Professional Documents
Culture Documents
2800 Electronic Mech Jan07 Compress
2800 Electronic Mech Jan07 Compress
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
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Perkins Confidential ‘Green’
Please Note
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Course Objectives
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Perkins Confidential ‘Green’
Worldwide „Off Road‟ Legislation Today
No Legislation Requirements
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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
0.50
0.45
Tier 3: 56kW<75
0.40
0.35 1980’s
Tier 3: 75kW<130
PM 0.30 Particulate Matter
(g/kWh)
0.25
(PM) 0.6g/kWh
Tier 3: 130kW<560
0.20
Oxides of
0.15 Tier 4B: 56kW<560
Tier 4A: 56kW<130
Nitrogen
0.10
Tier 4A: 130kW<560 (NOx) 10.00g/kWh
0.05
0
0 1 2 3 4 5 6
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Perkins Confidential ‘Green’
Electronic Engine Benefits
Electronic Engine Management system gives:
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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’
2306 and 2806 Engine Numbering
„F‟ Engine Family, 14.6 litre
Number of Cylinders
„H‟ Engine Family, 15.8 litre
„J‟ Engine Family, 18 litre
Country of Manufacture
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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
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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’
2306/2806 Product Features
Combined primary and Integral inlet manifold Radial seal
secondary „Eco‟ (18 litre horizontal) air filter
Fuel filters element
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Perkins Confidential ‘Green’
2306/2806 Product Features
Single stage 16 litre
high boost Composite
turbocharger top cover
Air to air
charge
Oil cooler cooler
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Perkins Confidential ‘Green’
2806 -18 litre Product Features
Twin exhaust Twin
manifolds turbochargers
Aluminium sump
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Perkins Confidential ‘Green’
Rocker Assemblies
Roller Type Rockers
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Perkins Confidential ‘Green’
Cylinder Head
Four Valve Mono-Block Cylinder Head
Four
Forged valves
steel per
overhead cylinder
camshaft
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Perkins Confidential ‘Green’
Valve Assemblies
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Perkins Confidential ‘Green’
Valve/Injector Clearance
Establishing Number 1 TDC
Turning
tool
TDC locator
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Perkins Confidential ‘Green’
Valve/Injector Clearance
Valve
„screw and locknut‟
adjuster
Injector adjuster
Injector
trim code
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Perkins Confidential ‘Green’
Valve/Injector Clearance
Machine shoulder
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Perkins Confidential ‘Green’
Valve/Injector Clearance
With Number 1 Cylinder at TDC compression stroke adjust
Inlet valves 1,2,4
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Perkins Confidential ‘Green’
Injector Sleeve
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Perkins Confidential ‘Green’
Injector Sleeve
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Perkins Confidential ‘Green’
Injector Sleeve
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Perkins Confidential ‘Green’
Camshaft
Long Overlap Camshaft
Drive gear
dowel location
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Perkins Confidential ‘Green’
Camshaft
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Perkins Confidential ‘Green’
Camshaft
Thrust Plate and Seal
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Perkins Confidential ‘Green’
Head Gasket/Spacer Plate
Oil seal
Coolant bobbin
Spacer plate
„Shim‟ gasket
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Perkins Confidential ‘Green’
Exhaust Manifold
Air gap
Thermal sleeve
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Perkins Confidential ‘Green’
Cylinder Block
Open Summit Cylinder Block
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Perkins Confidential ‘Green’
Cylinder Liners
Induction Hardened Liners
Rubber O rings
(2806)
2306 three lower liner „O‟ ring seals are all identical in size
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Perkins Confidential ‘Green’
Cylinder Liners
Protrusion
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Perkins Confidential ‘Green’
Pistons
2306 „Gallery Cooled‟ Articulated Piston
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Perkins Confidential ‘Green’
Pistons
2806-16 Articulated Piston
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Perkins Confidential ‘Green’
Piston/Con-Rod Assembly
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Perkins Confidential ‘Green’
Pistons
2806-18 Piston
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Perkins Confidential ‘Green’
Pistons/Con-Rod Assembly
