3406E ENGINE CONTROLS

ELECTRONIC UNIT INJECTION (EUI)

© 1999 Caterpillar Inc.

 FUEL GALLERY

EUI
EJECTORS

PRIMING PRESSURE
PUMP REGULATOR

ECM SECONDARY
FILTER FILTER BASE PRIMARY
(2 MICRON) FILTER
PRIMING PUMP TEMPERATURE
SENSOR RELIEF
CHECK VALVES VALVE
TRANSFER WATER
PUMP SEPARATOR

TANK
 3406E ENGINE SYSTEM BLOCK DIAGRAM (D400E)
ENGINE MOUNTED COMPONENTS

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR
GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
INLET AIR TEMPERATURE SENSOR
OIL PRESSURE SENSOR
ATMOSPHERIC PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR

 3406E SYSTEM BLOCK DIAGRAM (D400E)
MACHINE MOUNTED COMPONENTS

GROUND DISCONNECT SWITCH

BOLT
MACHINE INTERFACE CONNECTOR

24 V
UNSWITCHED POWER
ENGINE RETARDER SELECTOR SWITCH
1 15 AMP KEY
BREAKER MAIN SWITCH
2 LOW/MED/HIGH POWER
RELAY
3
4
MAIN POWER

2
3 MED THROTTLE SENSOR THROTTLE PEDAL
4 HIGH

GROUND LEVEL
SHUTDOWN SWITCH
ENGINE RETARDER LAMP

STARTING AID SWITCH + BATTERY RELAY ETHER START VALVE

CAT MONITORING SYSTEM
CYLINDER

10
15
20
AUT P ENGINE
5 25
R X100
MPH 44
0 km/h 30
24 V

ET SERVICE TOOL
CAT AND ATA DATA LINK
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
FUEL RPM TIMING FUEL INJECTION
FUEL QUANTITY BTDC CONVERT TIMING WAVE FORM
SELECT
TIMING DESIRED
TIMING
COOLANT COLD MODE
TEMPERATURE
 3406E COOLANT
ELECTRONIC GOVERNOR SHUTDOWNS TEMPERATURE
SENSOR

ECM
ELECTRONIC
GOVERNOR
6
5 FUEL FRC TORQUE
SIGNALS ENGINE THROTTLE
TO FUEL 4 INJECTION MAPS MAPS CONTROL
CONTROL ENGINE RPM
INJECTORS 3 LOGIC
2 TDC
1

SPEED/TIMING ENGINE RPM ENGINE RPM

SIGNAL

TURBO OUTLET AND

ATMOSPHERIC
TIMING PRESSURE SENSORS
WHEEL

SPEED/TIMING
SENSORS
 3406E (PASSIVE) SPEED/TIMING SENSORS
HIGH SPEED (UPPER)
SPEED/TIMING
SENSOR J44 P44
OR 1
BK 2

J1 P1

12 - HIGH SPEED S/T SENSOR

18 + HIGH SPEED S/T SENSOR
CRANKING (LOWER) TIMING CALIBRATION
SPEED/TIMING CONNECTOR ECM
SENSOR (3406E)
J20 P20 J26 P26
OR 1 2 723-PK 4 - CRANKING S/T/+TDC SENSORS
BK 2 1 724-PU 39 + CRANKING S/T/-TDC SENSORS

J2 P2

NOTE: P20/J26 POLARITY IS

TIMING CALIBRATION INTENTIONALLY REVERSED
PROBE

1 1 2
2 2 1

TIMING CALIBRATION
CABLE
 TIMING WHEEL
TDC
TDC CYLINDER No. 1
REF 4 REF

CRANKING SPEED/TIMING
SENSOR EXTRA TOOTH
2
HIGH SPEED/TIMING
SENSOR
TDC

1 TIMING
CALIBRATION RANGE ± 4°
REF REF

TIMING WHEEL
ROTATION TDC
TDC
5

FIRING ORDER: 1 5 3 6 2 4

REF 3 REF

TDC
 CRANKING
TIMING GEAR TOOTH TABLE
TABLE CRANKSHAFT CYLINDER
ENTRY ANGLE REFERENCE
A 30° NONE IDENTIFIED
B 30°
C 30°
D 30° HIGH
CRANKING
E 30° SPEED
SPEED CRANKSHAFT
F 30° SENSOR
SENSOR DEGREES
G 15°
H 15°
I 15°

