MODE
TEMPERATURE
 3500B COOLANT
ELECTRONIC GOVERNOR SHUTDOWNS TEMPERATURE
SENSOR

ECM
ELECTRONIC
8 GOVERNOR
7
SIGNALS 6 FUEL FRC TORQUE ENGINE
TO FUEL 5 INJECTION
THROTTLE
ENGINE RPM MAPS MAPS CONTROL
INJECTORS 4 CONTROL
3 LOGIC
2 TDC
1
SPEED/TIMING ENGINE RPM ENGINE RPM
SIGNAL
TURBO OUTLET AND
ATMOSPHERIC
TIMING PRESSURE SENSORS
WHEEL

SPEED/TIMING
SENSOR
 BASIC ENGINE BLOCK DIAGRAM
ECM
J4/P4 THROUGH P26
J19/P19 T/C CONNECTOR
J2

J1
8/12/16
GROUND BOLT
INJECTORS

P20/J20 J3/P3
MACHINE INTERFACE
SPEED/TIMING SENSOR
CONNECTOR
J21/P21 J48/P48
UNFILTERED OIL
COOLANT PRESSURE SENSOR
TEMPERATURE SENSOR

J32/P32 J29/P29 CRANKCASE

AFTERCOOLER PRESSURE SENSOR
TEMPERATURE SENSOR

J105/P105 J27/P27
ATMOSPHERIC
LOW OIL PRESSURE SENSOR
LEVEL SWITCH

FUEL FILTER J106/P106 J23/P23

TURBOCHARGER OUTLET
DIFFERENTIAL
PRESSURE SENSOR
PRESSURE SWITCH
J47/P47 J22/P22
FILTERED OIL
COOLANT
PRESSURE SENSOR
FLOW SWITCH

P30/J30 J28/P28 LEFT TURBOCHARGER

LEFT TURBOCHARGER INLET PRESSURE SENSOR
EXHAUST
TEMPERATURE SENSOR

P31/J31 J25/P25 RIGHT TURBOCHARGER

RIGHT TURBOCHARGER INLET PRESSURE SENSOR
EXHAUST
TEMPERATURE SENSOR
 SPEED/TIMING SENSOR

P2 J2

ECM
SPEED/TIMING
SENSOR P20 J20
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
 CYL. NO. 3
TDC REF
REF

SPEED/TIMING
SENSOR

CYL. NO. 4
TDC

REF

TIMING
CALIBRATION
RANGE ± 7°

50/50
CYL. NO. 8 TOOTH
TDC SLOT

80/20
TOOTH
SLOT

50/50 50/50
TOOTH TOOTH
SLOT SLOT
TIMING GEAR TOOTH TABLE
TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE CRANKING
A 80 % NONE IDENTIFIED
B 50 %
C 80 %
D 80 %
E 80 %
F 50 %
G 50 %
H 80 %

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

A B C D E F G H

TIMING WHEEL ROTATION

TIMING GEAR TOOTH TABLE
TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE CRANKING
A 80 % NONE IDENTIFIED
B 50 %
C 80 %
D 80 %
E 80 %
F 50 %
G 50 %
H 80 %

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

A B C D E F G H

TIMING WHEEL ROTATION

 TIMING GEAR TOOTH TABLE
TABLE PWM DUTY CYLINDER
ENTRY CYCLE REFERENCE NORMAL OPERATION
A 80 % NO
B 50 % CYL. NO. 1
C 80 % NO
D 80 % NO
E 80 % CYL. NO. 2
F 50 % NO
G 50 % NO
H 80 % CYL. NO. 7
TIMING WHEEL ROTATION

A B C D E F G H

60° BTDC (EEPROM) 60° BTDC (EEPROM)

ASSUMED ASSUMED
DES TIMING TDC DES TIMING TDC

DELAY NO. 1 NO. 2

INJECTION INJECTION

CYL. NO. 1 CYL. NO. 2

CYL. NO. 1 CYL. NO. 2 ACTUAL TDC
ACTUAL TDC
REFERENCE (CALIBRATED) REFERENCE (CALIBRATED)
 TIMING CALIBRATION SENSOR
P2 J2

