Installation Manual

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Perkins 1200F Series

Models MT, MU, MV, MW, BM and BN

ELECTRONIC APPLICATION &

INSTALLATION MANUAL

1204F-E44TA Four & six cylinder diesel

1204F-E44TTA engines for agricultural,

1206F-E70TA industrial, construction

1206F-E70TTA applications

Developed to meet EEC off-road mobile machinery Stage IV and U.S. EPA off-road Tier 4

Final legislation

Note: Information in this manual is preliminary and is subject to change or withdrawal

1200

Series

Perkins Engines Company Limite d

Peterborough, PE1 5FQ, United Kingdom

Tel: +44 (0)1733 583000

Fax: +44 (0)1733 582240

www.perkins.com

reserved. No part of this document may be reproduced in any form

or by any means, without prior written permission of Perkins Engines

Company Limited. The information in this document is substantially

correct at the time of printing and may be altered subsequentl y.

Publication No.TPD1836 – Production Issue 1, December 2014

Summary of content (256 pages)

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200 Series Perkins 1200F Series Models MT, MU, MV, MW, BM and BN ELECTRONIC APPLICATION & INSTALLATION MANUAL 1204F-E44TA 1204F-E44TTA 1206F-E70TA 1206F-E70TTA Four & six cylinder diesel engines for agricultural, industrial, construction applications Developed to meet EEC off-road mobile machinery Stage IV and U.S. EPA off-road Tier 4 Final legislation Note: Information in this manual is preliminary and is subject to change or withdrawal Publication No.
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Electrical & Electronic Application And Installation Manual CONTENTS 1.0 SAFETY .................................................................................................... 9 1.1 WARNING – WELDING ..................................................................................................................... 9 1.1.2 Warning - Electrostatic Paint Spraying .................................................................................. 9 1.1.3 Warning – Jump Starting ..........................
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Electrical & Electronic Application And Installation Manual 4.9.1 Actuator Driver Return ......................................................................................................... 46 4.9.2 Analogue Sensor Return ........................................................................................................ 46 4.9.3 Switch Return ........................................................................................................................ 47 4.9.4 Digital Return ............
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Electrical & Electronic Application And Installation Manual 7.3.3 Component I/O ...................................................................................................................... 84 7.4 1204F AFTERTREATMENT WIRING SCHEMATICS ........................................................................... 86 7.4.1 1204F DOC & SCR Schematic.............................................................................................. 86 7.4.2 1204F DOC, DPF & SCR Schematic ......................
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Electrical & Electronic Application And Installation Manual 11.1.3 Analogue Sensor Installation ............................................................................................ 132 11.1.4 Evaluating Component Compatibility (Testing) ................................................................ 132 11.2 PWM SENSOR - COMPATIBILITY .............................................................................................. 135 11.2.1 PWM Sensor Operation........................................
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Electrical & Electronic Application And Installation Manual 13.2.1 Datalink Driven Intelligent Displays ................................................................................. 175 13.2.2 Minimum Functional Specification for J1939 display....................................................... 175 13.3 LAMP OUTPUTS & OPERATION .................................................................................................. 176 13.3.1 Hardwired Lamp Outputs ..........................................
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Electrical & Electronic Application And Installation Manual 16.2.1 Low Speed Regeneration 1204F DOC + SCR only ........................................................... 208 16.3.2 Low Temperature Regeneration 1204F & 1206F DOC, DPF + SCR Products ............... 209 16.2 DEF SYSTEM OPERATION ......................................................................................................... 211 16.3 DEF SYSTEM MACHINE INTERFACE REQUIREMENTS ............................................................
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Electrical & Electronic Application And Installation Manual The information contained in this manual is confidential and proprietary to Perkins. It is intended for circulation only to Perkins employees, or to employees of OEMs intending to purchase and install Tier 4 Final/EU Stage IV Perkins engines in their equipment. Distribution of this material must be limited to personnel whose duties require knowledge of such material and is intended exclusively for their information and training.
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Electrical & Electronic Application And Installation Manual 1.0 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.
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Electrical & Electronic Application And Installation Manual • • Connect all 86 pins of the ECM J1 Connector directly to the spraying booth ground. Connect the engine block to ground at 2 points. Ensure that good screwed connections onto bright metal are used. 1.1.3 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.
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Electrical & Electronic Application And Installation Manual 2.0 Engine & Aftertreatment Component Overview 2.1 Main Engine Sensor and Actuator Detail 2.1.1 Electronic Control Module The A5:E2v2 & A5:E12 ECMs are electronic control devices that govern engine speed, torque output and manage the engines performance and emissions via a number of sensors and actuators. The Engine ECM is supplied with each engine and the variant is dependent upon the system voltage selected.
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Electrical & Electronic Application And Installation Manual It should be noted that in many cases a fault on any of these sensors, solenoids or switches will cause the engine to derate, or enter a limp home state due to their emissions critical nature. 2.1.3 Engine Speed The engine is fitted with two Hall effect speed sensors. The first is mounted on the engine to measure the crank speed and position and the other is used to measure the cam shaft speed, position and engine cycle.
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Electrical & Electronic Application And Installation Manual The oil pressure sensor measures engine oil pressure in kPa. Oil pressure is used for engine protection whereby if insufficient oil pressure is measured for a given speed, an event for low oil pressure would be raised. 2.1.6 Air System The engine air system contains the following electronic components.
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Electrical & Electronic Application And Installation Manual 2.2.3 Selective Catalytic Reduction (SCR) Technologies The SCR system supplied by Perkins with each Tier 4 Final engine family differs depending on the selected product. In principle however the 1204F and 1206F DEF systems are made up of the same core components as listed below; • • • • • • • DEF Tank and Header Unit. The Header controls feed of DEF out to the DEF pump and houses temperature and level sensors.
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Electrical & Electronic Application And Installation Manual 2.3 System Component Diagrams & Schematics 2.3.1 1204F Engine and Aftertreatment Layout Production Release Version 1.
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Electrical & Electronic Application And Installation Manual NOx NOx A1:E1 IGCEM ID Production Release Version 1.
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Electrical & Electronic Application And Installation Manual Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.3.
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Electrical & Electronic Application And Installation Manual NOx A1:E1 IGCEM ID Temperature Sensor Electronics DEF Heater DEF Heater NOx Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.4 Engine & Aftertreatment Component Layout Diagrams 2.4.1 1204F Principal Engine Electronic Components 2.4.1.
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Electrical & Electronic Application And Installation Manual 2.4.1.2 1204F Right Hand Side Engine View O N Drawing Ref N O Part Description Engine Cam Speed Sensor Engine exhaust back pressure valve Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.4.1.3 1204F Top Engine View V U T S P Drawing Ref P Q R S T U V Q R Part Description NRS Intake Pressure Sensor NRS Differential Pressure Sensor NRS Control valve Engine Fuel Rail Pressure Sensor NRS Temperature Sensor Engine Fuel Injector Connection Engine Fuel Injector Connection Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.4.2 1206F Principal Engine Electronic Components 2.4.2.
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Electrical & Electronic Application And Installation Manual 2.4.2.2 1206F Right Hand Side Engine View P O N Drawing Ref N O P Part Description Engine Secondary Speed Sensor Engine Turbo Outlet Temperature Sensor Engine Exhaust Back Pressure Valve Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.4.2.3 1206F Top Engine View S T Q R W U Drawing Ref Q R S T U V W V Part Description NRS Control Valve NRS Differential Pressure Sensor NRS Temperature Sensor NRS Intake Pressure Sensor Engine Fuel Injector Connection Engine Fuel Injector Connection Engine Fuel Rail Pressure Sensor Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 2.4.3 1204F AT Principal Components 2.4.3.1 DOC SCR A C B D Drawing Ref A B C D Part Description DEF Injector Aftertreatment Identification Module A1:E1 DOC Inlet Temperature Sensor SCR Inlet Temperature Sensor 2.4.3.
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Electrical & Electronic Application And Installation Manual 2.4.4 1206F AT Principal Components 2.4.4.1 DOC DPF SCR (Clean Emissions Module CEM) A C B E D Drawing Ref A B C D E Part Description DPF Inlet Temperature Sensor DPF Soot Sensor Antenna DEF Injector Aftertreatment Identification Module A1:E1 SCR Inlet Temperature Sensor Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 3.0 Customer System Overview Key Elements The following section provides details on both the mandatory and optional system connections that need to be made as part of the customers machine wiring harness. 3.1 Aftertreatment Configurations For an engine to be certified as Tier 4 Final/EU Stage IV compliant, it must demonstrate a particulate matter output of less than 0.02g/Kw.hr and a NOx output of less than 0.4g/Kw.
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Electrical & Electronic Application And Installation Manual DEF Injector 1204F DEF System Components 1204F NH3 Sensor DEF Injector 1206F PETU Communication PETU Power Supply IG CEM ID Module Water in Fuel Sensor Air Inlet Temperature Sensor 1204F 1204F 1204F no DPF only 1206F 1206F 1206F 1206F All All Section 7.0 Section 7.0 Section 9.0 Section 8.0 Section 8.0 Section 8.0 Section 9.0 Section 6.0 Section 6.0 3.
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Electrical & Electronic Application And Installation Manual 4.0 Power & Grounding Considerations 4.1 System Grounding Although the engine electronics are all directly grounded via the ECM connector, it is also necessary to ensure that the engine block is properly grounded, to provide a good return path for components such as the starter motor, alternator and cold start aids. Improper grounding results in unreliable electrical circuit paths.
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Electrical & Electronic Application And Installation Manual 4.1.3 Aftertreatment System Grounding Ground Point Option 1 Figure 4.1 Left Hand Side Grounding Location Grounding Point Option 2 Figure 4.1 Right Hand Side Grounding Location Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 4.2 System Voltage & Current Requirements Each Tier 4 Final/Stage IV engine comes supplied with an engine ECM controller and an SCR dosing control unit. Each controller has its own specific electrical requirements which need to be met for correct system operation. These electrical characteristics are shown in the following sections. 4.2.
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Electrical & Electronic Application And Installation Manual 1204F VOLTAGE SUPPLY SYSTEM 12V 24V 40 25 Max RMS Current* 24A 19A Suggested Fuse Rating** 35A 25A Min Running Voltage 9V 16V Max Running Voltage*** 16V 32V Max Peak Current (100ms) Table 4.2 1204F DEF System Voltage & Current Requirements 4.2.
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Electrical & Electronic Application And Installation Manual 4.3 ECM Power Supply & Circuit Resistance Often during engine cranking the battery voltage will drop to values much lower than the normal system operating voltage. Under these special conditions the ECM will operate with a minimum battery voltage of 7.3V. In this mode the ECM has reduced functionality to enable the use of a low supply voltage.
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Electrical & Electronic Application And Installation Manual American Wire Gauge 14 12 10 8 6 4 2 0 00 000 0000 mOhm at 20Deg C for Cable Length mohm/m at 4m 6m 8m 10m 20Deg C 2m 9.82 19.64 39.28 58.92 78.56 6.41 12.82 25.64 38.46 51.28 4.11 8.22 16.44 24.66 32.88 2.59 5.18 10.36 15.54 20.72 1.55 3.1 6.2 9.3 12.4 1.06 2.12 4.24 6.36 8.48 0.62 1.24 2.48 3.72 4.96 0.383 0.766 1.532 2.298 3.064 0.27 0.54 1.08 1.62 2.16 0.204 0.408 0.816 1.224 1.632 0.159 0.318 0.636 0.954 1.
