3500B ENGINE CONTROLS

ELECTRONIC UNIT INJECTION (EUI)

2002 Caterpillar Inc.

3516B FUEL SUPPLY CIRCUIT (793C)

FUEL
PRESSURE
REGULATOR
CYLINDER
HEAD

OIL RENEWAL
INJECTOR
ENGINE
BLOCK

PRIMING PUMP SUPPLY

FUEL TANK

FUEL
DIFFERENTIAL
PRESSURE
SWITCH
PRIMARY
FUEL
FILTER

FUEL
HEATER

FUEL
TRANSFER
PUMP

SECONDARY
FUEL FILTERS
(2 MICRON)

ECM

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2

COOLANT
TEMPERATURE
SENSOR
AFTERCOOLER
TEMPERATURE
SENSOR
LOW OIL
LEVEL
SWITCH

P20/J20

GROUND BOLT
J3/P3 MACHINE
INTERFACE
CONNECTOR

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

J106/P106

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

J28/P28

J29/P29

P31/J31

J103/P103
J113/P113

24 V

15 AMP
BREAKER

J21/P21

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

BATTERY

J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

WASTEGATE
CONTROL SOLENOID

308-YL

THROTTLE
BACK-UP
SWITCH

+ BATTERY

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

CYLINDER
RELAY

STARTING
AID SWITCH

ENGINE
ETHER START VALVE
USER DEFINED SHUTDOWN

+ BATTERY
TO
PRELUBRICATION
PUMP

TURBOCHARGER
OUTLET
PRESSURE SENSOR
CRANKCASE
PRESSURE
SENSOR

113-OR
J35/P35

P41/J41

ELECTRONIC SERVICE
TOOL CONNECTOR
TO VIMS, EPTC II OR
MONITORING SYSTEM

ENGINE FAN
CONTROL
SOLENOID

P84/J84

A/C ON
SWITCH

OIL RENEWAL
CONTROL SOLENOID
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

