400SeriesECGInstallationManual400seriesissue3 PDF

Perkins 400D Series
Models 403D-15, 403D-15T,

404D-22, 404D-22T, and 404D-22TA
ECG Electronic Governor

Application and Installation
Guide
TPD1657
Publication TPD1812 Production issue 1. Perkins Confidential: GREEN

Proprietary information of Perkins Engines Limited, all rights reserved. D16
This information is correct at the time of print
Published October 2012.
A&I Manual, Publication TPD1812 Production issue 2. Page 1 of 1

Contents 400D ECG
1.0 Introduction.................................................................................................................................. 3
1.1 APPLICABLE ENGINES ............................................................................................................... 3
1.2 SAFETY.................................................................................................................................... 3
1.2.1 Warning Welding .......................................................................................................... 4
1.2.2 Warning - Electrostatic Paint Spraying ............................................................................ 4
1.2.3 Washing and Painting Processes (Excluding Electrostatic) ............................................ 4
1.2.4 Warning Jump Starting ................................................................................................. 4
2.0 System Principals ........................................................................................................................ 5
2.1 COMPONENT OVERVIEW ............................................................................................................ 5
2.2 ELECTRONIC CONTROL MODULE (ECM)..................................................................................... 5
2.3 PROPORTIONAL ACTUATOR ...................................................................................................... 5
2.3.1 All speed .......................................................................................................................... 5
2.3.2 Operation ......................................................................................................................... 5
2.4 ENGINE SPEED SENSOR ............................................................................................................ 6
2.5 MAP SENSOR ........................................................................................................................... 6
2.6 ENGINE ELECTRONIC COMPONENT LOCATION ............................................................................. 7
3.0 Engine System Power and Grounding Considerations ............................................................... 8
3.1 GROUND CONNECTION TO ENGINE CYLINDER BLOCK.................................................................. 8
3.2 ECM POWER SUPPLY CONDUCTORS ......................................................................................... 8
3.3 ECM POWER SUPPLY RESISTANCE ........................................................................................... 8
3.4 VOLTAGE SUPPRESSION REQUIREMENT ..................................................................................... 8
3.5 ECM BODY TO CHASSIS MAXIMUM POTENTIAL DIFFERENCE ....................................................... 8
4.0 ECM Application Requirements .................................................................................................. 9
4.1 GOOD WIRING PRACTICES .......................................................................................................... 9
4.2 POWER SUPPLY ........................................................................................................................ 9
4.3 ELECTRICAL SYSTEM ECM DETAILS .......................................................................................... 9
4.4 WIRING SHIELDING .................................................................................................................... 9
4.5 VOLTAGE SUPPLY SYSTEM 12V ................................................................................................. 9
5.0 ECG ECM INSTALLATION ....................................................................................................... 10
5.1 ECG ECM MOUNTING ............................................................................................................ 10
5.2 ENGINE ECM VIBRATION ......................................................................................................... 10
5.3 MOUNTING RECOMMENDATIONS............................................................................................... 11
6.0 Speed Sensor installation.......................................................................................................... 13
6.1 FITTING TYPE 1 SPEED SENSOR................................................................................................ 13
6.2 FITTING TYPE 2 SPEED SENSOR................................................................................................ 13
7.0 Speed Control............................................................................................................................ 14
7.1 SPEED CONTROL TYPES ........................................................................................................... 14
7.1.1 Analogue sensor............................................................................................................ 14
7.1.2 PTO configurations ........................................................................................................ 14
7.1.3 Auto Idle (Machine sensed)........................................................................................... 14
7.1.4 MPTS ............................................................................................................................. 15
7.1.5 CAN J1939 .................................................................................................................... 15
7.1.6 Set speed warm up........................................................................................................ 15
8.0 Inputs......................................................................................................................................... 16
8.1 ENGINE PROTECTION INPUT ..................................................................................................... 16
9.0 Outputs ...................................................................................................................................... 17
9.1 REMOTE FAULT LAMP ............................................................................................................... 17
9.2 GLOW PLUG RELAY .................................................................................................................. 17
9.3 ALTERNATIVE OUTPUTS ........................................................................................................... 17
10.0 ECM pin usage ........................................................................................................................ 18
11.0 Wiring Diagrams/Electrical connections.................................................................................. 19
12.0 Trouble shooting...................................................................................................................... 31
12.1 FAULT CODES........................................................................................................................ 31
13.0 System set up requirements.................................................................................................... 33
13.1 HARDWARE REQUIREMENTS. ................................................................................................. 33
13.2 SOFTWARE REQUIREMENTS ................................................................................................... 34
13.3 GETTING STARTED WITH ACT SYSTEM .................................................................................. 34
14.0 ACT Operation and Set-up...................................................................................................... 35
14.1 FILE MENU ............................................................................................................................ 35
14.1.1 Convert ECG Cal to Text ............................................................................................. 35

Contents 400D ECG
14.1.2 Save ECG Cal to File................................................................................................... 35

14.1.3 View Cal File Comments ............................................................................................. 36
14.1.4 Convert Cal File to Text ............................................................................................... 36
14.1.5 View Text File .............................................................................................................. 36
14.1.6 Convert Cal File to Strategy ........................................................................................ 36
14.1.7 Convert a Cal File to a New Strategy (text) ................................................................. 36
14.2 CALIBRATE MENU .................................................................................................................. 36
14.2.1 Change ECG calibration .............................................................................................. 37
14.2.2 Download Cal File to ECG........................................................................................... 37
14.2.3 Compare ECG Call to file ............................................................................................ 37
14.2.4 Change ECG Password............................................................................................... 38
14.3.1 Parameter View ........................................................................................................... 38
14.3.2 Parameter Plot............................................................................................................. 38
14.3.3 Display faults ............................................................................................................... 39
14.3.4 Control strategy ........................................................................................................... 39
14.3.5 Parameter List ............................................................................................................. 39
15.0 CAN Operation ........................................................................................................................ 40
15.1 PARAMETER FORMAT ............................................................................................................ 40
15.2 Lost CAN input signal ..................................................................................................... 40
15.3 Data Frame ..................................................................................................................... 41
15.6.1 PGN 61444 ELECTRONIC ENGINE CONTROLLER 1 - EEC1 ................................................. 41
15.6.2 PGN 61443 ELECTRONIC ENGINE CONTROLLER 2 EEC .................................................. 42
15.6.3 PGN 65271 VEHICLE ELECTRICAL POWER 1 - VEP1.......................................................... 42
15.6.4 PGN 0 (R) TORQUE/SPEED CONTROL 1 - TSC1 ................................................................ 42
15.6.5 PGN 61183 ADDR_CLAIM .............................................................................................. 42
15.6.6. PGN 60159 (R) ADDR_CLAIM ....................................................................................... 42
16.0 ECG Configuration Settings .................................................................................................... 43
16.1 MAP SENSOR CONFIGURATION AND FUEL LIMITING (WHERE FITTED)....................................... 43
16.2 ECG CONFIGURATION CHARTS .............................................................................................. 46

1.0 Introduction 400ECG
1.0 Introduction
This document is intended to provide necessary information for correct installation of the ECG system
into 404D-22TA, 404D-22T, 404D-22, 403D-15T & 403D-15 Industrial engines into an off-highway
machine. This document is work in progress and will be regularly updated; its purpose is to convey
ECG installation information received from various sources.
Perkins Engine Company Ltd expects that there will be some additions and modifications to this
document as the engine platform matures. The Information herein is the property of Perkins and/or its
subsidiaries. Without written permission, any copying, transmission to others, and any use except that
for which it is loaned is prohibited.
The information contained is the best available at the time of authoring to describe the application and
installation requirements of production representative engine and software. During development
stages please ensure the Applications Engineering department is consulted before implementing any
of the features contained within this document.
Early project engines will not have all the features described in this document enabled. Contact the
Electronic Applications Team for latest information on software feature release dates.
1.1 Applicable Engines

404D-22TA
404D-22T
404D-22
403D-15T
403D-15
The following engines listed below are not currently available with electronic governing. If this is a
requirement please contact your local Perkins representative.
403D-17
403D-11
402D-05
1.2 Safety
Most accidents that involve product operation, maintenance and repair are caused by failure to
observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially
hazardous situations before an accident occurs. A person must be alert to potential hazards. This
person should also have the necessary training, skills and tools in order to perform these functions
properly.
The information in this publication has been based upon current information at the time of publication.
Check for the most current information before you start any job. Perkins dealers will have the most
current information.
Improper operation, maintenance or repair of this product may be dangerous. Improper operation,
maintenance or repair of this product may result in injury or death.
Do not operate or perform any maintenance or repair on this product until you have read and
understood the operation, maintenance and repair information.
Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The
warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work
method or an operating technique that is not specifically recommended by Perkins is used, you must
be sure that it is safe for you and for other people. You must also be sure that the product will not be
damaged and / or that the product will not be made unsafe by the procedures that are used.

1.0 Introduction 400ECG
1.2.1 Warning Welding
Welding can cause damage to the on engine electronics. The following precautions should be taken
before and during welding:
Turn the engine OFF.