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Electrical & Electronic Application And Installation Manual 4.3.1 Important Voltage Supply Circuit Considerations Poorly designed or installed ECM supply circuitry can lead to intermittent engine problems and reduce the engine ECM’s ability to maintain optimum performance under harsh conditions. To ensure that the integrity of the electrical supply circuit is not compromised during design and installation the following recommendations should be adhered to.
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Electrical & Electronic Application And Installation Manual Product 1204F* 1204F & 1206F 1204F & 1206F 1204F & 1206F 1204F & 1206F 1204F & 1206F 1204F & 1206F Component Voltage A5:E12 12V Only A5:E2v2 12 & 24V (dual voltage) Starter Motor 12 or 24V Alternator 12 or 24V NRS Valve 12 or 24V Fuel System (Pump) 12 or 24V Exhaust Back Pressure 12 or 24V Valve Table 4.
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Electrical & Electronic Application And Installation Manual 4.3.3 Battery (-) Connection The ECM requires Three un-switched battery negative inputs; the inputs should be permanently connected to the machine battery and all inputs must be used to ensure the ECM is supplied with an adequate connection to ground. Failure to use all three inputs could result in intermittent communication and or driver operation.
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Electrical & Electronic Application And Installation Manual 4.3.4 Correct method of ECM battery connection. Correct Power Supply Wiring • • • • ECM Positive wires connected direct to battery, not via starter motor Power supply wires go to all 3 positive pins and all 3 negative pins on the ECM Connector ECM Negative is wired to the battery rather than return through chassis. The engine is grounded to the machine chassis.
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Electrical & Electronic Application And Installation Manual 4.4 Engine ECM Power Supply Circuit Resistance Test Component Perkins part number TBD TBD Supplier Part number DRCP24-86PA 0460-20412141 N/A Quantity J1 Receptacle 1 Pins (positions 81-86 6 only) 2.2 Ohm Resistor N/A 1 200W Relay (low contact N/A N/A 1 resistance Pushbutton N/A N/A 1 Voltmeter N/A N/A 2 Table 4.8 ECM Power Supply Circuit Test Components V1 Voltmeter 1 2.
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Electrical & Electronic Application And Installation Manual Power Supply Circuit Resistance (mOhms) = 1000 * (R1 * (V2 – V1)/ V1) V1 = Voltmeter 1 Measured Value V2 = Voltmeter 2 Measured Value R1 = Measured Resistor Value Worked Example V1 = 11.8 V2 = 12 R1 = 2.21 Ohms 1000 * (2.21 * (12 – 11.8)/11.8) 1000 * (2.21 * 0.01695) 1000 * (0.0375) Harness Resistance = 37.5 mOhms Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 4.5 DEF System Power Supply Both the 1204F and 1206F aftertreatment DEF system require permanent battery + connections in order for the controllers to remain electrically active after the ignition signal to the engine ECM has been turned off.
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Electrical & Electronic Application And Installation Manual For more information on the DEF system purge operation for the 1204F product range please refer to section 16 of this document. 4.5.2 1206F DEF System Power Supply Connection The 1206F product range comes supplied with a DEF control system mounted to a single plate as part of a PETU (Pump, Electronics, Tank, Unit) or PEU (Pump, Electronics, Unit). The Supplied unit houses the components required for DCU power management.
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Electrical & Electronic Application And Installation Manual 4.6 Suppression of Voltage Transients 4.6.1 Suppression Methods & Best Practice Note: The installation of transient suppression at the source of the transient is required. The use of inductive devices such as relays and solenoids can result in the generation of voltage transients in electrical circuits.
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Electrical & Electronic Application And Installation Manual Suppression resistors are a low-cost alternative and can be less stressful on relay coils. Resistor selection should be determined by the voltage applied across the coil, the resistance of the coil, maximum power dissipation allowed, and the level of transient voltage to be tolerated. For example, if the coil is 50 Ohms and the voltage applied is 24V, an 82 Ohm suppression resistor would allow the transient voltage to reach –39.6V (V = IR = -.
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Electrical & Electronic Application And Installation Manual 4.8 Powering The Engine ECM Via Auxiliary Power Supplies If the engine is to be supplied with electrical power via any other means than a standard machine battery arrangement, care must be taken when choosing the power supply. Engine ECM’s powered by devices such as switch mode power supplies can be particularly troublesome due to the intermittent high current load demands of the engine ECM during engine operation.
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Electrical & Electronic Application And Installation Manual 4.9.3 Switch Return All of the following Features and switches must be connected back to the engine ECM J1 GND switch return pin 36. ECM Feature Regen Readiness IVS 1 IVS 2 / Throttle Arbitration PTO Mode On / Off / MPTS 2 Raise / Resume / MPTS 3 Lower / Set / MPTS 4 PTO Disengage / MPTS 1 Speed Select 1 & 2 / User Defined Shutdown Overspeed Verify Switch J1 Pin Location 74 75 66 51 52 43 67 68 50 Table 4.11 Switch to Ground Connections 4.9.
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Electrical & Electronic Application And Installation Manual 5.0 Connectors & Wiring Harness Requirements This section provides details on each of the connector that must be used to connect the mandatory engine and aftertreatment electrical components. 5.1 Engine ECM J1 Connector The engine ECM connector for the Tier 4Final/Stage IV engine A5:E2 V2 ECM is an 86 pin connector.
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Electrical & Electronic Application And Installation Manual 5.1.2 Tightening The OEM Connector Connector tightening torque = 6Nm +/- 1Nm 5.1.3 ECM Connector Wire Gauge Sealing Capability Connector cavity Assignment and max cable diameter to meet sealing requirements. Connector Cavity Identification 1 - 80 81 - 86 Wire Gauge ISO Metric Capability AWG Capability mm 16, 18, 20 0.5 - 1 12, 14 2-3 Table 5.2 Connector Sealing Capability Sealing Capability mm 1.6 - 3.15 3 - 5.3 5.1.
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Electrical & Electronic Application And Installation Manual Figure 5.2 ECM J1 Dress Cover 5.1.7 Machine Crimping For High Volume Production For high volume and automated crimping solutions please contact the supplier directly for tooling details. 5.2 Engine ECM J1 Connector I/O Pin Position 1 2 3 4 ECM Driver 3.75A PWM Driver LS3 3.75A PWM Driver HS2 3.75A PWM Driver LS2 2.
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Electrical & Electronic Application And Installation Manual 30 31 32 33 34 35 36 37 38 39 40 41 Analogue Return 300mA Sinking 5 300mA Sinking 4 Passive Analogue I/P 1 Passive Analogue I/P 2 Passive Analogue I/P 3 STG Return Differential PWM I/P 1(+) Differential PWM I/P 1(-) 300mA Sinking 7 300mA Sinking 6 ACT/Pass Select I/P 2 (Pass) 42 43 ACT/Pass Select I/P 1 (Pass) STG I/P 13 44 45 46 47 48 49 50 STG I/P 14 Reserved 2A On/Off Sourcing 7 STG I/P 15 300mA Sinking 8 Sourcing Return STG I/P 10 51 52 5
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Electrical & Electronic Application And Installation Manual 79 80 81 82 83 84 85 86 ACT Analogue/PWM In 1 (Prog) ACT Analogue/PWM In 2 (Prog) Battery Battery Battery Battery + Battery + Battery + Switch Analogue Throttle 1/PWM Throttle 1 Analogue Throttle 2/PWM Throttle 2 ECM Power Return ECM Power Return ECM Power Return ECM Power Supply ECM Power Supply ECM Power Supply 18AWG 18AWG 14AWG 14AWG 14AWG 14AWG 14AWG 14AWG Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 5.3 ECM Connector Assembly & Disassembly Correct assembly and disassembly of the ECM J1 connector is required to minimise the risk of terminal damage, incorrect contact connection and connector mis-alignment. All of these failure modes can lead to intermittent engine fault conditions which may be difficult to diagnose. The following guidelines must be adhered to when working with the connector. Figure 5.3 Engine ECM J1 Connector 5.3.
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Electrical & Electronic Application And Installation Manual Figure 5.5 TPA Removal Tools Once the TPA is removed the connector can be populated with the required terminal population. To insert the sockets into the connector push the wire through from the back of the connector until the locking tab clicks into place. Miss aligned socket Open latch, socket will get push out when installing the TPA Figure 5.
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Electrical & Electronic Application And Installation Manual Once all terminals are correctly inserted into the connector body replace the TPA taking care to ensure that correct alignment of the terminals is maintained. Do not use excessive force when reinstalling the TPA. TPA Locking tab Figure 5.7 TPA Fitment Once The TPA is installed over the connector terminals the TPA will be locked into place by the two locking tabs as shown in figure 5.7 5.3.
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Electrical & Electronic Application And Installation Manual 5.4 Diagnostic Connector A 9 pin diagnostic connector is fitted to the engine wiring harness on all industrial engines. The diagnostic connector enables connection to both the proprietary PDL data links via the EST service tool and the J1939 data link, which can be accessed by most third party diagnostic tools.
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Electrical & Electronic Application And Installation Manual cables for the diagnostic power supply are not required, as diagnostic hardware should draw no more than 1Amp total. 5.4.3 Pin Information Please note that all pins shown below in table 5.6 must be connected when installing a diagnostic connector. Care should also be taken when installing the connector as incorrect connections at the back of the connector are easily made.
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Electrical & Electronic Application And Installation Manual 5.5 Mandatory Engine & Aftertreatment Connectors Please refer to Appendix 1 for complete connector lists including sealing requirements for GXL wiring systems and terminal part numbers. 5.6 Connector Terminal Contacts There are a number of different terminals available to suit each connector. These terminals and their part numbers are shown in table 5.7.
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Electrical & Electronic Application And Installation Manual All connectors, seals and terminals shown throughout this document have been specified to suit the SAE J1128 GXL or TXL cabling standard. If other wiring standards are to be used the following points must be considered.
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Electrical & Electronic Application And Installation Manual ISO Conductor Size (mm2) GXL Equivalent Dia 0.5 0.75 1 1.25 1.5 2 2.5 3.0 20 18 16 14 12 1.1 1.3 1.5 1.7 1.8 2.0 2.2 2.4 Wall Thickness Nominal (mm) 0.6 0.6 0.6 0.6 0.6 0.6 0.7 0.7 Wall Thickness Minimum (mm) 0.48 0.48 0.48 0.48 0.48 0.48 0.56 0.56 Max Cable Diameter (mm) 2.3 2.5 2.7 2.95 3.0 3.3 3.6 4.1 5.8 Harness Wiring Standards The following are general “good practice” guidelines for wire harness design and installation.
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Electrical & Electronic Application And Installation Manual 5.8.2 Harness Bends Near Connectors Harness bends within 25mm of the ECM J1 connector should be avoided. Bending a harness too close to the connector causes the connector seal to be stretched away from the wire, reducing its sealing capability to dirt and moisture. To avoid this the wires should exit perpendicular to the connector before curving as necessary for routing as shown in figure 5.11.
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Electrical & Electronic Application And Installation Manual carrying small signal currents. In particular, high current and signal wires should not run parallel in the same harness bundle for any significant distance. Ideally, if high current wires must be in proximity to signal wires then they should cross at right angles. The engine wire harness should not be used by the installer as a support for any components that are not supplied as part of the engine system.
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Electrical & Electronic Application And Installation Manual 6.0 Customer Connection Of Engine Components The Tier 4Final/Stage IV 1204 to 1206 product range requires the customer to install some engine performance critical electrical sensors / components. Details of these components are shown below. Component Product Installation Instruction Location 6.1 6.2 Water In Fuel Switch All Ambient Air Temperature All Sensor Engine Electrical Fuel Lift All Pump Glow Plugs All Table 6.
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Electrical & Electronic Application And Installation Manual 6.1.3 WIF Switch Installation Figure 6.1 Water In Fuel Switch 363-5084 The WIF switch is supplied connected to the bottom of the primary fuel filter. The switch is supplied with a flying lead connection, which provides the connection point for the customer to connect the switch to the ECM J1 connector. The part numbers required to connect the switch to the ECM are shown in table 6.3.
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Electrical & Electronic Application And Installation Manual Figure 6.3 Air Inlet Temperature Sensor 6.2.2 Ambient Air Temperature Sensor Configuration All engines are supplied programmed with a standard 5oC air inlet temperature sensor offset to calculate the local ambient air temperature being breathed by the engine. This offset value is fixed and requires no in application calibration.