SPEED/TIMING ECM
SENSOR P20 J20
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 -
TIMING CALIBRATION P1 J1
SENSOR P26
1
2

TIMING CALIBRATION
CONNECTOR
 TIMING CALIBRATION

TIMING
WHEEL

REFERENCE EDGE TO TDC DISTANCE

REFERENCE
ASSUMED ACTUAL
EDGE
CYL. NO. 1 TDC CYL. NO. 1 TDC

-7° +7° TIMING

REFERENCE
TIMING CALIBRATION ±7° OFFSET
SENSOR SIGNAL

MAXIMUM TIMING REFERENCE OFFSET ± 7 DEGREES

 INJECTION CURRENT WAVEFORM
ONE CYCLE

PULL-IN PEAK CURRENT

CURRENT FLOW

HOLD-IN PEAK CURRENT

0 1 2 3 4 5
TIME (MILLISECONDS)
FUEL SYSTEM COLD MODES
• Speed Control
• Fuel Limiting
• Injection Timing
• Injector Cold Mode Cutout
• Ether Injection
FUEL SYSTEM LIMITS
• Maximum Horsepower
• Maximum Torque
• Fuel Ratio
• Cold Mode Limit
• Cranking Fuel Limit
 FUEL SYSTEM DERATES

• Automatic Altitude Compensation

• Automatic Filter Compensation
• Engine Warning Derate
• High and Low Boost Derate
FUEL SUPPLY SYSTEM
 3516B FUEL SUPPLY CIRCUIT (793C)
FUEL
PRESSURE
REGULATOR
OIL RENEWAL CYLINDER
HEAD
INJECTOR
ENGINE
BLOCK
PRIMING PUMP SUPPLY

FUEL TANK FUEL

SECONDARY
DIFFERENTIAL
FUEL FILTERS
PRESSURE
(2 MICRON)
SWITCH

PRIMARY ECM
FUEL FUEL
FILTER TRANSFER
FUEL PUMP
HEATER
 CYLINDER HEADS
MUI AND EUI
MUI EUI
 ELECTRONIC
UNIT INJECTOR

SECONDARY FUEL
FILTER PRESSURE
REGULATOR
ECM
TRANSFER
PUMP
FUEL TANK
PRIMARY
FILTER FUEL
TANK
 3500B SYSTEM POWER SUPPLIES

• ECM: 24 VOLTS

• SPEED/TIMING SENSORS: 12.5 VOLTS

• INJECTORS: 105 VOLTS

• ANALOG SENSORS: 5 VOLTS

• DIGITAL SENSORS: 8 VOLTS

• WASTEGATE CONTROL SOLENOID: 0 - 24 VOLTS

 ECM POWER SUPPLY BLOCK DIAGRAM

BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM

P26 T/C CONNECTOR
ECM
J4/P4 THROUGH GROUND DISCONNECT
J19/P19 BOLT SWITCH BATTERY
J2 (FRAME)

J1
GROUND BOLT (ENGINE)
15 AMP 24 V
J3/P3 MACHINE BREAKER
INTERFACE
8/12/16 CONNECTOR
INJECTORS
113-OR

KEY START
SWITCH
 ECM POWER SUPPLY CIRCUIT

ENGINE BATTERY ENGINE BLOCK

AND CHARGING GROUND BOLT
SYSTEM
MACHINE INTERFACE P1 J1 ECM
(-) CONNECTOR
24 VOLTS DC 229-BK-14 05
BREAKER 229-BK-14 11 (-) BATTERY
(+) 1 150-RD-14 04 (+) BATTERY
15 A
2 150-RD-14 06
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
105-RD B ST