J4/P4 THROUGH
J19/P19
J2

COOLANT
TEMPERATURE
SENSOR
AFTERCOOLER
TEMPERATURE
SENSOR
LOW OIL
LEVEL
SWITCH

P20/J20

GROUND BOLT
J3/P3 MACHINE
INTERFACE
CONNECTOR

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

J106/P106

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

J28/P28

J29/P29

P31/J31

J103/P103
J113/P113

24 V

15 AMP
BREAKER

J21/P21

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

BATTERY

J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

WASTEGATE
CONTROL SOLENOID

308-YL

THROTTLE
BACK-UP
SWITCH

+ BATTERY

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

CYLINDER
RELAY

STARTING
AID SWITCH

ENGINE
ETHER START VALVE
USER DEFINED SHUTDOWN

+ BATTERY
TO
PRELUBRICATION
PUMP

TURBOCHARGER
OUTLET
PRESSURE SENSOR
CRANKCASE
PRESSURE
SENSOR

113-OR
J35/P35

P41/J41

ELECTRONIC SERVICE
TOOL CONNECTOR
TO VIMS, EPTC II OR
MONITORING SYSTEM

ENGINE FAN
CONTROL
SOLENOID

P84/J84

A/C ON
SWITCH

OIL RENEWAL
CONTROL SOLENOID
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
FUEL QUANTITY
COOLANT
TEMPERATURE

TIMING

DEGREES BTDC

FUEL RPM
SELECT
TIMING
COLD MODE

DESIRED
TIMING
BTDC

CONVERT
DESIRED
TIMING

FUEL INJECTION
TIMING WAVE FORM

3500B
ELECTRONIC GOVERNOR

COOLANT
TEMPERATURE
SENSOR

SHUTDOWNS

ECM
8
7
SIGNALS 6
TO FUEL 5
INJECTORS 4
3
2
1

ELECTRONIC
GOVERNOR
FUEL
INJECTION
CONTROL

SPEED/TIMING
SIGNAL

ENGINE RPM

TORQUE
MAPS

ENGINE
CONTROL
LOGIC

THROTTLE

TDC
ENGINE RPM

ENGINE RPM

TIMING
WHEEL
SPEED/TIMING
SENSOR

FRC
MAPS

TURBO OUTLET AND

ATMOSPHERIC
PRESSURE SENSORS

BASIC ENGINE BLOCK DIAGRAM

ECM
P26
T/C CONNECTOR

J4/P4 THROUGH
J19/P19

J2
J1

8/12/16
INJECTORS

GROUND BOLT

P20/J20

J3/P3

J21/P21

J48/P48

J32/P32

J29/P29

J105/P105

J27/P27

J106/P106

J23/P23

SPEED/TIMING SENSOR

COOLANT
TEMPERATURE SENSOR

AFTERCOOLER
TEMPERATURE SENSOR

LOW OIL
LEVEL SWITCH
FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

UNFILTERED OIL
PRESSURE SENSOR

CRANKCASE
PRESSURE SENSOR

ATMOSPHERIC
PRESSURE SENSOR

TURBOCHARGER OUTLET
PRESSURE SENSOR
J47/P47

J22/P22

P30/J30

J28/P28

LEFT TURBOCHARGER
INLET PRESSURE SENSOR

P31/J31

J25/P25

RIGHT TURBOCHARGER
INLET PRESSURE SENSOR

COOLANT
FLOW SWITCH

LEFT TURBOCHARGER
EXHAUST
TEMPERATURE SENSOR

RIGHT TURBOCHARGER
EXHAUST
TEMPERATURE SENSOR

MACHINE INTERFACE
CONNECTOR

FILTERED OIL
PRESSURE SENSOR

SPEED/TIMING SENSOR
P2 J2

SPEED/TIMING
SENSOR

ECM
P20 J20
OR
BK
WH

TIMING CALIBRATION
CONNECTOR

A
B
C

P26
1
2

996-GN
998-BR
999-WH
F723-PK
F724-PU

32
29
38
18
12
P1 J1

+V TIMING
DIGITAL RETURN
PRIMARY ENGINE SPEED
TIMING CAL +
TIMING CAL -

CYL. NO. 3
TDC

REF

REF
SPEED/TIMING
SENSOR
CYL. NO. 4
TDC
REF
TIMING
CALIBRATION
RANGE 7
50/50
TOOTH
SLOT

CYL. NO. 8
TDC

80/20
TOOTH
SLOT

50/50
TOOTH
SLOT

50/50
TOOTH
SLOT

TIMING GEAR TOOTH TABLE

TABLE PWM DUTY CYLINDER
CYCLE
ENTRY
REFERENCE
A
B
C
D
E
F
G
H
80/20 %

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

CRANKING

NONE IDENTIFIED

80/20 %

80/20 %

80/20 %

50/50%

TIMING WHEEL ROTATION

50/50%

TIMING GEAR TOOTH TABLE

TABLE PWM DUTY CYLINDER
CYCLE
ENTRY
REFERENCE
A
B
C
D
E
F
G
H
80/20 %

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

CRANKING

NONE IDENTIFIED

80/20 %

80/20 %

80/20 %

50/50%

TIMING WHEEL ROTATION

50/50%

TIMING GEAR TOOTH TABLE

TABLE PWM DUTY CYLINDER
ENTRY
CYCLE
REFERENCE
80 %
NO
A
50
%
CYL. NO. 1
B
80 %
NO
C
80 %
NO
D
80 %
CYL. NO. 2
E
50 %
NO
F
50 %
NO
G
80 %
CYL. NO. 7
H

NORMAL OPERATION

TIMING WHEEL ROTATION

DELAY

CYL. NO. 1
REFERENCE

ASSUMED
TDC

ASSUMED
TDC

DES TIMING

NO. 1
INJECTION
CYL. NO. 1
ACTUAL TDC
(CALIBRATED)

60 BTDC (EEPROM)

60 BTDC (EEPROM)
DES TIMING

NO. 2
INJECTION
CYL. NO. 2
REFERENCE

CYL. NO. 2
ACTUAL TDC
(CALIBRATED)