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Electrical & Electronic Application And Installation Manual ECM J1 Connector AIR INLET TEMPERATURE SENSOR 1 2 29 ANALOG SENSOR 5V RETURN 34 AIR INLET TEMPERATURE SENSOR Figure 6.5 Air Inlet Temperature Installation Wiring The sensor requires a M18 x 1.5 (metric) or ¾ -16 (Imperial) thread and should be installed after the air cleaner with a tightening torque of 20+/-3Nm. It should be noted that the sensor is supplied without an O-ring.
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Electrical & Electronic Application And Installation Manual Supply of the lift pump control really is the responsibility of the OEM. An example relay specification is shown in figure 6.5 below. When mounting the relay the following must be considered; - Mounting location of the relay does not exceed the temperature and vibration limits of the chosen component. - The relay must not be mounted under any circumstances to the engine.
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Fuse (See Note A) Electrical & Electronic Application And Installation Manual Figure 6.6 ELP Installation Schematic Note A: The lift pump supply cables and the associated fuse rating will be dependent upon the overall system voltage. Table 6.6 gives details of the max continuous current rating for each pump. The fuse rating selected should be specified to protect the cable size used. Note: For more information regarding mechanical installation and mounting please refer to the Mechanical A&I Manual. 6.3.
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Electrical & Electronic Application And Installation Manual Engine harness 2 way Connector Fuel Pump 2 way Connector ENGINE FUEL LIFT PUMP + 1 1 ENGINE FUEL LIFT PUMP + RETURN 2 2 RETURN Figure 6.7 ELP Wiring Note: For more information regarding mechanical installation and mounting please refer to the Mechanical A&I Manual. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 7.0 1204F Connecting To The Engine Aftertreatment The Perkins 1204F Tier 4 Final/Stage IV engine range can be supplied with two different aftertreatment system configurations. The following section provides guidance on the electrical installation of these systems and should be used in conjunction with section 9 Component Installation Requirements. 7.1 DOC + DPF + SCR 3 4 Install In <85 DegC Ambient Temp e.g.
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Electrical & Electronic Application And Installation Manual 7.1.2 Electrical Connections The DOC+DPF+SCR aftertreatment systems are supplied directly from the factory with all components shown in figure 7.1. Some components are supplied fitted to the aftertreatment system whilst others must be fitted by the customer. The table below provides an overview for the mounting requirements of each sensor.
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Electrical & Electronic Application And Installation Manual Figure 7.2 Connector Detail 7.1.3 Component I/O 7.1.3.1 DOC Inlet Temperature Sensor Pin 1 2 Description XRDG (0V) DOC Inlet Temp Perkins P/N TBD TBD Supplier P/N AMP 282110-1 AMP 282110-1 To Pin XNOx Con (24) XNOx Con (9) Supplier P/N AMP 282110-1 AMP 282110-1 To Pin XNOx Con (24) XNOx Con (8) Supplier P/N AMP 282110-1 AMP 282110-1 To Pin XNOx Con (24) XNOx Con (10) 7.1.3.
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Electrical & Electronic Application And Installation Manual 7.1.3.
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Electrical & Electronic Application And Installation Manual 7.2 DOC + SCR 7.2.1 System Architecture 2 3 1 DEF Injector DOC SCR Catalyst NOx AMOX NOx 7 Ambient Temp <85 DegC e.g. Cab Mounting Ambient Temp <85 DegC e.g. Cab Mounting 5 6 4 NH3 Ambient Temp <105DegC e.g. Cab Mounting Figure 7.3 DOC+SCR System Architecture Component Reference 1 2 3 4 5 6 7 Component Description A&I Installation Instruction Location Section 9.6 DOC Inlet Temperature Sensor DEF Injector Section 7.3.2.
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Electrical & Electronic Application And Installation Manual Component DOC Inlet Temperature Sensor On AT Module Additional Requirements Requires Wiring Back to Tenneco XNOx Connector By OEM DEF Injector Yes Requires Wiring Back to Tenneco XNOx Connector By OEM SCR Inlet Yes Requires Wiring Back to Temperature Sensor Tenneco XNOx Connector By OEM Tailpipe Ammonia No Requires Installation by OEM Sensor and wiring back to the engine ECM J1 connector Tailpipe Outlet NOx No Sensor must be fitted and wired Sens
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Electrical & Electronic Application And Installation Manual 7.2.3 Component I/O 7.2.3.
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Electrical & Electronic Application And Installation Manual 7.3 1204F DEF System 7.3.1 System Architecture 2 1 Header Unit DEF Level DEF Temp MAIN POWER RELAY DEF Tank DEF Quality Coolant Diverter Valve 3 Tenneco XNOx DCU DEF Dosing Pump Unit Line Heater Pressure Sensor Encl. Heater DC Pump Line Heater Line Heater 5 4 DEF Injector 6 Figure 7.5 Tier 4F 1204F DEF System Architecture Component Reference 1 2 3 4 5 6 Component Description A&I Installation Instruction Location Section 7.3.2.
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Electrical & Electronic Application And Installation Manual 7.3.2 PEU Electrical Connections & Component Installation Requirements The 1204F Pump Electronics Unit and DEF Tank is supplied direct from the factory in the form of loose parts. The following parts require mounting to the machine chassis by the OEM. 7.3.2.1 DCU Main Power Relay The DCU main power relay is required to manage the operation of the Tenneco XNOx DCU.
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Electrical & Electronic Application And Installation Manual Flying Lead is 300mm long Figure 7.6 Tenneco XNOx DCU and Pump Unit With Factory Supplied Harness Connection to the 31 pin customer interface connector is made using one of the two part numbers listed below in table 7.6. The choice of which will be dependent upon the wire gauge diameter used. Figure 7.
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Electrical & Electronic Application And Installation Manual Figure 7.8 pin Receptacle Machine Mounting Requirements The interface connector requires mounting to a machine structure using a lock washer and nut as shown in figure 7.8 7.3.2.3 DEF Tank Coolant Diverter Valve The coolant diverter valve is provided by Perkins to enable the control of engine coolant out to the Urea thaw element within the DEF tank.
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Electrical & Electronic Application And Installation Manual 7.3.2.4 DEF Tank & Header Unit The DEF tank header unit is used to provide a means of thawing the DEF within the tank via engine coolant connections. In addition the header unit houses a DEF level switch which is used to communicate the level of DEF within the tank and as a feed into emissions control strategies. A DEF Temperature sensor is also used as an input to the coolant diverter valve control strategy. Figure 7.
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Electrical & Electronic Application And Installation Manual 7.3.2.6 Tenneco XNOx Heated Lines The DEF system Heated lines are required to prevent DEF from freezing within the fluid supply and return lines. As with the 1206F engine system, these DEF lines are provided by Perkins at various lengths to accommodate the position of the DEF system equipment within the machine design. A table of the available heated line lengths are shown below in table 7.10. Line Length m 1.5 2.0 3.0 4.0 1.5 2.0 3.0 4.0 4.5 1.
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Electrical & Electronic Application And Installation Manual Figure 7.13 2-way Heated Line Plug Connector Component Description 2-way plug Wedge lock A Wedge lock B Wedge lock C Wedge lock D Sockets Perkins Part Supplier Part Number Number TBD Deutsch DT06-2S-CE05 TBD Deutsch W2SA-P012 TBD Deutsch W2SB-P012 TBD Deutsch W2SC-P012 TBD Deutsch W2SD-P012 2900A009 Deutsch 0462-201-16141 Table 7.11 DEF Heated Line Mating Connections Quantity 12V 24V 1 1 2 N/A N/A 2 1 N/A N/A 1 6 6 Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 7.3.3 Component I/O 7.3.3.1 DCU Main Power Relay Pin 30 85 86 87 Description Main Power Feed Coil + Coil Power Out Normally Open Contact Terminal P/N Customer Selected Customer Selected Customer Selected Customer Selected 87A NC Contact Customer Selected To Pin Fused Batt + ECM J1 (5) ECM J1 (15) Ammonia (1) DEF Header Unit (4) XNOx DCU (56, 59, 62) N/A 7.3.3.
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Electrical & Electronic Application And Installation Manual 23 CAN C - TBD 24 XDRG (0V) TBD 25 26 27 28 29 30 31 Not Used Not Used Not Used Not Used Not Used Not Used Not Used 2900A011 2900A011 2900A011 2900A011 2900A011 2900A011 2900A011 1631 Deutsch 0462-2011631 Deutsch 0462-2011631 Deutsch 114017 Deutsch 114017 Deutsch 114017 Deutsch 114017 Deutsch 114017 Deutsch 114017 Deutsch 114017 ECM J1 (18) SCR T (1) DOC T (1) DPF T (1) N/A N/A N/A N/A N/A N/A N/A 7.3.3.
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Electrical & Electronic Application And Installation Manual 7.4 1204F Aftertreatment wiring Schematics 7.4.1 1204F DOC & SCR Schematic Note 1: Selected fuse must be specified to meet cable requirements and system current requirements as detailed in table 4.2.2. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 7.4.2 1204F DOC, DPF & SCR Schematic Note 1: Selected fuse must be specified to meet cable requirements and system current requirements as detailed in table 4.2.2. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 8.0 1206F Connecting To The Engine Aftertreatment This section provides connection details for all IG CEM unit components, which require connection back to the engine ECM J1 connector. 8.1 IG CEM 8.1.1 System Architecture The Perkins Integrated CEM unit comprises of a DOC, DPF Can as well as the SCR catalyst unit contained within one package.
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Electrical & Electronic Application And Installation Manual NOx A1:E1 IGCEM ID Temperature Sensor Electronics NOx Figure 8.2 IG CEM System Architecture Component Reference 1 2 3 4 5 6 Component Description A&I Installation Instruction Location Section 9.1 Section 9.2 Section 8.2.2.5 Section 9.2 Section 9.5 Section 9.4 DPF Soot Sensor Engine Out NOx Sensor DEF Injector Tailpipe Out NOx Sensor IG CEM ID Module Combined DPF & SCR Inlet Temp Table 8.
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Electrical & Electronic Application And Installation Manual the IG CEM there is also a requirement for the customer to install some emission critical hardware. More details are given in the following section. 8.1.2 IG CEM Electrical Connections The IG CEM aftertreatment systems are supplied directly from the factory with all components shown in figure 8.2. Some components are supplied fitted to the aftertreatment system whilst others must be fitted by the customer.
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Electrical & Electronic Application And Installation Manual 8.1.3 Component I/O 8.1.3.1 Engine ECM J1 Connector Pin 14 Description 3.
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Electrical & Electronic Application And Installation Manual 8.1.3.3 Engine Out Nox Sensor Connector Pin 1 2 3 4 5 6 Description ECM Controlled Batt + N/A N/A Ground CAN C J1939 CAN C J1939 + Perkins P/N 2900A016 Terminal P/N Deutsch 0462-201-1631 To Pin ECM J1 (57) 2900A011 2900A011 2900A016 2900A016 2900A016 Deutsch 114017 Deutsch 114017 Deutsch 0462-201-1631 Deutsch 0462-201-1631 Deutsch 0462-201-1631 N/A N/A ECM J1 (14) ECM J1 (18) ECM J1 (17) 8.1.3.
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Electrical & Electronic Application And Installation Manual 8.2 1206F Pump Electronics & Tank Unit (PETU) This section provides connection details for all PETU components, which require connection back to the engine ECM J1 Connector. 8.2.1 PETU System Architecture The PETU (Pump, Electronics and Tank Unit) is a self-contained DEF storage and controlled distribution unit. The unit consists of a PEU (Pump Electronics Unit), Tank Header unit and a Tank.
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Electrical & Electronic Application And Installation Manual DEF System Configuration Perkins Supplied PETU Application Sections 8.2.2.1 8.2.2.2 8.2.2.3 or 8.2.2.4 8.2.2.5 Perkins PETU with Remote PEU 8.2.2.1 8.2.2.2 8.2.2.3 or 8.2.2.4 8.2.2.5 Perkins Header with PEU 8.2.2.1 8.2.2.2 8.2.2.3 or 8.2.2.4 8.2.2.5 8.2.2.6 Table 8.3 Applicable A&I 8.2.
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Electrical & Electronic Application And Installation Manual 8.2.2.1 PETU Power Supply Connection Power supply connections to the PETU are supplied pre-terminated at a 4way connector mounted on the side of the PEU. The unit requires fused unswitched battery connection for power supply to the DEF controller and pump. Electrical connection requirements and installation schematic are shown below. Figure 8.
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Electrical & Electronic Application And Installation Manual Component Perkins Part Number Supplier Part Number Description 12-way 18-14AWG TBD AMP 776437-1 Connector Terminal Socket 2900A016 AMP 0462-201-1631 Sealing Plug 2900A011 AMP 114017 Table 8.
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Electrical & Electronic Application And Installation Manual In every case the electrical connection point for the heated lines to the PEU are supplied as part of the PEU assembly. No installation wiring needs to be completed by the customer to activate the heated lines. However each line is supplied with a 2 way Ampseal connector which requires mating with the correct heated line connection on the PEU as shown in figure 8.9.
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Electrical & Electronic Application And Installation Manual Component Description Suction Line 2 way Socket Return to tank 2 way Socket Injector pressure 2 way Socket 18AWG Pins Perkins Part Number TBD Supplier Part Number AMP 776534-1 1 TBD AMP 776534-2 1 TBD AMP 776534-3 1 TBD Deutsch 0460-202-1631 Table 8.7 DEF Line Electrical Connections Quantity 6 8.2.2.5 DEF Injector Connection The DEF unit Injector is supplied mounted within the IGCEM unit at the outlet of the DPF and Pre-SCR catalyst.
