2800 Electronic, Mech Jan07

Perkins 23/25/2800 Series Diesel Engine Training

Perkins Product Training

Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

Domestics Fire

Exits

Breaks Lunch Toilets Smoking Mobile

Phones

Health

& Safety


Please Note 





The product training information is distributed for informational purposes only. It is not to be construed as creating or becoming part of Perkins Engines contractual or warranty obligations The appropriate service literature, including ‘Service Bulletins’ now available on the www.perkins.com Secured Website, should always be the final authority and source of information Wiring Diagrams/Electrical Drawings, wire numbers and connection points may change.


Course Objectives At the end of the course the delegates will be able to – •Show technicians strip down techniques and the use of special tools •EST(Electronic Service Tool) and fault diagnosis procedures specific to 23/25/2800


Worldwide „Off Road‟ Legislation Today

No Legislation Requirements

Environmental Protection Agency / European Union Regional Legislation


„Off Road‟ Emissions Legislation Tier 0 "A" rated engines can be used in regions without Emissions Legislation.

Tier 1 "B" rated engines are suitable for regions with Tier 1/Stage I Emissions Legislation

Tier 2 "C" rated engines are suitable for regions with Tier 2/Stage II Emissions Legislation.

Tier 3 "D" rated engines are suitable for regions with Tier 3/Stage III Emissions Legislation.


„Off Road‟ Industrial - Ever Cleaner Engines 0.50 0.45

Tier 3: 56kW<75

0.40

1980’s

0.35 PM (g/kWh)

Tier 3: 75kW<130

0.30

Particulate Matter (PM) 0.6g/kWh

0.25 Tier 3: 130kW<560

0.20 0.15

Oxides of Nitrogen (NOx) 10.00g/kWh

Tier 4B: 56kW<560

Tier 4A: 56kW<130

0.10

Tier 4A: 130kW<560

0.05 0 0

1

2

3

4

5

NOx; NOx + HC (g/kWh)


6

Electronic Engine Benefits Electronic Engine Management system gives:          

Improved Specific Fuel Consumption (SFC) through precise control of Injection Timing and Duration. Machine protection under extreme operating conditions. Easy servicing and fault diagnostics, Electronic Service Tool, (EST) Exceeds emissions legislation and has a lower noise level. Better engine ‘responsiveness’. Improved reliability,engine monitoring and protection. Further cost savings through integration into ‘Genset' design (CAN) Improved torque, different torque curves available, torque ‘shaping’ Rating changes available, Base Load, Prime, Standby, 1500/1800 Configuration files, gives the customer flexibility, droop, etc




2306 and 2806 Engine Numbering „F‟ Engine Family, 14.6 litre

Number of Cylinders

„H‟ Engine Family, 15.8 litre „J‟ Engine Family, 18 litre Country of Manufacture

FGA 06 - 1234 - U - 5678 - K Engine Serial Number Generator Set Engine

Build List

Year of Manufacture 03

A = TAG 1 (Turbo-Air to air charge cooled-Genset) B = TAG 2 (Turbo-Air to air charge cooled-Genset) D = TAG 3 (Turbo-Air to air charge cooled-Genset)


Engine Ratings - Definitions Base Load or Continuous 

 

Unlimited hours usage, load factor 100% of published base load/continuous power 10% overload available 1 hour in 12 Power available for continuous full load

Prime Power 



Unlimited hours usage, load factor 80% of published prime power over 24 hours 10% overload available 1 hour in 12

Standby (maximum) 



Power available at variable load in the event of a mains power network failure, up to a maximum of 500 hours/year of which 300 hours may be continuous No overload is permitted and the load factor is 100%


2300/2800 Series Engines Electronic Control System, Identical

Economic Power  Mechanically actuated Electronically controlled Unit Injection.(MEUI) Optimum turbo-charging, excellent fuel atomisation (30,000 PSI) and combustion, very low emissions. Reliable Power  Low oil usage and wear rates, high compression ratios ensure clean rapid starting. World Wide Support from 4000 Distributors. Compact, Efficient Power  Exceptional power to weight ratio, compact size, excellent service access for ease of maintenance


2300/2800 - Engine Component Changes Noticeable Physical Differences - Air Filter Size Performance Related  Pistons  Connecting Rods  Liner  Ring Pack  Crankshaft  Turbo  Air Cleaner Package Size Related  Radiator  Charge Cooler  Fan and Cowling


2306/2806 Product Features Combined primary and secondary „Eco‟ Fuel filters

Integral inlet manifold (18 litre horizontal)

Fuel transfer pump

Radial seal air filter element

Unique wiring harness

Timing Calibration Probe access hole

ADEM 3 ECM With Perkins software


2306/2806 Product Features Single stage high boost turbocharger

16 litre

Composite top cover

Oil cooler

Air to air charge cooler

„Ecoplus‟ full flow oil filtration

Torsional vibration damper Composite oil pan


2806 -18 litre Product Features Twin turbochargers

Twin exhaust manifolds

External oil feed to the cylinder head

Large output coolant pump

30% larger capacity oil cooler

New oil filler tube Aluminium sump


Rocker Assemblies Roller Type Rockers

Second oil pressure feed to cylinder head 18 Litre (external) Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

Cylinder Head

Four Valve Mono-Block Cylinder Head Four valves per cylinder

Forged steel overhead camshaft


Valve Assemblies One of three oil feed drillings


Valve/Injector Clearance Establishing Number 1 TDC

Turning tool

TDC locator


Valve/Injector Clearance Valve „screw and locknut‟ adjuster

Injector adjuster Injector trim code

Button and „O‟ ring


Valve/Injector Clearance Tool CH11149

Checking correct adjustment

Machine shoulder


Valve/Injector Clearance With Number 1 Cylinder at TDC compression stroke adjust  Inlet valves 1,2,4  Exh valves 1,3,5 Injectors 3,5,6 With Number 6 Cylinder at TDC compression stroke adjust  Inlet valves 3,5,6  Exh valves 2,4,6 Injectors 1,2,4 Clearances  Inlet valves 0.38mm (0.015in)  Exh Valves 0.76mm (0.030in)  Injectors 78.0mm (3.07in)

Tool N° CH11149


Injector Sleeve 





A stainless steel sleeve is used in the injector bore to seal the coolant The sleeve is sealed using three ‘O’ rings. However, combustion gases are sealed by the injector seating on the metal in the cylinder head bore. The ‘O’ ring seal fitted on the injector nozzle provides a combustion gas seal until a carbon dam is formed.


