©
2002 Caterpillar
All Rights Reserved
Printed in U.S.A.
SENR1064-05
January 2002
3408E and 3412E Industrial Engines
Electrical System
4CR1-UP
7PR1-UP
BDT1-UP
BFT1-UP
0
20
25
5
15
10
+
-
Engine Oil
Pressure Sensor
Atmospheric
Pressure Sensor
Fuel
Pressure Sensor
Battery
Disconnect
Switch
15 Amp
Breaker
15 Amp
Breaker
Breaker
Keyswitch
Warning Lamp
Diagnostic Lamp
Customer Installed
Service Tool
Connector
Throttle
Position Sensor
Coolant
Level Sensor
Auxiliary
Temperature Sensor
Auxiliary
Pressure Sensor
Electronics
Ground Stud
Maintenance
Due Lamp
Engine Monitoring
System (EMS)
Display Modules
OEM Installed Switches:
PTO Enable
PTO Ramp Up/Down
PTO Interrupt
Remote Shutdown
Starting Aid Override
Overspeed Verify
Intermediate Engine Speed
Maintenance Due Reset
Torque Limit
Inlet Air Shutoff
Solenoid & Relay
SMMS
NOTE:
Components within
this area are
recommendations
Customer
Connector
Engine Coolant
Temperature Sensor
Intake Manifold Air
Temperature Sensor
Electronic Control Module (ECM)
Primary Engine
Speed/Timing Sensor
Caterpillar Supplied
Engine Service
Tool Connector
J3
P3
J60
J35/P35
P34/J34
Ether
Solenoid & Relay
J42
P21/J21
Secondary Engine
Speed/Timing Sensor
P20/J20
P44/J44
P49/J49
P27/P27
P22/J22
J89/P89
J52/P52
through
J58/P58
8 or 12
HEUI Injectors
J46/P46
Injection Actuation
Pressure Control
Valve (IAPCV)
Injection Actuation
Pressure Sensor
P45/J45
P26/J26
P109/J109
P114/J114
J23/P23
Turbocharger
Outlet
Pressure Sensor
Fuel
Temperature Sensor
P43/J43
Engine Oil
Temperature Sensor
P51/J51
Battery
24VDC
TOP VIEW
Timing Calibration
(TC) Probe
Connector
J26/P26
ECM
Connector
J2/P2
ECM
Connector
J1/P1
Customer
Connector
J3
Electronics
Ground
Stud
Injection
Actuation
Pressure
Control Valve
Engine Oil
Temperature
Sensor
Engine Oil
Pressure
Sensor
Atmospheric
Pressure
Sensor
Back-Up Engine
Speed/Timing
Sensor
Primary Engine
Speed/Timing
Sensor
Fuel
Temperature
Sensor
Engine Coolant
Temperature
Sensor
Turbo Outlet
(Intake Manifold Air)
Pressure Sensor
Injection
Actuation
Pressure
Sensor
Caterpillar Supplied
Engine Service
Tool Connector
J60
Coolant Temperature Sensor
Connector (P21)
View B-B
Coolant Flow Switch
View A-A
Coolant Flow Switch
Connector
Fuel Temperature Sensor
Secondary Speed/Timing Sensor
Oil Pressure Sensor
Oil Temperature Sensor
Injection Actuation Pressure Control Valve
Atmospheric Pressure Sensor Connector (J22)
Engine Coolant Temperature Sensor
Connector (P43)
Fuel Temperature Sensor
Connector (P51)
Top View
Odd Cylinder Bank
Secondary Engine Speed/Timing
Sensor Connector (J44)
J2
J1
Cold Start
Oil
Reservoir
High
Pressure
Oil Pump
Injection
Actuation
Pressure
Control
Valve
Oil
Cooler
Lubrication
Oil Pump
Oil
Filter
To Lubrication System
Oil
Sump
Fuel
Tank
Fuel
Transfer
Pump
Primary
Fuel Filter
Water
Separator
Engine
Oil Temperature
Sensor
Cooldown
Circuit
Oil Pressure
Sensor
Secondary
Fuel Filter
Pressure
Regulating
Valve
Injection Actuation
Pressure Sensor
Fuel Temperature
Sensor
Hydraulic Electronic
Unit Injectors (HEUI)
High Pressure
Oil Manifold
High Pressure
Oil Manifold
Electronic Control Module
Fuel System Block Diagram
8 or 12 Hydraulic
Electronic Unit
Injectors
ECM
Wire Gauge Pin # Socket #
14 9W-0852 9W-0844
16 - 18 8T-8729 8T-8730
Wire Gauge Pin # Socket #
14 9W-0852 9W-0844
16 - 18 8T-8729 8T-8730
Wire Gauge Pin # Socket #
14 9W-0852 9W-0844
16 - 18 8T-8729 8T-8730
4-Pin DT Connector
3E-3376 Receptacle As.