Place the ignition keyswitch in the OFF position
Disconnect the negative battery cable from the battery. If the machine is fitted with a battery
disconnect switch then open the switch
Clamp the ground cable of the welder to the component that will be welded.
Place the clamp as close as possible to the weld.
Protect any wiring harnesses from welding debris and splatter.
DO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or
any other electronic components in order to ground the welder.
1.2.2 Warning - Electrostatic Paint Spraying
The high voltages used in electrostatic paint spraying can cause damage to on engine electronics. The
damage can manifest itself through immediate failure of components, or by weakening electronic
components causing them to fail at a later date.
Electrostatic painting is not recommended. In circumstances where the engine must be painted using
electrostatic processes, it is necessary to provide technical details of the applied voltage, estimated
current and maximum process exposure time. Electrostatic panting is not permitted without prior
consent.
As a minimum where the electrostatic process characteristics are acceptable it is necessary to use a
common ground for all circuits, including engine sensors, aftertreatment sensors and Glow Plug
control units and all other engine electronic circuits. All pins must be connected to a common ground.
The engine ECM cannot be painted using electrostatic processes.
1.2.3 Washing and Painting Processes (Excluding Electrostatic)
The ECM must not be painted without prior consent. Painting the ECM will reduce heat dissipation
capability of the ECM. Perkins recommends that theECM not be painted. If in special circumstances
the ECM needs to be painted details of chemicals, covering thickness, color and finish must be
provided to ensure compatibility. The flash light and label must remain visable
1.2.4 Warning Jump Starting
Jump-starting an engine can cause higher than normal voltages to appear across the battery
terminals. Care must be taken that this does not exceed the recommended maximum voltage for the
ECM. and engine sensors. The maximum permitted continuous voltage is 16V.

2.0 System Principles 400ECG
2.0 System Principals

A microprocessor based controller processes the signals from the speed sensor and MAP sensor (22T
and 22TA only). The signal received from the speed sensor is then compared to the desired speed
setting. The signal from the MAP sensor provides boost (turbo) pressure monitoring and is used by the
ECM to reduce Free acceleration smoke (FAS )during boost.
The output of the controller is a pulse width modulated(PWM) signal. The output signal drives a
proportional actuator. The actuator converts the signal to an output shaft to move the fuel metering
rack and it is proportional to the duty cycle of the pulse width modulated signal.
2.1 Component Overview

The main components of the ECG system are listed below and shown in Fig 2.1:
Controller (ECM) (1)

Proportional Actuator (2)
Speed sensor (3)
Manifold Absolute Pressure (MAP) Sensor (4) -optional for turbocharged engines.
Fig 2.1.
2.2 Electronic Control Module (ECM)

The ECG ECM is an electronic control device that, via an electronic actuator, governs engine speed
and in some cases torque dependant upon information received from input sensors. The ECM should
be mounted off the engine following the guidelines in this document. The device has two connections
sockets J1 and J2, refer to wiring specifications diagrams/schematics for details, there are no
permanent 12volt positive supplies required to the ECM when not in use.
2.3 Proportional Actuator

The engine fuel system comprises of lift pump and the electrically controlled governed (ECG) high-
pressure inline fuel Injection pump. The ECG ECM controls fuel delivery to the Injectors by controlling
a fuel-metering actuator valve. The high-pressure fuel pump provides high-pressure fuel to the
Injectors, the quantity determined by a number of ECG ECM inputs, including: Throttle position sensor
(desired speed), engine speed and Manifold pressure (Turbo systems).
2.3.1 All speed

The engine is governed by an 'All Speed Governor', also known as a Variable Speed Governor. Fig
2.2 illustrates the torque and speed characteristics of this governor.
2.3.2 Operation
The All Speed Engine Governor will attempt to hold a constant engine speed for a given throttle
position. The governor senses engine speed and meters the fuel supply to the engine such that the
engine speed remains constant or varies with the load in a predetermined manner.
The all speed governor is also known as 'variable speed' or 'full range engine speed governor'. All
speed refers to the fact that the engine governor operates across the full engine speed operating
range.

The governor strategy has control parameters classed as governor gains, which determine the engine
response and engine stability. These gains are 'tuned' by Perkins to ensure that they are configured
for optimum performance under both steady state and transient conditions. As these requirements
vary from one application to another it maybe necessary to conduct further tuning to obtain optimal
performance for a particular machine.
Under default conditions the engine is set to operate with isochronous governing across the engine
speed range, during which the engine fuelling is bound by the mechanical torque curve. Note that the
engine may not be capable of reaching the mechanical torque curve in some circumstances. For
example, if the turbocharger is not providing the required boost pressure, then
the fuel will be limited so that the engine does not emit black smoke when Intake Pressure Fuel control
(IPFC) is activated.
Fig 2.2
2.4 Engine Speed Sensor

The engine is fitted with a speed sensor. It is mounted on the engine flywheel housing to measure the
engine crankshaft speed. The crankshaft speed sensor is a inductive pick-up type sensor, which
targets the engine flywheel starter ring gear teeth. The ECM is programmable to measure the number
of pulses received from the sensor and then determine engine speed. The engine uses the speed
sensor on cranking and engine running.
operation.** If the crankshaft speed signal is lost during engine running or cranking then the engine will
stop/fail to start.
2.5 MAP sensor

The engine air system may contain an Intake Manifold Pressure Sensor (MAP) also called boost
pressure sensor. The intake manifold pressure sensor measures the air pressure inside the intake
manifold, after the turbo.
The sensor is used to determine pressure within the manifold and then return a signal relative to the
manifold pressure to the ECM as a monitored input. The MAP sensor input is used as a parameter to
calculate air fuel ratio limits where a reduction in turbo free acceleration smoke is required.
If the MAP sensor return signal exceeds set parameters (such as open or short circuit) a default value
is used by the software resulting is less effective control of fuel air ratio and acceleration smoke. A

fault code will be returned if MAP sensor return signal is exceeding set parameters. If the ECG system
is to be fitted retrospectively then procedures need to be followed to remove the mechanical boost
control system (22T and 22TA only).
2.6 Engine Electronic Component location
Crankshaft speed sensor Flywheel housing

Manifold pressure sensor Inlet manifold housing
Electronic Actuator- Rear of injector pump
ECM- Customer location (see mounting locations)

3.0 Engine System Power and Grounding considerations 400ECG
3.0 Engine System Power and Grounding Considerations

3.1 Ground Connection to Engine Cylinder Block.
An engine cylinder block ground point is required on all machines in addition to the engine starter
motor ground, which also requires a separate ground connection. It is important to avoid system
ground potential differences. The maximum potential difference between ECM switch to ground
references and the cylinder block is 1V. The ECM ground connections must be separate from the
cylinder block and must be routed directly to the battery.
3.2 ECM Power Supply Conductors

To prevent voltage drop, avoid sharing and feeding the engine ECM supply circuit with or via other
machine component circuits.
The minimum recommended conductor cross-section for each ECM pin is from (1.5mm)
AWG16 to (1.0mm) AWG18.
The maximum recommended end of life resistance for the total circuit, including positive and
negative conductors is 50mOhms.
When calculating the resistance of a circuit it is important to consider the resistance of the cable and
connection points of the entire circuit.
3.3 ECM Power Supply Resistance

The recommended machine end of life total ECM power supply circuit resistance is 50mOhms. Perkins
advise a target resistance of 40mOhms.
3.4 Voltage Suppression Requirement

The ECM must be protected against high voltage spikes, also known as load dump. The factory fitted
Alternators are fitted with load dump protection as standard to protect the engine ECM. Load dump
protection protects against high transient voltages sometimes seen when switching
inductive components in the system circuit. The factory fitted alternators protect for voltages higher
than 25V-30V depending on the alternator selected.
If an alternator is not used or a non-standard alternator is selected the engine electrical system must
be designed to provide load dump protection for the engine ECM. The maximum permissible transient
voltage measured at the ECM is 30Vdc.
3.5 ECM Body to Chassis Maximum Potential Difference

The measured potential difference between the ECM body and ECM battery ground should be kept to
a minimum. Ideally there should be no difference.
The maximum permissible difference is 1V.

4.0 ECM Application Requirements 400ECG
4.0 ECM Application Requirements

4.1 Good wiring practices
Good wiring practices include: routing signals separated by type, keeping power & signals separated,
and twisting signal/return pairs as well as power & return pairs. Engine speed signal, MAP sensor and
variable speed input wires must be grounded as close to terminal J1-04 as possible. Wiring shielding
is to be used as indicated on the wiring diagrams.
4.2 Power Supply

The ECG ECM requires no permanent electrical power feed when not in use. A key switched fused
12v supply is to be used to power up the ECG system
The ECG power source is to be direct from the battery (via fuse/switch) to minimize volt drop losses to
the system when engine cranking.
System fuse rating is slow blow 10amp (@ 12v)
4.3 Electrical System ECM Details

The ECG ECM has working range of 9 to 30 Vdc reverse polarity protected, however, the actuator
restricts the working voltage to 9-15Vdc.
4.4 Wiring shielding

Wiring shielding is to be used as per wiring diagrams and are to be grounded near to ECM plug J1 pin
04.
4.5 Voltage Supply System 12V

Minimum ECM Voltage 9V,
Maximum ECM Voltage 15V
Reverse polarity protected.