TIMING CALIBRATION SENSOR

P2 J2
ECM

SPEED/TIMING
SENSOR

P20 J20
OR
BK
WH

TIMING CALIBRATION
SENSOR

996-GN
998-BR
999-WH
F723-PK
F724-PU

A
B
C

32
29
38
18
12
P1 J1

P26
1
2

TIMING CALIBRATION
CONNECTOR

+V TIMING
DIGITAL RETURN
PRIMARY ENGINE SPEED
TIMING CAL +
TIMING CAL -

TIMING CALIBRATION
TIMING
WHEEL

REFERENCE EDGE TO TDC DISTANCE

REFERENCE
EDGE

ASSUMED
CYL. NO. 1 TDC

-7
TIMING CALIBRATION
SENSOR SIGNAL

+7
7

MAXIMUM TIMING REFERENCE OFFSET 7 DEGREES

ACTUAL
CYL. NO. 1 TDC

TIMING
REFERENCE
OFFSET

INJECTION CURRENT WAVEFORM

ONE CYCLE

CURRENT FLOW

PULL-IN PEAK CURRENT

HOLD-IN PEAK CURRENT

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
CYLINDER
HEAD

OIL RENEWAL
INJECTOR
ENGINE
BLOCK

PRIMING PUMP SUPPLY

FUEL TANK

FUEL
DIFFERENTIAL
PRESSURE
SWITCH
PRIMARY
FUEL
FILTER

FUEL
HEATER

FUEL
TRANSFER
PUMP

SECONDARY
FUEL FILTERS
(2 MICRON)

ECM

CYLINDER HEADS
MUI AND EUI
MUI

EUI

ELECTRONIC
UNIT INJECTOR

SECONDARY
FILTER
ECM

FUEL
PRESSURE
REGULATOR

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

APPLICATION BLOCK DIAGRAM

BASIC ENGINE BLOCK DIAGRAM

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2

GROUND
BOLT
(FRAME)

DISCONNECT
SWITCH

BATTERY

J1
GROUND BOLT (ENGINE)

8/12/16
INJECTORS

J3/P3 MACHINE
INTERFACE
CONNECTOR

15 AMP
BREAKER

24 V

113-OR
KEY START
SWITCH

ECM POWER SUPPLY CIRCUIT

ENGINE BATTERY
AND CHARGING
SYSTEM

ENGINE BLOCK
GROUND BOLT

(-)
24 VOLTS DC
(+)

BREAKER
15 A

10 AMP

MACHINE INTERFACE
ECM
P1 J1
CONNECTOR
229-BK-14 05
(-) BATTERY
229-BK-14 11
(+) BATTERY
150-RD-14 04
1
150-RD-14 06
2
KEY SWITCH ON
113-OR 23
26
113-OR
P3 J3
112-PU
308-YL

117-RD
105-RD

200-BK

R
C OFF
S
B ST
KEY START SWITCH

ECM CONNECTORS
40 PINS, WIRE SIDE
P2
1

P1
4

12

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
BK
WH

A
B
C

996-GN
998-BR
999-WH

32
29
38
18
12
P1 J1

+V TIMING
DIGITAL RETURN
ENGINE SPEED
TIMING CAL +
TIMING CAL -

3512B INJECTOR WIRING SCHEMATIC

INJECTOR
SOLENOIDS
SOL 1
SOL 3

J52/P52
1
2
3
4

P2 J2

ECM

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
SOL 2
SOL 4

1
2
3
4
J53/P53

SOL 5
SOL 7

1
2
3
4
J57/P57

SOL 6
SOL 8

1
2
3
4
J54/P54

SOL 9
SOL 11

1
2
3
4
J58/P58

SOL 10
SOL 12

1
2
3
4

ENGINE COOLANT
TEMPERATURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

FILTERED OIL
PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

J21 P21

P1 J1

ECM

A
B
C

36
30

+V ANALOG SUPPLY
ANALOG RETURN

P22 J22
A
B
C
P23 J23

TURBO OUTLET
PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

A
B
C
P25 J25

RIGHT TURBO INLET

PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

A
B
C
P27 J27

ATMOSPHERIC
PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

LEFT TURBO INLET

PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

A
B
C
P28 J28
A
B
C
P43 J43

CRANKCASE
PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

A
B
C
P48 J48

UNFILTERED OIL
PRESSURE SENSOR

+V ANALOG
ANALOG RETURN
SIGNAL

A
B
C

3500B ANALOG SENSOR

POWER SUPPLY
5 0.5 VOLTS

THROTTLE
POSITION SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL

J35 P35
A
B
C

FAN
SPEED SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL

J84 P84
A
B
C

LEFT EXHAUST
TEMPERATURE SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL

J30 P30
A
B
C

RIGHT EXHAUST
TEMPERATURE SENSOR
+V DIGITAL
DIGITAL RETURN
SIGNAL

J31 P31
A
B
C

P1 J1
29
35

ECM
+ V DIGITAL SUPPLY
- V DIGITAL RETURN

DIGITAL SENSOR
POWER SUPPLY
8 0.5 VOLTS

WASTEGATE CONTROL SOLENOID

POWER SUPPLY
0 TO 1.04 Amps PWM

WASTEGATE CONTROL
SOLENOID VALVE
SUPPLY
RETURN

J41 P41

P2 J2

A
B

29
35

ECM
WASTEGATE CONTROL
PWM DRIVER & SOLENOID RETURN

3500B ELECTRONIC
SENSORS AND SYSTEMS

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2

GROUND BOLT

P20/J20
SPEED/TIMING
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR
LOW OIL
LEVEL
SWITCH