Injector Sleeve

A line contact seal is attained

A failed seal results in blow by and a hot injector


Injector Sleeve


Camshaft

Long Overlap Camshaft

Injector lobe

Valve lobes

Drive gear dowel location


Camshaft


Camshaft

Thrust Plate and Seal


Head Gasket/Spacer Plate Oil seal Cylinder head gasket Coolant bobbin

Spacer plate Oil feed O ring „Shim‟ gasket


Exhaust Manifold Air gap Thermal sleeve


Cylinder Block

Open Summit Cylinder Block


Cylinder Liners

Induction Hardened Liners

Oil soaked filler band

Rubber O rings (2806)

2306 three lower liner „O‟ ring seals are all identical in size


Cylinder Liners Protrusion


Pistons 2306 „Gallery Cooled‟ Articulated Piston Oil cooling spray cutaways

Oil cooling gallery


Pistons

2806-16 Articulated Piston

Cooling oil reservoir


Piston/Con-Rod Assembly

Tightening con-rod bolts


Pistons

2806-18 Piston


Pistons/Con-Rod Assembly 2806-18 Piston

Big end cap secured by four bolts

Oil supply to small end bearing


Piston Cooling Jets

Piston cooling jet alignment tool Part Number GE50004


Piston Cooling Jets 2806-18

Piston Connecting rod Entry to cooling gallery

Piston cooling jet pipe assembly


Crankshaft Thrust washer position


Crankshaft 2806-18


Crankshaft

Grooved main bearing fitted to block

180° thrust washers fitted to block


Block Stiffener Plates

2300 Series

2800 Series 16 litre Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

Torsional Damper

Hasse and Wrede Damper 1. 2. 3. 4. 5.

Housing Casing Inertia Ring (mass) Bearings Silicone Fluid

2

Block Stiffener Plate 2800 18 litre


Timing Gears Coolant pump drive gear position

„Pendulum‟ camshaft gear

Adjustable idler gear

Compound gear assembly

Idler gear Crankshaft gear Fuel transfer pump

Oil pump gear position


Timing Gears

Pendulum Camshaft Gear

Timing case

Rotating balance weights

Locating dowel

Alignment marks

Timing gear


Timing Gears

Checking Gear Backlash


Crankshaft Seals Seal Removal/Fitting

 

Crankshaft Seals

Gear case-split protection ring

Oil Seal and Wear Sleeve

Wear sleeve ‘crimp’ tool

  

Must be fitted as assembly Must not be separated Must be fitted dry


Crankshaft Seals Blue seal (rear)

Green seal (front)


Induction System 2809-18


Induction System 

Air Filter Type

Single medium duty paper element



Max Air Inlet Temp

60°C (140°F)

Initial Restriction (inlet depression new)

2.5kPa

Maximum Inlet Depression (with dirty filter)

6.2Kpa

Max Pressure Drop (across charge cooler)

14Kpa (2.03 psi)

Maximum Charge Air Temp at high (ambient conditions)

260°C (500°F)

Turbo Charger

2306 Allied Signal GT 50 2806 Borge Warner S 500 2806-18 twin Borge Warner S310












Induction System Radial Seal Filters


Induction System Turbochargers

Single stage „high boost‟ turbochargers No oil priming required


Induction System 2806-18 Turbochargers Rear turbocharger

Exhaust gas outlet


Forward turbocharger

Induction System

Air Charge Cooling/Radiator

C A O O I L R A N T


Induction System 2806-18

Air charge Coolant

cooling / radiator Turbo boost air

Boost air

Coolant


Induction System


Fuel System EUI Location

Trim code, Below barcode

Put lever here to remove Injector


Fuel System Injector Seals

O ring seals

„Sacrificial‟ compression „O‟ ring

6 hole injector nozzle

Do not re-use seals


Fuel System

Low Pressure Fuel System

Priming pump Venting points Fuel return Secondary filter Transfer pump

Fuel supply

Primary filter


Fuel System

Fuel Cooler/Return

Flow =413 litres/h at 1500 Flow =457 litres/h at 1800 Return flow dependant on engine load – Thermostat.


Fuel System

Fuel Transfer Pump

Fuel System

Ecoplus Fuel Filtration


Fuel System

Ecoplus Fuel Filtration Identification

Oil Fuel Secondary

Fuel primary


Fuel System

Ecoplus Fuel Filtration From transfer pump

Supply to head

Temp sensor

To transfer pump Hand primer By-pass valve

From Tank Return from head Return to cooler

Pressure Relief Valve


Air vent

Fuel System Non-return/PRV


Lubrication System 

Type

Wet sump - full flow system



Oil pump

Gear driven - with PRV



Capacity - total system

68 litres



Sump maximum

60 litres



Sump minimum

45 litres



Lube oil temp - normal (sump)

95°C



Lube oil temp - maximum

113°C



Lube oil pressure - rated speed

2.7-6 bar (40-88psi)



Lube oil pressure - min rated speed

2 bar (30psi)



Oil pressure relief valve opening pressure 6.1 bar (88psi)


Lubrication System

Composite „High Capacity‟ Sump


Lubrication System Oil Pump


Lubrication System Ecoplus Oil Filtration

Sampling point

O/P switch

Filter by-pass valve

Cooler by-pass valve


Lubrication System 2806-18

Oil cooler assembly

Re-positioned oil filler tube Re-designed Oil filter head


Cooling System



Capacity of engine

20.8 Litres



Capacity of complete system

50 Litres



Pressure cap setting

70kPa (0.7 Bar) (10psi)



Thermostat operating range

Starts 88°C. Fully open 98°C



Coolant pump

Gear driven, centrifugal type



Radiator

Aluminium core, composite tanks



Fan

Plastic, 8 blade, pusher type.