2806-18 Piston
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Perkins Confidential ‘Green’
Piston Cooling Jets
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Piston Cooling Jets
2806-18
Piston
Connecting rod
Entry to cooling
gallery
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Perkins Confidential ‘Green’
Crankshaft
Thrust washer position
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Perkins Confidential ‘Green’
Crankshaft
2806-18
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Perkins Confidential ‘Green’
Crankshaft
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Perkins Confidential ‘Green’
Block Stiffener Plates
2300 Series
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Perkins Confidential ‘Green’
Torsional Damper
Hasse and Wrede Damper
1. Housing
2. Casing
3. Inertia Ring (mass)
4. Bearings
5. Silicone Fluid
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Timing Gears
Coolant pump „Pendulum‟
drive gear camshaft gear
position
Adjustable
Compound idler gear
gear
assembly
Idler gear
Crankshaft gear
Fuel transfer
Oil pump gear pump
position
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Timing Gears Timing case
Pendulum Camshaft Gear
Rotating
balance
weights
Alignment
marks
Locating
dowel
Timing gear
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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 Crankshaft Seals
Oil Seal and Wear Sleeve
Wear sleeve ‘crimp’ tool
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Crankshaft Seals
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Perkins Confidential ‘Green’
Induction System
2809-18
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Perkins Confidential ‘Green’
Induction System
Air Filter Type Single medium duty paper element
Max Air Inlet Temp 60°C (140°F)
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 260°C (500°F)
at high (ambient conditions)
Turbo Charger 2306 Allied Signal GT 50
2806 Borge Warner S 500
2806-18 twin Borge Warner S310
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Perkins Confidential ‘Green’
Induction System
Radial Seal Filters
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Perkins Confidential ‘Green’
Induction System
Turbochargers
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Perkins Confidential ‘Green’
Induction System
2806-18 Turbochargers
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Perkins Confidential ‘Green’
Induction System
Air Charge Cooling/Radiator
C
A O
O
I L
R A
N
T
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Induction System
2806-18
Air charge
Coolant cooling / radiator
Turbo boost air
Boost air
Coolant
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’
Fuel System
EUI Location
Trim code,
Below barcode
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Perkins Confidential ‘Green’
Fuel System
Injector Seals
O ring seals
„Sacrificial‟
compression „O‟ ring
6 hole
injector nozzle
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Fuel System
Low Pressure Fuel System
Priming pump
Venting points
Fuel return
Secondary filter
Transfer pump Fuel supply Primary filter
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Perkins Confidential ‘Green’
Fuel System
Fuel Cooler/Return
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Fuel System Fuel System
Fuel Transfer Pump Ecoplus Fuel Filtration
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Perkins Confidential ‘Green’
Fuel System
Ecoplus Fuel Filtration Identification
Oil
Fuel Secondary Fuel primary
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Fuel System
Ecoplus Fuel Filtration
Supply to head
Return from
head
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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) 95°C
Lube oil temp - maximum 113°C
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)
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Perkins Confidential ‘Green’
Lubrication System
Composite „High Capacity‟ Sump
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Perkins Confidential ‘Green’
Lubrication System
Oil Pump
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Perkins Confidential ‘Green’
Lubrication System
Ecoplus Oil Filtration
Sampling
point O/P switch
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Perkins Confidential ‘Green’
Lubrication System
2806-18
Oil cooler
assembly
Re-positioned
oil filler
tube
Re-designed
Oil filter
head
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Perkins Confidential ‘Green’
Cooling System
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Cooling System
Air Charge Cooling/Radiator
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Cooling System
Thermostat Housing
Thermostat
Flow to radiator
Thermostat seal
By-pass
return to
coolant pump
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/25/2800 Series
Temperature and Pressure Sensors
Coolant
Temp Sensor Inlet Manifold
Air Temp Sensor
Inlet Manifold
Air Pressure
sensor
