Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential Green
Perkins 23/25/2800 Series Diesel Engine Training Perkins Product Training Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Domestics Fire Exits Breaks Lunch Toilets Smoking Mobile Phones Health & Safety Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Please Note The product training information is distributed for informational purposes only. It is not to be construed as creating or becoming part of Perkins Engines contractual or warranty obligations The appropriate service literature, including Service Bulletins now available on the www.perkins.com Secured Website, should always be the final authority and source of information Wiring Diagrams/Electrical Drawings, wire numbers and connection points may change. Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Course Objectives At the end of the course the delegates will be able to
Show technicians strip down techniques and the use of special tools EST(Electronic Service Tool) and fault diagnosis procedures specific to 23/25/2800
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Worldwide Off Road Legislation Today Environmental Protection Agency / European Union Regional Legislation No Legislation Requirements Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Off Road Emissions Legislation Tier 0 "A" rated engines can be used in regions without Emissions Legislation.
Tier 1 "B" rated engines are suitable for regions with Tier 1/Stage I Emissions Legislation
Tier 2 "C" rated engines are suitable for regions with Tier 2/Stage II Emissions Legislation.
Tier 3 "D" rated engines are suitable for regions with Tier 3/Stage III Emissions Legislation.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Off Road Industrial - Ever Cleaner Engines 0 0 1 0.05 0.10 0.15 0.20 0.25 0.30 0.35 0.40 0.45 0.50 2 3 4 5 6 Tier 3: 56kW<75 Tier 3: 75kW<130 Tier 3: 130kW<560 Tier 4A: 56kW<130 Tier 4A: 130kW<560 Tier 4B: 56kW<560 NO x ; NO x + HC (g/kWh) PM (g/kWh) 1980s Particulate Matter (PM) 0.6g/kWh
Oxides of Nitrogen (NOx) 10.00g/kWh Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Engine Benefits Electronic Engine Management system gives:
Improved Specific Fuel Consumption (SFC) through precise control of Injection Timing and Duration. Machine protection under extreme operating conditions. Easy servicing and fault diagnostics, Electronic Service Tool, (EST) Exceeds emissions legislation and has a lower noise level. Better engine responsiveness. Improved reliability,engine monitoring and protection. Further cost savings through integration into Genset' design (CAN) Improved torque, different torque curves available, torque shaping Rating changes available, Base Load, Prime, Standby, 1500/1800 Configuration files, gives the customer flexibility, droop, etc Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green FGA 06 - 1234 - U - 5678 - K F Engine Family, 14.6 litre H Engine Family, 15.8 litre J Engine Family, 18 litre A = TAG 1 (Turbo-Air to air charge cooled-Genset) B = TAG 2 (Turbo-Air to air charge cooled-Genset) D = TAG 3 (Turbo-Air to air charge cooled-Genset) Generator Set Engine Number of Cylinders Engine Serial Number Country of Manufacture Year of Manufacture 03 Build List 2306 and 2806 Engine Numbering Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Ratings - Definitions Base Load or Continuous Unlimited hours usage, load factor 100% of published base load/continuous power 10% overload available 1 hour in 12 Power available for continuous full load Prime Power Unlimited hours usage, load factor 80% of published prime power over 24 hours 10% overload available 1 hour in 12 Standby (maximum) Power available at variable load in the event of a mains power network failure, up to a maximum of 500 hours/year of which 300 hours may be continuous No overload is permitted and the load factor is 100% Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Engines Electronic Control System, Identical Economic Power Mechanically actuated Electronically controlled Unit Injection.(MEUI) Optimum turbo-charging, excellent fuel atomisation (30,000 PSI) and combustion, very low emissions. Reliable Power Low oil usage and wear rates, high compression ratios ensure clean rapid starting. World Wide Support from 4000 Distributors. Compact, Efficient Power Exceptional power to weight ratio, compact size, excellent service access for ease of maintenance Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 - Engine Component Changes Noticeable Physical Differences - Air Filter Size Performance Related Pistons Connecting Rods Liner Ring Pack Crankshaft Turbo Air Cleaner Package Size Related Radiator Charge Cooler Fan and Cowling Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Combined primary and secondary Eco Fuel filters Integral inlet manifold (18 litre horizontal) Fuel transfer pump Timing Calibration Probe access hole ADEM 3 ECM With Perkins software Unique wiring harness Radial seal air filter element 2306/2806 Product Features Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Composite oil pan Composite top cover Oil cooler Ecoplus full flow oil filtration Single stage high boost turbocharger Torsional vibration damper Air to air charge cooler 16 litre 2306/2806 Product Features Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2806 -18 litre Product Features Twin exhaust manifolds External oil feed to the cylinder head
Twin turbochargers
Large output coolant pump New oil filler tube Aluminium sump 30% larger capacity oil cooler