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

J106/P106

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

J28/P28

J29/P29

P31/J31

J103/P103
J113/P113

24 V

15 AMP
BREAKER

J3/P3 MACHINE
INTERFACE
CONNECTOR

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

BATTERY

J1

8/12/16
INJECTORS

COOLANT
TEMPERATURE
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

THROTTLE
BACK-UP
SWITCH

WASTEGATE
CONTROL SOLENOID

308-YL

+ BATTERY

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

CYLINDER
RELAY

STARTING
AID SWITCH

ENGINE
ETHER START VALVE
USER DEFINED SHUTDOWN

+ BATTERY
TO
PRELUBRICATION
PUMP

TURBOCHARGER
OUTLET
PRESSURE SENSOR
CRANKCASE
PRESSURE
SENSOR

113-OR
J35/P35

P41/J41

ELECTRONIC SERVICE
TOOL CONNECTOR
TO VIMS, EPTC II OR
MONITORING SYSTEM

ENGINE FAN
CONTROL
SOLENOID

P84/J84

A/C ON
SWITCH

OIL RENEWAL
CONTROL SOLENOID
FAN SPEED SENSOR

SPEED/TIMING SENSOR
P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

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
J4/P4 THROUGH
J19/P19

ECM

J2
J1

8/12/16
INJECTORS

GROUND BOLT

P20/J20
SPEED/TIMING
SENSOR
COOLANT
TEMPERATURE
SENSOR

J21/P21

AFTERCOOLER TEMPERATURE SENSOR

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1
8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

OIL PRESSURE SENSORS

P26
J4/P4 THROUGH
J19/P19

ECM
T/C
CONNECTOR
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

J3/P3 MACHINE
INTERFACE
CONNECTOR

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

49.3

320

46.4

300

43.5

280

40.6

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
8.7

60
600

700

800

900

1000

1100

1200

1300

1400

ENGINE RPM
kPa x 0.145 = PSI

1500

1600

1700

1800

1900

2000

OIL PRESSURE IN PSI

OIL PRESSURE IN kPa

OIL PRESSURE MAP

340

ATMOSPHERIC PRESSURE SENSOR

ECM

P26
J4/P4 THROUGH
J19/P19

T/C
CONNECTOR
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J27/P27

ATMOSPHERIC
PRESSURE
SENSOR

ENGINE POWER DERATING MAP

100%

7,500

98%

8,210

96%

8,920

94%

9,630

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

ALTITUDE IN FEET

PERCENT OF FULL LOAD POWER

ACCORDING TO ATMOSPHERIC PRESSURE

ECM

P26
J4/P4 THROUGH
J19/P19

T/C
CONNECTOR
J2
J1

8/12/16
INJECTORS

GROUND BOLT

P20/J20
SPEED/TIMING
SENSOR
COOLANT
TEMPERATURE
SENSOR
AFTERCOOLER
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J27/P27

J28/P28

J25/P25

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

TURBOCHARGER
INLET
PRESSURE
SENSORS

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%

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR
COOLANT
TEMPERATURE
SENSOR
AFTERCOOLER
TEMPERATURE
SENSOR

GROUND BOLT

P20/J20

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J27/P27

J28/P28

J25/P25

J23/P23

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR

TURBOCHARGER
OUTLET
PRESSURE
SENSOR

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J27/P27

J28/P28

J25/P25

J23/P23

J29/P29

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR

CRANKCASE
PRESSURE
SENSOR

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
8/12/16
INJECTORS

SPEED/TIMING
SENSOR

J1

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

LOW OIL
LEVEL
SWITCH

J25/P25

J23/P23

J29/P29

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR

ENGINE
SWITCHES

EUI SWITCH CIRCUITS

LOW OIL
LEVEL
SWITCH

J105 P105
SIGNAL
DIGITAL RETURN

FUEL FILTER
SIGNAL
DIFFERENTIAL
DIGITAL RETURN
PRESSURE
SWITCH
COOLANT
FLOW
SWITCH

P1 J1

1
2

F719-BR
998-BR

ECM

24

LOW OIL LEVEL

F725-WH
998-BR

17

FUEL FILTER SW

412-BU
998-BR

26
29

COOLANT FLOW
DIGITAL RETURN

J106 P106

1
2

J47 P47
SIGNAL
DIGITAL RETURN

1
2

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
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