30° 30° 30° 30° 30° 30° 15° 15° 15°

A B C D E F G H I

TIMING WHEEL ROTATION

 AFTER PATTERN RECOGNITION
TIMING GEAR TOOTH TABLE
TABLE CRANKSHAFT CYLINDER
ENTRY ANGLE REFERENCE
A 30° CYL NO 5 FIRING ORDER 153624
B 30°
C 30°
D 30° CYL NO 1
E 30°
F 30°
CRANKING HIGH
SPEED G 15° SPEED CRANKSHAFT
SENSOR H 15° SENSOR DEGREES
I 15°
TIMING WHEEL ROTATION

30° 30° 30° 30° 30° 30° 15° 15° 15°

A B C D E F G H I

CYL NO. 3 CYL NO. 5 CYL NO. 5 CYL NO. 1 CYL NO. 1
TDC REFERENCE TDC REFERENCE TDC
EDGE EDGE
 TIMING GEAR TOOTH TABLE
TABLE CRANKSHAFT CYLINDER
ENTRY ANGLE REFERENCE NORMAL OPERATION
A 30° CYL NO 5
B 30°
C 30°
D 30°
CRANKING E 30° CYL NO 1 HIGH
SPEED F 30° SPEED CRANKSHAFT
SENSOR G 15° SENSOR DEGREES
H 15°
I 15°
TIMING WHEEL ROTATION
30° 30° 30° 30° 30° 30° 15° 15° 15°

A B C D E F G H I

62° BTDC (EEPROM) 62° BTDC (EEPROM)

DES TIMING DES TIMING

DELAY NO. 5 DELAY NO. 1

INJECTION ASSUMED INJECTION
ASSUMED
TDC TDC
CYL NO. 3 CYL NO. 5 CYL NO. 5 CYL NO. 1 CYL NO. 1
TDC REFERENCE TDC REFERENCE TDC
EDGE (CALIBRATED) EDGE (CALIBRATED)
 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 LIMITS
• Maximum Horsepower
• Maximum Torque
• Fuel Ratio
• Cold Mode Limit
• Cranking Fuel Limit
FUEL SYSTEM COLD MODES

• Speed Control
• Fuel Limiting
• Injection Timing
• Ether Injection
 3406E SPEED/TIMING SENSOR CALIBRATION CIRCUIT

HIGH SPEED (UPPER)

SPEED/TIMING
SENSOR
J44 P44
OR 1
BK 2 P1 J1

12 - HIGH SPEED S/T SENSOR

18 + HIGH SPEED S/T SENSOR

TIMING CALIBRATION TIMING CALIBRATION ECM

PROBE CABLE (3406E)
P26
1 2 723-PK 4 - CRANKING S/T/+TDC SENSORS
2 1 724-PU 39 + CRANKING S/T/-TDC SENSORS

TIMING CALIBRATION P2 J2
CONNECTOR

CRANKING (LOWER)
SPEED/TIMING
SENSOR
J20 P20 J26
OR 1 2 NOTE: P20/J26 POLARITY IS
BK 2 1 INTENTIONALLY REVERSED
 TIMING CALIBRATION PROBE
INSTALLATION

TDC SLOT CRANKSHAFT

COUNTERWEIGHT

MACHINED FACE
DIRECTION OF
ROTATION

TIMING CALIBRATION ENGINE BLOCK

PROBE (SHOWN FROM REAR)

AIR GAP
 TIMING CALIBRATION

TIMING
WHEEL

REFERENCE EDGE TO TDC DISTANCE

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

-4° +4°
TIMING CALIBRATION ±4° TIMING REFERENCE
SENSOR SIGNAL OFFSET
(MAXIMUM RANGE
± 4 DEGREES)

25 ENGINE DEGREES
FUEL SUPPLY SYSTEM
 FUEL GALLERY

EUI
EJECTORS

PRIMING PRESSURE
PUMP REGULATOR

ECM SECONDARY
FILTER FILTER BASE PRIMARY
(2 MICRON) FILTER
PRIMING PUMP TEMPERATURE
SENSOR RELIEF
CHECK VALVES VALVE
TRANSFER WATER
PUMP SEPARATOR

TANK
 FUEL GALLERY

EUI
EJECTORS

PRIMING PRESSURE
PUMP REGULATOR

ECM SECONDARY
FILTER FILTER BASE PRIMARY
(2 MICRON) FILTER
PRIMING PUMP TEMPERATURE
SENSOR RELIEF
CHECK VALVES VALVE
TRANSFER WATER
PUMP SEPARATOR