3E-3377 Wedge
3E-3374 Wedge
102-8814 Seal
3E-3373 Plug As.
3E-4367 Ring
3E-8557 Bolt
8T-9834 Connector As.
9X-3132 Seals
9X-1343 Receptacle As.
40-Pin DRC Connector
DEUTSCH IPD
DRC16-40S
40 39 38 37 36 35 34 33 32 31
10
20
40
30
26
36
16
6
5
15
25
35
21
11
31
1
102-8804 Receptacle Kit 102-8809 Plug Kit
10
40
36
6
5
35
31
1
40-Pin Deutsch Connector
110-6844 Seal
or
9-Pin HD10 Receptacle
8T-8736 Receptacle
A
B
C
D
E
F
G
H
J
3-Pin DT Connector
3E-3307 Receptacle As.
3E-3371 Wedge
3E-3368 Wedge
102-8813 Seal
104-2921 Plug As.
102-8803 Receptacle Kit
102-8808 Plug Kit
110-6845 Plug As.
or
110-6846 Plug As.
(Service Replacement)
110-6845 Plug As.
110-6846 Plug As.
Wire Gauge Pin # Socket #
14 9W-0852 9W-0844
16 - 18 8T-8729 8T-8730
Wire Gauge Pin # Socket #
14 9W-0852 9W-0844
16 - 18 8T-8729 8T-8730
Jack/Plug Functional Description
J1/P1 Electronic Control Module (ECM) Connector (key C)
J2/P2 Electronic Control Module (ECM) Connector (key D)
J3/P3 Customer Connector (40-Pin)
J114/P114 Auxiliary Temperature Sensor Connector (3-Pin)
J109/P109 Auxiliary Pressure Sensor Connector (3-Pin)
J20/P20 Primary Speed/Timing Sensor Connector (3-Pin)
J21/P21 Coolant Temperature Sensor Connector (3-Pin)
J22/P22 Oil Pressure Sensor Connector (3-Pin)
J23/P23
Turbocharger Compressor Outlet Pressure Sensor Connector
(3-Pin)
P26 Timing Calibration Connector (2-Pin)
J27/P27 Atmospheric Pressure Sensor Connector (3-Pin)
J34/P34 Coolant Level Sensor Connector (3-Pin)
J35/P35 Throttle Position Sensor Connector (3-Pin)
J42 Customer Installed Service Tool Connector
J43/P43 Fuel Temperature Sensor Connector (3-Pin)
J44/P44 Backup Speed/Timing Sensor Connector (3-Pin)
J45/P45 Injection Actuation Pressure Sensor Connector (3-Pin)
J46/P46
Injection Actuation Pressure Control Valve Sensor Connector-
(2-Pin)
J49/P49 Fuel Pressure Sensor Connector (3-Pin)
J51/P51 Engine Oil Temperature Sensor Connector (3-Pin)
J52/P52 #1, #3 Hydraulic Electronic Unit Injector Connector (4-Pin)
J53/P53 #5, #7 Hydraulic Electronic Unit Injector Connector (4-Pin)
J54/P54 #9, #11 Hydraulic Electronic Unit Injector Connector (4-Pin)
J56/P56 #2, #4 Hydraulic Electronic Unit Injector Connector (4-Pin)
J57/P57 #6, #8 Hydraulic Electronic Unit Injector Connector (4-Pin)
J58/P58
#12, #10 Hydraulic Electronic Unit Injector Connector
(4-Pin)
J60 Service Tool Connector (9-Pin)
J89/P89 Inlet Air Temperature Sensor Connector (3-Pin)
Electrical Connectors and Functions
Customer Connector (J3)
J56
P56
J57
P57
J58
P58
J54
P54
J53
P53
J52
P52
P26 J26
P43/J43
P51/J51
J22/P22
J27/P27
J23/P23
P21/J21
J44/P44