LOW OIL
LEVEL
SWITCH

J25/P25

J23/P23

J29/P29

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR
CRANKCASE
PRESSURE
SENSOR
WASTEGATE
CONTROL SOLENOID

WASTEGATE
CONTROL
SOLENOID

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1
8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

P31/J31

J29/P29

LOW OIL
LEVEL
SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR
RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

EXHAUST
TEMPERATURE
SENSORS

TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR
WASTEGATE
CONTROL SOLENOID

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

GROUND BOLT

P20/J20

15 AMP
BREAKER

J3/P3 MACHINE
INTERFACE
CONNECTOR

COOLANT
TEMPERATURE
SENSOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

P31/J31

J29/P29

LOW OIL
LEVEL
SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR
RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR
WASTEGATE
CONTROL SOLENOID

BATTERY

24 V

113-OR
J35/P35

THROTTLE
POSITION
SENSOR

308-YL KEY START

SWITCH

PULSE WIDTH MODULATED SIGNALS

10%
ON
DUTY = 10%
CYCLE
OFF
50%
ON
DUTY = 50%
CYCLE
OFF
90%

1 CYCLE

ON
DUTY = 90%
CYCLE
OFF
DUTY CYCLE = PERCENT OF TIME ON VS PERCENT OF TIME OFF

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2
J1

8/12/16
INJECTORS

GROUND BOLT
J3/P3 MACHINE
INTERFACE
CONNECTOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

P31/J31

J29/P29

SPEED/TIMING
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR
LOW OIL
LEVEL
SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR
RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

THROTTLE
POSITION
SENSOR

113-OR
J35/P35

308-YL

THROTTLE
BACK-UP
SWITCH

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR
TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR
WASTEGATE
CONTROL SOLENOID

BATTERY

24 V

15 AMP
BREAKER

P20/J20

COOLANT
TEMPERATURE
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
BACK-UP
SWITCH

KEY START
SWITCH

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19

GROUND
BOLT

J2
J1

8/12/16
INJECTORS

GROUND BOLT

P20/J20
SPEED/TIMING
SENSOR

J3/P3 MACHINE
INTERFACE
CONNECTOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

J28/P28

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

P31/J31

J29/P29

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR
RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

THROTTLE
POSITION
SENSOR

113-OR
J35/P35

TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR
WASTEGATE
CONTROL SOLENOID

308-YL

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

THROTTLE
BACK-UP
SWITCH

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

BATTERY

24 V

15 AMP
BREAKER

COOLANT
TEMPERATURE
SENSOR

LOW OIL
LEVEL
SWITCH

DISCONNECT
SWITCH

GROUND
LEVEL
SHUTDOWN
SWITCH

USER DEFINED SHUTDOWN

USER SHUTDOWN
DEVICE

J3

P2 J2

12

ECM
USER SHUTDOWN

ETHER INJECTION SYSTEM

ECM
ETHER SWITCH
998-BR

P1 J1
F720-GN
998-BR
710-BR
707-WH

25
29
40
22

ETHER REQUEST
DIGITAL RETURN
ETHER ON
ETHER HOLD

+24V

315-GN

317-YL

317-YL

P37 J37
1
2

ETHER ON RELAY
F707-WH
315-GN

ETHER HOLD RELAY

START AID
RESISTOR
K984-GY

200-BK

ETHER
SOLENOID VALVE

P26 T/C CONNECTOR

J4/P4 THROUGH
J19/P19

J2

GROUND BOLT

P20/J20

J3/P3 MACHINE
INTERFACE
CONNECTOR

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

AFTERCOOLER
TEMPERATURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

J106/P106

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR
RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