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Electrical & Electronic Application And Installation Manual 8.2.2.6 Tank Header Connection (Remote PEU Only) For those customers requiring a remote mounted PEU the customer is responsible for the connection of the Perkins supplied header unit back to the PEU unit. The header unit comes supplied with a flying lead connection that requires connection to the mating 3 way interface connector on the PEU as shown in figure 8.12. 3-way PEU Connector 3-way Header Connector Figure 8.
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Electrical & Electronic Application And Installation Manual 8.2.3 Component I/O 8.2.3.
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Electrical & Electronic Application And Installation Manual 8.3 1206F Aftertreatment Wiring Schematic Note 1: Selected fuse must be specified to meet cable requirements and system current requirements as detailed in table 4.2.3. Note 2: Second CAN C termination resistor is provided as part of the factory supplied PETU harness. Note 3: CAB A must be fitted with 2 x 120Ohm resistors. Both resistors are to be supplied by the customer. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 9.0 Component Installation Requirements This section provides the individual emissions system components insta1llation requirements. For details of the specific components required for each engine and AT system please refer to sections 5 and 6 of this document. 9.1 DPF Soot Sensor 9.1.
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Electrical & Electronic Application And Installation Manual seals. Fasten the control box using washers and two M6 bolts to a tightening torque of 12Nm +/-3Nm. Figure 9.1 DPF Soot Sensor Orientations The Electronic control box has a maximum ambient operating temperature of 85oC and a minimum of –40oC. It must be mounted in a location where it will not exceed these temperatures. The antennas are supplied screwed into the DPF.
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Electrical & Electronic Application And Installation Manual Component Description 6-way Connector Plug Connector Sockets 18AWG Blanking Plug Perkins Part Number Supplier Part Number T409233 2900A016 AMP 776433-3 Deutsch 0462-201-1631 2900A011 Deutsch 114017 Table 9.1 DPF Soot Sensor Electrical Connector Quantity 1 5 1 Connector Pin Assignment 1 VBatt 2 Ground 3 Unused 4 J1939 CAN C 5 J1939 CAN C + 6 CAN Shield (if supported) Table 9.
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Electrical & Electronic Application And Installation Manual • • • If tie wraps are used to clamp the cables then care must be taken to ensure that they do not clamp the cable excessively causing the damage to the coaxial cable itself. Cables must be supported at regular intervals to ensure that the cable is correctly supported. Retention points are to be located at approximate intervals of 200 to 450mm on any cable runs to provide the required support.
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Electrical & Electronic Application And Installation Manual 9.2 NOx Sensor 9.2.1 NOx Sensor Operation There are two NOx sensors required for the Tier4 Final/Stage IV product range. These sensors are required to correctly operate and monitor the aftertreatment system. The sensing unit used in each operate in the same way however to prevent incorrect harness connection the mating connections have different keying. Figure 9.
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Electrical & Electronic Application And Installation Manual 9.2.2 NOx Sensor Configuration No specific configuration is required to enable the correct operation of this sensor. 9.2.3 NOx Sensor Installation 9.2.3.1 NOx Sensor Control Unit Installation It is the customers responsibility to mount the NOx sensors. The location of NOx sensor control unit must meet the criteria described below. Additional mechanical installation requirements can be found in the Mechanical A&I manual.
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Electrical & Electronic Application And Installation Manual • • Harness must be secured every 6” or 150mm or less. Bend radius of the harness must be >=20mm. Good Cable Support Example Figure 9.7 NOx sensor Cable Support Bad Cable Support Example Harness Not support and exit from rear of sensor >15Deg Figure 9.8 Improper NOx Sensor Cable Support For machines where relative motion between the first harness clipping point and the rear of the sensor a security loop needs to be used as shown below.
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Electrical & Electronic Application And Installation Manual Figure 9.9 NOx Sensor Harness Clipping Routing and clipping of the NOx sensor cable must not result in any of the temperature limits stated in table 9.6 being exceeded. Under no circumstances should the NOx sensor cable be tie wrapped to the sensor boy as shown below as during operation the sensing unit will heat to temperatures above 200DegC, which will cause damage to the sensor cable.
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Electrical & Electronic Application And Installation Manual Connector Sockets 18AWG Blanking Plug Pin Location 1 2 3 4 5 6 2900A016 Deutsch 0462-201-1631 2900A011 Deutsch 114017 Table 9.7 NOx Sensor Connector Part Number 8 4 Description Terminal Socket P/N Vs From ECM J1 Connector 0462-201-1631 J1939 114017 Address Select 114017 GND 0462-201-1631 J1939 0462-201-1631 J1939 + 0462-201-1631 Table 9.
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Electrical & Electronic Application And Installation Manual Figure 9.13 Ammonia (NH3) Sensor and Controller 9.3.2 Ammonia (NH3) Sensor Configuration No electronic configuration of the ammonia sensor is required. 9.3.3 Ammonia (NH3) Sensor Installation There are two pieces of ammonia sensor hardware for which the OEM has responsibility for installation, the sensing unit and the control unit. Both parts of the ammonia device are supplied loose with each DOC & SCR only engine.
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Electrical & Electronic Application And Installation Manual designed to accommodate an M6 fixing and washer tightened to a torque of 11Nm +2/-1 tolerance. 9.3.3.2 Ammonia (NH3) Sensor Cable Routing & Support As with the engine NOx sensor the cable routing and support is critical to the correct operation of the component over the life of the machine. To ensure component integrity the cable connection back to the sensing control unit must adhere to the following installation criteria.
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Electrical & Electronic Application And Installation Manual For further information regarding correct NH3 sensor cable installation and strain relief please refer to section 9.2.3.2. 9.3.3.3 Ammonia (NH3) Sensor Controller Electrical Connection The electrical connection made to the NH3 sensor is made via a 4 way connector as shown in figure 9.16 The NH3 sensor uses the CAN C data link for status communication and requires wiring as part of the customers machine harness as shown in figure 9.17 Figure 9.
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Electrical & Electronic Application And Installation Manual Figure 9.17 NH3 Sensor Wiring 9.4 DPF In and SCR PerkinsIn Combined Temp Sensor (1206F) 9.4.1 DPF & SCR Temp Sensor Operation The DPF and SCR Inlet temperature sensors are used to ensure the correct operation of the engine aftertreatment system. Both temperature sensors are routed back to a 4 way Ampseal connector for ease of connection back to the engine ECM J1 connector as shown below. Figure 9.18 DPF and SCR Inlet Temperature Sensor 9.4.
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Electrical & Electronic Application And Installation Manual 9.4.3 DPF & SCR Temp Sensor Installation The DPF and SCR Inlet temperature sensor is fitted with a 4-way Ampseal connector. The mating connector to be mounted onto the customers machine wiring harness is 239-7349. Terminal assignment for the 4-way Ampseal connector is shown in Table 9.13. Figure 9.
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Electrical & Electronic Application And Installation Manual 9.5 IG CEM ID Module 9.5.1 IG CEM ID Module Operation The DPF identification module is supplied with all Tier 4 Final/Stage IV engines. The module is used on engine start-up to verify that the aftertreatment part number corresponds to that stored within the engine ECM. The ECM carries out the part number verification for the first 25 hours of engine operation only.
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Electrical & Electronic Application And Installation Manual Figure 9.22 ID Module Tether location Once the aftertreatment has been fitted into the machine and connected to the engine mechanically the ID module must be removed from the transit position by cutting the tie wrap shown in figure 9.23 The remaining tie wrap is fitted with a fir tree for mounting into a threaded hole at some location on the machine chassis.
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Electrical & Electronic Application And Installation Manual Figure 9.24 DOC, DPF & SCR ID Module Transit Mounting Location 9.5.3.3 1206F DOC, DPF & SCR ID Module Mounting The module is supplied attached to a sensor mounting plate, which forms part of the overall aftertreatment system. No ID module installation is required by the OEM. The OEM is responsible however for connecting the DPF ID module to the engine ECM J1 connector as part of the machine wiring harness. 9.5.3.
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Electrical & Electronic Application And Installation Manual Pin Location 1 2 3 4 5 6 Description Terminal Socket P/N ID Module 5V Sensor Supply Not Used AT ID Digital Signal Not Used Not Used 0V Sensor Return Table 9.
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Electrical & Electronic Application And Installation Manual 9.6 DOC, DPF & SCR Inlet Temperature Sensors (1204F) 9.6.1 DOC, DPF & SCR Inlet Temperature Sensor Operation The 1204F DOC, DPF & SCR Inlet temperature sensors are required for accurate control / monitoring of the engine aftertreatment system. The number of temperature sensors required for each individual engine range is dependent upon the chosen aftreatreatment recipe.
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Electrical & Electronic Application And Installation Manual • Further fixation points maybe required depending on cable routing. • All excess cable length must be secured to the machine body to prevent damage by friction / abrasion with surrounding components. Connection to each inlet temperature sensor is made using a 2 pin Ampseal connector as shown in figure 9.29 and table 9.18 Each specific sensor terminal assignments are shown in table 9.19. Figure 9.
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Electrical & Electronic Application And Installation Manual Figure 9.30 DOC, DPF & SCR Electrical Schematic Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 10.0 Starting and Stopping the Engine 10.1 Starting the Engine Unlike mechanically controlled fuel systems no customer connection to the fuel pump solenoid is necessary. To activate the engine ECM un-switched battery voltage needs to be constantly supplied to pins 84, 85, 86 (Batt +) and 81, 82, 83 (Batt -), as well as constant switched battery voltage applied to pin 69.
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Electrical & Electronic Application And Installation Manual installation of a starting and charging system please refer to Tier 4F Starting and Charging System A&I Manual. 10.2 Stopping the Engine (and Preventing Restart) There is often some confusion about the different methods and devices used to either stop the engine or to prevent it from starting.
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Electrical & Electronic Application And Installation Manual in series with the ignition keyswitch input to provide a remote stop feature. It is recommended that the switch is a latched contact type as closing the switch whilst the engine is shutting down could cause the engine to restart. In the event of Delayed Engine shutdown being activated as a protection feature on the 1206F product range a 4 position key switch is recommended.
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Electrical & Electronic Application And Installation Manual 10.2.3 User Defined Shutdown Switch (Remote Shutdown) 10.2.3.1 User defined Shutdown Switch Operation Remote stop is intended to provide a convenient method of stopping the engine.
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Electrical & Electronic Application And Installation Manual 10.2.4 Delayed Engine Shutdown (1206F Only) 10.2.4.1 Operation The delayed engine shutdown software feature is designed to protect the aftertreatment system from damage during engine hot shutdown events. Failure to cool the system sufficiently during engine shutdown may result in operator Inducements on re-start and a reduction in the service life of the system.
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Electrical & Electronic Application And Installation Manual 10.2.4.3 Intake Air Shutoff Valve Installation The intake air shutoff valve is controlled by the engine ECM using an electrical solenoid. The solenoid requires electrical connection to the engine ECM as shown in figure 10.3. 53 AIR SHUTOFF SOLENOID 49 2A ACTUATOR DRIVER RETURN Figure 10.3 Intake Air Shutoff Valve Installation Wiring 10.2.5 Overspeed Verify Switch The overspeed verify switch compliments the Air Intake Shutoff feature.
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Electrical & Electronic Application And Installation Manual 10.2.7 Engine Emergency Stops It is the customer responsibility to complete a risk assessment on their product when considering the use and function of an emergency stop device. If residual risks remain on the product that the customer wants to mitigate by use of an emergency stop function, the following methods of emergency stopping the engine may be considered.
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Electrical & Electronic Application And Installation Manual 11.0 Engine Speed Demand It is necessary to select a device that converts the speed requirements of the engine operator or controller to an electrical signal recognized by the engine ECM. There are five types of speed demand input: • • • • • Pulse Width Modulation (PWM) Sensor Analogue Sensor Throttle lock (PTO mode) - also known as “engine speed cruise control” or “set speed control”.