J20/P20
J45/P45
P46
P47
J60
F702/GN
G468/GN
F426/BU
CYL HD
SOL 12
CYL HD
SOL 10
TORQUE LIMIT SW
+BAT. (UNSWITCHED)
ATA DATA LINK -
ATA DATA LINK +
CAT DATA LINK -
CAT DATA LINK +
-BATTERY
-BATTERY
AUXILIARY PRESS. SNSR
DIAGNOSTIC LAMP
WARNING LAMP
STARTING AID SW
ETHER START VALVE RELAY
DIGITAL SNSR POWER (+8V)
+BAT. (UNSWITCHED)(NOTE B)
MAINTENANCE OVERDUE LAMP
COOLANT LEVEL SNSR
PTO INTERUPT SW
REMOTE SHUTDOWN SW (NO)
INTERMEDIATE SPEED SW
J1939 SHIELD
J1939 DATA +
J1939 DATA -
OVERSPEED VERIFY SW
KEYSWITCH
PTO ENABLE SW
PTO RAMP UP SW
PTO RAMP DOWN SW
UNUSED
ENGINE OIL TEMPERATURE
SPEED/TIMING SNSR POWER
INJR ACTN PRESS.
DIG SNSR RETURN
ANLG SNSR PWR (+5V)
ANLG SNSR RETURN
UNUSED
THROTTLE POSITION SNSR
AUXILIARY TEMP SNSR
MAINTENANCE CLEAR SW
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
UNUSED
COOLANT TEMP
FUEL TEMP
ATMOSPHERIC PRESSURE
TURBO OUTLET PRESSURE
OIL PRESSURE
FUEL PRESSURE
INLET AIR TEMP
SOLENOID RETURN
AIR SHUTOFF SOLENOID
UNUSED
INJR 11
INJR 12
INJR COMMON 1&3
INJR COMMON 2&4
INJR COMMON 5&7
INJR COMMON 6&8
INJR COMMON 9&11
INJR COMMON 10&12
INJR ACTN PRESS. VALVE RET
INJR ACTN PRESS. CONT VALVE
INJR 1
INJR 2
INJR 3
INJR 4
INJR 5
INJR 6
INJR 7
INJR 8
INJR 9
INJR 10
J1/P1
J2/P2
ECM
F723/PK
F724/PU
150/OR
229/BK
893/GN
892/BR
E793/BU
E794/YL
+BAT.
-BAT.
J1939 SHIELD
CAT DATA LINK +
CAT DATA LINK -
J1939 DATA +
J1939 DATA -
ATA DATA LINK -
ATA DATA LINK +
40
18
12
6
1
7
3
9
5
11
17
22
27
25
34
35
4
21
24
28
2
8
15
10
16
13
23
14
20
19
26
31
32
37
38
39
29
36
30
33
24
25
1
3
4
6
10
30
36
39
9
15
20
23
8
2
14
7
13
19
31
12
5
11
17
21
27
33
35
29
16
40
26
34
32
28
38
22
37
18
A
B
C
D
E
F
G
H
J
F723/PK
F724/PU
CYL HD
SOL 9
CYL HD
SOL 11
1
2
F710/BR
F723/PK
F724/PU
150/OR
E793/BU
E794/YL
892/BR
893/GN
229/BK
229/BK
G469/BU
F707/WH
F706/PU
F720/GN
F709/BU
A700/OR
150/OR
F424/YL
F719/BR
F708/YL
F715/PU
F716/WH
A234/BK
K900/YL
K990/GN
F722/OR
113/OR
F717/YL
F718/BU
F721/GY
412/BU
E795/YL
996/GN
E796/GN
999/WH
F732/PK
998/BR
997/OR
993/BR
995/BU
A751/YL
A747/GY
A746/PK
994/GY
F714/PK
F713/OR
E799/BR
F701/BR
F700/BU
A711/PU
A712/BR
F726/YL
F727/BU
F728/BR
F729/GN
F730/GY
F731/OR
E797/WH
E798/PK
A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY
A707/PU
A708/BR
A709/OR
A710/GY
997/OR
A751/YL
993/BR
997/OR
E795/YL
993/BR
997/OR
994/GY
993/BR
997/OR
A747/GY
993/BR
997/OR
A746/PK
993/BR
997/OR
995/BU
993/BR
998/BR
996/GN
F732/PK
996/GN
998/BR
999/WH
A
C
B
+5V
SIGNAL
GND
+5V
SIGNAL
GND
A
C
B
A
C
B
+5V
SIGNAL
GND
+5V
SIGNAL
GND
A
C
B
A
C
B
+5V
SIGNAL
GND
+5V
SIGNAL
GND
A
C
B
B
A
C
GND
+12V
SIGNAL
UNUSED
INJR ACTN PRESS.