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Rocker Assemblies Roller Type Rockers Second oil pressure feed to cylinder head 18 Litre (external) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Forged steel overhead camshaft Four valves per cylinder Cylinder Head Four Valve Mono-Block Cylinder Head Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green One of three oil feed drillings Valve Assemblies Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green TDC locator Turning tool Valve/Injector Clearance Establishing Number 1 TDC Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Valve screw and locknut adjuster Injector adjuster Injector trim code Button and O ring Valve/Injector Clearance Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Tool CH11149 Machine shoulder Checking correct adjustment Valve/Injector Clearance Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Valve/Injector Clearance With Number 1 Cylinder at TDC compression stroke adjust Inlet valves 1,2,4 Exh valves 1,3,5 Injectors 3,5,6 With Number 6 Cylinder at TDC compression stroke adjust Inlet valves 3,5,6 Exh valves 2,4,6 Injectors 1,2,4 Clearances Inlet valves 0.38mm (0.015in) Exh Valves 0.76mm (0.030in) Injectors 78.0mm (3.07in) Tool N CH11149 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Injector Sleeve A stainless steel sleeve is used in the injector bore to seal the coolant The sleeve is sealed using three O rings. However, combustion gases are sealed by the injector seating on the metal in the cylinder head bore. The O ring seal fitted on the injector nozzle provides a combustion gas seal until a carbon dam is formed.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green A failed seal results in blow by and a hot injector Injector Sleeve A line contact seal is attained Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Injector Sleeve Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Valve lobes Injector lobe Drive gear dowel location Camshaft Long Overlap Camshaft Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Camshaft Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Camshaft Thrust Plate and Seal Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Cylinder head gasket Spacer plate Shim gasket Oil feed O ring Coolant bobbin Oil seal Head Gasket/Spacer Plate Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Thermal sleeve Air gap Exhaust Manifold Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Cylinder Block Open Summit Cylinder Block Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Oil soaked filler band Rubber O rings (2806) 2306 three lower liner O ring seals are all identical in size Cylinder Liners Induction Hardened Liners Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Cylinder Liners Protrusion Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Oil cooling gallery Oil cooling spray cutaways Pistons 2306 Gallery Cooled Articulated Piston Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Cooling oil reservoir Pistons 2806-16 Articulated Piston Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Tightening con-rod bolts Piston/Con-Rod Assembly Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Pistons 2806-18 Piston Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Big end cap secured by four bolts Oil supply to small end bearing Pistons/Con-Rod Assembly 2806-18 Piston Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Piston cooling jet alignment tool Part Number GE50004 Piston Cooling Jets Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Piston cooling jet pipe assembly Entry to cooling gallery Connecting rod Piston Piston Cooling Jets 2806-18 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Thrust washer position Crankshaft Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Crankshaft 2806-18 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Grooved main bearing fitted to block 180 thrust washers fitted to block Crankshaft Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Block Stiffener Plates 2300 Series 2800 Series 16 litre Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2 Torsional Damper Hasse and Wrede Damper
1. Housing 2. Casing 3. Inertia Ring (mass) 4. Bearings 5. Silicone Fluid Block Stiffener Plate 2800 18 litre Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Pendulum camshaft gear Adjustable idler gear Idler gear Fuel transfer pump Crankshaft gear Oil pump gear position Compound gear assembly Coolant pump drive gear position Timing Gears Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Locating dowel Rotating balance weights Timing Gears Pendulum Camshaft Gear Timing case Alignment marks Timing gear Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Timing Gears Checking Gear Backlash Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Crankshaft Seals Seal Removal/Fitting Gear case-split protection ring Wear sleeve crimp tool Must be fitted as assembly Must not be separated Must be fitted dry Crankshaft Seals Oil Seal and Wear Sleeve Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Blue seal (rear) Green seal (front) Crankshaft Seals Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Induction System 2809-18 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Induction System Air Filter Type Single medium duty paper element Max Air Inlet Temp 60C (140F) Initial Restriction 2.5kPa (inlet depression new) Maximum Inlet Depression 6.2Kpa (with dirty filter) Max Pressure Drop 14Kpa (2.03 psi) (across charge cooler) Maximum Charge Air Temp 260C (500F) at high (ambient conditions) Turbo Charger 2306 Allied Signal GT 50 2806 Borge Warner S 500 2806-18 twin Borge Warner S310 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Induction System Radial Seal Filters Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Single stage high boost turbochargers No oil priming required Induction System Turbochargers Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Exhaust gas outlet Forward turbocharger Rear turbocharger Induction System 2806-18 Turbochargers Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green A I R C O O L A N T Induction System Air Charge Cooling/Radiator Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Air charge cooling / radiator Boost air Coolant Turbo boost air Coolant Induction System 2806-18 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Induction System Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Trim code, Below barcode Fuel System EUI Location Put lever here to remove Injector Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green O ring seals 6 hole injector nozzle Sacrificial compression O ring Do not re-use seals Fuel System Injector Seals Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Transfer pump Primary filter Fuel supply Fuel return Venting points Priming pump Fuel System Low Pressure Fuel System Secondary filter Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Flow =413 litres/h at 1500