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Electrical & Electronic Application And Installation Manual 11.1 Analogue Sensor 11.1.1 Analogue Sensor Operation Two inputs are available for Analogue throttle devices, which may be pedal, lever or cable operated. The Analogue sensor gives a DC Analog output in the range 0.5 to 4.5 volts, when connected to the engine ECM. The ECM provides a regulated 5V 200mA power supply. The Analog sensor should use non-contact Hall effect technology.
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Electrical & Electronic Application And Installation Manual 11.1.3 Analogue Sensor Installation ECM J1 Connector ANALOGUE THROTTLE SENSOR 1 30 ACTIVE ANALOGUE RETURN 79 ANALOGUE 1 THROTTLE SENSOR INPUT 72 5V ANALOGUE POWER 75 IDLE VALIDATION SW 1 36 STG RETURN ECM J1 Connector ANALOGUE THROTTLE SENSOR 2 30 ACTIVE ANALOGUE RETURN 80 ANALOGUE 2 THROTTLE SENSOR INPUT 72 5V ANALOGUE POWER 66 IDLE VALIDATION SW 2 36 STG RETURN Figure 11.2 Analogue Throttle Sensor wiring Diagram 11.1.
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Electrical & Electronic Application And Installation Manual Idle Validation Switch Test Circuit 2K Normal supply voltage of device (Hall Effect Devices only) IVS V+ Device Under Test IVS 13V DC IVS ground V2 11.1.4.1 Test Procedure Test 1: Output at Min position Place the Device Under Test (DUT) in its minimum or “released” condition. Measure the voltage V1. Test 2: Output at Min position: forced Without causing damage, pull the pedal/ handle hard against the minimum travel end stop.
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Electrical & Electronic Application And Installation Manual If the DUT is a potentiometer type device, disconnect it from the test circuit and measure the resistance across the track (from V+ to V-). 11.1.4.2 Required Values If the results obtained from the tests above are in the ranges specified below, then the device will be compatible with the default values in the ECM. Test 1 2 3 4 5 6 7 8 9 Parameter Units Min Nominal Output at Min position Volts 0.45 0.6 Output at Min position: forced Volts 0.4 0.
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Electrical & Electronic Application And Installation Manual 11.2 PWM Sensor - Compatibility 11.2.1 PWM Sensor Operation A pulse width modulated signal is a signal whose voltage is either at a maximum or a minimum. The duration of the on time as opposed to the off time determines the strength of the outputted signal. This means that the outputted PWM signal takes the form of a square wave as shown in figure 11.3.
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Electrical & Electronic Application And Installation Manual 11.2.2 PWM Sensor Configuration When mounted on the pedal and lever the target duty cycle should be as shown in figure 11.2. It is possible however to deviate from these values by adjusting the throttle configuration within EST. All PWM sensors used should have a sinking driver with a frequency of 500Hz (+/- 50Hz). The sensor must give a valid output within 150ms of the main power being supplied to the sensor.
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Electrical & Electronic Application And Installation Manual 11.3 Throttle Lock (PTO mode) 11.3.1 Throttle Lock Mode Operation Throttle Lock mode has also previously been referred to as “PTO Mode”, “engine speed cruise control” or “set speed control” Throttle Lock mode is a cost effective way to control engine speed as it only requires switched inputs. Another benefit is that it can be used in an application where it is necessary to control the engine speed from several different points on the machine.
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Electrical & Electronic Application And Installation Manual • idle. If the signal is removed at any point the engine will remain at the ACTUAL engine speed. Set / Resume mode. This mode provides the full Throttle Lock mode functionality and uses all 5 available functions. This is the standard Throttle Lock format. The following sections describe the operation of each of the mode switches and configurable settings. 11.3.1.
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Electrical & Electronic Application And Installation Manual Each of the two speeds can be set with a default RPM value via the service tool, and then new values set by pressing the Set button whilst the engine is in operation. When the Set button is pressed the actual engine speed will be stored as the new Set speed value for which ever Set speed channel is selected at the time (1 or 2).
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Electrical & Electronic Application And Installation Manual 11.3.1.8 Example of Throttle Lock Mode Operation It is recognized that the precise function of the PTO mode is difficult to understand from a written text document, especially for Engineers for whom English is not their first language. The following table illustrates the operation of the PTO mode feature. In this example the preset speed 1 has been set on the service tool to 1800rpm.
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Electrical & Electronic Application And Installation Manual 11.3.2 Throttle Lock Mode Configuration Four parameters must be configured using Perkins EST prior to using the Throttle Lock feature. The parameters are listed in the main configuration screen and are shown below.
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Electrical & Electronic Application And Installation Manual load may mean that the desired engine speed is not achieved (lug curve operation). The example below describes the feature operation under load conditions. Example The operator using the ‘raise/resume’ switch increases desired engine speed to 2000rpm. Load is applied to the engine, which lugs the engine speed down to 1500rpm.
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Electrical & Electronic Application And Installation Manual operated via individual or combined switching devices such as rotary switches. Care should be taken however when selecting switches to ensure that they are break before make. This is a very powerful and flexible feature that may be used in a number of ways. For example: • • • Principal speed control method for hydrostatic machines where engine speed is selected and then not required to be frequently changed by the operator.
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Electrical & Electronic Application And Installation Manual Physical Position 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Switch 4 Switch 3 Physical Position Enabled Open Open Open No Open Open Closed Yes Open Closed Open Yes Open Closed Closed Yes Closed Open Open Yes Closed Open Closed Yes Closed Closed Open Yes Closed Closed Closed Yes Open Open Open No Open Open Closed No Open Closed Open No Open Closed Closed No Closed Open Open Yes Closed Open Closed Yes Closed Closed Open No Closed Closed Closed Yes Tab
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Electrical & Electronic Application And Installation Manual • • • • • Max Wins. The highest speed demand is the one that controls the engine. This is the default configuration Manual Selection switch. A switch input can be used to define which speed input has control. This is particularly useful in applications where there are 2 driver seat positions. TSC1 override. As described above, the TSC1 message over J1939 will override speed demand from any other source. Intermediate engine speed switch.
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Electrical & Electronic Application And Installation Manual 11.9 Engine Limp Home Speed The engine limp home speed setting is a configurable default engine speed to which the engine controls in the event of a throttle pedal failure. This limp home speed is configurable using ET to a value between 800rpm and 1800rpm. The default value is set to 1200rpm. It is recommended that the limp home speed is set to a different value than the engine low idle.
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Initial Lower Position Lower Deadzo ne Position Lower stic gno Dia imit er L Low Limit Electrical & Electronic Application And Installation Manual 5% 0% 5% 10% 20% r ve e rL n so atio n t Se Ro U ne n zo itio ad os De rP e p p U ial nit er pp 5% I 70% Uppe Limit ition r Pos 85% Sensor 95% Diagnostic Upper Limit 100% Pedal Rotation Lock Screws Foot Force Pedal Figure 11.
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Electrical & Electronic Application And Installation Manual 11.10.1 Throttle Parameter Description Diagnostic Lower Limit The lower diagnostic limit is the absolute minimum raw value accepted as a valid signal by the engine ECM. Any values below this point will flag appropriate diagnostics and invoke the limp-home strategy. Most analogue devices are classed as faulted with a voltage of 0.
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Electrical & Electronic Application And Installation Manual prevent a possible open or short circuit being mistaken for a valid signal, for similar reasons a PWM duty cycle should not go above 95% duty cycle. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 11.10.2 Throttle Calibration Function Initial Lower Position Lower Deadz one it tion Lim Posi Lower er Low stic gno Dia it Lim When the engine ECM is active the raw throttle signal is continuously monitored. The following diagrams explain how the automatic calibration functions. The adjustment screws in the diagram have been purposely adjusted and differ from the previous throttle pedal diagram.
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Electrical & Electronic Application And Installation Manual Initial Lower Position Lower Deadz one it tion Lim Posi Lower er Low stic gno Dia it Lim deadzone the desired engine speed will change. In this case the lever would have to move 14% of the raw signal (9% + 5% deadzone) before desired engine speed changes. This is situation is undesirable.
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dzone Initial Lower Position Lower Dea n Limit Positio Lower imit er L Low stic gno Dia Electrical & Electronic Application And Installation Manual 5% 0% 5% 10% 20% r ve e rL n so atio n t Se Ro 5% e on on dz s iti ea Po rD er pe p p p U lU tia Ini 70% r Uppe im ion L Posit it 85% Sensor OUTPUT 75% 95% Diagnostic Upper Limit 100% Pedal Rotation Lock Screws Foot Force Pedal Figure 11.
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dzone Initial Lower Position Lower Dea n Limit Positio Lower imit er L Low stic gno Dia Electrical & Electronic Application And Installation Manual 5% 0% 5% 10% 20% r ve e rL n so atio n t Se Ro e on on dz s iti ea Po rD er pe p p p U lU tia Ini 70% 5% r Uppe im ion L Posit it 85% Sensor OUTPUT 75% 95% Diagnostic Upper Limit 100% Pedal Rotation Lock Screws Foot Force Pedal Figure 11.
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Electrical & Electronic Application And Installation Manual 11.10.3 Idle Validation Switch Analogue devices must use an idle validation switch. The idle validation switch is required to validate that a change in signal is indeed valid and not a potential electrical fault. Two parameters need to be defined for correct operation. When configured the engine ECM continually monitors the speed demand request and the Idle validation switch.
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Electrical & Electronic Application And Installation Manual Idle Validation Switch ON OFF OFF ON ON OFF 5% 21% 25% 5% Sensor 100% Pedal Rotation Lock Screws Foot Force Pedal Figure 11.13 Idle validation switch transition 11.11 Definition of Engine Speed Points There are a number of engine speed configuration points available for configuration by the customer.
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Electrical & Electronic Application And Installation Manual Engine Governor Operating Power Kw Area Peak / Rated Power 180 165 150 135 120 105 90 75 60 45 30 15 High Speed Governor Curve (Run Out Line) LILL LI LIUL RSLL Speed Rev/Min RS RSUL HILL HI HIUL Figure 11.14 Example Power Curve With All Available Speed Settings 11.11.1 Engine Low Idle 11.11.1.1 Engine Low Idle Operation The engine low idle speed determines the minimum allowable engine speed during normal engine operation i.e.
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Electrical & Electronic Application And Installation Manual Varying the Rated speed and High Idle settings can alter the gradient of this line and the resulting governor response. Note: For more information regarding the interaction between the RS and HI settings along with the HSG please refer to section 17. Note: Under some circumstances the engine may not be able to reach the desired HI setting under full throttle conditions due to machine torque requirement at this speed. 11.11.2.
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Electrical & Electronic Application And Installation Manual 12.0 Cold Weather Engine Operation & Starting Aids There are two types of start aid available for all Tier 4 engines, they are, glow plugs (fitted as standard to all engines) and ether (customer configurable option). Engines can be purchased with both start aids enabled however it should be noted that under no circumstances will the glow plugs and ether system be used in conjunction with one another for safety reasons.
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Electrical & Electronic Application And Installation Manual Start Aid Control Key ON Engine Coolant Temperature Sensor ECM selects coldest temperature Intake Manifold air temperature Air Inlet Temperature Temperature <= +5 degC ? N No Start Aid required Coolant Temp Temperature <=-25 degC? Engine ECM Initiates Ether dosing Operator crank engine when lamp turns off Pre-heat map Ti m e ECM activates Wait to Start Lamp and Glow Plugs for period determined from Pre-heat map Operator Cranks the Eng
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Electrical & Electronic Application And Installation Manual 12.1 Control of Glow Plugs by the Engine ECM 12.1.1 Glow Plug System Operation Glow plugs are fitted as standard to all Tier 4 Final/Stage IV engines. When the ignition keyswitch is on, the engine ECM will monitor the coolant temperature and the inlet air temperature and decide whether the glow plugs are required. If so, the ECM will activate the glow plug relay and supply current to the engine glow plugs.