5.0 ECG ECM Installation 400ECG
5.0 ECG ECM INSTALLATION

5.1 ECG ECM Mounting
To ensure best endurance for both mechanical vibrations and humidity the ECG ECM must be
mounted in accordance with requirements listed below and precautions illustrated in Fig 5.1. Details
of the ECM dimensions are shown in Fig 5.2.
Fig 5.1
The ECM must be mounted off Engine

The ECG ECM must be located so that :
The operating temperature is maintained between - 40 and + 185 F ( - 40 to +85
C).
The vibration does not exceed 6 Gs from 40 to 2000 Hz. Vibration isolation should
be used if required.
It is protect the from direct exposure to impact or abrasion.
There is adequate space around the unit for servicing and wiring.
The ECG unit and associated wires must not be installed near high-voltage or high-current
vices. If this is not possible then the unit and all connected and associated wires must be
appropriately shielded..
The cable from the ECM must be secured using a suitable P clip.
The ECM must be orientated to ensure no fluid is allowed to build on the surface of the ECM
or allowed to track into the
5.2 Engine ECM Vibration

The ECM is designed for chassis or frame mounting. The vibration levels produced by the engine
exceed the limits of the ECM design and therefore it is essential that the ECM should be mounted
away from the engine and any associated components with the same vibration profile.
Under no circumstances should the ECM be mounted to the engine.

5.3 Mounting Recommendations
Hard Mounting
Hard mounting the ECM is the preferred method, providing the vibration environment is suitable. If
there is an existing isolated structure in the application such as a cab or operator platform then that
may provide the lowest vibration environment for the ECM. Where possible mounting brackets should
be avoided, direct mounting to stiff structures is recommended. If this is not possible the bracket
should be of a stiff design. Avoid mounting on large flat panels such as fuel tanks or engine covers,
particularly in the centre, to avoid any panel resonances.
Isolation Mounting
If a suitable hard mounting location cannot be found, then isolation (iso) mounts may be considered to
reduce the vibration input to the ECM. The development of a suitable isolation system may be more
difficult however. The iso mounts must be optimized to the mass and mounting orientation of the
ECM, and the application inputs.
Measurement Method
A Power Spectrum Density (PSD) measurement is required for each installation.
Vibration data should be measured on the ECM in positions defined by the test procedure. A vibration
profile for the application should be created based on a combination of several typical operating
conditions. Data should be gathered for each
of the three orthogonal axis of the ECM, vertical, axial (fore-aft), and transverse (side-side). The levels
from several typical operating conditions should be measured. These may then be combined into a
composite typical vibration profile for that application.
The exact operating conditions should be reflect typical machine use, and be repeatable.
Please contact your Application Engineer for details of the measurement points.

Fig 5.2 Controller dimensions

6.0 Speed Sensor Installation 400ECG
6.0 Speed Sensor installation

Speed sensor installation is critical in order to prevent permanent damage to sensor and erratic
performance or non start situations.
There are currently two types of speed sensors that may be fitted.
1. External thread 3/8-24 UNF with protruding inductive tip and thread adaptor ring.
2. External thread M18x1.5 with flush inductive tip
Both types of sensor have a threaded locking ring to secure the sensor in correct placement. Sensor 1
requires the flywheel tooth to be in line with threaded hole where the sensor is to be fitted, as light
contact between the flywheel tooth tip and the sensor inductive tip will be used as an initial reference
point for clearance gap setting.
6.1 Fitting type 1 speed sensor.

Fit thread adaptor into flywheel housing and tighten. Carefully screw speed sensor into adaptor until
light contact with top of flywheel tooth is obtained. Unscrew sensor back (away from tooth) by of a
turn and lock into position using locking ring.
When all system connections are complete and if fitment of sensor is successful then ECM lamp
should illuminate on cranking, if this is not the case the sensor should be screwed in a further 1/16th of
a turn and test again. Repeat as necessary, but do not screw sensor in more than 3/16th of a turn in
total. Use the locking ring to secure sensor in place after every adjustment. If using feeler gauges a
gap of 0.25mm should be set.
6.2 Fitting type 2 speed sensor.

Carefully screw speed sensor into adaptor until light contact with top of flywheel tooth is obtained.
Unscrew sensor back (away from tooth) by 1/2 of a turn and lock into position using locking ring to
tightening torque of 37NM +/- 4NM.
When all system connections are complete and If fitment of sensor is successful then ECM lamp
should illuminate on cranking. If using feeler gauges a gap of 0.75mm should be set.

7.0 Speed Control 400ECG
7.0 Speed Control

It is necessary to select a device that converts the desired speed of the engine operator or controller to
an electronic signal recognized by the ECM.
The speed demand type must be carefully considered and be appropriate for the application. The
options must be selected at the time of order so that the ECM will be configured correctly for the
control device selected. Consult your Applications Engineer for more information.
7.1 Speed control types

There are five types of speed demand input:
1. Analogue sensor*
2. PTO (cruise control / set speed) or Auto idle.
3. Multi-position throttle switches (MPTS) / Rotary switch
4. CAN J1939 interface (TSC1 1939)
5. Machine sensed auto idle
7.1.1 Analogue sensor

Analogue sensors should use non-contact Hall effect technology within a set voltage range. A voltage
above or below this range will indicate an open or short circuit.
A robust potentiometer contact sensor (throttle sensor) designed for use in vehicles may also be
considered. A resistance value of 3-5k is recommended.
* Under no circumstances should ordinary carbon track or wire wound potentiometers be used as they
will not be reliable.
If an idle verification switch (IVS) is configured in conjunction with sensor, and analogue sensor and
IVS inputs do not agree, the engine speed will operate at 10% of actual position of analogue sensor
input.
Analogue input parameters may be preset for volume production.
To calibrate the analogue sensor refer to System Set up section 13 of this guide and Mode settings
on page 47. Once in mode 255 run the throttle sensor through its full range of travel, the system file
will automatically learn and store the range values in its memory.
7.1.2 PTO configurations

PTO configurations can be set to switched inputs to allow:
Engage PTO function (disengage variable speed inputs)
Ramp up speed (speed raise button)
Ramp down speed (speed lower button)
The rate of ramp-up / ramp down speed can be configured, as can requested rate of speed change.
Setting must be specified at time of order.
As a safety feature, when the engine is initially turned on, the mode is assumed to be PTO OFF
regardless of the PTO switch setting. Users have to cycle the PTO switch OFF and then back ON
to enable PTO input.
An auxiliary output for indicator lamp may be used to indicate PTO on mode. This lamp could also be
used for fault indication and would differentiate between PTO on and fault read by signal type
output (flashing/permanently on)
7.1.3 Auto Idle (Machine sensed)

Note: In this instance the IVS pin is used as a machine switched system to indicate there is a no
load status and cannot be used in conjunction with analogue speed idle conformation.
Auto-idle mode is a configurable switchable function and is possible as a set speed (Normally idle)
input. When selected, the engine speed will reduce to a set (idle) speed when the idle verification
(machine function) is active after a set ramp down time, for instance, when machine has not been

7.0 Speed Control 400ECG
used for specified time. Once load has been detected the pre-determined speed will be resumed.
This function is not an option if MPTS (Multi position Throttle switch) speed control is a selected.
7.1.4 MPTS
MPTS (Multi position throttle switch) or rotary switch configuration can be set to switchable inputs to
allow up to four pre-determined engine speeds (these speeds must be specified at time of order), The
rate of engine speed change (ramp up/down rate) can be also configured between selected speeds
(rate of speed change may be adversely affected by engine load). Refer to wiring diagrams to ensure
correct switch configuration. In order to incorporate these switched inputs, determine the speed mode
that is required for the application.
7.1.5 CAN J1939

CAN J1939 interface is also possible using TSC1. CAN communications require the use of
appropriately rated cable and each end of the communication bus to be terminated with two 120 Ohms
from CANH to CANL at their ends.
7.1.6 Set speed warm up

Within the configurable software is a set speed warm up this feature will hold the engine at a pre-
determined speed for a pre-determined time after start up.

8.0 Inputs 400ECG
8.0 Inputs
Several supply inputs may be required (power and switched), power on supply from the power switch
must take priority to pin J1-09 for volts positive. Ground supply for ECM (J1-04) must be direct from
the battery. All other inputs to the ECM requiring a ground or positive battery supply must be suitably
connected to the supplying cable (after fuse and power on switch for positive) or close to the ECM pin
for the supplying ground.
8.1 Engine protection input

Controlled shutdown for engine protection can be configured by a switchable ground input to J2-09 in
the event of engine system failure such as below threshold oil pressure or engine temperature
overheating. These input switches can be set in parallel so if any one of them exceeds parameters the
engine will shut down. Engine protection shutdown will cause the governor actuator pin to move to a
position of zero fueling, it will not switch off the ECM.