Flow =457 litres/h at 1800
Return flow dependant on engine load Thermostat. Fuel System Fuel Cooler/Return Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Fuel System Ecoplus Fuel Filtration Fuel System Fuel Transfer Pump Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Fuel Secondary Fuel primary Oil Fuel System Ecoplus Fuel Filtration Identification Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green From Tank To transfer pump From transfer pump Temp sensor Return to cooler Return from head Pressure Relief Valve Air vent Supply to head Hand primer By-pass valve Fuel System Ecoplus Fuel Filtration Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Fuel System Non-return/PRV Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Lubrication System Type Wet sump - full flow system Oil pump Gear driven - with PRV Capacity - total system 68 litres Sump maximum 60 litres Sump minimum 45 litres Lube oil temp - normal (sump) 95C Lube oil temp - maximum 113C Lube oil pressure - rated speed 2.7-6 bar (40-88psi) Lube oil pressure - min rated speed 2 bar (30psi) Oil pressure relief valve opening pressure 6.1 bar (88psi)
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Lubrication System Composite High Capacity Sump Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Lubrication System Oil Pump Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Sampling point O/P switch Filter by-pass valve Cooler by-pass valve Lubrication System Ecoplus Oil Filtration Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Oil cooler assembly Re-positioned oil filler tube Re-designed Oil filter head Lubrication System 2806-18 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Cooling System Capacity of engine 20.8 Litres Capacity of complete system 50 Litres Pressure cap setting 70kPa (0.7 Bar) (10psi) Thermostat operating range Starts 88C. Fully open 98C Coolant pump Gear driven, centrifugal type Radiator Aluminium core, composite tanks Fan Plastic, 8 blade, pusher type. Maximum temperature. Top tank - 103C Recommended Coolant. 50% extended life coolant, 50% de-ionised clean water. Coolant Life 3,000 hours or six years - max Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Composite top and bottom radiator tanks ELC coolant to be used at all times
Cooling System Air Charge Cooling/Radiator Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Thermostat Thermostat seal Flow to radiator By-pass return to coolant pump Cooling System Thermostat Housing Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Coolant Temp Sensor Inlet Manifold Air Pressure sensor Fuel Temp Sensor Inlet Manifold Air Temp Sensor Engine Oil and Atmospheric Pressure Sensors Location of Calibration Probe (Plugged) 23/25/2800 Series Temperature and Pressure Sensors Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Control Module 40 Pin Customer Connection (J3) 110 Volt MEUI Solenoid Feeds ECM On Engine Connector (J2) Cam Speed/ Position Sensor Crank Speed/Position Sensor 9 Pin Diagnostic Connector 23/2800 Series Connections and Speed/Position Sensors Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 Series Electrical System
36-1 TOOTH CRANK GEAR 36+1 TOOTH CAM GEAR Internal Injector Harness Engine Oil Pressure Inlet Manifold Sensor Crank Speed/Timing Cam Speed/Timing Atmospheric Pressure Sensor Calibration Probe Jack 1 (J1) Jack 2 (J2) Fuel Temperature Sensor Coolant Temperature Sensor Inlet Manifold Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 On Engine Wiring Harness ECM J2/44 Injector Common Cylinders 1 & 2 Injector Cyl 1 Injector Cyl 2 Injector Cyl 3 Injector Cyl 4 Injector Cyl 5 Injector Cyl 6 J2/45 J2/46 J2/55 J2/54 J2/39 J2/38 J2/37 J2/36 Injector Common Cylinders 3 & 4 Injector Common Cylinders 5 & 6 Injector Cylinder 6 Injector Cylinder 5 Injector Cylinder 4 Injector Cylinder 3 Injector Cylinder 2 Injector Cylinder 1 5 7 6 10 3 11 2 12 1 J300 P300 A C +5V Signal B Return A C +5V Signal B Return A C +5V Signal B Return Atmospheric Pressure Sensor J2/2 J2/14 J2/3 J2/24 J2/32 J2/33 J2/35 J2/40 Turbo Outlet Pressure Sensor Oil Pressure Sensor J2/18 +5VDC Supply Analogue Return Fuel Temperature Inlet Air Temperature Return Inlet Air Temperature Sensor C Signal B Return Coolant Temperature Sensor C Signal B Return Fuel Temperature Sensor C Signal B Return Atmospheric Pressure Turbo Outlet Pressure Oil Pressure Coolant Temperature J2/48 J2/49 Crank Speed Timing - 2 Signal 1 Return Crankshaft Position Sensor Crank Speed Timing + Cam speed timing - Camshaft Position Sensor Cam Speed timing + J2/58 J2/59 2 Signal 1 Return J2/22 J2/23 2 Signal 1 Return Calibration Probe Calibration Probe + Calibration Probe - P2 J2 P203 J203 P200 J200 P201 J201 J100 P100 J105 P105 J103 P103 J401 P401 J402 P402 J400 P400 All fed from Jack 2 (J2) on the ECM Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Connectors A Reminder: Always use high quality connectors (Gold/Nickel Plated) Keep connections to a minimum Make sure all rubber seals are correctly fitted Remember
Bad connections cause resistance!