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Electrical & Electronic Application And Installation Manual Start Aid Control Key ON Engine Coolant Temperature Sensor ECM selects coldest temperature Air Inlet Temperature Temperature <= +5 degC ? N No Start Aid required Coolant Temp Y Pre-heat map Operator crank engine when lamp turns off Intake Temp ECM activates Wait to Start Lamp and Glow Plugs for period determined from Pre-heat map The operator should wait until after the Pre-heat period before cranking.
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Electrical & Electronic Application And Installation Manual 12.1.2 Glow Plug System Configuration If operation of engine glow plugs is not required, then no control hardware is required to be installed. Please note that whilst both Glow plugs and ether can be fitted to the same engine, the start aids cannot be operated at the same time for safety reasons. Please do not under any circumstances bypass the ECM control of either start aid. 12.1.
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Electrical & Electronic Application And Installation Manual Parameter Specification Requirements Temperature Limit -40°C To +85°C Vibration Limit 10Grms Coil Hold In current < 2Amps N/O Contact Current See table 12.1 Suppression Diode Table 12.2 Glow Plug Relay Specification Note: All relays must be mounted off engine to reduce the risk of component failure due to engine vibration. Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 12.2 Ether Cold Start Systems 12.2.1 Ether start Operation The ether solenoid control is available to drive a relay and/or solenoid to control ether delivery to the intake manifold. The ECM controls the ECM output when conditions dictate the use of an Ether starting aid. Perkins offers an optional ether start system matched to each engine’s particular cold start strategy.
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Electrical & Electronic Application And Installation Manual Figure 12.5 Example Ether Control Valve The mating connector for both the 12 and 24V Ether solenoid options are shown below in figure 12.6. The part numbers required for the ether solenoid connection are also shown in table 12.4. Figure 12.
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Electrical & Electronic Application And Installation Manual 9 ETHER START AID SOLENOID 49 ACTUATOR DRIVER RETURN ETHER START AID SOLENOID Figure 12.7 Ether Solenoid Electrical Connection Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 12.3 Heated Breather 12.3.1 Heated Breather Operation For applications operating in temperatures below –25°C there is a requirement for a heated breather canister and insulated hose to be fitted to all Tier 4 Final/Stage IV products. The thermostatically controlled heater is configured to turn on at –12 and off at –1°C and prevents water vapour from freezing within the breather system under cold climate conditions.
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Electrical & Electronic Application And Installation Manual 12.3.3 Heated Breather Installation The heated breather canister is controlled via a thermostatic switch and requires fused connection to the machine battery. The breather is both 12 and 24V compatible however the wiring to the breather is voltage dependant as shown below in figure 12.9. The current consumption of the unit is also dependent upon supply voltage with 24V being 2A and 12V 4A.
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Electrical & Electronic Application And Installation Manual 12.4.2 Cold Weather Regeneration Aid Configuration No configuration is required for this feature as all engine software contains the ability to increase engine speed to aid regeneration when required. 12.4.3 Cold Weather Regeneration Aid Installation For those applications wishing to activate the elevated engine idle strategy pin 46 of the engine ECM J1 connector must be connected to pin 18 the ground switch return pin.
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Electrical & Electronic Application And Installation Manual 12.5.3 Aftertreatment Ambient Air Temp Sensor Installation The Perkins temperature sensor part number 191-6587 and mating components listed below are required for this feature to operate correctly. Figure 12.
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Electrical & Electronic Application And Installation Manual 12.6 Engine Soft Start Protection 12.6.1 Engine Soft Start Protection Operation After starting, a soft start strategy is employed which holds the engine speed at low idle or 850rpm depending on which is lowest for a duration between 1 and 25 seconds to allow engine systems to stabilise. Under normal system conditions, the trigger to exit the soft start strategy is oil pressure.
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Electrical & Electronic Application And Installation Manual • • During Soft start SPN 3551 will be transmitted with a 00 status (Not sufficiently Lubricated). Post Soft start SPN 3551 will be transmitted with 01 status (Sufficiently Lubricated). Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 13.0 Operator Indicators & Fault Displays 13.1 Engine & AT Diagnostic Systems Both the engine and aftertreatment systems are fitted with a number of sensors and actuators designed to provide tight control over engine performance and emissions management. Each of these devices also enable the engine management system to closely monitor the health of the system and react as necessary when fault conditions occur.
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Electrical & Electronic Application And Installation Manual DES Active Yes if DES is x ✓ Indicator enabled Table 13.1 Mandatory Indicator Requirements 13.1.1 Monitoring System Fault Status Levels All engine and aftertreatment fault indicators are assigned a warning category indicator (WCI), which indicates the severity of the specific diagnostic, event or emissions critical failure. The high level operation of the indicator control strategy is shown below in figure 13.1.
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Electrical & Electronic Application And Installation Manual 13.2 Gauge Drivers If a needle type analogue gauge is required to display an engine parameter such as engine speed, oil pressure, or coolant temperature, it is recommended that the OEM use a gauge or display that can use the parameters broadcast by the ECM on the J1939 datalink. As an alternative, traditional single wire gauge ‘senders’ may be used if a suitable tapping is available.
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Electrical & Electronic Application And Installation Manual To support new standards and requirements, Perkins may add to the fault code table. Therefore, any active engine fault codes including those not recognized or referenced should be displayed. 13.3 Lamp Outputs & Operation 13.3.1 Hardwired Lamp Outputs All mandatory engine and aftertreatment indicators are provided as standard as dedicated ECM outputs. Engine ECM pin allocation for each of these indicators is shown below in table 13.
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Electrical & Electronic Application And Installation Manual 13.3.
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Electrical & Electronic Application And Installation Manual N/A Wait To Disconnect Indicator Wait To Disconnect Used to indicate that the engine and DEF system are active. N/A * Indicator required for all 1206F engines configured with Delayed Engine Shutdown Active. More details in section 16.3.1. 13.3.4 Engine Shutdown Indicator 13.3.4.
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Electrical & Electronic Application And Installation Manual 13.3.5.1 Engine Warning Indicator Operation The Warning lamp is used to alert the operator of an engine operating condition that has the potential to cause engine damage. The lamp will illuminate when an active diagnostic or event code is raised. The warning lamp will flash for any diagnostics that cause an engine derate or any event code with a severity level 2 or greater. 13.3.5.
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Electrical & Electronic Application And Installation Manual The Engine wait To Start Indicator is also available via J1939 as shown below. Function Warning Indicator Status PGN FEE4 SPN / Byte 1081 / 4 Start bit 1 Length 2 Applicable States 00 (OFF) 01 (ON) 13.3.7 Oil Pressure Indicator 13.3.7.
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Electrical & Electronic Application And Installation Manual EPA emissions regulations. For more details regarding the use of the emissions system malfunction indicator please refer to section 14 of this document. 13.3.8.2 Emissions System Malfunction Indicator Configuration No configuration of the emissions system malfunction indicator is required. 13.3.8.
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Electrical & Electronic Application And Installation Manual Function Low DEF Level Indicator PGN SPN / Byte FE56 5245 / 5 Start bit 6 Length 3 Applicable States 000 (OFF) 001 (ON) 13.3.10 Wait To Disconnect Indicator 13.3.10.1 Wait To Disconnect Indicator Operation The wait to disconnect Indicator is a mandatory fit item used to alert the machine operator that the Engine & DEF system are still active and the battery isolation switch should not be used.
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Electrical & Electronic Application And Installation Manual switch OFF until the engine exhaust temperature has dropped below a defined threshold. The DES indicator will illuminate whilst the DES cool down procedure is active. Further information regarding the DES procedure and operation can be found in section 16.0 of this document. 13.3.11.
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Electrical & Electronic Application And Installation Manual It should be noted however that Tier4 Final legislation mandates the use of some specific system controls and failure reactions in the form of derates etc which cannot be disabled or adjusted. The following sections provide details of these exceptions and how they operate. 14.1 General Information The engine monitoring system includes two parts.
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Electrical & Electronic Application And Installation Manual measuring an engine parameter above the configurable threshold level a warning is triggered (Event Code), which is logged by the engine ECM and the appropriate lamp driver is activated. 14.1.1.2 De-rate Each monitored parameter that uses the derate function has its own derate trigger threshold and map. If the derate threshold is equaled or exceeded by any parameter, a derate protection will be set active and the engine will derate.
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Electrical & Electronic Application And Installation Manual Parameters which have Fixed Factory Set Thresholds Oil Pressure No Yes No Table 14.2 Available Engine Monitoring System Parameters Yes It should be noted that when engine shutdowns are enabled the following system response is true. • • • Severity Level 1 (least severe) = Engine warning Severity Level 2 (moderate severity) = Engine Derate Severity Level 3 (most severe) = Engine Shutdown 14.1.
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Electrical & Electronic Application And Installation Manual Engine coolant temperature rises to a value above the severity level 3 threshold. Engine action = Event code E361-3 (or J1939 110-00) is raised and the engine warning lamp is activated. The engine stores the event code but does not begin to shut down due to the engine monitoring system shutdowns being disabled. 14.
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Electrical & Electronic Application And Installation Manual 14.2.1.2 Coolant Temperature Monitoring Mode Configuration The high engine coolant temperature threshold settings are available for adjustment within Perkins EST for all monitoring system severity levels.
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Electrical & Electronic Application And Installation Manual 14.2.2.3 Engine Oil Pressure Monitoring Mode Installation No installation is required for the engine oil pressure monitoring function. 14.2.3 Intake Manifold Temperature 14.2.3.1 Intake Manifold Temperature Monitoring Mode Operation The engine intake manifold air temperature is monitored by the engine management system to ensure that the engine remains emissions compliant when high intake manifold temperatures are measured.
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Electrical & Electronic Application And Installation Manual 14.2.4 Engine Overspeed 14.2.4.1 Engine Overspeed Monitoring Mode Operation The engine ECM will automatically monitor engine speed to protect the engine from exceeding a pre-defined maximum value. This function is employed to protect both the engine and the drivetrain components from high engine speeds. The Engine Overspeed function can be configured at both Severity L1 and Severity L3.
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Electrical & Electronic Application And Installation Manual 14.2.5 High NRS Temperature 14.2.5.1 High NRS Temperature Operation The engine control system monitors the NRS gas temperature in order to prevent the temperature exceeding allowable levels. This monitoring system parameter is required to prevent component damage due to excessive NRS temps. The High NRS temperature protection supports Severity L1 and Severity L2 only.
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Electrical & Electronic Application And Installation Manual 14.3 Emissions Critical Components Monitoring & Protection Tier 4 Final /Stage IV Emissions standards stipulate that the use of operator inducements are mandatory for all SCR equipped non road engines. The term Inducement covers any actions intended to alert / prompt the operator of a machine to repair or perform maintenance on the emissions control system.
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Electrical & Electronic Application And Installation Manual Inducement escalation codes applicable to section 14.3.2.1 & 14.3.2.2 • • • 5246-15 – Aftertreatment SCR Operator Inducement Severity High – Least Severe (Level 1) 5246-16 - Aftertreatment SCR Operator Inducement Severity High – Moderate Severity (Level 2) 5246-0 - Aftertreatment SCR Operator Inducement Severity High – Most Severe (Level 3) Inducement escalation codes applicable to section 14.3.2.
