Perkins 23/25/2800 Series
Diesel Engine Training
Domestics
Fire Exits
Breaks
Lunch
Toilets
Smoking
Mobile Phones
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
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
Worldwide „Off Road‟ Legislation Today
„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
„Off Road‟ Industrial - Ever Cleaner Engines
0.05
0.10
0.15
0.20
0.25
0.30
0.35
0.40
0.45
0.50
Tier 3: 56
kW<75
Tier 3: 75
kW<130
Tier 3: 130
kW<560
Tier 4A: 56
kW<130
Tier 4A: 130
kW<560
Tier 4B: 56
kW<560
PM
(g/kWh)
1980’s
Particulate Matter
(PM) 0.6g/kWh
Oxides of
Nitrogen
(NOx) 10.00g/kWh
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’
FGA 06 - 1234 - U - 5678 - K
„F‟ Engine Family, 14.6 litre
„H‟ Engine Family, 15.8 litre
„J‟ Engine Family, 18 litre
A = TAG 1 (
T
urbo-
A
ir to air charge cooled-
G
enset)
Generator Set
Engine
Number of Cylinders
Engine Serial Number
Country of Manufacture
Year of Manufacture 03
Build List
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
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
Combined primary and
secondary „Eco‟
Fuel filters
Integral inlet manifold
(18 litre horizontal)
Fuel transfer
pump
Timing
Calibration
ADEM 3 ECM
With Perkins
Unique wiring
harness
Radial seal
air filter
element
2306/2806 Product Features
Composite
top cover
Oil cooler
„Ecoplus‟ full
flow
oil filtration
Single stage
high boost
turbocharger
Torsional
vibration
damper
Air to air
charge
cooler
16 litre
2306/2806 Product Features
2806 -18 litre Product Features
Twin exhaust
manifolds
External oil feed
to the cylinder
head
Twin
turbochargers
Large output
coolant pump
New oil filler
tube
30% larger
capacity oil
cooler
Rocker Assemblies
Forged
steel
overhead
camshaft
Four
valves
per
cylinder
Cylinder Head
One of three oil
feed drillings
TDC locator
Turning
tool
Valve/Injector Clearance
Valve
„screw and locknut‟
adjuster
Injector adjuster
Injector
trim code
Button and „O‟ ring
Tool CH11149
Checking correct
adjustment
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)
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.
A failed seal
results in
blow by and a
hot injector
Injector Sleeve
A line
contact seal
is attained
Valve lobes
Injector lobe
Drive gear
dowel location
Camshaft
Camshaft
Cylinder head gasket
Spacer plate
„Shim‟ gasket
Oil feed O ring
Coolant bobbin
Oil seal
Thermal sleeve
Air gap
Cylinder Block
Oil soaked filler band
Rubber O rings
(2806)
Cylinder Liners
Cylinder Liners
Oil cooling spray cutaways
Pistons
Cooling oil reservoir
Pistons
Tightening con-rod bolts
Pistons
Big end cap secured by
four bolts
Oil supply to small end
bearing
Pistons/Con-Rod Assembly
Piston cooling jet
alignment tool
Part Number GE50004
Piston cooling jet
pipe assembly
Entry to cooling
gallery
Connecting rod
Piston
Piston Cooling Jets
Thrust washer position
Crankshaft
Grooved main bearing
fitted to block
180° thrust washers
fitted to block
Block Stiffener Plates
2
Torsional Damper
Hasse and Wrede Damper
1. Housing
2. Casing
3. Inertia Ring (mass)
4. Bearings
5. Silicone Fluid
„Pendulum‟
camshaft gear
Adjustable
idler gear
Idler gear
Fuel transfer
pump
Crankshaft gear
Oil pump gear
Compound
gear
assembly
Coolant pump
drive gear
position
Timing Gears
Locating
dowel
Rotating
balance
weights
Timing Gears
Pendulum Camshaft Gear
Timing case
Alignment
marks
Timing Gears
Crankshaft Seals
Seal Removal/Fitting
Gear case-split protection ring
Wear sleeve ‘crimp’ tool
Must be fitted as assembly
Crankshaft Seals
Blue seal (rear)
Green seal (front)
Induction System
Induction System
Air Filter Type
Single medium duty paper element
Max Air Inlet Temp
60°C (140°F)
Initial Restriction
2.5kPa
(inlet depression new)
Maximum Inlet Depression 6.2Kpa
(with dirty filter)
Max Pressure Drop
14Kpa (2.03 psi)
(across charge cooler)
Maximum Charge Air Temp 260°C (500°F)
at high (ambient conditions)
Turbo Charger
2306 Allied Signal GT 50
2806 Borge Warner S 500
Induction System
Single stage „high boost‟ turbochargers
Induction System
Exhaust gas outlet
Forward turbocharger
Rear turbocharger
Induction System
A
I
R
C
O
O
L
A
N
T
Induction System
Air charge cooling / radiator
Boost air
Turbo boost air
Coolant
Induction System
Trim code,
Below barcode
Fuel System
EUI Location
Put lever here
O ring seals
6 hole
injector nozzle
„Sacrificial‟
compression „O‟ ring
Fuel System
Fuel return
Venting points
Priming pump
Fuel System
Flow =413 litres/h at 1500
Flow =457 litres/h at 1800
Return flow dependant on
engine load – Thermostat.