Maximum temperature.

Top tank - 103°C



Recommended Coolant.

50% extended life coolant, 50% de-ionised clean water.



Coolant Life

3,000 hours or six years - max


Cooling System

Air Charge Cooling/Radiator

Composite top and bottom radiator tanks ELC coolant to be used at all times


Cooling System Thermostat Housing

Thermostat Flow to radiator Thermostat seal By-pass return to coolant pump


23/25/2800 Series

Temperature and Pressure Sensors Coolant Temp Sensor

Inlet Manifold Air Temp Sensor

Inlet Manifold Air Pressure sensor

Fuel Temp Sensor Location of Calibration Probe (Plugged)


Engine Oil and Atmospheric Pressure Sensors

23/2800 Series

Connections and Speed/Position Sensors 110 Volt MEUI Solenoid Feeds Cam Speed/ Position Sensor

9 Pin Diagnostic Connector 40 Pin Customer Connection (J3)

Crank Speed/Position Sensor ECM “On Engine” Connector (J2)


Electronic Control Module

23/25/2800 Series Electrical System Internal Injector Harness

Jack 2 (J2)

Jack 1 (J1)

Crank Speed/Timing 36-1 TOOTH CRANK GEAR

Coolant Temperature Sensor Cam Speed/Timing

Fuel Temperature Sensor

36+1 TOOTH CAM GEAR

Inlet Manifold Sensor Inlet Manifold Sensor

Atmospheric Pressure Sensor

Engine Oil Pressure

Calibration Probe


23/25/2800 „On Engine‟ Wiring Harness ECM 5 7 6 10 3 11 2 12 1 Injector Cyl 1

Injector Cyl 2

Injector Cyl 3

Injector Cyl 4

Injector Cyl 5

Injector Cyl 6

J2/44 J2/45 J2/46 J2/55 J2/54 J2/39 J2/38 J2/37 J2/36

Injector Common Cylinders 1 & 2 Injector Common Cylinders 3 & 4 Injector Common Cylinders 5 & 6 Injector Cylinder 6 Injector Cylinder 5 Injector Cylinder 4 Injector Cylinder 3 Injector Cylinder 2 Injector Cylinder 1

J2/2 J2/14 J2/3

+5VDC Supply Atmospheric Pressure Analogue Return

J2/40

Turbo Outlet Pressure

J2/24

Oil Pressure

J2/32

Coolant Temperature

J300 P300

Atmospheric Pressure Sensor A C B

+5V Signal Return

P203 J203 Turbo Outlet Pressure Sensor A C B

+5V Signal Return

All fed from Jack 2 (J2) on the ECM

P200 J200 Oil Pressure Sensor +5V Signal Return

A C B P201 J201

Coolant Temperature Sensor Signal Return

C B J100 P100

Fuel Temperature Sensor Signal Return

C B

J2/33

Fuel Temperature

J2/35 J2/18

Inlet Air Temperature Return

J2/48 J2/49

Crank Speed Timing + Crank Speed Timing -

J2/58 J2/59

Cam Speed timing + Cam speed timing -

J2/22 J2/23

Calibration Probe + Calibration Probe -

J105 P105 Inlet Air Temperature Sensor Signal Return

C B

J103 P103 Crankshaft Position Sensor Signal Return

2 1 J401 P401

Camshaft Position Sensor Signal Return

2 1

J402 P402 Calibration Probe Signal Return

1 2 J400 P400

P2 J2


Connectors – A Reminder:  

 

Always use high quality connectors (Gold/Nickel Plated) Keep connections to a minimum

Make sure all rubber seals are correctly fitted Remember… Bad connections cause resistance! Resistance causes voltage drop! Lack of a rubber seal caused this To happen to an ECM! Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

Effects of „Bad‟ (Resistance) Connections „P‟ Plug

24v dc

„J‟ Jack

Possible „Bad‟ Connections

Has the same effect as….Resistances in circuit 1 volt

24v dc

Don‟t forget all connections!

2 volt

Resistors

0.1 volt

Lamp 24v dc

Don‟t forget all connections!

Lamp

1 volt


19.9v dc

23/25/2800 Series MEUI Injection  



Mechanically actuated by the cam shaft Injection controlled by the 110 Volt Solenoid

The length of time the Solenoid is energized, and the timing of the energization are both controlled by the Electronic Control Module (ECM)

Mechanically Actuated Electronically Controlled Unit Injector Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

110 Volt Solenoid

23/25/2800 Series MEUI Injector 110v dc injector solenoid

“Poppet” Valve Shut when energised

Off

+

110v Supply

Flow „Poppet‟ Valve Principals


MEUI Injector

„O‟ Rings

Poppet Valve de-energised


Fuel chamber

Worn MEUI Injector Poppet Valves

„O’ Rings

Wear on seat, caused by dirty fuel. Primary Filter 10 microns, Secondary, 2 microns Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

MEUI Injector Location Injector „trim code‟

Injector trim code

Fuel chamber

Intake Extended life manifold coolant

Torque setting on solenoid Screws 2.5 Nm (22 lb in)


Electronic Control Module (ECM) Inside the ECM is the management system that controls  Speed Governing   

 

Air/Fuel Ratio Start/Stop Sequence Engine Protection Devices Diagnostics 110 Volt Injector Pulses Jack 2 (J2) all “on engine” mounted components

Jack 1 (J1) Customer interface, power supply etc


Basic System – A3-ECM Interactions Control

Inputs Digital speed Adjust analogue speed Adjust PWM speed Adjust Push buttons/switches fault reset,injection disable,lower/raise digital speed, etc,etc

Outputs

PROCESSOR Cables/ Connectors

Cables/ Connectors

MEMORY (Engine Programme) Power supply for 5 volt 6.5 volts and 8 volts

Cables/ Connectors

5 volt + 8 volt Power Supplies Cables/ Connectors

Electronic Service Tool

CAN

110 Volt DC pulse for Injectors Digital output for speed control

ECM power supply, 24 v

PDL

Voltage to operate diagnostic lamps and crank terminate relay

J 1939 Engine Control

J 1939 Diagnostic Code Reader


2300/2500/2800 „Off Engine‟ Wiring Diagram Machine Wiring Schematic, All Options This Wiring Supplied By OEM Crank Terminate (Engine Running Signal)

Notes:

J1- 70 Jack - Customer connection. Also J3 - 40 Jack - Customer connection

Outputs may be used to drive lamps or relays.