CONTROL VALVE
+12V
RETURN
SIGNAL
A
B
C
A
C
B
E798/PK
E797/WH
1
2
412/BU
998/BR
997/OR
E796/GN
993/BR
+5V
SIGNAL
RETURN
CYL HD
SOL 2
CYL HD
SOL 4
CYL HD
SOL 6
CYL HD
SOL 8
CYL HD
SOL 7
CYL HD
SOL 5
A701/GY
A703/BR
F726/YL
A705/BU
A707/PU
F728/BR
F709/OR
A711/PU
F730/GY
F731/OR
A712/BR
A710/GY
F729/GN
A708/BR
A706/GY
F727/BU
A704/GN
A702/PU
1
2
MAX LENGTH 40 METERS
6
5
4
3
2
1
CYL HD
SOL 3
(NOTE F)
CYL HD
SOL 1
OPTIONAL REMOTE
TACHOMETER OR
QUAD GAGE
(NOTES E & J)
PTO RAMP
UP/DOWN SWITCH
(NOTE J)
QUAD GAGE
(NOTE E)
TACHOMETER
(NOTE E)
MAIN UNIT
(NOTE E)
40
39
38
37
36
32
31
30
29
28
27
26
24
22
21
19
18
17
16
12
11
10
9
8
6
3
33
4
7
13
23
20
35
34
25
15
14
5
2
1
0
5
10
15
20
25
30
RPM X100
6
5
4
3
2
1
150/OR
150/OR
F701/BR
E799/BR
G468/GN
F719/BR
A700/OR
998/BR
G469/BU
F702/GN
997/OR
993/BR
F709/BU
F720/GN
F426/BU
F710/BR
F715/PU
F716/WH
F722/OR
F708/YL
F717/YL
F700/BU
F718/BU
F721/GY
F424/YL
F707/WH
F706/PU
113/OR
892/BR
893/GN
E794/YL
E793/BU
E797/WH
E798/PK
A234/BK
K900/YL
K990/GN
1
2
4
5
11
36
8
9
20
19
33
10
14
15
22
38
12
21
27
28
40
23
29
3
30
39
13
24
25
37
26
6
7
31
32
34
35
16
17
18
(NOTE D)
CB
(NOTE C)
CB
(NOTE B)
CB
PTO ENABLE SW
PTO INTERUPT SW
OVERSPEED VERIFY SW
INTERMEDIATE SPEED SW
MAINTENANCE
OVERDUE LAMP
OPTIONAL EMS DISPLAY MODULES
+24V
- BAT.
US/METRIC
SCROLL FORWARD
CAT DATA LINK -
CAT DATA LINK +
UNUSED
WARNING LAMP
WARNING
BACKLIGHT LAMP PWR
SCROLL BACKWARD
1
2
3
4
5
6
7
8
9
10
11
12
+ BAT.
- BAT.