KEY START SWITCH

 ECM CONNECTORS
40 PINS, WIRE SIDE

P2 P1
1 2 3 4 5 6 1 2 3 4 5 6

7 12 7 12

13 18 13 18

19 22 19 22

23 28 23 28

29 34 29 34

35 36 37 38 39 40 35 36 37 38 39 40
 SPEED/TIMING SENSOR POWER SUPPLY
12.5 ± 1 VOLTS
P2 J2

ECM
SPEED/TIMING
SENSOR P20 J20

OR A 996-GN 32 +V TIMING
BK B 998-BR 29 DIGITAL RETURN
WH C 999-WH 38 ENGINE SPEED
18 TIMING CAL +
12 TIMING CAL -
P1 J1
 3512B INJECTOR WIRING SCHEMATIC
INJECTOR J52/P52 ECM
P2 J2
SOLENOIDS
SOL 1 1 A701-GY 16 SOLENOID 1 POWER
2 F726-YL 05 SOLENOID 1/3 RETURN
SOL 3 3 A703-BR 32 SOLENOID 3 POWER
4 F726-YL

J56/P56
1 A702-PU 40 SOLENOID 2 POWER
SOL 2
2 F727-BU 11 SOLENOID 2/4 RETURN
3 A704-GN 34 SOLENOID 4 POWER
SOL 4
4 F727-BU

J53/P53

SOL 5 1 A705-BU 32 SOLENOID 5 POWER

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

J57/P57

SOL 6 1 A706-GY 28 SOLENOID 6 POWER

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

J54/P54
1 A709-OR 37 SOLENOID 9 POWER
SOL 9
2 F730-GY 27 SOLENOID 9/11 RETURN
3 A711-PU 31 SOLENOID 11 POWER
SOL 11
4 F730-GY

J58/P58

SOL 10 1 A710-GY 18 SOLENOID 10 POWER

2 F731-OR 33 SOLENOID 10/12 RETURN
SOL 12 3 A712-BR 12 SOLENOID 12 POWER
4 F731-OR
 J21 P21 P1 J1 ECM
+V ANALOG A 36 +V ANALOG SUPPLY
ENGINE COOLANT ANALOG RETURN
ANALOG RETURN B 30
TEMPERATURE SENSOR SIGNAL C

P22 J22
+V ANALOG A
FILTERED OIL
ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P23 J23
+V ANALOG A
TURBO OUTLET
ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P25 J25
3500B ANALOG SENSOR
RIGHT TURBO INLET +V ANALOG A

PRESSURE SENSOR
ANALOG RETURN
SIGNAL
B
C
POWER SUPPLY
P27 J27 5 ± 0.5 VOLTS
+V ANALOG A
ATMOSPHERIC
ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P28 J28
+V ANALOG A
LEFT TURBO INLET B
ANALOG RETURN
PRESSURE SENSOR SIGNAL C

P43 J43
+V ANALOG A
CRANKCASE ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P48 J48
+V ANALOG A
UNFILTERED OIL
ANALOG RETURN B
PRESSURE SENSOR SIGNAL C
 THROTTLE
POSITION SENSOR J35 P35 P1 J1 ECM
+V DIGITAL A 29 + V DIGITAL SUPPLY
DIGITAL RETURN B 35 - V DIGITAL RETURN
SIGNAL C

FAN
SPEED SENSOR J84 P84
+V DIGITAL A
DIGITAL RETURN B
DIGITAL SENSOR
SIGNAL C POWER SUPPLY
8 ± 0.5 VOLTS
LEFT EXHAUST
TEMPERATURE SENSOR J30 P30
+V DIGITAL A
DIGITAL RETURN B
SIGNAL C

RIGHT EXHAUST
TEMPERATURE SENSOR J31 P31
+V DIGITAL A
DIGITAL RETURN B
SIGNAL C
 WASTEGATE CONTROL SOLENOID
POWER SUPPLY
0 TO 1.04 Amps PWM

WASTEGATE CONTROL
SOLENOID VALVE J41 P41 ECM
P2 J2
SUPPLY A 29 WASTEGATE CONTROL
RETURN B 35 PWM DRIVER & SOLENOID RETURN
 3500B ELECTRONIC