TANK
 3406E EUI
SYSTEM POWER SUPPLIES

• ECM: 24 VOLTS
• INJECTORS: 105 VOLTS
• ANALOG SENSORS: 5 VOLTS
• DIGITAL SENSORS: 8 VOLTS
 3406E SYSTEM BLOCK DIAGRAM (D400E)
ECM POWER SUPPLY COMPONENTS

GROUND DISCONNECT SWITCH

MACHINE BOLT
CONNECTOR

24 V
UNSWITCHED POWER
ENGINE RETARDER SELECTOR SWITCH
15 AMP KEY
1
BREAKER MAIN SWITCH
2 LOW/MED/HIGH POWER
RELAY
3
MAIN POWER
4

3 MED THROTTLE SENSOR THROTTLE PEDAL

4 HIGH

GROUND LEVEL
SHUTDOWN SWITCH ENGINE RETARDER LAMP

STARTING AID SWITCH + BATTERY RELAY ETHER START VALVE

CAT MONITORING SYSTEM
CYLINDER
10
15
20
AUT P
ENGINE
5 25
X100
R
24 V 0 MPH
km/h
30 44

ET SERVICE TOOL
CAT AND ATA DATA LINK
 ECM POWER SUPPLY CIRCUIT

DISCONNECT ENGINE BLOCK

SWITCH GROUND BOLT
BATTERY
ECM (3406E)
P1 J1
(-)
24 VOLTS DC
229-BK-14 05 (-) BATTERY
(+) 15 A 1 150-OR-14 06 (+) BATTERY
CIRCUIT BREAKER
2 102-RD-16 04 UNSWITCHED PWR
P3 J3
10 AMP

C OFF
S ON
B ST

KEY 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

MACHINE INTERFACE CONNECTOR

40 PINS, WIRE SIDE
P3
1 2 3 4 5 6 7 8 9 10

11 15 16 20

21 25 26 30

31 32 33 34 35 36 37 38 39 40
INJECTOR WIRING SCHEMATIC

ECM
J91 P91 P2 J2 (3406E)
12 L983-WH 5 INJECTOR RETURN 1 & 2
10 L984-OR 17 INJECTOR RETURN 3 & 4
8 L985-YL 27 INJECTOR RETURN 5 & 6
6 A706-GY 34 INJECTOR 6 POWER
5 A705-BU 28 INJECTOR 5 POWER
4 A704-GN 22 INJECTOR 4 POWER
3 A703-BR 18 INJECTOR 3 POWER
2 A702-PU 12 INJECTOR 2 POWER
1 A701-GY 6 INJECTOR 1 POWER
11
9
7
 J21 P21 P2 J2
ECM (3406E EUI)
+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

TURBO INLET
P25 J25 ANALOG SENSOR
+V ANALOG A
PRESSURE SENSOR
(IF INSTALLED)
ANALOG RETURN
SIGNAL
B
C
POWER SUPPLY
P27 J27 5 ± 0.2 VOLTS
+V ANALOG A
ATMOSPHERIC ANALOG RETURN B
PRESSURE SENSOR SIGNAL C

P88 J88
+V ANALOG A
INLET AIR ANALOG RETURN B
TEMPERATURE SENSOR SIGNAL C

P43 J43
+V ANALOG A
FUEL TEMPERATURE ANALOG RETURN B
SENSOR SIGNAL C
 DIGITAL SENSOR
POWER SUPPLY
8 ± 0.5 VOLTS

THROTTLE
POSITION SENSOR J35 P35 P1 J1 ECM (3406E EUI)
+V DIGITAL A 29 + V DIGITAL SUPPLY
DIGITAL RETURN B 35 - V DIGITAL RETURN
SIGNAL C
ELECTRONIC SENSORS
AND
SYSTEMS
 SPEED/TIMING SENSORS

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR GROUND BOLT

MACHINE INTERFACE
CONNECTOR
 ANALOG SENSORS
Coolant temperature

Atmospheric pressure

Turbocharger outlet pressure

Lubrication oil pressure

Fuel temperature

Inlet air temperature

 COOLANT TEMPERATURE SENSOR

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR
 FUEL TEMPERATURE SENSOR

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
 INLET AIR TEMPERATURE SENSOR
6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
INLET AIR TEMPERATURE SENSOR
 ATMOSPHERIC PRESSURE SENSOR

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR
GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
INLET AIR TEMPERATURE SENSOR