9.0 Outputs 400ECG
9.0 Outputs
Other than the ECM output to the electronic governor, various auxiliary output configurations are
possible, however the maximum current draw on each auxiliary output is 200ma.
9.1 Remote fault lamp

A remote fault lamp can be configured using an auxiliary output, this output can be varied to display
different features such as Flashing = fault , On= PTO selected or Auto Idle selected.
9.2 Glow plug relay

The ECM can also be configured to control a glow plug relay (controlled via output from pin J2-04 max
current draw 200ma), switching the relay for a pre-determined time dependant upon on/off signal input
to pin J2-09, however to prevent damage to the glow plug system, please contact your Perkins
application engineer for further information.
9.3 Alternative outputs

Details in 9.1 and 9.2 are typical uses for outputs from ECM, however they are not limited to these
functions and can be tailored to individual customer needs.

10.0 ECM pin usage 400ECG
10.0 ECM pin usage

The pin usage shown in Table 10.1 shows how ECM pins are allocated to particular inputs and
outputs. Due to the number of possible applications present there are in some cases a pin use Clash.
Whilst it is necessary in the case of Ground and battery fed 12v positive to have several connections
near to the ECM pin, it would not be possible to have signal wires (input or output) used for
multipurpose connections. Therefore careful consideration must be given to application essentials and
desirables to ensure there is no pin clash when choosing possible options.
Due to the versatility of the ECM a good range of input and output combinations are available, consult
your Perkins Application Engineer to enable best application for you machine

11.0 Wiring Diagrams/Electrical connectors 400ECG
11.0 Wiring Diagrams/Electrical connections

Wiring diagrams given on the following pages are examples only.

11.0 Wiring Diagrams/Electrical connectors 400ECG
Table 11.1

400 series ECG
ECM J1 & J2 Connector
400ECG
OFF
4
Page 21 of 22
ON
START 1 1.5mm (16AWG)
J1-09 KEY SWITCH (TERMINAL 15)
IDLE VERIFICATION SWITCH 1.0mm (18AWG) J2-05 IDLE VERIFICATION
1.5mm (16AWG)
GROUND AUX
2 OUTPUT 1.0mm (18AWG) J2-03
AUX 2 MAX 200mA DRAW
GROUND SWITCHED OUTPUT
START 3 Optional remote fault
code lamp
J1-01 COMMS TOOL CONNECTION
IGNITION KEY J1-11 COMMS TOOL CONNECTION
1.5mm (16AWG)
SWITCH J1-12 COMMS TOOL CONNECTION

1.0mm (18AWG)
J1-10 SPEED SENSOR INPUT (POS)
Speed sensor
J1-03 SPEED SENSOR INPUT (NEG)
1.0mm (18AWG)
Can 1939. J1-06 CAN LOW J1939
Optional speed
SPEED 4
input J1-07 CAN HIGH J1939
SWITCHED
SPEED
CONTROL
(optional) SPEED 3 1.0mm (18AWG)
J2-07 SPEED CONTROL 1 OPTIONAL
10 AMP
SLOW BLOW
A&I Manual, Publication TPD1812 Production issue 2.

SPEED 2 1.0mm (18AWG)
11.0 Wiring Diagrams/Electrical connectors
SPEED 1 - NO CONNECTION
1.0mm (18AWG) J2-11 5V REF
VARIABLE
+ - SPEED
CONTROL
1.0mm (18AWG)
1.0mm (18AWG)
J2-12 SPEED DEMAND SIGNAL
(optional) J2-02 SIGNAL RETURN
1.5mm (16AWG)
J1-04 BATTERY NEGATIVE SUPPLY
12v BATTERY (1)
SENSOR
1.0mm (18AWG) RETURN
1.0mm (18AWG) J2-01 MAP SIGNAL
MAP
1.0mm (18AWG)
J2-10 MAP SENSOR SUPPLY
60ma quick
To Glow Plugs blow
GLOW PLUG RELAY 1.0mm (18AWG) J1-05 GOVERNOR OUTPUT POS
Actuator 1.0mm (18AWG) J1-08 GOVERNOR OUTPUT NEG
1.0mm (18AWG) or 1.5mm (16AWG) AUX 2 MAX 200mA DRAW
J2-04 COLD START CONTROL
1.0mm (18AWG) J2-09 TEMPERATURE SWITCH
Fig 11.1
NB: All options shown cant be used simultaneously
400 series ECG SYSTEM USING ANALOGUE
ECM J1 & J2 Connector DESIRED ENGINE SPEED
INPUT & PTO INPUT
OFF
4
400ECG
ON
Page 22 of 23
GROUND AUX
1.0mm (18AWG)
1.5mm (16AWG)
OUTPUT
J2-03
2 Optional remote fault GROUND SWITCHED OUTPUT
1.0mm (18AWG)

START 3 code lamp
IGNITION KEY
1.0mm (18AWG)
Speed sensor
1.0mm (18AWG)
PTO RAMP UP 1.0mm (18AWG) J2-08 PTO RAMP UP
PTO RAMP DOWN 1.0mm (18AWG) J2-07 PTO RAMP DOWN
10 AMP
SLOW BLOW
PTO ENGAGE/DISENGAGE ANALOGUE CONTROL 1.0mm (18AWG) PTO ENGAGE/DISENGAGE
J2-06 ANALOGUE CONTROL

J1-06 CAN LOW J1939
J1-07 CAN HIGH J1939

1.0mm (18AWG) J2-11 5V REF
VARIABLE
+ - SPEED
CONTROL
1.0mm (18AWG)
1.0mm (18AWG)
1.5mm (16AWG)
12v BATTERY (1)
SENSOR
MAP 1.0mm (18AWG)
60ma quick
To Glow Plugs blow
ACTUATOR 1.0mm (18AWG) J1-08 GOVERNOR OUTPUT NEG
Fig 11.2
400 series ECG
SYSTEM USING SWITCHABLE
FOUR SPEED INPUT
400ECG
OFF
4
ON
Page 23 of 24
GROUND AUX
OUTPUT 1.0mm (18AWG) J2-03
Optional remote fault GROUND SWITCHED OUTPUT
1.5mm (16AWG)
2 code lamp
START 3
1.5mm (16AWG)

1.0mm (18AWG)
Speed sensor
1.0mm (18AWG)
Can 1939. J1-06 CAN LOW J1939
Optional speed
SPEED 4
input J1-07 CAN HIGH J1939
SWITCHED
SPEED
CONTROL
(optional) SPEED 3 1.0mm (18AWG)
10 AMP
SLOW BLOW

+ -
1.5mm (16AWG)
12v BATTERY (1)
SENSOR
MAP
1.0mm (18AWG)
60ma quick
To Glow Plugs blow
Fig 11.3
400 series ECG SYSTEM USING SWITCHABLE
400ECG
TWO SPEED INPUT AND MACHINE

SWITCHED AUTO IDLE
Page 24 of 25
OFF
4
ON
GROUND AUX
OUTPUT 1.0mm (18AWG) J2-03
Optional remote fault GROUND SWITCHED OUTPUT
1.5mm (16AWG)
2 code lamp
START 3
1.5mm (16AWG)

1.0mm (18AWG)
Speed sensor
1.0mm (18AWG)
J1-06 CAN LOW J1939
IDLE VERIFICATION SWITCH
MACHINE SENSED
J2-05 IDLE VERIFICATION
10 AMP
SLOW BLOW

AUTO IDLE SWITCH

J2-07 AUTO IDLE SWITCH
+ - SWITCHED
SPEED
CONTROL
J2-08 SPEED CONTROL 2 OPTION
(optional)
1.5mm (16AWG)
12v BATTERY (1)
SENSOR
MAP
1.0mm (18AWG)
60ma quick
To Glow Plugs blow
Fig 11.4
400 series ECG Analogue speed control and
ECM J1 & J2 Connector idle verification
400ECG
OFF
4
Page 25 of 26
ON
1.5mm (16AWG)
GROUND AUX
code lamp
1.5mm (16AWG)

1.0mm (18AWG)
Speed sensor
1.0mm (18AWG)
J1-06 CAN LOW J1939
MACHINE SENSED J2-05 IDLE VERIFICATION
10 AMP
SLOW BLOW


1.0mm (18AWG) J2-11 5V REF
VARIABLE
+ - SPEED
CONTROL
1.0mm (18AWG)
1.0mm (18AWG)
1.5mm (16AWG)
12v BATTERY (1)
SENSOR
MAP
1.0mm (18AWG)
60ma quick
To Glow Plugs blow
Fig 11.5
400 series ECG Analogue speed control and
ECM J1 & J2 Connector idle verification
400ECG
OFF
4
Page 26 of 27
ON
1.5mm (16AWG)
GROUND AUX
code lamp
1.5mm (16AWG)

1.0mm (18AWG)
Speed sensor
1.0mm (18AWG)
J1-06 CAN LOW J1939
MACHINE SENSED J2-05 IDLE VERIFICATION
10 AMP

SLOW BLOW

1.0mm (18AWG) J2-11 5V REF
VARIABLE
+ - SPEED
CONTROL
1.0mm (18AWG)
1.0mm (18AWG)
1.5mm (16AWG)
12v BATTERY (1)
SENSOR
MAP
1.0mm (18AWG)
60ma quick
To Glow Plugs blow
Fig 11.6
01 01
400ECG
3 3
02 02
Page 27 of 28
+ +
03 03
04 04
J1 05 J1 05
06 + 06 +
Grey 2 2
07 07
08 5 4 08 5 4
+ +
09 09
10 10
11 11
12 12
(1) J1 & J2 connector