SENSORS AND SYSTEMS

 BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM
P26 T/C CONNECTOR ECM
DISCONNECT
J4/P4 THROUGH
GROUND SWITCH
J19/P19 BATTERY
BOLT
J2

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR THROTTLE 113-OR
COOLANT J21/P21 J48/P48 POSITION J35/P35
UNFILTERED OIL 308-YL KEY START
TEMPERATURE SENSOR
PRESSURE SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL THROTTLE LEVEL
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH
+ BATTERY
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE CYLINDER
STARTING RELAY
SWITCH SENSOR
AID SWITCH ENGINE
FUEL FILTER J106/P106 J28/P28 LEFT
TURBOCHARGER ETHER START VALVE
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE USER DEFINED SHUTDOWN
+ BATTERY
SENSOR
COOLANT J47/P47 J25/P25 RIGHT TO ELECTRONIC SERVICE
FLOW TURBOCHARGER PRELUBRICATION TOOL CONNECTOR
SWITCH INLET PRESSURE PUMP TO VIMS, EPTC II OR
SENSOR MONITORING SYSTEM
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
ENGINE FAN
TEMPERATURE J29/P29 CRANKCASE P41/J41 CONTROL
SENSOR PRESSURE SOLENOID
SENSOR
RIGHT P31/J31 J103/P103
TURBOCHARGER WASTEGATE
EXHAUST CONTROL SOLENOID
P84/J84
J113/P113 A/C ON
TEMPERATURE OIL RENEWAL
SENSOR CONTROL SOLENOID SWITCH
FAN SPEED SENSOR
 SPEED/TIMING SENSOR

P26 T/C CONNECTOR ECM

J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR
 ANALOG SENSORS
• Coolant temperature sensor
• Aftercooler temperature sensor
• Oil pressure sensors
• Atmospheric pressure sensor
• Turbocharger inlet pressure sensors
• Turbocharger outlet (boost) sensor
• Crankcase pressure sensor
 COOLANT TEMPERATURE SENSOR

P26 T/C CONNECTOR ECM

J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21
TEMPERATURE
SENSOR
 AFTERCOOLER TEMPERATURE SENSOR
P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21
TEMPERATURE
SENSOR

AFTERCOOLER J32/P32
TEMPERATURE
SENSOR
 OIL PRESSURE SENSORS
P26 ECM
T/C
J4/P4 THROUGH
CONNECTOR
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS J3/P3 MACHINE
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
 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
 ATMOSPHERIC PRESSURE SENSOR
P26 ECM
J4/P4 THROUGH T/C
J19/P19 CONNECTOR

J2

8/12/16 J1
INJECTORS GROUND BOLT

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
J27/P27
ATMOSPHERIC
PRESSURE
SENSOR
 ENGINE POWER DERATING MAP
ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500
PERCENT OF FULL LOAD POWER

98% 8,210

96% 8,920

94% 9,630

ALTITUDE IN FEET
92% 10,340
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

 P26 ECM
J4/P4 THROUGH T/C
J19/P19 CONNECTOR

J2

J1
8/12/16
GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR
TURBOCHARGER
COOLANT
J21/P21 J48/P48 UNFILTERED OIL INLET
TEMPERATURE
SENSOR
PRESSURE
SENSOR
PRESSURE
J32/P32 J22/P22 FILTERED OIL SENSORS
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
J27/P27
ATMOSPHERIC
PRESSURE
SENSOR
J28/P28 LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
J25/P25 RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
 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%
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR
J21/P21 J48/P48
TURBOCHARGER
COOLANT UNFILTERED OIL
TEMPERATURE PRESSURE OUTLET
SENSOR SENSOR
PRESSURE
AFTERCOOLER J32/P32 J22/P22 FILTERED OIL
TEMPERATURE PRESSURE
SENSOR
SENSOR SENSOR
J27/P27
ATMOSPHERIC
PRESSURE
SENSOR