C

T

ECM K

Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit.

Shutdown (ECM latched out)

Diagnostic lamp lights when active system fault registered

G

J1/13

Crank Terminate Output

J1/10

Shutdown lamp Output

Action Alert

U

For full details of inputs/ outputs, refer to Installation Manual

Warning

P Diagnostics

(Different Diagram)

J1/19

Action Alert Lamp Output

J1/20

Warning Lamp Output

J1/31

Diagnostics Lamp Output

J1/28

Oil Pressure Lamp Output

J1/29

Coolant Temperature Lamp Output

J1/30

Overspeed Lamp Output

K Low Oil Pressure

O High Coolant Temp

N Overspeed

A

Off - Disabled - Stop Injection Disable On - Enabled - Run

J1/62

U

Injection Disable

Off On Critical Override (Disables Oil & Water shutdowns when on) 1500

K N

1500/1800 1800 rpm Select

J1/64

Shutdown Emergency Override

J1/56

1500/1800 rpm Select

J1/46

Droop/Isochronous

Isoch

Droop/ Droop Isochronous

A Y

Fault Reset

J1/41

Fault Reset

J1/49

Digital Speed Control Enable

Enable

Digital Speed Control

Digital Speed Control Disable

G

Lower Speed

P O

Raise Speed

O B B W R

Ground To PWM Speed Control

PWM +8V

„J1 Jack

W R B

Charging Alternator GRD

B

POS

B

Emergency Stop Button

R R Off

R

Key On Switch

Y

Circuit Breaker (16A)

Y G

Start Button

Starter Motor

G

R B

Battery 24V DC


Digital Ground Unswitched Battery Negative Ground PWM Input +8V Analogue Ground

J1/17

Analogue Speed Input

J1/2

+5V

J1/61

Unswitched Battery Negative

J1/63


J1/65


J1/48

Unswitched Battery Positive

J1/52


J1/53


J1/70

Switched Battery Positive

J1/50

J1939 Data Link +

J1/34

J1939 Data Link -

J1/42

J1939 Screen

J1/8

Perkins Data Link +

J1/9

N

-

Raise Speed

J1/18 J1/67 J1/5 J1/66

J1/3

B

680R

Lower Speed

J1/4

B

680R 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser

J1/59 J1/7

Perkins Data Link -

J1/55


J1/69


P1 J1

+ J H C G F D E A B

Main Battery Feed (Direct from starter/ battery)

9 Pin Perkins Data Link Connector

Power Supply to Service Tool

Some Typical Connections - ECM Inputs

CONTROL ECM

Analogue Speed Adjust

Outputs Shutdown Crank Terminate

Injection Disabled Diagnostics

Ignition Key Switch

+

-

+

-

5 volt to Sensors

+

ECM Power Supply, 24 v Communications Adapter 24 v

+

-

-

Power Supply, 24 v

J1939 PDL


23/2800 Series ECM „Jack‟ Connections

J2 (Jack 2) “On Engine” Mounted Components

J1 (Jack 1) Customer Side


ECM Grounding Grounding  Always ensure the ground straps are on the Engine and the ECM is connected to the engine block, via the ‘tag’ to prevent EMI, Electro Magnetic Interference, affecting the interior electronic circuits of the ECM. Warning!  When carrying out welding or electrostatic paint spraying, special precautions should always be followed.  These are listed in the Perkins Mechanical and Electronic Installation Manual. TSL 4262, & TSL 4247.


Electronic Control Module 

 

 



Nominal battery supply voltage 18-32 volts (Max 48 for 2 mins)  Approximately 2 - 6 amps in typical application  10-15 mA in ‘sleep mode’ (ignition off/ECM power on) High Reliability. External connectors most vulnerable: bent ‘jacks’, J1, J2 over tightened ECM plugs etc. No internal fuses or serviceable parts. Never replace an ECM without first connecting Electronic Service Tool (EST) and carrying out basic diagnostics. The ECM is the last component you should suspect.


O

Raise Speed

J1/18 J1/67 J1/5 J1/66

O B B W R

Ground

Digital Ground

J1/4

Unswitched Battery Negative Ground PWM Input +8V

J1/3

Analogue Ground

J1/17


J1/2

+5V

J1/61


J1/63


J1/65


J1/48


J1/52


J1/53


J1/70


J1/50

J1939 Data Link +

J1/34

J1939 Data Link -

J1/42

J1939 Screen

J1/8

Perkins Data Link +

J1/9

Perkins Data Link -

J1/55


J1/69


2300/2800 Series ECM Power Supplies To PWM Speed Control

PWM +8V

680R

+ to Diagnostics Lamps

5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser

- to Diagnostics Lamps

B W R

680R

B


B

B

POS

B


R R Off

R

Key On Switch

Y


Y G

Start Button

Starter Motor

G N R B

-

Battery 24V DC

P1 J1

+ J H C G F D E A B





Minimum J1 Connections, to run a 23/2800 Series Control ECM Injection Disabled

Ignition Key Switch

Note We do suggest that

a connection is made to the Perkins Electronic Service Tool (EST) to allow communication With Perkins Data Link (PDL) What are the Jack connection numbers?