1 1
(2) Actuator
01 01
(1) J1 & J2 connector (3) Speed sensor
02 Return
02
6
03 (2) Actuator 03 (4) Battery
04 04
(3) Speed sensor
6 (5) ECM power on switch
J2 05
J2 05
06 (4) Battery 06 (6) Variable speed control
Black
07 07
5V Ref
(5) ECM power on switch
08 08
Signal
09 (6) Speed selection switch 09
10 10
11
Two speed wiring 11
Variable speed wiring
12
diagram 12
diagram
(Non 22T or TA) (Non 22T or TA)
Fig 11.7
400ECG
01 01
3 3
02 02
Page 28 of 29
+ +
03 03
04 04
J1 05 J1 05
06 + 06 +
2 2
07 07
08 5 4 08 5 4
+ +
09 09
10 10
11 11 (1) J1 & J2 connector
12 12
(2) Actuator

1 1 6
(3) Speed sensor
(2) Actuator Remote lamp
01 01
(4) Battery
(3) Speed sensor
02 02
03 03 (5) ECM power on switch
(4) Battery
04 04
6 Over temperature switch (6) Remote lamp
J2 05
J2 05
(7) Engine protection
06 Glow plug relay (6) Glow plug realy
06 7 switches
07 07 Oil pressure switch
(7) Engine temperature switch
08 08
7
09 09
Temperature switch
10 10
11 11
Single set speed with engine
Single set speed with glow plug relay protection and remote lamp
12 12
output and temperature switch
Fig 11.8
400ECG
01 01
Page 29 of 30
3 3
02 02
+ +
03 03
04 04
J1 05 J1 05
06 + 06 +
2 2
07 07
08 5 4 08 5 4
+ +
09 09
10 10
11 11 (1) J1 & J2 connector

12 12
(2) Actuator

1 1 6
(3) Speed sensor
(2) Actuator Remote lamp
01 01
(4) Battery
(3) Speed sensor
02 02
03 03 (5) ECM power on switch
(4) Battery
04 04
6 Over temperature switch (6) Remote lamp
J2 05
J2 05
(7) Engine protection
06 Glow plug relay (6) Glow plug realy
06 7 switches
07 07 Oil pressure switch
(7) Engine temperature switch
08 08
7
09 09
Temperature switch
10 10
11 11
Single set speed with engine
Single set speed with glow plug relay protection and remote lamp
12 12
output and temperature switch
Fig 11.9
01 01
400ECG
3 3
02 02
+ +
Page 30 of 31
03 03
04 04
J1 05
+
J1 05
06 2 06 +
6 2
07 07
08 4 08 5 4
+ +
09 09
5
10 10
11 11
12 12
(1) J1 & J2 connector (1) J1 & J2 connector

(2) Governor
1 1
(2) Governor (3) Speed sensor

01 01 (4) Battery
(3) Speed sensor SWITCHED
SPEED
02 CONTROL
(optional)
02 (5) ECM power on switch
03 (4) Battery 03
(6) Switchable speed input
04 04 SPEED 4
7 SWITCHED SPEED
J2 05
(6) J1939 TSC1 CAN J2 05 CONTROL (optional)
06 Speed Control 06 6
07 (7) MAP sensor 07 SPEED 3
(Applicable on 404D-
08 22T &TA only) 08
SPEED 2
60ma quick
09 blow 09
Speed 1
10 10 (No connection)
11 11
Variable speed using Switchable Four speed
12 12
CAN J1939 TSC1 input. wiring diagram
Fig 11.10
12.0 Trouble Shooting 400ECG
12.0 Trouble shooting

All checks are to be carried out by a competent engineer.
Battery voltage supply to the ECM must be checked at power on and during cranking to
ensure ECM supply voltage does not fall below parameters.
Check wiring connections are clean and securely fitted.
Check actuator pin is free moving and clear of contamination.
If no signal is received from Speed sensor, and system had previously been operational,
check sensor pick-up tip for contamination.
Failure to adequately fuse protect the MAP 5v reference wire may result in
permanent ECM damage, never replace the fuse until fault cause has been rectified.
12.1 Fault codes

The ECM is capable of identifying certain fault conditions and alerting the user to them. A flashing LED
indicates the fault condition. The flashing LED is located on the casing of the ECM, however an LED
may be mounted remotely using an ECM output. The fault code list is shown in table 12. before
checking fault codes in table 12 please note the following:
No flash will be displayed if the ECM has a power supply failure.

When power is first applied to the ECM, the LED will flash once for one second to indicate the
power is on and LED is working.
If there are multiple faults, the LED will flash them in sequence. Count all the flash codes to
determine fault codes.
If there are no faults recorded, the LED will flash once and from then on will indicate the
detection of engine speed signal (engine cranking and running).
The controller will attempt to shutdown when some faults are encountered and may not permit
starting with faults 1,5 and 8 on Table 12 below.

12.0 Trouble Shooting 400ECG
Table 12.

13.0 System set up requirements 400ECG
13.0 System set up requirements

System configuration and PID set-up require the use of hardware (computer, interface module and
communications lead) and a software programme known as ACT. Higher volume orders may be
supplied with pre-configured ECM,s once specifications have been agreed and application testing has
been conducted.
The information on the following pages is to be used in conjunction with the Mode configuration and
calibration charts shown on page 47 onwards. Failure to use correct settings may result in engine
damage.
13.1 Hardware Requirements.

ACT interface tool and break out leads
PC compatible computer with serial communications port or suitable serial port to USB adapter
(USB1.1 or 2.0 RS232 Converter) and Windows 95/98/ME/2000/XP/Vista operating system
(Act has not been completely tested and verified under Vista and windows 7)
64 of available RAM memory and hard disk with at least 4MB of free disk space.
SVGA capable video card and screen/monitor capable of 256 colours and 800 x 600 display.
Fig 13.1

13.0 System set up requirements 400ECG
13.2 Software Requirements

The ACT software resides on the PC and communicates through the interface module to the ECM via
a breakout lead on J1 grey plug.
ACT software is available for download to your PC, contact your Perkins dealer/distributor for further
information. A pop up display box will require you to input which computer port is to be used to
communicate with ACT.
Important: Ensure power to your ECM is switched off before connecting the ACT and computer
interfaces
13.3 Getting Started with ACT System

Once software has been loaded onto the computer and all connections are complete as per diagram
13.31, switch on the power supply to ECM and click on software icon on the computer, no information
can be uploaded, viewed or downloaded until power supply to ECM is complete.
Connection Established Connection Not Established

14.0 ACT Operation and set-up 400ECG
14.0 ACT Operation and Set-up

Note; in the following sections, calibration file is referred to as Cal File and the ECM as ECG
Unless already pre-programmed to a required specification, the ECG will require a set up depending
upon inputs/outputs being used and general configuration of system. The current set up can be viewed
clicking File Save ECG file to TextEnter file save destination, this displays file current file in the
ECG, details of these instructions can be found later in this section. It is recommended that the virgin
file is saved on you computer and can be referred back to if required. The system prompts the
operator to save data under a file name and add comments to that file, this is particularly useful when
fine tuning the system to note engine behavior.
Caution: Take care when changing ECG parameters to ensure settings to not exceed engines
capability i.e; max speed.
14.1 File menu

The File Menu allows you to perform operations related to viewing, saving and converting files.
Note: Cal files saved are in binary form and not directly readable as text
Text files are saved in text form and not readable by ECG.
The following commands are available under the File Menu.

Save ECG Cal to File
View Cal File Comments
View Text File
Convert ECG Cal to Text
Convert Cal File to Text
Convert Cal File to Strategy
14.1.1 Convert ECG Cal to Text

File Convert ECG Cal to TextEnter your text file nameOK
This allows you to save the current ECG file in text form, but is not recognizable in its current format as
a file that can be sent back to the ECG
14.1.2 Save ECG Cal to File

File Save ECG Cal to FileEnter your file nameClick save.
This command allows you to save ECG calibration data to a designated file and add Cal File
comments (see view CAL file comments). This file format is only recognizable by ECG.

The ACT uploads the calibration set from ECG and saves it to a computer ACT file. This operation is
usually done after the controller has been calibrated for satisfactory engine performance but can also
be done at any othertime. The data is saved in a binary file format
14.1.3 View Cal File Comments

This command allows you to display the comments that are attached to a calibration file. Users add
comments when saving a calibration file. The comments help in tracking specific engine, application,
and environment data for which the calibration file was created.
14.1.4 Convert Cal File to Text

FileConvert Cal File to TextSelect fileopen
This allows a saved binary Cal File to be saved as a separate text file and be viewed in text format and
if required printed. A text format file cannot be downloaded to ECG.
14.1.5 View Text File

File View Text FileChoose file to viewOpen
This command allows you to view a saved text file, displaying calibration features including PIDs
14.1.6 Convert Cal File to Strategy

File Convert Cal File to StrategyEnter file to send to ECG
This command is used to convert old ACT files for use with controllers that have a different control
strategy version. ACT will Parse through all of the calibration parameters in the old ACT file and
search for the same calibration parameters in the new ACT file and assign values from the old
calibration.
14.1.7 Convert a Cal File to a New Strategy (text)

FileConvert Cal File to StrategyEnter name
ACT will read all of the calibration values from the controller create and save a text file with the
parameter names, values, and units, then display the file using the default text viewer.
14.2 Calibrate Menu

The Calibrate Menu allows you to perform operations related to ECG
calibration. The following commands are available:
Change ECG Calibration*
Download Cal File to ECG*
Compare ECG Cal to File Cal
Change ECG Password*
Calibration Wizard*
(*) These commands can be password protected to prevent unauthorized calibration changes. See
Change ECG Password for more information.