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Electrical & Electronic Application And Installation Manual 14.3.2.1 DEF Quality, Tampering & Dosing Interruption Inducement st Time 1 Occurrence Normal Operation Until Fault Inducement Time Repeat Occurrence Until Fault Inducement None Level 1 2.
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Electrical & Electronic Application And Installation Manual Notification None Emissions System Failure Lamp + Engine Shutdown Lamp 14.3.2.3 DEF Level – 1204F Initial Indication Inducement st Time 1 Occurrence Inducement Time Repeat Occurrence <20% DEF Level Reading None Level 1 <14% DEF Level Reading None Level 2 Level 3 Mild: reduced time <8.0% DEF Level Reading Reduced Time: >3.5% DEF Level Reading Severe: Reduced performance >3.
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Electrical & Electronic Application And Installation Manual 14.3.2.3 DEF Level – 1206F Initial Indication Inducement st Time 1 Occurrence Inducement Time Repeat Occurrence <20% DEF Level Reading None Level 1 <13.5% DEF Level Reading None Level 2 Level 3 Mild: reduced time <7.
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Electrical & Electronic Application And Installation Manual 14.3.3 Combined EU/EPA Inducement Strategy Configuration There are two configurable options provided in order for the operation of the Inducement strategy to be tailored to a particular machine types needs. These options are listed below.
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Electrical & Electronic Application And Installation Manual Figure 14.1 Inducement Reduced Time / Performance Configuration 14.3.3.2 Level 3 Engine Idle Down or Shutdown The Engine Idle Down or Shutdown option provides configurability of the engine response once a L3 Inducement has been activated. The default setting for all engines delivered from Perkins is Reduced Performance. 14.3.
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Electrical & Electronic Application And Installation Manual 14.3.5 Final Inducement Safe Harbor Mode. Safe harbor mode is a mode of operation that allows for full engine torque capability post Inducement Level 3 activation for a limited time period. This strategy is designed to allow a machine that has been forced to low idle or shutdown due to a system failure causing a Level 3 inducement to be moved to an area where re work can take place. Once the final inducement has been completed (section 14.3.4.
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Electrical & Electronic Application And Installation Manual 15.0 Monitored Inputs For Customer Fitted Sensors This section covers the optional switches and sensors available for the customer to install / connect. Some of the switches and sensors require the customer to both install them and provide the wiring harness connection to the engine ECM. Others are factory fitted and require the customer to provide a connection to the ECM only.
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Electrical & Electronic Application And Installation Manual this input in configurable from Normally open to normally closed depending upon the type of switch selected. Upon indication of a blocked intake the ECM will raise a severity level and associated event code (as shown below in table 15.3).
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Electrical & Electronic Application And Installation Manual The Air intake restriction switch is a 2 wire switch which requires connection to the switched battery + and pin 64 of the ECM J1 connector as shown in figure 15.2. Figure 15.2 Air Intake Restriction Switch Installation wiring 15.2 Coolant Level Switch 15.2.
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Electrical & Electronic Application And Installation Manual Low Coolant Level Monitoring Configuration Default Time Delay (sec) Set Points Value Range Default Range Default Severity L1 On 1 to 120sec 10 Severity L2 On 1 to 120sec 10 N/A N/A Severity L3 Off 1 to 120sec 10 Table 15.6 Low Coolant Level Monitoring Mode Operation Configuration Status 15.2.3 Coolant Level Switch Installation Figure 15.
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Electrical & Electronic Application And Installation Manual Service Tool Description Auxiliary Temperature J1939 description Auxiliary Temperature #1 Status Severity L1 SPN (J1939) 441 FMI (J1939) 17 Event Code 445-1 Severity L2 441 18 445-2 Severity L3 441 01 445-3 Table 15.
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Electrical & Electronic Application And Installation Manual Note: Do not splice the sensor signal wire for input to third party devices. Figure 15.7 Auxiliary Temperature Sensor T400032 Perkins Part Number T400032 2900A013 N/A N/A 2900A016 REQUIRED PARTS Supplier Part Number Description Qty N/A Temperature Sensor 1 (Auxiliary) N/A Connector Plug Kit 1 Deutsch DT06-2S-EP06 Connector Plug 1 Deutsch W2S-P012 Wedge Lock 1 Deutsch 0462-201-1631 Connector Socket 2 (Gold) Table 15.
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Electrical & Electronic Application And Installation Manual 15.5 Auxiliary Pressure Sensor 15.5.1 Auxiliary Pressure Sensor Operation The auxiliary pressure sensor feature is provided so the engine can monitor any external pressure and provide that pressure information via the J1939 CAN data link. The ECM can also protect the system in the event of excessive pressure by taking any action configured within the engine monitoring system as shown below in table 15.
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Electrical & Electronic Application And Installation Manual This sensor as with the auxiliary temperature sensor incorporates a pigtail harness as part of the sensor assembly. Special installation considerations for this type of sensor are given in section 5.8 of this document. An example of the auxiliary pressure sensor and the length of the pigtail are shown in figure 15.9 and the components required to connect the sensor to the engine ECM are shown in table 15.13 Figure 15.
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Electrical & Electronic Application And Installation Manual 16.0 Aftertreatment System Machine Integration 16.1 Aftertreatment System Operation The Perkins 1204F & 1206F product ranges use various combinations of aftertreatment technologies. In each case the chosen technologies have been selected as the optimal combination to meet the Tier 4 Final/Stage IV emissions standards. The table below provides details of the 1204F to 1206F product configurations.
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Electrical & Electronic Application And Installation Manual without any operator interaction; however, under some conditions when circumstances do not allow sufficient temperature increase, the strategy will demand an elevated engine speed up to 1200rpm. 16.2.1.1 Elevated Idle Regeneration Operation If the system has established that an elevated engine speed is required to facilitate aftertreatment regeneration the engine will broadcast this requirement via the PGN / SPN shown in table 16.
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Electrical & Electronic Application And Installation Manual 16.3.2.1 Low Temperature Regen (DPF) Operation Low Temperature Regeneration of the engine DPF requires temperatures in the region of 250 > 400DegC during machine operation. The regeneration control strategy also uses the exhaust backpressure valve when required to help elevate engine exhaust temperatures to allow the regeneration to take place. The DPF soot loading example shown in figure 16.
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Electrical & Electronic Application And Installation Manual DPF Soot Load 0 < 79% 80 < 89% 90 < 115% 116 < 126% 127 < 140% System Description From 0 to 79% soot loading applications requiring a moderate to high duty cycle should regenerate without any control system intervention. In some cases (low duty cycle or cold ambient) to DPF soot loading may exceed 79%. The Low Temperature regeneration system may take action to oxidize soot, depending on the machine operating conditions.
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Electrical & Electronic Application And Installation Manual • • • • DEF Tank Heated Lines x 3 DEF Tank Header (for temp, level and quality sensors) Engine Coolant diverter valve In all cases the engine ECM is used to control the activation of the DEF dosing strategy and metering requirements. The local DCU controller provides the individual system component control such as line heater activation and direct DEF injector control.
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Electrical & Electronic Application And Installation Manual Figure 16.3 DEF System State Control DEF becomes a solid form at temperatures below -11DegC. To ensure that the DEF remains soluble in cold ambient and NOx emissions can be controlled the DEF system is fitted with electrical heating elements within the DEF pump and around the DEF lines. Thaw of the fluid within the DEF tank is provided by the supply of engine coolant to the tank header unit via the operation of the coolant diverter valve.
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Electrical & Electronic Application And Installation Manual 16.3 DEF System Machine Interface Requirements 16.3.1 Delayed Engine Shutdown (1206F Only) 16.3.1.1 Delayed Engine Shutdown Operation Delayed engine shutdown is engine software feature available for the 1206F product range only to help protect system components from damage during a high exhaust temperature shutdown event.
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Electrical & Electronic Application And Installation Manual Scenario 1 DPF Outlet Temp ‘High’ Yes 2 No 3 No Air Inlet Temp Programmed Low Idle Speed No Effect <1000rpm Description Engine will continue to run at the programmed LI speed until the DPF out temperature is acceptable or for a maximum of 15 minutes.
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Electrical & Electronic Application And Installation Manual Figure 16.4 DES Operation Note: The use of the User Defined Shutdown input to the engine ECM to override DES will be logged within engine ECM memory as an abnormal engine shutdown event. This information may be used to refuse warranty where excessive use of the DES override has occurred. 16.3.1.2 Delayed Engine Shutdown Configuration Perkins EST can be used to enable / disable the Delayed engine Shutdown feature.
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Electrical & Electronic Application And Installation Manual Electrical Wiring It is recommended that a 4 position ignition keyswitch is used on all machines installed with the Delayed Engine Shutdown feature. The 4th position of the ignition key switch must be wired back to the engine User Defined Shutdown input via a relay.
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Electrical & Electronic Application And Installation Manual Operator Communication Due to the DES feature preventing an engine from automatically shutting down post ignition key switch OFF, it is important that the machine operator is made aware that DES is in operation. As shown in figure 16.4 a DES indicator can be used to alert an operator that DES is active and this indicator should be wired as shown in figure 16.7.
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Electrical & Electronic Application And Installation Manual 16.3.2 System Purge 16.3.2.1 DEF System Purge Operation Note: The System DEF must be purged of DEF on engine shutdown to protect the system components from damage due to DEF freezing. For this reason it is important that electrical power is maintained to the engine ECM and aftertreatment system after the ignition has been turned off.
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Electrical & Electronic Application And Installation Manual Max 30 + Tmin Tsec DES Active Purge Active ON Ignition Key Switch OFF Engine Speed Battery Disconnect Switch Wait To Disconnect Lamp Fig 16.
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Electrical & Electronic Application And Installation Manual 16.3.2.2 DEF System Purge Configuration The DEF system purge is a mandatory feature enabled as default for both the 1204F and 1206F product ranges. 16.3.2.3 DEF System Purge Installation The completion of the DEF purge cycle is dependent upon main power to the engine and aftertreatment being maintained for the Max purge time shown in table 16.
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Electrical & Electronic Application And Installation Manual In addition to the wiring shown in figure 16.12 it is also recommended that a label is positioned next to the Wait To Disconnect indicator to ensure that the operator is informed of the lamps purpose. An example Wait To Disconnect label is shown below. Figure 16.13 Example Label (433-9373) For those machines wishing to use a J1939 CAN message for communication of the operator purge procedure completion to the machine operator.
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Electrical & Electronic Application And Installation Manual J1939 Wait To Disconnect Indicator Control Scenario 1 – Indicator active While ECM is LIVE. Most likely used for those customers fitting the indicator next to a battery disconnect switch.
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Electrical & Electronic Application And Installation Manual Scenario 2 – Indicator only active when ignition switch is OFF and DEF system is Purging. Most likely used for those customers fitting the Wait To Disconnect Indicator within the machine cab. 1204F 1206F Production Release Version 1.
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Electrical & Electronic Application And Installation Manual When implementing SPN 4332 any message state other than 0111 means DEF system is still electrically live. Once 0111 is received then the system is in shutdown mode. For more information on the format of PGN 61475 please refer to section 19.0 of this document. 16.3.3 DEF Thaw 16.3.3.1 DEF Thaw Operation DEF becomes a solid at temperatures of -11DegC and below.