+

-

ECM Power Supply, 24 v


Ignition Circuit Ignition Key Switch  This switch may be used for a controlled engine stop. The ignition switch does not switch off power to the ECM. The ECM remains connected to the battery via a fuse/circuit breaker, even when the ignition is switched off. Can also be used to reset faults. The Electronic Service Tool (EST) cannot communicate with the ECM when the Ignition switch is off. Injection Disabled  If you want to stop the engine, use the ‘Injection Disabled’. This allows communication with the service tool (EST) to continue. Emergency Shut-down  This button, interrupts the main battery power supply to the ECM and stops the engine. Not Recommended, Don’t forget the ECM is a computer, you do not just ‘chop off ’ the power.


23/25/2800 Series Engine Mounted Sensors



Engine coolant temperature. Inlet manifold air temperature. Fuel temperature. Inlet manifold air pressure. Atmospheric/crankcase pressure. Engine oil pressure. Camshaft/crankshaft speed/timing.



Calibration probe (only in special circumstances)

     


2300/2800 Series – Temperature Sensors Engine Coolant Temperature Sensor 32

Signal Voltage

ECM Fuel Temperature Sensor 33

Signal Voltage

Inlet Air Temperature Sensor


35

Signal Voltage

18

0 Volts

23/2800 Series Temperature Sensor Operation ECM 5 Volts

R

Temperature Sensor Signal Ground


18 0 Volts

Engine Coolant Temperature Sensor EST Code 110 







Temperature can be viewed through the ECM in °C/°F via:  J1939 CAN link  Perkins Data Link (PDL) The sensor enables the cold start strategy Also enables the calculation of the fuel limit and engine timing Engine protection, Warning, Action Alert and Shutdown.


Coolant Temperature Sensor

Engine Coolant Temperature Sensor EST Code 110 (Typical Temperature Sensor graph) 4.8

110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)

Very cold Temp

Warning Temp 361 (1) Action Alert Temp 361 (2) Shutdown Temp 361 (3)

0.2

110-4 Signal shorted to a lower voltage (voltage under 0.2)

Temperature


Manifold Air Inlet Temperature Sensor EST Code 174 

  

Temperature can be viewed through the ECM in °C/°F via:  J1939 CAN link.  Perkins Data Link (PDL) The sensor enables the cold start strategy. Also enables the calculation of the fuel limit and engine timing Engine protection, warning and Action Alert.

Manifold Air Inlet Sensor

High inlet air temperatures lead to high exhaust temperatures, which can cause damage to exhaust system components (such as turbochargers and exhaust valves)


Engine Fuel Temperature Sensor EST Code 174   





Higher Temperature lower mass Lower Temperature greater mass Temperature can be viewed through the ECM in °C/°F via:  J1939 CAN link  Perkins Data Link (PDL) Also enables the calculation of the fuel limit and engine timing. Protection, Warning and Action Alert.


Fuel Temperature Sensor

Temperature Sensor Feeds, Harness Voltages

1

2



Fuel Temperature Sensor Coolant Temperature Sensor Intake Manifold Temperature Sensor



Voltage between 1 and 2

Wiring harness plug connections (check the harness to ECM)


2300/2800 Series Sensors Different Fault Codes and How they could be Created Engine Coolant Temperature Sensor 32

3 Intake Manifold Temperature Sensor Break

33

ECM „Jack 2‟

2 Fuel Temperature Sensor

1

2 35

18

Fault 1…………………………. Fault 2…………………………. Fault 3………………………….


2300/2800 Series Pressure Sensors Atmospheric/Crankcase Pressure Sensor 2

5 Volts

14

Signal Voltage

3

0 Volts

40

Signal Voltage

Intake Manifold Air Pressure Sensor

Engine Oil Pressure Sensor

24

Signal Voltage

ECM J2


23/25/2800 Series Pressure Sensor Operation

6.5 Volts

R

Pressure Sensor 5 Volt 2

3 0 Volts

Sensor ‘Fly Lead’

Main Engine Harness

ECM J2


Inlet Manifold Air Pressure Sensor EST Code 273 - (Code also known as Turbo Boost!) 

 

  

Pressure can be viewed in PSI and Kpa through the ECM via:  J1939 CAN link  Perkins Data Link (PDL) Used to determine mass air flow Enables the calculation of the correct air/fuel ratio Used for smoke limiting strategy Range 52 Kpa Abs. 472 Kpa Abs Protection- Warning and Action Alert.


Inlet Manifold Air Pressure Sensor

Inlet Manifold Air Pressure Values 2800 1800 rpm Full load 1/2 Load 1500 rpm Full Load 1/2 Load

2300 1800 rpm Full load 1/2 Load 1500 rpm Full Load 1/2 Load

Kpa Gauge Inlet Manifold Air Pressure Sensor

295 126 249 94

263 Half TA Luft

95

Kpa Gauge 205 119

195 71

234 Half TA Luft 71


Engine Oil Pressure Sensor EST Code 100



Pressure can be viewed in PSI and Kpa through the ECM via:

J1939 CAN link  Perkins Data Link (PDL) Protection,Warning,Action Alert Protection ‘mapped’ Range 106 Kpa to 1135 Kpa 

  


Engine Oil Pressure Sensor

Engine Oil Pressure Sensor EST Code 100 (Typical Pressure Sensor graph) 100-3 Shorted to a higher voltage or open circuit (over 4.8 volts)

4.8

Warning Pressure – E360-1

Action Alert Oil Pressure – E360-3

0.2

100-4 Signal shorted to a lower voltage (less than 0.2 volts)

Pressure


Atmospheric (Crankcase) Pressure Sensor EST Code 274 

 



Pressure can be viewed in PSI and Kpa, „absolute‟ through the ECM via:  J1939 CAN link.  Perkins Data Link (PDL) Used to calibrate the Inlet Air and Oil Pressure Sensors. With „Critical Override‟ active, if the sensor fails the engine will Derate by 10%. Range 40 Kpa A to 116 Kpa A