The data sheets 14.2A shows a list of configuration options and a description, explanation and mode
settings that may require entering when changing calibration settings, at any point when setting theses
configurations on the ACT system there is a help hot-key F1. Within the Spreadsheet there is a
reference to Mode, this is required for the ECG to recognize types of input required ie; CAN speed
input, switched speed input and number of switched speeds, if warm up time is required and Units for
how long to stay in warm up configuration etc.
14.2.1 Change ECG calibration

All adjustments are stored immediately in non-volatile memory in the ECG
unit. The ECG controller will retain the changes even if power is lost or the
ACT is disconnected.
CalibrateChange ECG CalibrationView filter(drop down menu)Highlight

parameter to view/changeChange parameter value if reqdEnter.
The new value is written to the controller and then read back, with the result placed in the ECG Value
field.
14.2.2 Download Cal File to ECG

The Download Cal File to ECG command allows you to download the entire calibration set from a file
to the ECG permanent memory. This is convenient one-step method for:
Reverting back to a known good calibration set after experimenting with
new calibration settings
Programming multiple ECG units for a particular application
The downloaded file may have been previously configured and calibrated for satisfactory engine
performance with another ECG unit.
14.2.3 Compare ECG Call to file

This command lets you check the differences in calibration sets between a saved file and the ECG
unit. The feature is useful, for example, to ensure that the saved file matches the calibration in the
ECG unit.
CalibrateCompare ECG file to CalSelect fileOK
Once all parameters have been processed, a message box will list the compare results. If the
parameters in the file match the controller, the following message box appears:
If there were mismatches, the following message will appear showing file differences.

You can save to file to enable differences to be compared at a later date.
14.2.4 Change ECG Password

This command allows you to add or change a password to protect certaincalibration features. The
option is useful, for example, to prevent unauthorizedchanges to a known good calibration set in the
ECG unit.
Once a password is added or changed, the following calibration features become password protected:
Change ECG Calibration
Download Cal File to ECG
Change ECG Password
ECG Calibration Wizard
At the start of any future sessions, if a password has been set, ACT will always prompt you to enter
the password to gain access to these features. You only need to enter the password once during any
session to gain access to all the password protected features.
CalibrateEnter password.
14.3.1 Parameter View
This command allows you to view certain operating variables in real time.
To view parameter values in Real Time:
MonitorParameter View.
Real time values are shown. The screen automatically starts reading values from the controller and
displaying the values.
To stop the updating, click on Stop, the button name will then change to Start. Clicking it again will
start updating again.
The parameters viewed can be changed/added to by selecting from the drop down configure menu
below the Start/stop option
14.3.2 Parameter Plot

The Parameter Plot command lets you view engine performance on screen in the form of a real-time
graph. This feature allows you to perturb the system and observe the response to fine tune engine
performance.
MonitorParameter Plot.

The application will launch and start the parameter plot view. The plot can be stopped and started as
required and saved to file in text form.
Parameters shown on the graph can be chosen from the configuration list and graph settings altered to
required resolutions.
PID setting are shown at the base of the graph and can be altered (even with engine running), the
PID`s will not change until new number has been input and the return/enter button has been clicked on
your computer
Plot parameters and inputs can be altered/set from the configure menu in the plot screen.
Monitorparameter plotconfigurechoose parameterSave.
A maximum of two plots can be displayed simultaneously.

If power supply to ECM is switched off, screen plot will be lost(unless previously saved under
save to file).
14.3.3 Display faults

This command allows you to display present faults in real-time. This means if new faults occur while
you are monitoring, the screen will automatically update to display the current faults. The display will
also show historical fault codes that have been previously logged but do not currently exist. Historical
fault codes are helpful when tracking down intermittent faults.
Monitordisplay faults.
Both current and historical faults are displayed in the separate box displays, these faults can be
cleared by clicking on clear historical faults or clear current faults. Individual faults displayed within
the same box cannot be cleared separately.
14.3.4 Control strategy

This command allows you to check the version of the control strategy in use. This information may be
needed for strategy identification purposes and for future updates.
14.3.5 Parameter List

The Parameter List screen allows the user to adjust which parameters are
displayed on the Parameter View display.
MonitorParameter listselect desired parameter and position
Type in a file name that reflects the purpose of the saved configuration and click Save. The view
configuration dialog will now display the selected file name in the title bar. Clicking Open will prompt
the user for a file name of a previously saved View Configuration. Select the desired file and click
Open. The View Configuration will be updated with the saved parameters.
The ACT application will always recall the default set of plot configuration parameters at application
startup, and does not recall the last used view setup file. So the view configuration will always start
with the default view. Several parameter view screens can be open with different configurations by
changing the configuration on the parameter list screen (F9 or Open), then opening a new Parameter
View.

15.0 CAN Operation 400ECG
15.0 CAN Operation

CAN connections:
CANL (J1-6) and CANH (J1-7) lines are used for CAN communications.
CAN networks must be terminated with a 120 +1% differential resistance at each end of the network.
It is necessary to terminate the network to prevent interference caused by signal reflections.
Depending on length, many CAN networks will not operate at all without the proper termination.
Generally it is recommended not to build the termination into a node since CAN is intended to be a
plug-n-play type network with RIUP (remove and insert under power).
However, no specific restrictions are placed on the inclusion of termination resistors in a node.
Termination resistors must be installed only at the physical ends of the network. Terminating other
midpoint units can overload the network and stop all communications. As a rule, no matter how many
units are on a network, there should never be more than two terminations installed.
Termination is a simple 120 watt, 1% metal film resistor placed between CAN high and CAN low
terminals (differential termination) on or near the two end units.
Data pair impedance 120 10% AT 1 MHZ

Cable capacitance 12 pF/ft at 1 kHz (nominal)
Capacitive unbalance 1200 pF/1000 ft at 1 kHz
Propagation delay 1.36 ns/ft (maximum)
DC resistance 6.9 W / 1000 ft @ 20 C (maximum
Data pair 19 strands, 1.0 mm corresponds to 18
AWG,individually tinned, 3 twists/foot
Power pair 19 strands, 1.5 mm corresponds to ~16
AWG,individually tinned, 3 twists/foot
Drain / shield wire 19 strands, tinned copper shielding braid or
shielding braid and foil
Cable type Twisted pair cable, 2x2 lines
Bend radius 20 x diameter during installation or 7 x
diameter fixed position
0.13 dB/100 ft @ 125 kHz (maximum)
Signal attenuation 0.25 dB/100 ft @ 500 kHz (maximum)
0.40 dB/100 ft @ 1000 kHz (maximum)
15.1 Parameter Format

The ECG uses a Little-Endian format when handling multiple-byte parameters (i.e. a position demand
of 50% is FF0F, not 0FFF). All parameters use this format unless otherwise specified.
15.2 Lost CAN input signal

When the EXTERNAL_ANALOG_MODE is configured to receive demanded speed from CAN, if new
demanded speed updates are not received within the configured CAN_LOST_DELAY a
CAN_DEFAULT_SPEED is taken. There is no fault indication. Desired speed will default to
CAN_Default_speed..

15.3 Data Frame

The ECG uses CAN 2B with 29-bit identifiers.
The Data Frame is the most common message type. It comprises the following
major parts:
The Arbitration Field which determines the priority of the message when two or more nodes
are contending for the bus. The Arbitration Field contains: a 29-bit Identifier (which also
contains two recessive bits: SRR and IDE) and the RTR bit.
The Data Field which contains zero to eight bytes of data.
The CRC Field which contains a 15-bit checksum calculated on most parts of the message.
This checksum is used for error detection.
An Acknowledgement Slot. Any CAN controller that has been able to correctly receive the
message sends an Acknowledgement bit at the end of each message. The transmitter checks
for the presence of the Acknowledge bit and retransmits the message if no acknowledge was
detected.
15.4 Device Identifier

The Device Identifier is a not configurable parameter. The default value contains manufacturer code
Perkins Governor identifier: 153. All the others fields are set to 0. Moreover CAN Source Address
cannot be changed by Address Claim Procedure. The default value is set to 0x00. It means that only
one ECG controller can exist on a single CAN link. If it is required (another device uses the same
source address) ECG CAN Source Address parameter can be modified by ACT Tool.
15.5 Transmitted and Received CAN Messages

The following information is sent over the CAN:
Engine speed
Vehicle Battery Status
Engine Shutdown Request
The following information is sent over the CAN upon request:

Address Claim
The ECG CAN Controller receives the following information over CAN:
Speed Setpoint
Address Claim
15.6 Supported Frames

15.6.1 PGN 61444 Electronic Engine Controller 1 - EEC1
Engine related parameters.
Transmission Repetition Rate: 20 ms
Data Length: 8
Default Priority: 3
Parameter Group Number: 61444 (0xF004)
Start Position Length Parameter Name SPN

4-5 2 bytes Engine Speed 190
7.1 4 bits Engine Starter Mode 1675
Engine Starter Mode SPN assumes starter motor sense at SW2 input.