Fuel System
Fuel System
Ecoplus Fuel Filtration
Fuel System
Oil
Fuel System
From
Tank
To
transfer
pump
From
transfer
pump
Temp sensor
Return from
head
Supply to head
Hand
primer
By-pass
valve
Fuel System
Fuel System
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)
Lubrication System
Lubrication System
Sampling
point
O/P switch
Filter by-pass
valve
Cooler by-pass
valve
Lubrication System
Oil cooler
assembly
Re-positioned
oil filler
tube
Re-designed
Oil filter
head
Lubrication System
2806-18
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
Composite top and bottom radiator tanks
Cooling System
Thermostat
Thermostat seal
Flow to radiator
By-pass
return to
coolant pump
Cooling System
Thermostat Housing
Coolant
Temp Sensor
Inlet Manifold
Air Pressure
sensor
Fuel Temp Sensor
Inlet Manifold
Air Temp Sensor
Engine Oil and
Atmospheric
23/25/2800 Series
Electronic Control
40 Pin Customer
Connection (J3)
110 Volt MEUI Solenoid Feeds
Cam Speed/
Position Sensor
Crank
Speed/Position
Sensor
9 Pin
Diagnostic
Connector
23/2800 Series
23/25/2800 Series Electrical System
36-1 TOOTH CRANK GEAR 36+1 TOOTH CAM GEAR
Internal Injector Harness
Crank Speed/Timing
Cam Speed/Timing
Jack 1 (J1)
Jack 2 (J2)
Fuel Temperature Sensor
Coolant Temperature Sensor
23/25/2800 „On Engine‟ Wiring Harness
ECM J2/44 Injector Common Cylinders 1 & 2
Injector Cyl 1 Injector Cyl 2 Injector Cyl 3 Injector Cyl 4 Injector Cyl 5 Injector Cyl 6 J2/45 J2/46 J2/55 J2/54 J2/39 J2/38 J2/37 J2/36
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 5 7 6 10 3 11 2 12 1 J300 P300 A C +5V Signal B Return A C +5V Signal B Return A C +5V Signal B Return Atmospheric Pressure Sensor
J2/2 J2/14 J2/3 J2/24 J2/32 J2/33 J2/35 J2/40 Turbo Outlet Pressure Sensor
Oil Pressure Sensor
J2/18
+5VDC Supply Analogue Return
Fuel Temperature
Inlet Air Temperature Return Inlet Air Temperature Sensor
C Signal
B Return Coolant Temperature Sensor
C Signal
B Return Fuel Temperature Sensor
C Signal
B Return
Atmospheric Pressure
Turbo Outlet Pressure
Oil Pressure
Coolant Temperature
J2/48
J2/49 Crank Speed Timing -2
Signal 1 Return Crankshaft Position Sensor
Crank Speed Timing +
Cam speed timing -Camshaft Position Sensor
Cam Speed timing + J2/58 J2/59 2 Signal 1 Return P203 J203 P200 J200 P201 J201 J100 P100 J105 P105 J103 P103 J401 P401
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!
Effects of „Bad‟ (Resistance) Connections
24v dc
Possible
„Bad‟
Connections
Lamp
24v dc
Resistors
Lamp
Has the same effect as….Resistances in circuit
1 volt
2 volt
24v dc
19.9v dc
„J‟ Jack
„P‟ Plug
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)
M
echanically Actuated
E
lectronically Controlled
110v dc injector solenoid
“Poppet” Valve
Shut when energised
23/25/2800 Series MEUI Injector
+
110v
Supply
Off
-
Flow
„O‟
Rings
„
O’ Rings
Worn MEUI Injector Poppet Valves
Injector „trim code‟
Injector trim code
Fuel chamber
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
Basic System – A3-ECM Interactions
Inputs
Outputs
Cables/
Connectors
Digital speed Adjust
analogue speed
Adjust
PWM speed Adjust
Push
buttons/switches
fault reset,injection
disable,lower/raise
digital speed,
etc,etc
ECM power supply,
24 v
Control
Voltage to operate
diagnostic lamps
and crank terminate
relay
5 volt + 8 volt
Power Supplies
110 Volt DC pulse
for Injectors
Digital output
for speed control
Cables/
Connectors
Cables/
Connectors
Cables/
Connectors
PDL
PROCESSOR
MEMORY
(Engine
Programme)
Power supply
for 5 volt
6.5 volts and
8 volts
CAN
J 1939
2300/2500/2800 „Off Engine‟ Wiring Diagram
J1- 70 Jack - Customer connection.