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/2800 Series
Connections and Speed/Position Sensors
110 Volt MEUI Solenoid Feeds
Cam Speed/
Position Sensor
9 Pin
Diagnostic
Connector
40 Pin Customer
Crank Connection (J3)
Speed/Position
Sensor
Electronic Control
Module
ECM “On Engine” Connector (J2)
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/25/2800 Series Electrical System
Internal Injector Harness
Jack 2 (J2)
Jack 1 (J1)
Crank Speed/Timing
36-1 TOOTH
CRANK
Cam Speed/Timing
Fuel Temperature Sensor
36+1 TOOTH
CAM GEAR
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/25/2800 „On Engine‟ Wiring Harness
ECM
P203 J203
Turbo Outlet Pressure Sensor
+5V
Signal
A
C J2/40 Turbo Outlet Pressure
All fed from Jack 2 (J2) on the ECM
Return B
P200 J200
+5V A
Signal C J2/24 Oil Pressure
Return B
P201 J201
J100 P100
J105 P105
J103 P103
Crankshaft Position Sensor
P2 J2
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Perkins Confidential ‘Green’
Connectors – A Reminder:
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Effects of „Bad‟ (Resistance) Connections
„P‟ Plug „J‟ Jack
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Perkins Confidential ‘Green’
23/25/2800 Series MEUI Injection
Mechanically Actuated
Electronically Controlled
Unit
Injector 110 Volt Solenoid
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/25/2800 Series MEUI Injector
110v dc injector solenoid
“Poppet” Valve
Shut when energised
Off
+
110v
Supply
-
Flow
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
MEUI Injector
„O‟
Rings
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Worn MEUI Injector Poppet Valves
„O’ Rings
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Perkins Confidential ‘Green’
MEUI Injector Location
Fuel chamber
Intake
Extended life manifold
Torque setting on solenoid
coolant
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)
Air/Fuel Ratio
Start/Stop Sequence
Engine Protection Devices
Diagnostics
110 Volt Injector Pulses
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
Basic System – A3-ECM Interactions
Electronic J 1939
Service Diagnostic
Tool Code Reader
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Perkins Confidential ‘Green’
2300/2500/2800 „Off Engine‟ Wiring Diagram
Machine Wiring Schematic, All Options
This Wiring Supplied By OEM
(Different Diagram)
K
Low Oil Pressure
J1/28 Oil Pressure Lamp Output
O
High Coolant Temp
J1/29 Coolant Temperature Lamp Output
N
Overspeed
J1/30 Overspeed Lamp Output
A
Off - Disabled - Stop
J1/62 Injection Disable
Injection Disable On - Enabled - Run U
Off
On J1/64 Shutdown Emergency Override
Critical Override K
(Disables Oil & Water shutdowns
when on)
1500
J1/56 1500/1800 rpm Select
1500/1800 1800 N
rpm Select Isoch
J1/46 Droop/Isochronous
Droop/ Droop A
Isochronous
J1/41 Fault Reset
Fault Reset Y
Enable
J1/49 Digital Speed Control Enable
Digital Speed Control Disable G
Digital J1/59 Lower Speed
Speed P
Control Lower Speed
„J1 Jack
5K Analogue J1/3 Analogue Ground
Speed Setting B
Potentiometer or J1/17 Analogue Speed Input
Input from Load W
Sharer/Synchroniser J1/2 +5V
680R R
J1/61 Unswitched Battery Negative
B
Charging
Alternator J1/63 Unswitched Battery Negative Main
B Battery
GRD POS J1/65 Unswitched Battery Negative Feed
Emergency B (Direct
Stop Button J1/48 Unswitched Battery Positive from
R starter/
J1/52 Unswitched Battery Positive battery)
R
J1/53 Unswitched Battery Positive
Off R
J1/70 Switched Battery Positive
Key On Y
Switch
J1/50 J1939 Data Link +
Circuit Y
Breaker (16A) J1939 Data Link -
J1/34
G
J1/42 J1939 Screen
Start Button
Starter J1/8 Perkins Data Link +
Motor G
J1/9 Perkins Data Link -
N
J1/55 Unswitched Battery Positive Power
R Supply to
J1/69 Unswitched Battery Negative Service
B Tool
- + P1 J1
Battery
9 Pin Perkins Data
24V DC J H C G F D E A B Link Connector
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Perkins Confidential ‘Green’
Some Typical Connections - ECM
Inputs Outputs
CONTROL
ECM Shutdown
Analogue
Speed Adjust
Crank Terminate
Injection Disabled
Diagnostics
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
23/2800 Series ECM „Jack‟ Connections
J2 (Jack 2) J1 (Jack 1)
“On Engine” Mounted Components Customer Side
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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.
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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
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.
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Perkins Confidential ‘Green’
Raise Speed O
J1/18 Digital Ground
O J1/67 Unswitched Battery Negative
B
Ground J1/5 Ground
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Perkins Confidential ‘Green’
Minimum J1 Connections, to run a
23/2800 Series
Control
ECM
Note
Injection Disabled We do suggest that
a connection is made to the
Perkins Electronic Service Tool
(EST) to allow communication
With Perkins Data Link (PDL)
Ignition Key Switch
What are the Jack connection
numbers?