ATMOSPHERIC PRESSURE SENSOR

 ENGINE POWER DERATING MAP
ACCORDING TO ATMOSPHERIC PRESSURE
100% 7,500

98% 8,210
PERCENT OF FULL LOAD POWER

96% 8,920

94% 9,630

92% 10,340

ALTITUDE IN FEET
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

 OIL PRESSURE SENSOR

6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR
GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
INLET AIR TEMPERATURE SENSOR
OIL PRESSURE SENSOR
ATMOSPHERIC PRESSURE 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
 TURBOCHARGER OUTLET PRESSURE SENSOR
6 DRIVERS
ENGINE
HARNESS

3 RETURNS

J2
ENGINE RETARDER
SOLENOIDS ECM
J1

HIGH SPEED/TIMING SENSOR

CRANKING TIMING CALIBRATION

SPEED/TIMING SENSOR CONNECTOR
GROUND BOLT
COOLANT TEMPERATURE SENSOR
MACHINE INTERFACE
CONNECTOR

FUEL TEMP SENSOR EXTENSION TO REMOTE

FILTER (D400E)
INLET AIR TEMPERATURE SENSOR
OIL PRESSURE SENSOR
ATMOSPHERIC PRESSURE SENSOR

TURBO OUTLET PRESSURE SENSOR

DIGITAL SENSORS AND CIRCUITS

• Throttle Position Sensor

 ENGINE SPEED CONTROL SYSTEM COMPONENTS
GROUND DISCONNECT SWITCH
BOLT
MACHINE INTERFACE CONNECTOR

24 V
UNSWITCHED POWER
ENGINE RETARDER SELECTOR SWITCH
1 15 AMP KEY
MAIN SWITCH
BREAKER
2 LOW/MED/HIGH POWER
3
RELAY
4
MAIN POWER

2
3 THROTTLE SENSOR THROTTLE PEDAL
4

GROUND LEVEL
SHUTDOWN SWITCH ENGINE RETARDER LAMP

STARTING AID SWITCH + BATTERY RELAY ETHER START VALVE

CAT MONITORING SYSTEM
CYLINDER
ENGINE
15 AUT P
10 20
5
25
X100
R 0 MPH 30
44
24 V km/h

ET SERVICE TOOL
CAT AND ATA DATA LINK
 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
 GROUND LEVEL SHUTDOWN SWITCH CIRCUIT

ECM (3406E EUI)

GROUND LEVEL
SHUTDOWN SWITCH P1 J1
1
2 GND LVL SHUTDOWN (NO)
2
8 GND LVL SHUTDOWN (NC)
3 DIGITAL RETURN
29
 USER DEFINED SHUTDOWN CIRCUIT

ECM (3406E EUI)

J3 P2 J2

USER SHUTDOWN 12 1 USER SHUTDOWN

DEVICE
 ETHER INJECTION SYSTEM ECM (3406E)
P2 J2

ETHER SWITCH J3 P3 P1 J1

9 998-BR 29 DIGITAL RETURN

38 25 ETHER SWITCH
720-GY
21 710-BR 40 ETHER ON

+ P37 J37 FROM

1
CYLINDER
2
+24V
RELAY
ETHER
START VALVE TO ENGINE
 SERVICE CAT DATA LINK
TOOL
CONNECTOR
ADEM II
ELECTRONIC
CONTROL LAPTOP
COMPUTER
MODULE
(ECM) CONTROL SERVICE TOOL

CAT
ELECTRONIC TECHNICIAN
7X1701

COMMUNICATION
ADAPTER

15 AUT P
10 20
5
25
X100
R 44
TRANSMISSION 24 V
0 MPH
km/h
30

ELECTRONIC
CONTROL
MODULE

CATERPILLAR MONITORING SYSTEM

DISPLAY UNIT
 CAT DATA LINK CIRCUIT

TRANSMISSION CONTROL CATERPILLAR

MODULE MONITORING SYSTEM

Cat Data Link + 9 5 Cat Data Link +

Cat Data Link - 3 14 Cat Data Link -

ENGINE ECM

J42 P3 J3 P1 J1
D 7 893-GN 9 Cat Data Link +
E 6 892-BR 3 Cat Data Link -
SERVICE TOOL
H 31 E794-YL 7 ATA Data Link +
CONNECTOR
J 32 E-793-BU 1 ATA Data Link -
MACHINE INTERFACE
CONNECTOR
 LOGGED EVENTS
• High coolant temperature

• Loss of coolant flow

• Low (lube) oil pressure

• User defined shutdown

• Air inlet restriction

• Engine overspeed
 CATERPILLAR MONITORING SYSTEM

P
15 AUT

10 20

5
25
X100
R
24 V
0 MPH 30 44
km/h