Resistance causes voltage drop! Lack of a rubber seal caused this To happen to an ECM! Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Effects of Bad (Resistance) Connections
24v dc Lamp Possible Bad Connections 24v dc Lamp Resistors Has the same effect as.Resistances in circuit 1 volt 2 volt 0.1 volt 1 volt 24v dc 19.9v dc J Jack P Plug Dont forget all connections! Dont forget all connections! Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 Series MEUI Injection Mechanically actuated by the cam shaft Injection controlled by the 110 Volt Solenoid The length of time the Solenoid is energized, and the timing of the energization are both controlled by the Electronic Control Module (ECM)
Mechanically Actuated Electronically Controlled Unit Injector 110 Volt Solenoid Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 110v dc injector solenoid Poppet Valve Shut when energised 23/25/2800 Series MEUI Injector + 110v Supply Off - Flow Poppet Valve Principals Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Poppet Valve de-energised O Rings Fuel chamber MEUI Injector Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green O Rings Worn MEUI Injector Poppet Valves Wear on seat, caused by dirty fuel. Primary Filter 10 microns, Secondary, 2 microns Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Injector trim code Injector trim code Extended life coolant Intake manifold Fuel chamber MEUI Injector Location Torque setting on solenoid Screws 2.5 Nm (22 lb in) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Control Module (ECM) Inside the ECM is the management system that controls Speed Governing Air/Fuel Ratio Start/Stop Sequence Engine Protection Devices Diagnostics 110 Volt Injector Pulses Jack 2 (J2) all on engine mounted components Jack 1 (J1) Customer interface, power supply etc Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Basic System A3-ECM Interactions Inputs Outputs Cables/ Connectors Digital speed Adjust analogue speed Adjust PWM speed Adjust
Push buttons/switches fault reset,injection disable,lower/raise digital speed, etc,etc
ECM power supply, 24 v
Control Voltage to operate diagnostic lamps and crank terminate relay
5 volt + 8 volt Power Supplies
110 Volt DC pulse for Injectors
Digital output for speed control Cables/ Connectors Cables/ Connectors Cables/ Connectors Electronic Service Tool PDL PROCESSOR
MEMORY (Engine Programme)
Power supply for 5 volt 6.5 volts and 8 volts CAN J 1939 Diagnostic Code Reader J 1939 Engine Control Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2500/2800 Off Engine Wiring Diagram
J1- 70 Jack - Customer connection. Also J3 - 40 Jack - Customer connection
Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active systemfault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input fromLoad Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpmSelect Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V J1 Jack (Different Diagram) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Some Typical Connections - ECM Inputs Outputs ECM Power Supply, 24 v CONTROL E C M Shutdown Diagnostics Analogue Speed Adjust Crank Terminate Injection Disabled Power Supply, 24 v + - + - 5 volt to Sensors + - J1939 PDL + - Ignition Key Switch Communications Adapter 24 v Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/2800 Series ECM Jack Connections J1 (Jack 1) Customer Side J2 (Jack 2) On Engine Mounted Components Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green ECM Grounding Grounding Always ensure the ground straps are on the Engine and the ECM is connected to the engine block, via the tag to prevent EMI, Electro Magnetic Interference, affecting the interior electronic circuits of the ECM. Warning! When carrying out welding or electrostatic paint spraying, special precautions should always be followed. These are listed in the Perkins Mechanical and Electronic Installation Manual. TSL 4262, & TSL 4247.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Control Module Nominal battery supply voltage 18-32 volts (Max 48 for 2 mins) Approximately 2 - 6 amps in typical application 10-15 mA in sleep mode (ignition off/ECM power on)
High Reliability. External connectors most vulnerable: bent jacks, J1, J2 over tightened ECM plugs etc. No internal fuses or serviceable parts. Never replace an ECM without first connecting Electronic Service Tool (EST) and carrying out basic diagnostics. The ECM is the last component you should suspect.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series ECM Power Supplies Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V + to Diagnostics Lamps - to Diagnostics Lamps Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Minimum J1 Connections, to run a 23/2800 Series ECM Power Supply, 24 v Control ECM Injection Disabled + - Ignition Key Switch Note We do suggest that a connection is made to the Perkins Electronic Service Tool (EST) to allow communication With Perkins Data Link (PDL)
What are the Jack connection numbers? Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Ignition Circuit Ignition Key Switch This switch may be used for a controlled engine stop. The ignition switch does not switch off power to the ECM. The ECM remains connected to the battery via a fuse/circuit breaker, even when the ignition is switched off. Can also be used to reset faults. The Electronic Service Tool (EST) cannot communicate with the ECM when the Ignition switch is off. Injection Disabled If you want to stop the engine, use the Injection Disabled. This allows communication with the service tool (EST) to continue. Emergency Shut-down This button, interrupts the main battery power supply to the ECM and stops the engine. Not Recommended, Dont forget the ECM is a computer, you do not just chop off the power.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 Series Engine Mounted Sensors Engine coolant temperature. Inlet manifold air temperature. Fuel temperature. Inlet manifold air pressure. Atmospheric/crankcase pressure. Engine oil pressure. Camshaft/crankshaft speed/timing.