Also J3 - 40 Jack - Customer connection
Machine Wiring Schematic, All Options
Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual
Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31
Action Alert Lamp Output Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30 Overspeed Lamp Output
J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser
Unswitched Battery Positive
J1/61 Unswitched Battery Negative
J1/63 J1/65 J1/52 J1/53 J1/48
J1/70 Switched Battery Positive
J1/3 J1/17 J1/2
Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link -J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link
-J1/55 Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N R 680R 680R
This Wiring Supplied By OEM
Shutdown
J1/10 Shutdown lamp Output G
J1/13 Crank Terminate Output K
Crank Terminate (Engine Running Signal)
Injection Disable
J1/64 Shutdown Emergency Override K
J1/62 Injection Disable U
Off - Disabled - Stop On - Enabled - Run Off
On (Disables Oil & Water shutdowns
when on)
Off On
Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative
Unswitched Battery Positive Power Supply to Main Battery Feed (Direct from starter/ battery) (ECM latched out)
1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O
Raise Speed O J1/7 Raise Speed
J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control
CT PWM Ground +8V
„J1 Jack
(Different Diagram)
Some Typical Connections - ECM
Inputs
Outputs
ECM Power Supply,
CONTROL
E C M
Shutdown
Diagnostics
Analogue
Speed Adjust
Crank Terminate
Injection Disabled
+
-
+
-
5 volt to
Sensors
+
-
23/2800 Series ECM „Jack‟ Connections
J1 (Jack 1)
Customer Side
J2 (Jack 2)
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
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.
2300/2800 Series ECM Power Supplies
Machine Wiring Schematic, All Options
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28
Oil Pressure Lamp Output
J1/29
Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
Unswitched Battery Positive
J1/61
Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link
-J1939 Screen
J1/8
Perkins Data Link +
J1/9
Perkins Data Link
-J1/55
J1/69
Charging
Alternator
GRD
POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
N
R
B
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10
Shutdown lamp Output
G
J1/13
Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64
Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Negative
Power
Supply to
Service
Tool
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7
Raise Speed
O
J1/49
Digital Speed Control Enable
G
J1/59
Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable
Digital Speed Control
C
T
PWM
Ground
+8V
+
to Diagnostics Lamps
- to Diagnostics Lamps
Minimum J1 Connections, to run a
23/2800 Series
ECM Power Supply,
Control
ECM
Injection Disabled
+
-
Ignition Key Switch
Note
W
e 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?
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
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.
32
33
35
ECM
Engine Coolant Temperature Sensor
Fuel Temperature Sensor
Signal Voltage
Signal Voltage
Inlet Air Temperature Sensor
Signal Voltage
18
ECM
Temperature Sensor
R
5 Volts
0 Volts
Signal
Ground
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)
110-4 Signal shorted to a lower voltage (voltage under 0.2)
110-3 Signal shorted to a higher voltage or open circuit (voltage over 4.8)
0.2
4.8
Shutdown Temp 361 (3)
Very cold Temp
Action Alert Temp 361 (2)
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
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
Voltage between 1 and 2
Wiring harness plug connections
(check the harness to ECM)
2
1
Fuel Temperature Sensor
Coolant Temperature Sensor
Intake Manifold Temperature Sensor
32
33
2
35
18
3
2
ECM „Jack 2‟
Engine Coolant Temperature Sensor
Fuel Temperature Sensor
Intake Manifold Temperature Sensor
Fault 1……….