CAT DATA LINK -
CAT DATA LINK +
ATA DATA LINK +
ATA DATA LINK -
REMOTE SHUTDOWN SW
TORQUE LIMIT SW
MAINTENANCE CLEAR SW
+BAT. (UNSWITCHED)
+BAT. (UNSWITCHED)
AIR SHUTOFF SOLENOID
SOLENOID COMMON
AUXILIARY TEMP SNSR
COOLANT LEVEL SNSR
DIG SNSR PWR (+8V)
DIG SNSR RETURN
AUXILIARY PRESS. SNSR
THROTTLE POSITION SNSR
ANLG SNSR PWR (+5V)
ANLG SNSR RETURN
ETHER START VALVE RELAY
STARTING AID SW
MAINTENANCE CLEAR SW
TORQUE LIMIT SW
REMOTE SHUTDOWN SW
INTERMEDIATE SPEED SW
OVERSPEED VERIFY SW
PTO INTERRUPT SW
PTO ENABLE SW
UNUSED
PTO RAMP UP SW
PTO RAMP DOWN SW
MAINTENANCE OVERDUE LAMP
DIAGNOSTIC LAMP
WARNING LAMP
UNUSED
KEYSWITCH INPUT
CAT DATA LINK -
CAT DATA LINK +
ATA DATA LINK +
ATA DATA LINK -
15A
15A
STARTING AID SW
A
B
C
E
D
F
G
J
H
ST
ON
OFF
B
S
C
R
G S
MTR BAT
SM
CIS
GND
ALT
-
+
DIAGNOSTIC LAMP
BATTERY
8
7
6
5
4
3
2
1
MAX LENGTH 30 METERS
J3/P3
(J42)
CUST. SUPPLIED ENG
SERVICE TOOL CONN
WARNING LAMP
15A
CB
(NOTE B)
(NOTE H)
(NOTE G)
NOTE J: REFER TO THE INSTALLATION GUIDE FOR ADDITIONAL
INSTALLATION DETAILS
NOTE H: WHEN THE SHUTDOWN SWITCH IS CONNECTED TO BATTERY
(-) THE ECM DISABLES THE FUEL INJECTION SIGNAL.
THIS ACTION CAUSES THE ENGINE TO SHUTDOWN WHILE
LEAVING THE ECM POWERED TO MONITOR ENGINE
DIAGNOSTICS
NOTE G: 16 AWG WIRE
NOTE F: THE DEFAULT SETTING FOR THE EMS IS METRIC UNITS.
IF METRIC UNITS ARE REQUIRED NO CONNECTION IS .
NEEDED IF U.S. UNITS ARE REQUIRED, A PERMANENT
CONNECTION TO BATTERY (-) IS REQUIRED
NOTE E: ONE MAIN EMS MODULE IS REQUIRED FOR EACH DESIRED
MONITORING STATION. THE TACHOMETER AND/OR QUAD
GAGE UNITA ARE OPTIONAL AND WILL NOT OPERATE
WITHOUT CONNECTION TO A MAIN EMS MODULE
NOTE D: PIN 22 ON THE EMS MAIN MODULE 40 PIN CONNECTOR
MUST BE CONNECTED TO BATTERY (-) FOR PROPER
OPERATION
NOTE C: PLACE APPROPRIATE CIRCUIT PROTECTION
NO ADDITIONAL CONNECTIONS ARE ALLOWED TO ANY
WIRES WITHOUT CATERPILLAR ENGINEERING APPROVAL
UNLESS OTHERWISE SPECIFIED:
ALL WIRES TO BE 18 AWG OR LARGER SAE J1128 TYPE
SEE SAE J1708
COMPONENTS ARE SHOWN WITH THE KEY OFF
ELIMINATION OF ANY COMPONENTS SHOWN WILL DISABLE
CERTAIN ENGINE FEATURES. CONTACT CATERPILLAR
ENGINEERING WHEN CONSIDERING COMPONENT REMOVAL
NOTE A: THE CUSTOMER CONNECTOR BRACKET GROUND STUD MUST
HAVE A DIRECT WIRE CONNECTION TO BATTERY (-). THIS
CONNECTION CAN BE MADE AT THE STARTER (-) TERMINAL.
NOTE B: TO AVOID LOSS OF JOB DATA STORED BY THE ECM,
DISCONNECT SWITCHES SHOULD NOT INTERRUPT EITHER
THE ECM BATTERY (-) OR UNSWITCHED BATTERY (+) LINES
NOTE K: THIS OPTIONAL FEATURE NOT AVAILABLE ON ALL SYSTEMS.
