Installation Manual

Electrical & Electronic Application And Installation Manual
Production Release Version 1.0
Page 2
CONTENTS
1.0 SAFETY .................................................................................................... 9
1.1 W ARNING – W ELDING ..................................................................................................................... 9
1.1.2 Warning - Electrostatic Paint Spraying .................................................................................. 9
1.1.3 Warning – Jump Starting ...................................................................................................... 10
2.0 ENGINE & AFTERTREATMENT COMPONENT OVERVIEW ................ 11
2.1 M AIN E NGINE S ENSOR AND A CTUATOR D ETAIL ........................................................................... 11
2.1.1 Electronic Control Module .................................................................................................... 11
2.1.2 Fuel System ........................................................................................................................... 11
2.1.3 Engine Speed ......................................................................................................................... 12
2.1.4 NRS (NOx Reduction System) ................................................................................................ 12
2.1.5 Core Engine System ............................................................................................................... 12
2.1.6 Air System .............................................................................................................................. 13
2.1.7 Emissions System Assist Devices ........................................................................................... 13
2.2 A FTERTREATMENT S YSTEM S ENSOR & A CTUATOR D ETAILS ........................................................ 13
2.2.1 PM Capture Devices ............................................................................................................. 13
2.2.3 Selective Catalytic Reduction (SCR) Technologies ............................................................... 14
2.3 S YSTEM C OMPONENT D IAGRAMS & S CHEMATICS ........................................................................ 15
2.3.1 1204F Engine and Aftertreatment Layout ............................................................................. 15
2.3.2 1206F Engine and Aftertreatment Layout ............................................................................. 18
2.4 E NGINE & A FTERTREATMENT C OMPONENT L AYOUT D IAGRAMS ................................................. 20
2.4.1 1204F Principal Engine Electronic Components .................................................................. 20
2.4.2 1206F Principal Engine Electronic Components .................................................................. 23
2.4.3 1204F AT Principal Components .......................................................................................... 26
2.4.4 1206F AT Principal Components .......................................................................................... 27
3.0 CUSTOMER SYSTEM OVERVIEW KEY ELEMENTS ........................... 28
3.1 A FTERTREATMENT C ONFIGURATIONS ........................................................................................... 28
3.2 T IER 4F M ANDATORY I NSTALL C OMPONENTS .............................................................................. 28
3.3 O PTIONAL C USTOMER I NSTALLED C OMPONENTS ......................................................................... 29
4.0 POWER & GROUNDING CONSIDERATIONS ....................................... 30
4.1 S YSTEM G ROUNDING .................................................................................................................... 30
4.1.1 Ground Stud On Starter Motor .............................................................................................. 30
4.1.2 Engine Block Ground Connection ......................................................................................... 30
4.1.3 Aftertreatment System Grounding ......................................................................................... 31
4.2 S YSTEM V OLTAGE & C URRENT R EQUIREMENTS ........................................................................... 32
4.2.1 Engine ECM .......................................................................................................................... 32
4.2.2 1204F DEF System ................................................................................................................ 32
4.2.3 1206F DEF System ................................................................................................................ 33
4.2.4 System Effect on Alternator Specification ............................................................................. 33
4.3 ECM P OWER S UPPLY & C IRCUIT R ESISTANCE ............................................................................. 34
4.3.1 Important Voltage Supply Circuit Considerations ................................................................ 36
4.3.2 Battery (+) Connection ......................................................................................................... 36
4.3.3 Battery (-) Connection ........................................................................................................... 38
4.3.4 Correct method of ECM battery connection. ......................................................................... 39
4.3.5 Incorrect method of ECM battery connection. ...................................................................... 39
4.4 E NGINE ECM P OWER S UPPLY C IRCUIT R ESISTANCE T EST ........................................................... 40
4.4.1 Test Procedure ...................................................................................................................... 40
4.5 DEF S YSTEM P OWER S UPPLY ....................................................................................................... 42
4.5.1 1204F DEF System Power Supply connection ...................................................................... 42
4.5.2 1206F DEF System Power Supply Connection ..................................................................... 43
4.6 S UPPRESSION OF V OLTAGE T RANSIENTS ....................................................................................... 44
4.6.1 Suppression Methods & Best Practice .................................................................................. 44
4.7 D IRECT B ATTERY CONNECTION REQUIREMENTS ........................................................................... 45
4.8 P OWERING T HE E NGINE ECM V IA A UXILIARY P OWER S UPPLIES ................................................. 46
4.9 S ENSOR C OMMON C ONNECTIONS .................................................................................................. 46