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Electrical & Electronic Application And Installation Manual * DES indicator is only recommended for those machines installing the Delayed Engine Shutdown Feature. 16.3.4.1 DEF Level Gauge Requirements In addition to the specific DEF system indicators described in table 16.8 the machine must also be fitted with a DEF level gauge. Whilst specific DEF level gauge requirements may differ between geographical machine operating territories, Perkins require a DEF level gauge to be constantly visible.
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Electrical & Electronic Application And Installation Manual 17.0 Engine Governor 17.1 Min / Max Governing 17.1.1 Min / Max Governing Operation The min/max engine speed governor will provide an approximate amount of power for a given throttle position. Engine speed is allowed to vary between the low idle and high idle engine speed settings. This governor essentially only ‘governs’ engine speed when at the minimum or maximum allowed engine speed.
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Electrical & Electronic Application And Installation Manual Rated Speed 1000 Engine Torque Curve High Speed Governor Operating Area TORQUE (Nm) 800 Low Speed Governor Operating Area 600 Engine Throttle Position Equates to an Approximate Engine Power Output Within This Region 400 200 High Idle max = Rated speed + 12% 0 0 500 Low Idle Speed 1000 1500 ENGINE SPEED (RPM) 2000 2500 High Idle Speed Figure 17.1 Min Max Governor Operating Regions 17.1.
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Electrical & Electronic Application And Installation Manual type is recommended for use on applications with a constant operating speed and applications with manual transmissions. The all speed governor is also known as ‘variable speed’ or ‘full range engine speed governor’ The governor strategy calculates the fuel quantity required to keep the actual engine speed equal to the desired engine speed.
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Electrical & Electronic Application And Installation Manual Example Governing1 - showing droop and HSG slopes approximately equal. Flywheel Torque RS HILL HIUL HI Droop governor 2200 2200 2600 2354 7% all speed RS HSG P DROO HIUL HILL Speed (RPM) HI 800 2200 1800 Figure 17.2 Engine with Droop settings Example Governing 2 – Showing isochronous droop but with a shallow HSG slope.
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Electrical & Electronic Application And Installation Manual mode selection section 16.5 of this document for more information on the configuration of these switches. 17.2.3 Engine All Speed Governing Installation The All Speed engine governing feature requires no special installation other than a method of engine speed demand. Please refer to the engine speed demand section 11.0 of this document for more information on the methods supported by the engine ECM. 17.
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Electrical & Electronic Application And Installation Manual Torque RS HSG2 HSG1 HILL HI1 HI2 HIUL = RS + 12% Engine Speed RPM Figure 17.4 HSG Run out Example 17.4.2 Engine High Speed Governor Configuration The high speed governor run out line gradient can be configured using the service tool and the mode selection feature as described in section 17.5 of this document. This is achieved by modifying RS or HI or both.
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Electrical & Electronic Application And Installation Manual Table 17.1 Engine Mode Selection Table It should be noted that the engine mode switch 2 input is also used for the following feature; • Mode Switch 2 or Inlet Air Restriction Switch If this alternative feature is required then associated mode switch function cannot be used. If an invalid switch position is selected a fault code will be raised (1743 -2) and the feature will revert to its last good state.
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Electrical & Electronic Application And Installation Manual 18.0 Datalink Support Both the 1200 series Tier 4 Final/Stage IV product range is supplied with a customer J1939 CAN bus connection as part of the ECM J1 connector. The J1939 standard is a widely used protocol, which operates on a standard CANBus system. All J1939 enabled devices will operate on this datalink and the remainder of this section details the basic requirements for J1939 communication.
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Electrical & Electronic Application And Installation Manual • • • • The bus is linear and should be terminated with 120Ohm resistors at either end. It is a common mistake to use one 60Ohm resistor instead of two 120Ohm resistors. This does not work correctly however. Maximum bus length is 40m. The terminating resistors should not be contained in network nodes. Network nodes are connected to the bus via stubs of maximum recommended length 1m. 18.1.
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Electrical & Electronic Application And Installation Manual 18.2 Connection and Use of the J1939 CAN Bus There is one J1939 Datalink available for customer connection on each of the engine families and this is CAN A. The CAN A datalink can therefore be used to connect the engine ECM to machine controllers, transmission controllers, instrumentation gauges etc. All of the general installation criteria for a CAN network detailed in section 18.
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Electrical & Electronic Application And Installation Manual 19.
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Electrical & Electronic Application And Installation Manual Engine's Desired Operating Speed AMBIENT CONDITIONS Barometric Pressure Ambient Air Temperature FEF5 65269 6 FEF6 ENGINE FLUID LEVEL/PRESSURE 1 Engine Oil Pressure Coolant Level ENGINE TEMPERATURE 1 Engine Coolant Temperature FEEF FEEE 65270 65263 65262 6 6 6 FDB4 ENGINE FLUID LEVEL/PRESSURE 2 Engine Injector Metering Rail 1 Pressure AFTERTREATMENT 1 DIESEL EXHAUST FLUID TANK 1 INFORMATION FEDB FE56 64948 65243 65110 6 6 6
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Electrical & Electronic Application And Installation Manual Aftertreatment 1 Diesel Exhaust Fluid Tank Level Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature Aftertreatment Selective Catalytic Reduction Operator Inducement Active ENGINE FUEL/LUBE SYSTEMS (EFS) Engine Oil Priming State FE6A AFTERTREATMENT 1 SCR DOSING SYSTEM INFORMATION 1 Aftertreatment 1 SCR System State ENGINE TEMPERATURE 3 (ET3) Engine Charge Air Cooler 1 Outlet Temperature F023 AFTERTREATMENT 1 SCR EXHAUST GAS TEMPERATURE 1 Af
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Electrical & Electronic Application And Installation Manual AFTERTREATMENT 1 SCR ELECTRONIC CONTROL MODULE INFORMATION Aftertreatment 1 Diesel Exhaust Fluid Control Module Relay Control Aftertreatment 1 Diesel Exhaust Fluid Control Module Power Supply COLD START AIDS Engine Start Enable Device 1 Engine Start Enable Device 2 ELECTRONIC ENGINE CONTROLLER 12 Aftertreatment 1 Intake Gas Sensor Power Supply Aftertreatment 1 Outlet Gas Sensor Power Supply AFTERTREATMENT 1 DIESEL OXIDATION CATALYST (A1DOC) Aftert
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Electrical & Electronic Application And Installation Manual Temperature 1 TURBOCHARGER WASTEGATE (TCW) Engine Turbocharger Wastegate Actuator 1 Position ENGINE CONFIGURATION 1 (EC1) Engine Speed At Idle, Point 1 Percent Torque at Idle Point 1 Engine Speed At Point 2 Percent Torque At Point 2 Engine Speed At Point 3 Percent Torque At Point 3 Engine Speed At Point 4 Percent Torque At Point 4 Engine Speed At Point 5 Percent Torque At Point 5 Engine Speed At High Idle, Point 6 Reference Engine Torque POWER TA
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Electrical & Electronic Application And Installation Manual Software Identification 234 200 Bytes ASCII N/A 0 255 965 2 Onwards 1 Number Of Software Identification Fields Auxiliary Input/Output Status 1 Auxiliary I/O #01 Auxiliary I/O #02 Auxiliary I/O #03 Auxiliary I/O #04 Auxiliary I/O #05 Auxiliary I/O #06 Auxiliary I/O #07 Auxiliary I/O #08 Auxiliary I/O #09 Auxiliary I/O #10 Auxiliary I/O #11 Auxiliary I/O #12 Auxiliary I/O #13 Auxiliary I/O #14 Auxiliary I/O #15 Auxiliary I/O Channel #1 Auxi
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Electrical & Electronic Application And Installation Manual Auxiliary Pressure 1 OFF HIGHWAY ENGINE CONTROL SELECTION Engine Alternate Rating Select Engine Alternate Droop Accelerator 1 Select Engine Alternate Droop Accelerator 2 Select Engine Alternate Droop Remote Accelerator Select OPERATOR PRIMARY INTERMEDIATE SPEED CONTROL STATE Operator Primary Intermediate Speed Select State OFF HIGHWAY ENGINE CONTROL SELECTION STATES Alternate Rating Select State Engine Alternate Droop Accelerator 1 Select State En
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Electrical & Electronic Application And Installation Manual Requested Percent Fan Speed ** TSC1 Engine Override Control Mode Engine Override Control Mode Priority Engine Requested Speed/Speed Limit Engine Requested Torque/Torque Limit OPERATOR INDICATORS Water In Fuel Indicator ENGINE HOURS Engine Total Hours Of Operation ENGINE OPERATING INFORMATION (EOI) Engine Operating State 0 0 3 62579 6 Tx FEE5 65253 6 On Req 64914 1 8 bits % 0.4%/bit 0 100 695 897 1.1 1.
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Electrical & Electronic Application And Installation Manual Occurrence Count Previously Active Diagnostic Trouble Codes (DM2) Suspect Parameter Number* Failure Mode Identifier Occurrence Count FECB 65227 1216 6.1 7 bits Status 1 Count/bit 0 126 1214 1215 1216 3-5.6 5.1 6.1 19 bits 5 bits 7 bits Status Status Status 1 SPN/bit 1 FMI/bit 1 Count/bit 0 0 0 524287 31 126 6 Production Release Version 1.
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Electrical & Electronic Application And Installation Manual 20.0 J1939 Parameters – Detailed Descriptions Note: The PGN numbers are written in some documents in decimal form (e.g.61444). This document will use the Hexadecimal form (e.g. F004) as it is easier to remember and simpler to decode when using tools to analyse traffic on the CAN J1939 bus. 20.
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Electrical & Electronic Application And Installation Manual 20.2 J1939 Section 71 – TSC1 Operation 20.2.1 Torque Speed Control (TSC1) Operating Principles The TSC1 message is a J1939 PGN designed to allow the Torque/Speed control of an engine via the CAN bus. This message can be used by any electronic control module to request or limit the engine speed / torque output.
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Electrical & Electronic Application And Installation Manual above 1800rpm is requested then the engine speed will not respond and be limited to 1800rpm. 20.2.1.4 Engine Torque Limiting The Engine Torque limiting function, when configured limits the max torque output of the engine to a value determined as a percentage of the max available torque for the particular rating curve being operated. Figure 20.
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Electrical & Electronic Application And Installation Manual 20.2.2 Torque Speed Control (TSC1) Message Configuration & Control The Torque/Speed control #1 (TSC1) PGN allows electronic control devices connected to the CAN network to request or limit engine speed. This feature is often used as part of a closed loop engine control system with broadcast message parameters such as engine speed (EEC1). Usage is particularly common in machines that have complex hydraulic systems.
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Electrical & Electronic Application And Installation Manual 20.2.1.3 TSC1 Continuous Fault Handling: [Disabled] (Default) This mode is also known as Transient fault detection, it is suitable for applications where there is more than one throttle input into the ECM, for instance, in a wheeled excavator where the analogue throttle is used to control road speed, but TSC1 is used to control the machine hydraulics. The TSC1 message will override any other speed demand such as PWM throttle pedal.
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Electrical & Electronic Application And Installation Manual Appendix Appendix 1 Complete System Connector Lists 1204F Connector Parts List Connector & Wedge Locks Connector Name ECM J1 Connector J1939 Terminating Resistor Plug J1939 Terminating Resistor Receptacle Diagnostic Connector Tailpipe Out Nox Turbo Out Nox Air Inlet Temp Water In Fuel Aftertreatment ID Module Ammonia Sensor Fuel Lift Pump XNOx Connector DOC, DPF & SCR Temp Coolant Diverter Valve DEF Heated Lines Supplier Part Number Qty Wedge
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Electrical & Electronic Application And Installation Manual Terminals, Blanking plugs and Wire Seals Connector Name Terminal Supplier Terminal Part Number Qty Blanking Plug Supplier Blanking Plug Part Number Qty Wire Seal Supplier Wire Seal Part Number Qty ECM J1 Connector Deutsch 1062-20-0377 1062-12-0166 80 6 Deutsch N/A 0413-204-2005 N/A 60 N/A N/A N/A N/A N/A N/A N/A J1939 Terminating Resistor Plug J1939 Terminating Resistor Receptacle Diagnostic Connector Tailpipe Out Nox Turbo Out
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Electrical & Electronic Application And Installation Manual 1206F Connector Parts List Connector & Wedge Locks Connector Name ECM J1 Connector J1939 Terminating Resistor Plug J1939 Terminating Resistor Receptacle Diagnostic Connector Tailpipe Out Nox Turbo Out Nox Air Inlet Temp Water In Fuel Aftertreatment ID Module DPF Soot Sensor Fuel Lift Pump * PETU Comms Connector PETU Power DPF & SCR Combined Temp DEF Heated Line suction DEF Heated Line Return DEF Heated Line Pressure DEF Fluid Injector Supplier P
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Electrical & Electronic Application And Installation Manual Terminals, Blanking plugs and Wire Seals Connector Name Terminal Supplier Terminal Part Number Qty Blanking Plug Supplier Blanking Plug Part Number Qty Wire Seal Supplier Wire Seal Part Number Qty ECM J1 Connector Deutsch 1062-20-0377 1062-12-0166 80 6 Deutsch N/A 0413-204-2005 N/A 60 N/A N/A N/A N/A N/A N/A N/A J1939 Terminating Resistor Plug J1939 Terminating Resistor Receptacle Diagnostic Connector Deutsch 0462-201-16141
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Electrical & Electronic Application And Installation Manual Production Release Version 1.