Calibration probe (only in special circumstances) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 32 33 35 18 ECM Engine Coolant Temperature Sensor Fuel Temperature Sensor Signal Voltage Signal Voltage 0 Volts Inlet Air Temperature Sensor Signal Voltage 2300/2800 Series Temperature Sensors Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 18 ECM Temperature Sensor R 5 Volts 0 Volts Signal Ground 23/2800 Series Temperature Sensor Operation Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Coolant Temperature Sensor EST Code 110 Temperature can be viewed through the ECM in C/F via: J1939 CAN link Perkins Data Link (PDL) The sensor enables the cold start strategy Also enables the calculation of the fuel limit and engine timing Engine protection, Warning, Action Alert and Shutdown. Coolant Temperature Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Coolant Temperature Sensor EST Code 110 (Typical Temperature Sensor graph) 110-4 Signal shorted to a lower voltage (voltage under 0.2)
110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)
Temperature 0.2 4.8 Shutdown Temp 361 (3) Very cold Temp Action Alert Temp 361 (2) Warning Temp 361 (1) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Manifold Air Inlet Temperature Sensor EST Code 174 Temperature can be viewed through the ECM in C/F via: J1939 CAN link. Perkins Data Link (PDL) The sensor enables the cold start strategy. Also enables the calculation of the fuel limit and engine timing Engine protection, warning and Action Alert. Manifold Air Inlet Sensor High inlet air temperatures lead to high exhaust temperatures, which can cause damage to exhaust system components (such as turbochargers and exhaust valves) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Fuel Temperature Sensor EST Code 174 Higher Temperature lower mass Lower Temperature greater mass Temperature can be viewed through the ECM in C/F via: J1939 CAN link Perkins Data Link (PDL) Also enables the calculation of the fuel limit and engine timing. Protection, Warning and Action Alert. Fuel Temperature Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Voltage between 1 and 2
Wiring harness plug connections (check the harness to ECM) 2 1 Fuel Temperature Sensor Coolant Temperature Sensor Intake Manifold Temperature Sensor
Temperature Sensor Feeds, Harness Voltages Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 32 33 2 35 18 3 2 ECM Jack 2 Engine Coolant Temperature Sensor Fuel Temperature Sensor Intake Manifold Temperature Sensor Fault 1. Fault 2. Fault 3. Break 1 2300/2800 Series Sensors Different Fault Codes and How they could be Created Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2 3 40 24 14 ECM J2 Engine Oil Pressure Sensor Intake Manifold Air Pressure Sensor 5 Volts Signal Voltage 0 Volts Signal Voltage Atmospheric/Crankcase Pressure Sensor Signal Voltage 2300/2800 Series Pressure Sensors Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2 3 ECM J2 Pressure Sensor R 5 Volt 6.5 Volts 0 Volts Sensor Fly Lead Main Engine Harness 23/25/2800 Series Pressure Sensor Operation Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Inlet Manifold Air Pressure Sensor EST Code 273 - (Code also known as Turbo Boost!) Pressure can be viewed in PSI and Kpa through the ECM via: J1939 CAN link Perkins Data Link (PDL) Used to determine mass air flow Enables the calculation of the correct air/fuel ratio Used for smoke limiting strategy Range 52 Kpa Abs. 472 Kpa Abs Protection- Warning and Action Alert. Inlet Manifold Air Pressure Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Inlet Manifold Air Pressure Sensor Inlet Manifold Air Pressure Values
2800 Kpa Gauge 1800 rpm Full load 295 1/2 Load 126 1500 rpm Full Load 249 263 Half TA Luft 1/2 Load 94 95
2300 Kpa Gauge 1800 rpm Full load 205 1/2 Load 119 1500 rpm Full Load 195 234 Half TA Luft 1/2 Load 71 71 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Oil Pressure Sensor EST Code 100 Pressure can be viewed in PSI and Kpa through the ECM via: J1939 CAN link Perkins Data Link (PDL) Protection,Warning,Action Alert Protection mapped Range 106 Kpa to 1135 Kpa Engine Oil Pressure Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Oil Pressure Sensor EST Code 100 (Typical Pressure Sensor graph) 100-4 Signal shorted to a lower voltage (less than 0.2 volts) 100-3 Shorted to a higher voltage or open circuit (over 4.8 volts) Pressure 0.2 4.8 Warning Pressure E360-1 Action Alert Oil Pressure E360-3 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Atmospheric (Crankcase) Pressure Sensor EST Code 274 Pressure can be viewed in PSI and Kpa, absolute through the ECM via: J1939 CAN link. Perkins Data Link (PDL) Used to calibrate the Inlet Air and Oil Pressure Sensors. With Critical Override active, if the sensor fails the engine will Derate by 10%. Range 40 Kpa A to 116 Kpa A Atmospheric Pressure Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Series De-rate Information The 2306 / 2806 series engine electronic control, does not automatically de-rate at high altitudes or high ambient temperatures The de-rate information for this engine can be obtained from Perkins Engines Applications Department These de-rate limits must be adhered to or severe engine damage may result