J28/P28

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

J29/P29

WASTEGATE
CONTROL SOLENOID

308-YL

+ BATTERY

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

CYLINDER
STARTING
AID SWITCH

ENGINE
RELAY

ETHER START VALVE

USER SHUTDOWN

TURBOCHARGER
OUTLET
PRESSURE SENSOR

CRANKCASE
PRESSURE
SENSOR

113-OR
J35/P35

THROTTLE
BACK-UP
SWITCH

P41/J41
P31/J31

24 V

15 AMP
BREAKER

COOLANT
TEMPERATURE
SENSOR

LOW OIL
LEVEL
SWITCH

BATTERY

J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

DISCONNECT
SWITCH

GROUND
STUD

ECM

ENGINE FAN
CONTROL
SOLENOID

P84/J84

A/C ON
SWITCH
FAN SPEED SENSOR

DEMAND FAN
CONTROL

CAT DATA LINK

SERVICE TOOL
CONNECTOR

COMMUNICATION
ADAPTER
CAT
ELECTRONIC TECHNICIAN

VIMS

ADEM II
ELECTRONIC
CONTROL
MODULE
(ECM)

MAIN MODULE

LAPTOP
COMPUTER

VIMS DISPLAY MODULES

TYPICAL CAT DATA LINK CIRCUIT

POWER TRAIN CONTROL
MODULE
Cat Data Link +
Cat Data Link -

SERVICE TOOL
CONNECTOR

VIMS
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

P1 J1
9
3
7
1

ECM
Cat Data Link +
Cat Data Link ATA Data Link +
ATA Data Link -

PRELUBRICATION SYSTEM
ECM
P1 J1
F709-BU
998-BR

+24V

140-BU

337-WH

PRELUBRICATION
RELAY

34
29

1
2

PRELUBRICATION
DIGITAL RETURN

PRELUBRICATION
MOTOR

200-BK
MOTOR

PUMP
RELAY

LOGGED EVENTS

APPLICATION SPECIFIC
SYSTEMS

3516B OIL RENEWAL CIRCUIT (793C)

FUEL
PRESSURE
REGULATOR
CYLINDER
HEAD

OIL RENEWAL
INJECTOR
ENGINE
BLOCK
PRIMING PUMP SUPPLY

FUEL TANK
SECONDARY
FUEL FILTERS
(2 MICRON)

PRIMARY
FUEL
FILTER
FUEL
HEATER

FUEL
TRANSFER
PUMP

ECM

BASIC ENGINE BLOCK DIAGRAM

APPLICATION BLOCK DIAGRAM

P26 T/C CONNECTOR

ECM

J4/P4 THROUGH
J19/P19
J2

COOLANT
TEMPERATURE
SENSOR
AFTERCOOLER
TEMPERATURE
SENSOR
LOW OIL
LEVEL
SWITCH

GROUND BOLT

P20/J20

J21/P21

J48/P48

UNFILTERED OIL
PRESSURE
SENSOR

J32/P32

J22/P22

FILTERED OIL
PRESSURE
SENSOR

J105/P105

J27/P27

J106/P106

COOLANT
FLOW
SWITCH

J47/P47

J25/P25

P30/J30

J23/P23

RIGHT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

J28/P28

J29/P29

P31/J31

J103/P103
J113/P113

24 V

15 AMP
BREAKER

J3/P3 MACHINE
INTERFACE
CONNECTOR

FUEL FILTER
DIFFERENTIAL
PRESSURE SWITCH

LEFT
TURBOCHARGER
EXHAUST
TEMPERATURE
SENSOR

BATTERY

J1

8/12/16
INJECTORS

SPEED/TIMING
SENSOR

DISCONNECT
SWITCH

GROUND
BOLT

THROTTLE
POSITION
SENSOR

ATMOSPHERIC
PRESSURE
SENSOR
LEFT
TURBOCHARGER
INLET PRESSURE
SENSOR
RIGHT
TURBOCHARGER
INLET PRESSURE
SENSOR

THROTTLE
BACK-UP
SWITCH

WASTEGATE
CONTROL SOLENOID

308-YL

+ BATTERY

KEY START
SWITCH
GROUND
LEVEL
SHUTDOWN
SWITCH

CYLINDER
RELAY

STARTING
AID SWITCH

ENGINE
ETHER START VALVE
USER DEFINED SHUTDOWN

+ BATTERY
TO
PRELUBRICATION
PUMP

TURBOCHARGER
OUTLET
PRESSURE SENSOR
CRANKCASE
PRESSURE
SENSOR

113-OR
J35/P35

P41/J41

ELECTRONIC SERVICE
TOOL CONNECTOR
TO VIMS, EPTC II OR
MONITORING SYSTEM

ENGINE FAN
CONTROL
SOLENOID

P84/J84

A/C ON
SWITCH

OIL RENEWAL
CONTROL SOLENOID
FAN SPEED SENSOR