15.6.2 PGN 61443 Electronic Engine Controller 2 EEC

Identifies electronic engine control related parameters.
Transmission Repetition Rate: 50 ms
Data Length: 8
Default Priority: 3
Parameter Group Number: 61443 (0xF003)

1.1 2 bits Accelerator Pedal 1 Low idle Switch 558
2 1 byte Accelerator Pedal Position 1 91
15.6.3 PGN 65271 Vehicle Electrical Power 1 - VEP1

Transmission Repetition Rate: 1 s
Data Length: 8
Default Priority: 6
Parameter Group Number: 65271 (0xFEF7)

7-8 2 bytes Keyswitch Battery Potential 158
15.6.4 PGN 0 (R) Torque/Speed Control 1 - TSC1

Data Length: 8
Default Priority: 3
Parameter Group Number: 0 (0x0)

2-3 2 bytes Engine Requested Speed/Speed limit 898
This frame is preceded by the unit only when EXTERNAL_ANALOG_INPUT is set to 40 (CAN Input)
otherwise this frame is ignored by the unit.
If this frame is not received by unit within the configured CAN_LOST_DELAY, desired
speed will go to CAN_DEFAULT_SPEED.
15.6.5 PGN 61183 ADDR_CLAIM

Transmission Repetition Rate: After Power-up, On Demand
Data Length: 8
Parameter Group Number: 61183 (0xEEFF)
Start Position Length Parameter Name

3.6 11 bits Manufacturer Code
This frame is sent by the unit at the start or on demand from the master. Value of Pre-set Code is
always set to 153. The other values in this frame are set to 0.
15.6.6. PGN 60159 (R) ADDR_CLAIM

Data Length: 3
Parameter Group Number: 60159 (0xEAFF)
Data = [0x00, 0xEE, 0x00]
When the unit receives this frame from the master then ADDR_CLAIM frame is sent by the
unit.

16.0 ECG Configuration Settings
400ECG

16.1 MAP Sensor Configuration and Fuel Limiting (where fitted)
On engines with turbo fitted, a MAP sensor is used and provides turbo boost (manifold pressure)
feedback to the EGR for the purpose of reducing FAS
MAP Operation and Fuel limiting

This feature allows user to limit fuelling based on either or both of:
MAP sensor value (Intake pressure fuel control IPFC)
Engine speed (Speed based fuel control)
Fuel limiting is achieved by controlling the actuator current.
Calibration parameters needing configuration SW_OPTIONS2

Fuel limiting is enabled by entering 1 to specific bits in SW_OPTIONS2 parameter.
Intake pressure fuel control: SW_OPTIONS2 bit 0
Speed based fuel control: SW_OPTIONS_2 bit 1
For example, if all other bits SW_OPTIONS2 are to be set to zero, both fuel limiting
variants will be enabled when with writing value 00000011.
Note that remaining bits in this parameter control various other features and should be
left unchanged when calibrating fuel limiting (default is zero).
MAP_CAL_ADC_X1, MAP_CAL_ADC_X2, MAP_CAL_ADC_Y1,

MAP_CAL_ADC_Y2
These values set two points for the MAP sensor value to map pressure conversion line MAP sensor
values are described as a numbers in range 01023, where 0 corresponds to 0V voltage and 1023
corresponds to 5V voltage. Below picture shows the resulting line.
Map_bar [bar]
MAP_CAL_MBAR_Y2
MAP_CAL_MBAR_Y1
Adc_map_filt
MAP_CAL_ADC_X1
MAP_CAL_ADC_X2

400ECG
MAP _AD_OR_H, MAP _AD_OR_L

These values set minimum and maximum map sensor values. If the sensor value is outside these
limits, map sensor out of range fault is raised.
LUT_MAP_X1 LUT_MAP_X5, LUT_MAP_Y1 LUT_MAP_Y5

These parameters form the 5-point curve that is used to determine maximum actuator current based
on MAP pressure if intake pressure fuel control is used.
LUT_MAP_Xn are set to the given map pressure values (in bars). LUT_MAP_Yn
are set to maximum actuator current values (in milliamps) that correspond to the
given map pressure.
Current limit values are interpolated for map pressure values between defined points. See the figure
below of example MAP table:
Curr_limit-map (mA)
LUT_MAP_Y5
LUT_MAP_Y2
LUT_MAP_Y1
map_bar (bar)
LUT_MAP_X1 LUT_MAP_X5
LUT_MAP_X2

400ECG
Curr_limit-map (mA)
LUT_MAP_Y5
LUT_MAP_Y2
LUT_MAP_Y1
map_bar (bar)
LUT_MAP_X1 LUT_MAP_X5
LUT_MAP_X2
LUT_SPEED_X1 LUT_SPEED_X5, LUT_ SPEED _Y1 LUT_SPEED_Y5

These parameters form the 5-point curve that is used to determine maximum actuator current based
on engine speed if speed based fuel control is used. Configuration is similar to LUT_MAP parameters.
CURR_LIM_I_GAIN
Integral gain for current limiting controller. It is used to remove steady state actuator current excess
over maximum current. Maximum value should be used while still maintaining stability.
CURR_LIM_P_GAIN
Proportional gain for current limiting controller. It is used to improve current limiting response time.
Maximum value should be used while still maintaining stability.
CURR_LIM_IDUTY_REL_LMX
This parameter is used to improve current controller response time in the situation when actuator
current is crossing the maximum value. Decreasing this value will decrease current overshoot but may
result in unwanted fuel limiting when actuator current is close to the limit.
Calibration Procedure
Enable intake pressure fuel limiting or speed based fuel limiting with appropriate bit in
SW_OPTIONS2. Both variants may be enabled simultaneously. If Intake pressure fuel control is used,
user must configure MAP sensor input to calculate pressure in bars correctly. Also, the out of range
limits should be changed from default values to be able to detect broken or unconnected sensor.
Current limit tables for the either or both of MAP value and engine speed need to be configured. These
tables define the maximum actuator current for the given input value. Overall fuel supply for a given
actuator current will be constant, with reasonably small influence of temperature, supply voltage, etc.
It should be noted that in most cases the actuator current to shaft position relationship is nonlinear.

400ECG
As the device does not control actuator current directly, closed loop regulator is required to decrease
dutycycle when maximum current is exceeded. Normally its enough to adjust CURR_LIM_I_GAIN,
CURR_LIM_P_GAIN,
CURR_LIM_IDUTY_REL_LMX as described above to get fast and stable response. In some
situations, other parameters grouped in ACT tool Actuator Current Limiting category may also need
adjusting.
16.2 ECG Configuration charts

Data Sheet 14.2A 16.0 ECG Configuration Settings 400ECG
External Analogue Input Modes
Mode Configuration Description/options
000 No external analogue input Use speed switch or momentary switch.
001 Trim Mode Use external Throttle sensor to trim the selected set speed. The speed selected by the set speed
switches is adjusted by plus or minus Set_Speed_Trim. The set speed is bounded by
101 Trim Mode, Reverse throttle sensor Set_Speed_Min/Max
002 Set Speed with throttle sensor
012 Set Speed with Throttle sensor, PTO availible Use external Throttle sensor to adjust set speed between Set_Speed_Min and Set_Speed_Max.
PTO is availible where indicated and allows switching from Throttle sensor selected speed to
switched selected speed. Auxiliary output can be configured to indicate PTO state. Ramp rate
102 Set Speed with Reverse Throttle sensor limits are still in effect
112 Set Speed + Reverse Throttle sensor, PTO Availible
003 Drive by wire, No IVS
013 Drive by wire, No IVS PTO Availible

Use Throttle sensor to adjust set speed between Set_Speed_max . If IVS is not used, ECG must
103 Drive by wire, IVS closed at idle see minimum throttle position after power up before command for off idle will be accepted. Can
be used with IVS. PTO is available where indicated and allows switching from throttle Throttle
113 Drive by wire, IVS closed at idle, PTO availible sensor selected speed to switched selected Speed.Auxiliary Output can be configured to
indicate PTO state. Ramp rates limits are still in effect.
203 Drive by wire, IVS open at idle
213 Drive by wire, IVS open at idle, PTO availible
Uses IVS as brake input- will go to idle when detects no machine load for specified time(
023 Drive by wire, PTO availible, Brake mode
Brake_Delay) Otherwise similar to 013.
123 Auto Idle, throttle sensor reverse acting

Uses IVS as brake input, sw1 as auto idle on/off switch, otherwise similar to Mode 02. Mode 223
is for clockwise increasing throttle, Mode 123 is for anti-clockwise increasing throttle
223 Auto Idle, throttle sensor foward acting
Uses CAN signal provided by VCU (vehicle controller unit) to adjust desired speed this diables
40 CAN speed input
other analogue input modes. I f no CAN signal received it will default to CAN default value
255 APS Calibration mode Analogue throttle scope calibration setting mode only.