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Atmospheric/Crankcase Pressure Sensor (DT06-3S) Oil Pressure Sensor (DT06-3S) Intake Manifold Air Pressure Sensor (DT06-3S)
C A B Voltage between A and B Voltage between B and C Voltage between A and C Pressure Sensor Feeds, Harness Voltages Wiring Harness Plug Connections, (Checks the harness to ECM) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Sensors Different Fault Codes and How they could be Created 2 3 40 24 14 3 2 ECM J2 Engine Oil Pressure Sensor Intake Manifold Air Pressure Sensor 5 Volts Signal Voltage 0 Volts Signal Voltage Atmospheric/Crankcase Pressure Sensor Signal Voltage 1 Fault 1. Fault 2. Fault 3. Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Crankshaft Gear 36 - 1 tooth Crankshaft Speed/Position Sensor EST Code 190 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Camshaft Gear 36 + 1 tooth Camshaft Speed/Position Sensor EST Code 342 (Speed and timing Sensor 2) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Crankshaft Sensor Resistance between 1 and 2
Camshaft Sensor Resistance between 1 and 2
Run Engine and Measure output AC Voltage or Frequency from each Sensor - one at a time 2 1 2 1 Crankshaft Speed/Position Sensor fly lead Camshaft Speed/Position Sensor fly lead Checking Speed/Position Sensors Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Additional Sensors/Senders Oil pressure sender CV18339/3 and adapter 3Y-2888 Coolant temperature sender CV18338/5 and adapter OE51375 Speed Sensor CV18338 and Harness CV18965 Coolant Level switch Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Oil Pressure Switch Temperature Switch Coolant Level sensor Additional Engine Sensors/Senders Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Wiring Diagram Customer side (Jack 1) Outputs - may be used to drive lamps or relays. (0.3 A, 1.0 A and 1.5 A) Crank terminate should be a relay to monitor starter motor in the OEM panel Diagnostic lamp, lights when active fault code registered, or any of the outputs are disconnected/open circuit Inputs - injection disable, RPM select, digital speed control, raise/lower, droop/isochronous, etc For full details of inputs and outputs refer to the installation manual (2800,TSL 4262. 2300, TSL 4267) This drawing for indication only! Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active systemfault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input fromLoad Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpmSelect Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Gen-Set Desired Engine Speed/Load Control The software in the ECM provides the flexibility to cater for Four types of control.
Digital Control Pulse Width Modulated Analogue Control CAN J1939 Control Typical Pressure Sensor Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Digital Speed/Load Control Enables speed control by digital load-sharing and synchronizing equipment The Engine can interface directly with manual synchronizing selector switches, relays or push buttons When the ECM is working on Digital Speed Control there are three inputs that can be used. Digital Speed Control Enable Digital Speed Control Ramp Rate Digital Speed Control Raise/Lower Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Digital Speed/Load Control Digital speed control (enable/disable) Lower speed (pushbutton/relay contact) Raise speed (pushbutton/relay contact) Digital speed control ramp rate, (default 10 rpm/sec) This can be adjusted via the Electronic Service Tool Speed adjustment ranges +150 150 rpm Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series PWM Speed Control Intended for use with a customers load-sharing unit The PWM signal 500 Hz, duty cycle 10-90% Speed adjustment 24% to +8% (0% is rated speed) For 50 Hz 1141 to 1621 rpm For 60 Hz 1369 to 1945 rpm Typical Pressure Sensor Note for Calibration: If the PWM input is selected on the configuration screen but not connected on the OEMs side, the ECM will default the speed to 1100, (and log a diagnostic code 91-8)
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Analogue Speed Control Speed adjustment 10% to +10% (0% is rated speed) For 50 Hz 1350 to 1650 rpm For 60 Hz 1620 to 1980 rpm Typical Pressure Sensor Note for Calibration: If the Analogue input is selected on the configuration screen but not connected on the OEMs side, the ECM will default the speed to 1100, (and log a diagnostic code 1690-8) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Analogue Speed Adjustments Resistive track potentiometer Provide linear voltage output (0.5v to 4.5v) Two series resistors keep voltage away from fault region V o l t a g e
o / p
4.5V
-10%
+10%
0.5V Fault Region Fault Region 1500/1800 RPM Rated Speed
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Engine Speed/Ratings Selection Engine Rating,Duties,Speed can be set within limits set by the torque maps The rating of the Engine is selectable via the EST in Configuration The Function will be selected at the time of manufacture or in service via the Electronic Service Tool.