+ -
ECM Power Supply,
24 v
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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, Don’t forget the ECM is a
computer, you do not just ‘chop off ’ the power.
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Perkins Confidential ‘Green’
23/25/2800 Series Engine Mounted Sensors
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved
Perkins Confidential ‘Green’
2300/2800 Series – Temperature Sensors
32 Signal Voltage
ECM
Fuel Temperature Sensor
33 Signal Voltage
18 0 Volts
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Perkins Confidential ‘Green’
23/2800 Series Temperature Sensor Operation
ECM
5 Volts
R
Temperature Sensor
Signal
18
Ground 0 Volts
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Perkins Confidential ‘Green’
Engine Coolant Temperature Sensor
EST Code 110
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Perkins Confidential ‘Green’
Engine Coolant Temperature Sensor
EST Code 110 (Typical Temperature Sensor graph)
110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)
4.8
0.2
110-4 Signal shorted to a lower voltage (voltage under 0.2)
Temperature
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Perkins Confidential ‘Green’
Manifold Air Inlet Temperature Sensor
EST Code 174
Temperature can be viewed Manifold Air Inlet
through the ECM in °C/°F via: Sensor
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.
High inlet air temperatures lead to high
exhaust temperatures, which can cause
damage to exhaust system components
(such as turbochargers and exhaust valves)
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Perkins Confidential ‘Green’
Engine Fuel Temperature Sensor
EST Code 174
Fuel Temperature
Higher Temperature lower mass Sensor
Lower Temperature greater mass
Temperature can be viewed through
the ECM in °C/°F via:
J1939 CAN link
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Perkins Confidential ‘Green’
Temperature Sensor Feeds, Harness Voltages
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Perkins Confidential ‘Green’
2300/2800 Series Sensors
Different Fault Codes and How they could be Created
32
3
Intake Manifold Temperature Sensor
Break 33
ECM „Jack 2‟
2
1 2
Fuel Temperature Sensor
35
18
Fault 1………………………….
Fault 2………………………….
Fault 3………………………….
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Perkins Confidential ‘Green’
2300/2800 Series Pressure Sensors
2 5 Volts
14 Signal Voltage
3 0 Volts
Intake Manifold Air Pressure Sensor
40 Signal Voltage
24 Signal Voltage
ECM J2
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Perkins Confidential ‘Green’
23/25/2800 Series Pressure Sensor Operation
6.5 Volts
R
Pressure Sensor
5 Volt
2
3
0 Volts
Sensor ‘Fly Lead’ Main Engine Harness
ECM J2
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Perkins Confidential ‘Green’
Inlet Manifold Air Pressure Sensor
EST Code 273 - (Code also known as Turbo Boost!)
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Perkins Confidential ‘Green’
Inlet Manifold Air Pressure Values
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Perkins Confidential ‘Green’
Engine Oil Pressure Sensor
EST Code 100
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Perkins Confidential ‘Green’
Engine Oil Pressure Sensor
EST Code 100 (Typical Pressure Sensor graph)
Pressure
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Perkins Confidential ‘Green’
Atmospheric (Crankcase) Pressure Sensor
EST Code 274
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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
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Pressure Sensor Feeds, Harness Voltages
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2300/2800 Series Sensors
Different Fault Codes and How they could be Created
Atmospheric/Crankcase Pressure Sensor
1 2 5 Volts
14 Signal Voltage
3 0 Volts
Intake Manifold Air Pressure Sensor
40 Signal Voltage
2
Engine Oil Pressure Sensor
24 Signal Voltage
3
ECM J2
Fault 1………………………….
Fault 2………………………….
Fault 3………………………….