Atmospheric Pressure Sensor

2800 Series De-rate Information 





The 2306 / 2806 series engine electronic control, does not automatically de-rate at high altitudes or high ambient temperatures The de-rate information for this engine can be obtained from Perkins Engines Applications Department These de-rate limits must be adhered to or severe engine damage may result


Pressure Sensor Feeds, Harness Voltages C

B

A



Voltage between A and B



Voltage between B and C



Voltage between A and C

Atmospheric/Crankcase Pressure Sensor (DT06-3S) Oil Pressure Sensor (DT06-3S) Intake Manifold Air Pressure Sensor (DT06-3S)

Wiring Harness Plug Connections, (Checks the harness to ECM)


2300/2800 Series Sensors Different Fault Codes and How they could be Created Atmospheric/Crankcase Pressure Sensor

1

2

5 Volts

14

Signal Voltage

3

0 Volts

40

Signal Voltage

24

Signal Voltage

Intake Manifold Air Pressure Sensor

2 Engine Oil Pressure Sensor

3 Fault 1…………………………. Fault 2…………………………. Fault 3………………………….


ECM J2

Crankshaft Speed/Position Sensor EST Code 190

Crankshaft Gear 36 Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

- 1 tooth

Camshaft Speed/Position Sensor EST Code 342 (Speed and timing Sensor 2)

Camshaft Gear 36

+ 1 tooth Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’

Checking Speed/Position Sensors 1

2

Crankshaft Speed/Position Sensor ‘fly lead’

1





Crankshaft Sensor Resistance between 1 and 2 Camshaft Sensor Resistance between 1 and 2

2

 Camshaft Speed/Position Sensor ‘fly lead’

Run Engine and Measure output AC Voltage or Frequency from each Sensor - one at a time


Additional Sensors/Senders Coolant Level switch Coolant temperature sender CV18338/5 and adapter OE51375

Speed Sensor

CV18338 and Harness CV18965

Oil pressure sender

CV18339/3 and adapter 3Y-2888


Additional Engine Sensors/Senders

Temperature Switch

Coolant Level sensor

Oil Pressure Switch


Machine Wiring Schematic, All Options This Wiring Supplied By OEM

2800 Wiring Diagram

Crank Terminate (Engine Running Signal)

Notes: Outputs may be used to drive lamps or relays.

C

T




G U

Warning

P

Customer side (Jack 1)  Outputs - may be used to drive lamps or relays. (0.3 A, 1.0 A and 1.5 A)  Crank terminate should be a relay to monitor starter motor in the OEM panel  Diagnostic lamp, lights when active fault code registered, or any of the outputs are disconnected/open circuit  Inputs - injection disable, RPM select, digital speed control, raise/lower, droop/isochronous, etc  For full details of inputs and outputs refer to the installation manual

J1/13


J1/10


J1/19


J1/20

Warning Lamp Output

J1/31


Action Alert


(2800,TSL 4262. 2300, TSL 4267) This drawing for indication only!

ECM K

Diagnostics

K Low Oil Pressure

O High Coolant Temp

N Overspeed

A


U

J1/28


J1/29


J1/30


J1/62

Injection Disable

J1/64


J1/56


J1/46

Droop/Isochronous


K N

1500/1800 1800 rpm Select

Isoch


A Y

Fault Reset

J1/41

Fault Reset

J1/49


Enable



G

Lower Speed

P O

Raise Speed

O B B W R


PWM +8V

B

680R 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser

B W R

680R

B


B

POS

B


R R Off

R

Key On Switch

Y


Y G

Start Button

Starter Motor

G N R B

-

Battery 24V DC


J1/59

Lower Speed

J1/7

Raise Speed

J1/18 J1/67 J1/5 J1/66

Digital Ground

J1/4


J1/3

Analogue Ground

J1/17


J1/2

+5V

J1/61


J1/63


J1/65


J1/48


J1/52


J1/53


J1/70


J1/50

J1939 Data Link +

J1/34

J1939 Data Link -

J1/42

J1939 Screen

J1/8

Perkins Data Link +

J1/9

Perkins Data Link -

J1/55


J1/69


P1 J1

+ J H C G F D E A B




Gen-Set Desired Engine Speed/Load Control The software in the ECM provides the flexibility to cater for Four types of control.    

Digital Control Pulse Width Modulated Analogue Control CAN J1939 Control

Typical Pressure Sensor


Digital Speed/Load Control 





Enables speed control by digital load-sharing and synchronizing equipment

The Engine can interface directly with manual synchronizing selector switches, relays or push buttons When the ECM is working on Digital Speed Control there are three inputs that can be used.  Digital Speed Control Enable  Digital Speed Control Ramp Rate  Digital Speed Control Raise/Lower


Diagnostics

J1/31


J1/28


J1/29


K O Digital Speed/Load Control Low Oil Pressure

High Coolant Temp

N

 



Digital speed control (enable/disable) Overspeed Lamp Output J1/30 A Lower speed (pushbutton/relay contact) Overspeed

Off - Disabled - Stop

J1/62

Injection Disable

J1/49


J1/59

Lower Speed

J1/7

Raise Speed

J1/18 J1/67 J1/5 J1/66

Digital Ground

Raise speed (pushbutton/relay contact) Shutdown Emergency Override J1/64 K  Digital speed control ramp rate, (default 10 rpm/sec) 1500/1800 rpm Select J1/56 N  This can be adjusted via the Electronic Service Tool Droop/Isochronous J1/46 A  Speed adjustment ranges +150 –150 rpm Fault Reset J1/41 Injection Disable On - Enabled - Run

U

Off

On Critical Override (Disables Oil & Water shutdowns when on) 1500 1500/1800 1800 rpm Select

Isoch


Y

Fault Reset

Enable



G

Lower Speed

P Raise Speed


PWM +8V

O

O B B W Limited 2006 - All Rights Reserved Proprietary Information of Perkins Engines Company Perkins Confidential ‘Green’ J1/4 R