For example: 2300 Series - 2306C-E14TAG2, 2306C-E14TAG3 The ECM has torque limit maps: 1500 rpm prime power 1800 rpm prime power 1500 rpm base load - continuous 1800 rpm base load - continuous 1500 rpm standby maximum power 1800 rpm standby maximum power
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Series Engine Protection There are three alarm levels provided which are defined as: Level 1 - Operator Warning To warn the operator or machine control system of a possible condition within the ECM control system that requires the operators attention. Level 2 Action (called De-rate or Alert) To inform the operator or machine control system to take action to enable the proper control of the system (i.e. to externally de-rate or reduce speed). This is normally used by the OEM to stop the engine. Level 3 Shutdown To inform the operator or machine control system that the ECM has shutdown due to an operating condition reaching an unacceptable level; or if in the critical override condition, that the product is now operating in a condition outside of its scope of supply and may cause injury or be damaged in such a way as to invalidate the warranty
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Protection Device Warning Action Alert Shutdown High Coolant Temp Low Oil Pressure Engine Over-speed Inlet Manifold Air Pressure High Inlet Manifold Air Temp High Fuel Temp
There is not a warning, alert, shutdown on atmospheric it purely logs a diagnostic code, the diagnostic lamp comes on, the oil pressure is then invalid and we trigger the oil pressure lamp and the shutdown Warnings, Action Alert and Shutdown Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Series Lamp Outputs The ECM provides individual outputs to drive warning lamps and/or relays to indicate each of the following fault conditions:
Active Fault Codes (Diagnostics) High Coolant Temperature Low Oil Pressure Over-speed Level 1 (Warning) Level 2 (Action Alert) Level 3 (Shutdown) Lamp Outputs. The outputs have a maximum current value as below. Shutdown and Crank Terminate = 1.5 amps. Action Alert and Warning = 1 amp. Diagnostics, Oil Pressure, Coolant Temperature, Overspeed = 0.3 amps.
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Customer Outputs Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V - Negative + Positive Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Injection Disable/Critical Override When critical override has been enabled in the service tool - the switch when 'open' allows the protection to be over ridden, the switch when closed enables the normal protection - the diagram reads the opposite. The idea was that if you've enabled a feature to over ride protection and the wire drops off then the fail safe results in you being able to run to destruction.
Critical Override Not Recommended, ignores oil pressure, coolant temperature, atmospheric pressure shutdowns when on
Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V + 24 Volts Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Series Switch Inputs 1500/1800 rpm Selection Switch to ground to select 1800 rpm. Enabling of this input is controlled via the Electronic Service Tool (EST) Droop/Isochronous Switch to ground for droop governing. Enabling of this switch input and Percentage droop is set using the EST Fault Reset This switch is used for clearing faults after an engine shutdown, switch to ground for fault reset.(Faults cleared by turning the Ignition Switch off/on)
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Fault Diagnostics Electronic Service Tool (EST) Electronic Diagnostic Device (EDD) Generic Engine Monitor (GEM) Diagnostic Manual TSD 3453 Trouble Shooting Guide (TSG) Perkins Technical Marketing Information (PTMI) Workshop Manual TSD 3450 Installation Manual TSL 4262
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Fault Diagnostics Generic Engine Monitor (GEM 2200) Part Number 2800A003 Compact Robust Module, connects via J1939 CAN Several Languages Analogue Gauges Digital Readout Graphs Active Diagnostic Codes Audible Alarm 12/24 Volt Operation
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 9 Pin (Deutsch) Diagnostic Connector Machine Wiring Schematic, All Options 9 Pin Perkins Data Link Connector Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31 Action Alert Lamp Output Warning Lamp Output Diagnostics Lamp Output J1/28 Oil Pressure Lamp Output J1/29 Coolant Temperature Lamp Output J1/30 Overspeed Lamp Output J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 D E Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser A B G F C Battery 24V DC + - H J Unswitched Battery Positive P1 J1 J1/61 Unswitched Battery Negative J1/63 J1/65 J1/52 J1/53 J1/48 J1/70 Switched Battery Positive J1/3 J1/17 J1/2 Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link - J1939 Screen J1/8 Perkins Data Link + J1/9 Perkins Data Link - J1/55 J1/69 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R B 680R 680R This Wiring Supplied By OEM Shutdown J1/10 Shutdown lamp Output G J1/13 Crank Terminate Output K Crank Terminate (Engine Running Signal) Injection Disable J1/64 Shutdown Emergency Override K J1/62 Injection Disable U Off - Disabled - Stop On - Enabled - Run Off On (Disables Oil & Water shutdowns when on) Off On Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Negative Power Supply to Service Tool Main Battery Feed (Direct from starter/ battery) (ECM latched out) 1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control C T PWM Ground +8V Screen - Unused Used for Diagnostic Code Reader/ Generic Engine Monitor, (CAN) Controller Area Network, SAE J1939 Genset Control Used for Electronic Service Tool Perkins Data Link (PDL) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Engine Diagnostics Electronic Service Tool (EST) computer based. Many functions, reading of temperature, speed, pressures, etc Genuine network only (including some OEMs and Dealers) Configuration settings, histograms, graphing, data log, etc Installing/downloading flash files and full engine diagnostics.