J28/P28 LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
J25/P25 RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
J23/P23
TURBOCHARGER
OUTLET
PRESSURE SENSOR
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16
GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
J27/P27
ATMOSPHERIC CRANKCASE
PRESSURE
SENSOR
PRESSURE
J28/P28 LEFT SENSOR
TURBOCHARGER
INLET PRESSURE
SENSOR
J25/P25 RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
J23/P23
TURBOCHARGER
OUTLET
PRESSURE SENSOR

J29/P29 CRANKCASE
PRESSURE
SENSOR
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR

AFTERCOOLER J32/P32 J22/P22 FILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR

LOW OIL
J105/P105 J27/P27
ATMOSPHERIC
ENGINE
LEVEL PRESSURE
SENSOR
SWITCHES
SWITCH

FUEL FILTER J106/P106 J28/P28 LEFT

DIFFERENTIAL TURBOCHARGER
PRESSURE SWITCH INLET PRESSURE
SENSOR
COOLANT J47/P47 J25/P25 RIGHT
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
J23/P23
TURBOCHARGER
OUTLET
PRESSURE SENSOR

J29/P29 CRANKCASE
PRESSURE
SENSOR
 EUI SWITCH CIRCUITS
ECM
P1 J1
J105 P105
LOW OIL
SIGNAL 1 F719-BR 24 LOW OIL LEVEL
LEVEL
DIGITAL RETURN 2 998-BR
SWITCH

FUEL FILTER J106 P106

DIFFERENTIAL SIGNAL 1 F725-WH 17 FUEL FILTER SW
PRESSURE DIGITAL RETURN 2 998-BR
SWITCH

J47 P47
COOLANT
SIGNAL 1 412-BU 26 COOLANT FLOW
FLOW DIGITAL RETURN 2 998-BR 29 DIGITAL RETURN
SWITCH
DIGITAL SENSORS AND CIRCUITS

• Wastegate control

• Exhaust temperature

• Throttle position
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR

LOW OIL
J105/P105 J27/P27
ATMOSPHERIC
WASTEGATE
LEVEL PRESSURE
SENSOR
CONTROL
SWITCH

FUEL FILTER J106/P106 J28/P28 LEFT SOLENOID

DIFFERENTIAL TURBOCHARGER
PRESSURE SWITCH INLET PRESSURE
SENSOR
COOLANT J47/P47 J25/P25 RIGHT
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
J23/P23
TURBOCHARGER
OUTLET
PRESSURE SENSOR

J29/P29 CRANKCASE
PRESSURE
SENSOR

WASTEGATE
CONTROL SOLENOID
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH
J19/P19
J2

J1
8/12/16 GROUND BOLT
INJECTORS

P20/J20
SPEED/TIMING
SENSOR

COOLANT J21/P21 J48/P48 UNFILTERED OIL

TEMPERATURE PRESSURE
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
J105/P105 J27/P27
ATMOSPHERIC
EXHAUST
LOW OIL
LEVEL PRESSURE TEMPERATURE
SWITCH SENSOR
J106/P106 J28/P28 LEFT
SENSORS
FUEL FILTER
DIFFERENTIAL TURBOCHARGER
PRESSURE SWITCH INLET PRESSURE
SENSOR
COOLANT J47/P47 J25/P25 RIGHT
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
TEMPERATURE
SENSOR
RIGHT P31/J31 J29/P29 CRANKCASE
TURBOCHARGER PRESSURE
EXHAUST SENSOR
TEMPERATURE
SENSOR WASTEGATE
CONTROL SOLENOID
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH DISCONNECT
J19/P19 GROUND SWITCH BATTERY
BOLT
J2