+
SMMS
(NOTE A)
TERMINATION RESISTOR
174-3016
BATTERY
DISCONNECT
SWITCH
(NOTE B)
J56
P56
J57
P57
J53
P53
J52
P52
INJR COMMON 1&3
INJR COMMON 2&4
INJR COMMON 5&7
INJR COMMON 6&8
INJR 1
INJR 2
INJR 3
INJR 4
INJR 5
INJR 6
INJR 7
INJR 8
J2/P2
ECM
31
12
5
16
37
18
F726/YL
F727/BU
F728/BR
F729/GN
A701/GY
A702/PU
A703/BR
A704/GN
A705/BU
A706/GY
A707/PU
A708/BR
CYL HD
SOL 2
CYL HD
SOL 4
CYL HD
SOL 6
CYL HD
SOL 8
CYL HD
SOL 7
CYL HD
SOL 5
A701/GY
A703/BR
F726/YL
A705/BU
A707/PU
F728/BR
F729/GN
A708/BR
A706/GY
F727/BU
A704/GN
A702/PU
CYL HD
SOL 3
CYL HD
SOL 1
26
32
38
37
31
30
36
UNUSED
UNUSED
UNUSED
17
27
39
3408E INDUSTRIAL ENGINE INJECTOR SOLENOID CONNECTIONS ONLY
INJECTION ACTUATION PRESSURE
SENSOR
PRIMARY SPEED/TIMING
SENSOR
BACKUP SPEED/TIMING
SENSOR
COOLANT TEMPERATURE
SENSOR
TURBO OUTLET PRESSURE
SENSOR
ATMOSPHERIC PRESSURE
SENSOR
ENGINE OIL PRESSURE
SENSOR
ENGINE OIL TEMPERATURE
SENSOR
FUEL TEMPERATURE
SENSOR
UNUSED
3412E INDUSTRIAL ENGINE INJECTOR SOLENOID CONNECTIONS ONLY
REMOTE TC PROBE +
REMOTE TC PROBE -
TC PROBE +
TC PROBE -
PRIMARY SPEED/TIMING
BACKUP SPEED/TIMING
ACTN ACTUATION
STD ENGINE HARNESS WIRING
ALT ALTERNATOR
OPTIONAL ATTACH WIRING
CB CIRCUIT BREAKER
CUSTOMER SUPPLIED WIRING
CIS CUSTOMER IGNITION SWITCH
DIG DIGITAL
INJR INJECTOR
SM STARTING MOTOR
SMMS STARTING MAG SWITCH
ECM ELECTRONIC CONTROL MODULE
PWM PULSE WIDTH MODULATION
ABBREVIATION
WIRE CODE
1
2
3
4
1
2
3 4
1
23
4
1
2
3
4
1
2
3
4
1
2
3
4
1
23
4
1
23
4
1
23
4
1
23
4
(J49)
A
C
B
+5V
SIGNAL
RETURN
FUEL PRESSURE
SENSOR
997/OR
993/BR
F714/PK
C
A
B
SIG
+ BAT.
- BAT.
(P35)
(P34)
ETHER
VALVE
A
C
B
+8V
SIGNAL
RETURN
CIRCUITS WITHIN THIS AREA ARE RECOMMENDATIONS
(NOTE J)
(P19B)
+8V
SIGNAL
RETURN
A
C
B
(P114)
A
C
B
+5V
SIGNAL
RETURN
AIR SHUTOFF
SOLENOID
AUXILIARY TEMPERATURE
SENSOR (131-0427)
THROTTLE POSITION
SENSOR (161-8906)
AUXILIARY PRESSURE
SENSOR (161-9932)
COOLANT LEVEL
SENSOR (111-3794)
(P49)
A
C
B
+5V
SIGNAL
RETURN
FUEL PRESSURE
SENSOR
997/OR
993/BR
F714/PK
(NOTE K)
(NOTE K)
A
B
C
(P89/J89)
A
C
B
+5V
SIGNAL
RETURN
INLET AIR TEMP
SENSOR
997/OR
993/BR
F713/OR
120 ohms
J1939 DATA +
J1939 DATA -
A234/BK
TERMINATION RESISTOR
174-3016
A
B
C
120 ohms
A
B
C
A
B
C
K900/YL
K990/GN