Electronic Diagnostic Device, (EDD). Reads J 1939 Codes, available to anyone. Not a substitute for the EST. Ability to control Engine Speed Remotely Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Electronic Service Tool (EST) An element of TIPSS The Integrated Product Support Solution Common for all future Perkins Engines Hardware and software required Computer/Communications adapter Annual subscription Restricted to genuine networks
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green Diagnostic Fault Codes Active Diagnostic Codes Any fault that is currently Active on the engine. Logged Diagnostic Codes Faults that have occurred, Logged and been repaired. Logged Event Codes Problems Events that could cause permanent damage
110 3
FMI CID Component/circuit identifier Failure mode identifier Engine coolant temperature
E 361-1 High Engine Coolant Temperature (Warning) E 361-2 High Engine Coolant Temperature (Action Alert) E 361-3 High Engine Coolant Temperature (Shutdown) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green This Procedure is only necessary if the Diagnostic Code is present: The engine may run rough, emit white smoke or they may be no noticeable performance effects
If the ECM has been replaced and you are unable to take data from existing ECM, or if repairs have been completed to the engine drive train or possibly replaced Speed/Timing sensors The engine must be running at 1100 rpm for ECM calibration.
261-13 Engine Timing Calibration Required 23/25/2800 Speed/Timing Calibration Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green The probe measures the angular position of the crankshaft and compares this to the measurement coming from the Camshaft Speed/Timing Sensor. The ECM then makes a correction or calibration if necessary 1mm (0.040in) Timing Calibration Probe Installation Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green
Crankcase TDC Ref Point Crankshaft TDC Ref Position Crankcase Calibration access blank plug ECM Calibration ref position Distance between TDC position and ECM Calibration position approx 100/125 mm Calibration slot ECM Timing Calibration Location Position Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Immersion Heater 110V/240V immersion heaters and thermostat. Rated at 1500W, thermostat temperature range of 38 to 49C Immersion Heater Element Position Route harness to avoid heat from the exhaust manifold/turbocharger Thermostat Sensor Connect to: 110/240 Volt Power Supply Immersion Heater Element Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2300/2800 Series Cold Start Mode Timing Advance The ECM provides automatic timing advance in cold weather to compensate for the increased ignition delay of cold fuel and cold air Several conditions exist in cold engines which cause increased white smoke from incomplete combustion Conditions Triggered below 18 Deg C The inlet air is cold. The fuel is cold and does not ignite as easily Longer Ignition delay. The piston, cylinder wall and head are cold. The cold fuel does not burn as rapidly Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 2800 Series Governor Stability - Establish how much governor instability (rpm above and below rated speed) (Increasing governor proportional gain - hunt duration will Increase) (Decreasing governor proportional gain - hunt duration will Decrease) Adjustments 20 rpm below rated speed - adjust min stability and reduce proportional gain 20 rpm above rated speed - adjust max stability and reduce proportional gain Typical 2806 Governor proportional gain - 26,214 (range 1 - 39999) Governor maximum stability factor - 3146 Governor minimum stability factor - 1573 Type in value O and configuration will return to its default value
Note: Altering values can affect steady state and transient speed/response Make sure Overspeed is configured with the EST Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green If you need Technical advice contact our dedicated Engineers
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For URGENT queries only, telephone +44 (0)1733 582858 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 Series End of Course Questions 1. What reference voltage do we use to power the analogue speed adjustment, what are the Jack numbers? 2. What application could use Critical Override? 3. What would happen if I disconnected the oil pressure sensor? 4. What is the description for these fault codes: 110-3/100-4? 5. What could be the cause of the above faults? 6. What is the preferred method of stopping the engine? 7. Name the two sensors that monitor engine speed/position? 8. Will the engine still start with one speed/position sensor disconnected? Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential Green 23/25/2800 Series End of Course Questions (cont/d) 9. What does PWM stand for? 10. What type of Thermistor is in the temperature sensors? 11. What are the Jack connections for the ECM power supply? 12. What voltage would I expect between Jacks A,B,C,on the harness feeding the pressure sensors? 13. What voltage is expected across the temperature sensor plug with the sensor disconnected? 14. Why are diodes fitted across relays in an electronic engine? 15. A pressure sensor power supply open circuit will create which code? 16. How can I achieve 1100 RPM to calibrate the timing?