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL
AFTERCOOLER
TEMPERATURE PRESSURE
SENSOR SENSOR
J105/P105 J27/P27
THROTTLE
LOW OIL ATMOSPHERIC
LEVEL PRESSURE POSITION
SWITCH SENSOR
LEFT
SENSOR
FUEL FILTER J106/P106 J28/P28
DIFFERENTIAL TURBOCHARGER
PRESSURE SWITCH INLET PRESSURE
SENSOR
COOLANT J47/P47 J25/P25 RIGHT
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
TEMPERATURE
SENSOR
RIGHT P31/J31 J29/P29 CRANKCASE
TURBOCHARGER PRESSURE
EXHAUST SENSOR
TEMPERATURE
SENSOR WASTEGATE
CONTROL SOLENOID
 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
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH DISCONNECT
GROUND SWITCH BATTERY
J19/P19
J2 BOLT

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
P20/J20 INTERFACE
SPEED/TIMING CONNECTOR
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
J32/P32 J22/P22 FILTERED OIL THROTTLE
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP
SENSOR SENSOR SWITCH
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE
SWITCH SENSOR

FUEL FILTER J106/P106 J28/P28 LEFT THROTTLE

TURBOCHARGER
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE BACK-UP
SENSOR
COOLANT J47/P47 J25/P25 RIGHT SWITCH
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
TEMPERATURE
SENSOR
RIGHT P31/J31 J29/P29 CRANKCASE
TURBOCHARGER PRESSURE
EXHAUST SENSOR
TEMPERATURE
SENSOR WASTEGATE
CONTROL SOLENOID
 P26 T/C CONNECTOR ECM
J4/P4 THROUGH DISCONNECT
J19/P19 GROUND SWITCH BATTERY
J2 BOLT

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL LEVEL
AFTERCOOLER THROTTLE
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH

J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE
SWITCH SENSOR

FUEL FILTER J106/P106 J28/P28 LEFT

DIFFERENTIAL TURBOCHARGER GROUND
PRESSURE SWITCH INLET PRESSURE

J47/P47 J25/P25
SENSOR LEVEL
COOLANT RIGHT
FLOW TURBOCHARGER SHUTDOWN
SWITCH INLET PRESSURE
SENSOR SWITCH
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
TEMPERATURE
SENSOR
RIGHT P31/J31 J29/P29 CRANKCASE
TURBOCHARGER PRESSURE
EXHAUST SENSOR
TEMPERATURE
SENSOR WASTEGATE
CONTROL SOLENOID
 USER DEFINED SHUTDOWN

J3 P2 J2
ECM
USER SHUTDOWN
12 1 USER SHUTDOWN
DEVICE
 ETHER INJECTION SYSTEM
ECM
ETHER SWITCH
P1 J1
998-BR
F720-GN 25 ETHER REQUEST
998-BR 29 DIGITAL RETURN
710-BR 40 ETHER ON
707-WH 22 ETHER HOLD
+24V

P37 J37
315-GN 317-YL 317-YL
1
2
ETHER ON RELAY
START AID 200-BK ETHER
F707-WH RESISTOR
SOLENOID VALVE

315-GN K984-GY

ETHER HOLD RELAY

 P26 T/C CONNECTOR
J4/P4 THROUGH DISCONNECT
ECM GROUND SWITCH BATTERY
J19/P19
STUD
J2

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
INTERFACE
P20/J20
SPEED/TIMING CONNECTOR
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION
J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL THROTTLE LEVEL
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH
+ BATTERY
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE CYLINDER
SWITCH SENSOR STARTING
AID SWITCH ENGINE
FUEL FILTER J106/P106 J28/P28 LEFT
TURBOCHARGER RELAY ETHER START VALVE
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE USER SHUTDOWN
SENSOR
COOLANT J47/P47 J25/P25 RIGHT
FLOW TURBOCHARGER
SWITCH INLET PRESSURE
SENSOR
P30/J30 J23/P23
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
ENGINE FAN
TEMPERATURE
P41/J41 CONTROL
SENSOR
SOLENOID
RIGHT P31/J31 J29/P29 CRANKCASE
TURBOCHARGER PRESSURE DEMAND FAN
EXHAUST SENSOR
TEMPERATURE P84/J84
A/C ON CONTROL
SENSOR WASTEGATE SWITCH
CONTROL SOLENOID FAN SPEED SENSOR
 CAT DATA LINK