2300/2800 Series PWM Speed Control   

Intended for use with a customers load-sharing unit The PWM signal 500 Hz, duty cycle 10-90% Speed adjustment –24% to +8% (0% is rated speed)  For 50 Hz 1141 to 1621 rpm Typical Pressure Sensor  For 60 Hz 1369 to 1945 rpm Note for Calibration:

If the PWM input is selected on the configuration screen but not connected on the OEM’s side, the ECM will default the speed to 1100, (and log a diagnostic code 91-8)


2300/2800 Series Analogue Speed Control 

Speed adjustment –10% to +10% (0% is rated speed)  For 50 Hz 1350 to 1650 rpm  For 60 Hz 1620 to 1980 rpm Note for Calibration: Typical Pressure Sensor If the Analogue input is selected on the configuration screen but not connected on the OEM’s side, the ECM will default the speed to 1100, (and log a diagnostic code 1690-8)


2300/2800 Series Analogue Speed Adjustments 1500/1800 RPM





Resistive track potentiometer Provide linear voltage output (0.5v to 4.5v)

Two series resistors keep voltage away from fault region

4.5V

Fault Region

Voltage o/p



0.5V

Fault Region

+10%

-10% Rated Speed


Engine Speed/Ratings Selection   



Engine Rating,Duties,Speed can be set within limits set by the torque maps The rating of the Engine is selectable via the EST in „Configuration‟ The Function will be selected at the time of manufacture or in service via the Electronic Service Tool.

For example: 2300 Series 2306C-E14TAG2, 2306C-E14TAG3 The ECM has torque limit maps:  1500 rpm prime power  1800 rpm prime power  1500 rpm base load - continuous  1800 rpm base load - continuous  1500 rpm standby maximum power  1800 rpm standby maximum power


2800 Series Engine Protection There are three alarm levels provided which are defined as:  Level 1 - Operator Warning To warn the operator or machine control system of a possible condition within the ECM control system that requires the operators attention.  Level 2 – Action (called De-rate or Alert) To inform the operator or machine control system to take action to enable the proper control of the system (i.e. to externally de-rate or reduce speed). This is normally used by the OEM to stop the engine.  Level 3 – Shutdown To inform the operator or machine control system that the ECM has shutdown due to an operating condition reaching an unacceptable level; or if in the ‘critical override’ condition, that the product is now operating in a condition outside of its scope of supply and may cause injury or be damaged in such a way as to invalidate the warranty


Warnings, Action Alert and Shutdown Protection Device

Warning

Action Alert

Shutdown

High Coolant Temp







Low Oil Pressure







Engine Over-speed







Inlet Manifold Air Pressure





High Inlet Manifold Air Temp





High Fuel Temp





There is not a warning, alert, shutdown on atmospheric – it purely logs a diagnostic code, the diagnostic lamp comes on, the oil pressure is then invalid and we trigger the oil pressure lamp and the shutdown


2800 Series Lamp Outputs The ECM provides individual outputs to drive warning lamps and/or relays to indicate each of the following fault conditions: 

    



Active Fault Codes (Diagnostics) High Coolant Temperature Low Oil Pressure Over-speed Level 1 (Warning) Level 2 (Action Alert) Level 3 (Shutdown)



Lamp Outputs.



The outputs have a maximum current value as below.



Shutdown and Crank Terminate = 1.5 amps.



Action Alert and Warning = 1 amp.



Diagnostics, Oil Pressure, Coolant Temperature, Overspeed = 0.3 amps.


Machine Wiring Schematic, All Options Customer Outputs This Wiring Supplied By OEM

Crank Terminate (Engine Running Signal)

Notes: Outputs may be used to drive lamps or relays.

C

T

ECM K




G

J1/13


J1/10


J1/19


J1/20

Warning Lamp Output

J1/31


J1/28


J1/29

Coolant Temperature Lamp Out

J1/30


Action Alert

U


Warning

P Diagnostics

K Low Oil Pressure

O High Coolant Temp

N Overspeed

+ Positive - Negative


A U

J1/62

Injection Disable

J1/64




K

drive lamps or relays.

C

K



J1/10


J1/19


Injection Disable/Critical Override Diagnostic lamp lights when active system fault registered

Action Alert

U




G

When critical override Warning has been enabled in the service tool - the switch Warning Lamp Output J1/20 when 'open' allows the protection to be over ridden, the switch when closed P enables the normal Diagnostics protection - the diagram reads the opposite. TheOutput idea J1/31 Diagnostics Lamp K was that if you've enabled a feature to over ride protection and the wire Low Oilsafe Pressureresults in you being able to run to destruction. drops off then the fail Oil Pressure Lamp Output J1/28 O



High Coolant Temp

Coolant coolant Temperature Lamp Output J1/29 ‘Critical Override’ Not Recommended, Nignores oil pressure, temperature, atmospheric pressure shutdowns when on Overspeed Off - Disabled - Stop Injection Disable On - Enabled - Run

A U

J1/30


J1/62

Injection Disable

J1/64


J1/56


J1/46

Droop/Isochronous

J1/41

Fault Reset


+ 24 Volts

1500/1800 1800 rpm Select

K N Isoch

Droop/ Droop Isochronous Fault Reset

A Y


Enable

2800 Series Switch Inputs 1500/1800 rpm Selection  Switch to ground to select 1800 rpm. Enabling of this input is controlled via the Electronic Service Tool (EST) Droop/Isochronous  Switch to ground for droop governing. Enabling of this switch input and Percentage droop is set using the EST Fault Reset 

This switch is used for clearing faults after an engine shutdown, switch to ground for fault reset.(Faults cleared by turning the Ignition Switch off/on)


Electronic Fault Diagnostics  

  

  

Electronic Service Tool (EST) Electronic Diagnostic Device (EDD)

Generic Engine Monitor (GEM) Diagnostic Manual TSD 3453 Trouble Shooting Guide (TSG) Perkins Technical Marketing Information (PTMI) Workshop Manual TSD 3450 Installation Manual TSL 4262