16.0 ECG Configuration Settings 400ECG
Category Parameter Description Mode Unit Effect
023,123 Alters the time delay for going to auto idle once no
Brake_Delay Return to idle delay Sec
or 223 machine load is detected
See mode sheet, Determines type of desired speed input and how input
External_Anolog_Mode External analogue input configuration
page 47 is set up
Determines rate at which engine speed decreases
Engine Set Speed calibration
Ramp_ Down_Rate Engine Speed Ramp Down Rate Rpm/Sec

from previous set point
Determines rate at which engine speed increases
Ramp_up_Rate Engine Speed Ramp Up Rate Rpm/Sec
from previous set point
001 or
Set_Speed_1 Engine Set Speed 1 Rpm Desired engine speed when speed switch 1 is applied
101
001 or
101
001 or
101
001 or
101
Sets Minimum allowable speed from input, and low
Set_speed_Max Minimum Increment Speed Rpm
idle speed
Sets Maximum allowable speed from input, and high
Set_Speed_Min Maximum Decrement Speed Rpm
idle speed
Selected speed acceptable variation from desired
Set_Speed_Trim Engine Trim Speed Rpm
speed
Set speed at which engine will run in warm up period,
Set_Speed_Warmup Engine Warm Up Speed Rpm
unique PID,s can be set for this period
Sets time delay between switch being selected and
Speed_Decrease_Delay Multi-Speed Decrease Delay Time Sec
actual decrease taking place. 0 is no delay.
Multi-Speed 1,2,3,4 Selected 1 to 4 for number of switched inputs or 5 for
Switch_Configuration N/A
Variable Speed 5 momentary switch speed input
Time at which engine speed remains at warm up
Warm_Up_Time Time Spent At Warm Up Speed Sec
speed and PID,s. 0 allows no warm up speed.
Engine Speed Type Input to ECM, (Magnetic Type of engine speed input to ECM. 128 is Magnetic
Speed_Type 128 N/A
Pick-up) Pick Up (inductive)
Configuration
Speed Input
Input pulses per engine revolution (flywheel Input to ECM to determine one revolution of crank.
Pulses_Per_Rev 109 Number of
teeth) Number of pulses to equal 1 crank rev.
Rate at which ECM will measure engine speed ie; 6

Pulses_Per_Update Number of pulses untill next update 1-109 Number of
equals every 6 pulses/ring gear teeth
The fewer the pulses, the faster the update rate and
the lower the resolution

Unit
Category Parameter Description Mode Effect
Brake_up_Rate
Rate at which desired engine speed
When 023, 123 or Normally set for rapid increase when load to engine applied and
increases/decreases from /to idle speed RPM/Sec
223 are selected slower to return after load release
after brake input is activated
Brake_down_Rate
Speed Variables and Calibration
Set Speed Max 1, 2, 3 & 4

These parameters define the speed If two or more range switches are active simultaneously, low
ranges that will be used instead of When 001 or 101 speed range will be equal to highest Set_Speed_Min n value
RPM
Set_Speed_Min/Max when given speed are selected configured for active switches, high speed range will be equal to
range switch is active lowest Set_Speed_Max n value configured for active switches
Set Speed Min 1, 2, 3 & 4
Spd_Range_Down_Rate
Values define rates at which speed
0= change of speed at maximum rate engine can perform to with
increases/decreases when changing When 001 or 101
RPM/Sec given load. Values can be seperatly set for rapid increase and
speed ranges for the given analogue are selected
slow smooth decrease
input.
Spd_Range_Up_Rate
The analogue speed controller calibration is "automatic", set

external_analogue_mode to 255 and run throttle sensor through
External analogue mode calibration for
Input speed Calibration 255 N/A full range, the controller will auto-learn range valuesand store in
speed control throttle sensor
memory. Set external_analogue_mode back to desired speed
mode on completion

Category Parameter Description Mode Unit Effect

Engine run time before checking protection input
Engine_Protection_ Run_Time Sec 8000 = Disabled
Engine protection
switch Ie oil pressure
Engine_Protect_Time Switch delay before engine protection shutdown Sec Delay in shut down when engine protection shutdown is triggered
Actuator will shut down if overspeed is detected for specified time

Overspeed_RPM Actuator shutdown speed (max) RPM
(Overspeed-time) set to 0 to disable
Actuator will shut down if underspeed is detected for specified time
Underspeed_RPM Actuator shutdown speed (min) RPM
(underspeed-time)set to 0 to disable
Underspeed_Run_Time Run time before underspeed is checked Sec Time for which underspeed will be ignored
1 On when RPM exceeds set limits

Off when Critical Shutdown detected (requires separate relay to
2
switch engine off)
3 On when PTO Engaged
Output switched dependant on mode.
Auxiliary Output and throttle calibration
Auxiliary_Output_Mode N/A
0= no input 4 Not Used
5 Mimic ECG LED
6 Not Used
7 On when Auto idle selected
1 On when RPM exceeds set limits
Off when Critical Shutdown detected (requires separate relay to
2
switch engine off)
3 On when PTO Engaged
Output 2 switched dependant on mode.
Auxiliary_Output_2_Mode 4 N/A Not Used
0= no input
5 Mimic ECG LED
6 Not Used
7 On when Auto idle selected
Aux_output_RPM Engine speed at which output will be switched Used in conjunction with Auxiliary_Output_Mode when in mode 1
RPM
Aux_output2_RPM Engine speed at which output 2 will be switched Used in conjunction with Auxiliary_Ouptut2_Mode when in mode 1
Droop_Percentage Droop percentage required If no droop required, input 0

%
If exceeded for specified time the actuator will ramp down untill
Actuator current limit
High_Actfdbk-Lmx mA within limits for specified time

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Perkins 400D Series

Models 403D-15, 403D-15T,

ECG Electronic Governor

Publication TPD1812 Production issue 1. Perkins Confidential: GREEN

A&I Manual, Publication TPD1812 Production issue 2. Page 1 of 1

A&I Manual, Publication TPD1812 Production issue 2. Page 1 of 2

14.1.2 Save ECG Cal to File................................................................................................... 35

A&I Manual, Publication TPD1812 Production issue 2. Page 2 of 3

1.1 Applicable Engines

A&I Manual, Publication TPD1812 Production issue 2. Page 3 of 4

1.2.1 Warning Welding

Turn the engine OFF.

1.2.2 Warning - Electrostatic Paint Spraying

The engine ECM cannot be painted using electrostatic processes.

1.2.3 Washing and Painting Processes (Excluding Electrostatic)

1.2.4 Warning Jump Starting

A&I Manual, Publication TPD1812 Production issue 2. Page 4 of 5

2.0 System Principals

2.1 Component Overview

Controller (ECM) (1)

2.2 Electronic Control Module (ECM)

2.3 Proportional Actuator

2.3.1 All speed

A&I Manual, Publication TPD1812 Production issue 2. Page 5 of 6

2.4 Engine Speed Sensor

2.5 MAP sensor

A&I Manual, Publication TPD1812 Production issue 2. Page 6 of 7

2.6 Engine Electronic Component location

Crankshaft speed sensor Flywheel housing

A&I Manual, Publication TPD1812 Production issue 2. Page 7 of 8

3.0 Engine System Power and Grounding Considerations

3.2 ECM Power Supply Conductors

3.3 ECM Power Supply Resistance

3.4 Voltage Suppression Requirement

3.5 ECM Body to Chassis Maximum Potential Difference

A&I Manual, Publication TPD1812 Production issue 2. Page 8 of 9

4.0 ECM Application Requirements

4.2 Power Supply

4.3 Electrical System ECM Details

4.4 Wiring shielding

4.5 Voltage Supply System 12V

A&I Manual, Publication TPD1812 Production issue 2. Page 9 of 10

5.0 ECG ECM INSTALLATION

The ECM must be mounted off Engine

5.2 Engine ECM Vibration

A&I Manual, Publication TPD1812 Production issue 2. Page 10 of 11

5.3 Mounting Recommendations

A&I Manual, Publication TPD1812 Production issue 2. Page 11 of 12

Fig 5.2 Controller dimensions

A&I Manual, Publication TPD1812 Production issue 2. Page 12 of 13

6.0 Speed Sensor installation

6.1 Fitting type 1 speed sensor.

6.2 Fitting type 2 speed sensor.

A&I Manual, Publication TPD1812 Production issue 2. Page 13 of 14

7.0 Speed Control

7.1 Speed control types

7.1.1 Analogue sensor

7.1.2 PTO configurations

7.1.3 Auto Idle (Machine sensed)

A&I Manual, Publication TPD1812 Production issue 2. Page 14 of 15

7.1.5 CAN J1939

7.1.6 Set speed warm up

A&I Manual, Publication TPD1812 Production issue 2. Page 15 of 16