SERVICE TOOL COMMUNICATION

CONNECTOR ADAPTER
CAT
ELECTRONIC TECHNICIAN
LAPTOP
COMPUTER

ADEM II
ELECTRONIC
MAIN MODULE

CONTROL
MODULE
(ECM)
VIMS

VIMS DISPLAY MODULES

 TYPICAL CAT DATA LINK CIRCUIT

POWER TRAIN CONTROL VIMS

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
 PRELUBRICATION SYSTEM
ECM
P1 J1
F709-BU 34 PRELUBRICATION
998-BR 29 DIGITAL RETURN

+ 140-BU
337-WH
1
PRELUBRICATION
2
+24V PRELUBRICATION MOTOR
RELAY 200-BK
MOTOR

PUMP
RELAY
LOGGED EVENTS
APPLICATION SPECIFIC

SYSTEMS
 3516B OIL RENEWAL CIRCUIT (793C)
FUEL
PRESSURE
REGULATOR
CYLINDER
OIL RENEWAL
HEAD
INJECTOR
ENGINE
BLOCK
PRIMING PUMP SUPPLY

FUEL TANK
SECONDARY
FUEL FILTERS
(2 MICRON)

PRIMARY ECM
FUEL FUEL
FILTER TRANSFER
PUMP

FUEL
HEATER
 BASIC ENGINE BLOCK DIAGRAM APPLICATION BLOCK DIAGRAM
P26 T/C CONNECTOR ECM
DISCONNECT
J4/P4 THROUGH
GROUND SWITCH BATTERY
J19/P19
J2 BOLT

J1
8/12/16 GROUND BOLT 15 AMP
24 V
INJECTORS
J3/P3 MACHINE BREAKER
INTERFACE
P20/J20 CONNECTOR
SPEED/TIMING
SENSOR
THROTTLE 113-OR
COOLANT J21/P21 J48/P48 UNFILTERED OIL POSITION J35/P35 308-YL KEY START
TEMPERATURE PRESSURE SENSOR
SWITCH
SENSOR SENSOR
GROUND
J32/P32 J22/P22 FILTERED OIL THROTTLE LEVEL
AFTERCOOLER
TEMPERATURE PRESSURE BACK-UP SHUTDOWN
SENSOR SENSOR SWITCH SWITCH
+ BATTERY
J105/P105 J27/P27
LOW OIL ATMOSPHERIC
LEVEL PRESSURE CYLINDER
STARTING RELAY
SWITCH SENSOR
AID SWITCH ENGINE
FUEL FILTER J106/P106 J28/P28 LEFT
TURBOCHARGER ETHER START VALVE
DIFFERENTIAL
PRESSURE SWITCH INLET PRESSURE USER DEFINED SHUTDOWN
+ BATTERY
SENSOR
COOLANT J47/P47 J25/P25 RIGHT TO ELECTRONIC SERVICE
FLOW TURBOCHARGER PRELUBRICATION TOOL CONNECTOR
SWITCH INLET PRESSURE PUMP TO VIMS, EPTC II OR
SENSOR
P30/J30 J23/P23 MONITORING SYSTEM
LEFT TURBOCHARGER
TURBOCHARGER OUTLET
EXHAUST PRESSURE SENSOR
ENGINE FAN
TEMPERATURE J29/P29 CRANKCASE P41/J41 CONTROL
SENSOR PRESSURE SOLENOID
SENSOR
RIGHT P31/J31 J103/P103
TURBOCHARGER WASTEGATE
EXHAUST CONTROL SOLENOID
P84/J84
J113/P113 A/C ON
TEMPERATURE OIL RENEWAL
SENSOR CONTROL SOLENOID SWITCH
FAN SPEED SENSOR