Electronic Fault Diagnostics Generic Engine Monitor (GEM 2200) Part Number 2800A003  Compact Robust Module, connects via J1939 CAN  Several Languages  Analogue Gauges  Digital Readout  Graphs  Active Diagnostic Codes  Audible Alarm  12/24 Volt Operation


R B

J1/2

+5V

J1/61


Unswitched Battery Negative J1/63 B 9 Pin (Deutsch) Diagnostic Connector Unswitched Battery Negative J1/65 B

y n

R R Off

R

Key On witch

Y

6A)

Y G

Button

G N R B

J1/48


J1/52


J1/53


J1/70


J1/50

J1939 Data Link +

Used for Diagnostic Code Reader/ Generic Engine Monitor, (CAN) Controller Area Network, SAE J1939 Genset Control

J1/34

J1939 Data Link -

Screen - Unused

J1/42

J1939 Screen

J1/8

Perkins Data Link +

J1/9

Perkins Data Link -

J1/55


J1/69


P1 J1 J H C G F D E A B


Used for Electronic Service Tool Perkins Data Link (PDL) Power Supply to Service Tool



Electronic Engine Diagnostics 



Electronic Service Tool (EST) computer based.  Many functions, reading of temperature, speed, pressures, etc  Genuine network only (including some OEM’s and Dealers)  Configuration settings, histograms, graphing, data log, etc  Installing/downloading ‘flash files’ and full engine diagnostics. Electronic Diagnostic Device, (EDD).  Reads J 1939 Codes, available to anyone.  Not a substitute for the EST.  Ability to control Engine Speed Remotely


Electronic Service Tool (EST)  

    

An element of TIPSS The Integrated Product Support Solution

Common for all future Perkins Engines Hardware and software required Computer/Communications adapter Annual subscription Restricted to genuine networks


Diagnostic Fault Codes Active Diagnostic Codes  Any fault that is currently „Active‟ on the engine. Logged Diagnostic Codes  Faults that have occurred, „Logged‟ and been repaired. Logged Event Codes  Problems „Events‟ that could cause permanent damage

Engine coolant temperature

110

3

CID

FMI

Component/circuit identifier

Failure mode identifier

E 361-1 High Engine Coolant Temperature (Warning) E 361-2 High Engine Coolant Temperature (Action Alert) E 361-3 High Engine Coolant Temperature (Shutdown)


23/25/2800 Speed/Timing Calibration  

This Procedure is only necessary if the Diagnostic Code is present: The engine may run rough, emit white smoke or they may be noticeable performance effects

no

261-13 Engine Timing Calibration Required 



If the ECM has been replaced and you are unable to take data from existing ECM, or if repairs have been completed to the engine drive train or possibly replaced Speed/Timing sensors

The engine must be running at 1100 rpm for ECM calibration.


Timing Calibration Probe Installation

1mm (0.040in)

The probe measures the angular position of the crankshaft and compares this to the measurement coming from the Camshaft Speed/Timing Sensor. The ECM then makes a correction or calibration if necessary


ECM Timing Calibration Location Position Calibration slot

ECM Calibration ref position Distance between TDC position and ECM Calibration position approx 100/125 mm

Crankcase TDC Ref Point Crankshaft TDC Ref Position

Crankcase Calibration access blank plug


2300/2800 Series Immersion Heater 

110V/240V immersion heaters and thermostat. Rated at 1500W, thermostat temperature range of 38 to 49°C

Route harness to avoid heat from the exhaust manifold/turbocharger

Thermostat Sensor

Immersion Heater Element Position

Immersion Heater Element


Connect to: 110/240 Volt Power Supply

2300/2800 Series Cold Start Mode Timing Advance  The ECM provides automatic timing advance in cold weather to compensate for the increased ignition delay of cold fuel and cold air  Several conditions exist in cold engines which cause increased white smoke from incomplete combustion Conditions  Triggered below 18 Deg C  The inlet air is cold.  The fuel is cold and does not ignite as easily  Longer Ignition delay.  The piston, cylinder wall and head are cold.  The cold fuel does not burn as rapidly


2800 Series Governor Stability 





Make sure ‘Overspeed’ is configured with the EST

Establish how much governor instability (rpm above and below rated speed)  (Increasing governor proportional gain - hunt duration will Increase)  (Decreasing governor proportional gain - hunt duration will Decrease) Adjustments  20 rpm below rated speed - adjust min stability and reduce proportional gain  20 rpm above rated speed - adjust max stability and reduce proportional gain Typical 2806  Governor proportional gain - 26,214 (range 1 - 39999)  Governor maximum stability factor - 3146  Governor minimum stability factor - 1573  Type in value „O‟ and configuration will return to its default value

Note:

Altering values can affect steady state and transient speed/response


If you need Technical advice contact our dedicated Engineers Use the Request Form on the Perkins Secured Internet

http://www.perkins.com/perkins/cda/technicalSupportRequest/1,4077,,00.html

Or Send an email to

[email protected]

For URGENT queries only, telephone +44 (0)1733 582858


23/25/2800 Series End of Course Questions 1. What reference voltage do we use to power the analogue speed adjustment, what are the ‘Jack’ numbers? 2. What application could use ‘Critical Override? 3. What would happen if I disconnected the oil pressure sensor? 4. What is the description for these fault codes: 110-3/100-4?

5. What could be the cause of the above faults? 6. What is the preferred method of stopping the engine? 7. Name the two sensors that monitor engine speed/position? 8. Will the engine still start with one speed/position sensor disconnected?


23/25/2800 Series End of Course Questions

(cont/d)

9. What does PWM stand for? 10. What type of Thermistor is in the temperature sensors? 11. What are the ‘Jack’ connections for the ECM power supply? 12. What voltage would I expect between ‘Jacks A,B,C,on the harness feeding the pressure sensors?

13. What voltage is expected across the temperature sensor ‘plug’ with the sensor disconnected? 14. Why are diodes fitted across relays in an electronic engine? 15. A pressure sensor power supply open circuit will create which code? 16. How can I achieve 1100 RPM to calibrate the timing?


2800 Electronic, Mech Jan07

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