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Crankshaft Speed/Position Sensor
EST Code 190
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Camshaft Speed/Position Sensor
EST Code 342 (Speed and timing Sensor 2)
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Checking Speed/Position Sensors
Crankshaft Speed/Position
Sensor ‘fly lead’ Camshaft Sensor Resistance
between 1 and 2
1 2
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Additional Sensors/Senders
Coolant Level switch
Speed Sensor
CV18338 and Harness
CV18965
Oil pressure sender
CV18339/3 and adapter 3Y-2888
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Additional Engine Sensors/Senders
Temperature
Switch
Oil
Coolant Level sensor
Pressure
Switch
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Machine Wiring Schematic, All Options
This Wiring Supplied By OEM
N
J1/29 Coolant Temperature Lamp Output
Critical Override On
(Disables Oil & Water shutdowns K
when on)
1500
J1/56 1500/1800 rpm Select
Enable
J1/49 Digital Speed Control Enable
Digital Speed Control Disable G
droop/isochronous, etc
680R R
J1/61 Unswitched Battery Negative
B
Charging
Alternator J1/63 Unswitched Battery Negative Main
B Battery
GRD POS J1/65 Unswitched Battery Negative Feed
B
R starter/
J1/52 Unswitched Battery Positive battery)
R
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Gen-Set Desired Engine Speed/Load Control
Digital Control
Typical Pressure Sensor
Pulse Width Modulated
Analogue Control
CAN J1939 Control
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Digital Speed/Load Control
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Diagnostics
J1/31 Diagnostics Lamp Output
K
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2300/2800 Series Analogue Speed Control
Speed adjustment –10% to +10% (0% is rated speed)
For 50 Hz 1350 to 1650 rpm
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2300/2800 Series Analogue Speed
Adjustments
1500/1800 RPM
potentiometer
Provide linear voltage
Voltage o/p
output (0.5v to 4.5v)
Two series resistors
keep voltage away
from fault region 0.5V Fault Region
-10% +10%
Rated Speed
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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.
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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
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Warnings, Action Alert and Shutdown
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
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2800 Series Lamp Outputs
The ECM provides individual outputs to drive warning lamps
and/or relays to indicate each of the following fault conditions:
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Customer Outputs
Machine Wiring Schematic, All Options
This Wiring Supplied By OEM
Enable
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)
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Electronic Fault Diagnostics
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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
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J1/2 +5V
R
J1/61 Unswitched Battery Negative
B
9 Pin (Deutsch)
B
J1/63
J1/65
Diagnostic
Unswitched Battery Negative
Unswitched Battery Negative
Connector Main
Battery
Feed
y B (Direct
n J1/48 Unswitched Battery Positive from
R starter/
J1/52 Unswitched Battery Positive battery)
R
J1/53 Unswitched Battery Positive Used for Diagnostic Code Reader/
Off R Generic Engine Monitor, (CAN)
J1/70 Switched Battery Positive Controller Area Network, SAE J1939
Key On Y
witch
J1/50 J1939 Data Link + Genset Control
Y
6A)
J1/34 J1939 Data Link - Screen - Unused
G
J1/42 J1939 Screen
Button
G J1/8 Perkins Data Link + Used for Electronic Service Tool
J1/9 Perkins Data Link - Perkins Data Link (PDL)
N
J1/55 Unswitched Battery Positive Power
R Supply to
J1/69 Unswitched Battery Negative Service
B Tool
P1 J1
9 Pin Perkins Data
J H C G F D E A B Link Connector
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Electronic Engine Diagnostics
Electronic Service Tool (EST) computer based.
Many functions, reading of temperature, speed, pressures, etc
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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
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Diagnostic Fault Codes
Engine coolant temperature
Active Diagnostic Codes
Any fault that is currently
„Active‟ on the engine. 110 3
Logged Diagnostic Codes
Faults that have occurred,
„Logged‟ and been repaired.
Logged Event Codes CID FMI
Problems „Events‟ that could Component/circuit Failure mode
cause permanent damage identifier identifier
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23/25/2800 Speed/Timing Calibration
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.
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Timing Calibration Probe Installation
1mm (0.040in)
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
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ECM Timing Calibration Location Position
Calibration slot
Distance between
TDC position and
ECM Calibration
position approx
100/125 mm
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2300/2800 Series Immersion Heater
110V/240V immersion heaters and thermostat. Rated at
1500W, thermostat temperature range of 38 to 49°C
Route harness to avoid heat Thermostat
from the exhaust Sensor
manifold/turbocharger
Immersion
Heater
Element
Position
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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
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Make sure ‘Overspeed’ is
2800 Series Governor Stability - configured with the EST
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
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If you need Technical advice contact our dedicated Engineers
Use the Request Form
on the Perkins Secured Internet
http://www.perkins.com/perkins/cda/technicalSupportRequest/1,4077,,00.html
Or
Send an email to
technical_help@perkins.com
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23/25/2800 Series
End of Course Questions
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23/25/2800 Series
End of Course Questions (cont/d)
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