Break
1
2300/2800 Series Sensors
2
3
40
24
14
Engine Oil Pressure Sensor
Intake Manifold Air Pressure Sensor
5 Volts
Signal Voltage
0 Volts
Signal Voltage
Atmospheric/Crankcase Pressure Sensor
Signal Voltage
2300/2800 Series Pressure Sensors
2
3
ECM J2
Pressure Sensor
R
5 Volt
6.5 Volts
0 Volts
Sensor ‘Fly Lead’
Main Engine Harness
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 Sensor
Inlet Manifold Air Pressure Values
2800
Kpa Gauge
1800 rpm
Full load
295
1/2 Load
126
1500 rpm
Full Load
249
263 Half TA Luft
1/2 Load
94
95
2300
Kpa Gauge
1800 rpm
Full load
205
1/2 Load
119
1500 rpm
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)
100-4 Signal shorted to a lower voltage (less than 0.2 volts)
100-3 Shorted to a higher voltage or open circuit (over 4.8 volts)
0.2
4.8
Warning Pressure – E360-1
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%.
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
Atmospheric/Crankcase Pressure Sensor (DT06-3S)
Oil Pressure Sensor (DT06-3S)
Intake Manifold Air Pressure Sensor (DT06-3S)
C
A
B
Voltage between A and B
Voltage between B and C
Voltage between A and C
2300/2800 Series Sensors
Different Fault Codes and How they could be Created
2
3
40
24
14
3
2
ECM J2
Engine Oil Pressure Sensor
Intake Manifold Air Pressure Sensor
5 Volts
Signal Voltage
0 Volts
Signal Voltage
Atmospheric/Crankcase Pressure Sensor
Signal Voltage
1
Crankshaft Speed/Position Sensor
Camshaft Speed/Position Sensor
Crankshaft Sensor Resistance
between 1 and 2
Camshaft Sensor Resistance
between 1 and 2
Run Engine and Measure output
AC
Voltage or Frequency from
each Sensor - one at a time
2
1
2
1
Crankshaft Speed/Position
Sensor ‘fly lead’
Camshaft Speed/Position
Sensor ‘fly lead’
Additional Sensors/Senders
Coolant temperature sender
CV18338/5 and adapter OE51375
Speed Sensor
CV18338 and Harness
Temperature
Switch
2800 Wiring Diagram
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
(2800,TSL 4262. 2300, TSL 4267)
This drawing for indication only!
Machine Wiring Schematic, All Options
Notes: Outputs may be used to drive lamps or relays. Crank Terminate should be a relay used to disconnect the starter motor in OEM panel start circuit. Diagnostic lamp lights when active system fault registered For full details of inputs/ outputs, refer to Installation Manual
Action Alert Warning Diagnostics Low Oil Pressure High Coolant Temp Overspeed Critical Override To PWM Speed Control ECM J1/19 J1/20 J1/31
Action Alert Lamp Output Warning Lamp Output
Diagnostics Lamp Output
J1/28 Oil Pressure Lamp Output
J1/29 Coolant Temperature Lamp Output
J1/30 Overspeed Lamp Output
J1/18 J1/66 J1/5 J1/4 Digital Ground PWM Input Ground +8V J1/67 Key Switch Circuit Breaker (16A) Starter Motor Start Button Emergency Stop Button 5K Analogue Speed Setting Potentiometer or Input from Load Sharer/Synchroniser
Unswitched Battery Positive
J1/61 Unswitched Battery Negative
J1/63 J1/65 J1/52 J1/53 J1/48
J1/70 Switched Battery Positive
J1/3 J1/17 J1/2
Analogue Ground Analogue Speed Input +5V J1/50 J1/34 J1/42 J1939 Data Link + J1939 Data Link -J1939 Screen
J1/8 Perkins Data Link +
J1/9 Perkins Data Link
-Charging Alternator GRD POS U P K O N A B B W R B B W R B B B R R R Y Y G G N 680R 680R
This Wiring Supplied By OEM
Shutdown J1/10 Shutdown lamp Output
G
J1/13 Crank Terminate Output K
Crank Terminate (Engine Running Signal)
Injection Disable
J1/64 Shutdown Emergency Override K
J1/62 Injection Disable U
Off - Disabled - Stop On - Enabled - Run Off
On (Disables Oil & Water shutdownswhen on)
Off On
Unswitched Battery Negative Unswitched Battery Negative Unswitched Battery Positive Unswitched Battery Positive Unswitched Battery Negative
Main Battery Feed (Direct from starter/ battery) (ECM latched out)
1500/1800 rpm Select Droop/ Isochronous Fault Reset J1/56 J1/46 J1/41 1500/1800 rpm Select Droop/Isochronous Fault Reset N A Y 1500 1800 Droop Isoch O Raise Speed J1/7 Raise Speed O
J1/49 Digital Speed Control Enable G J1/59 Lower Speed P Lower Speed Enable Digital Speed Control Disable Digital Speed Control
CT
PWM Ground +8V
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
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
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Digital Speed/Load Control
Digital speed control (enable/disable)
Lower speed (pushbutton/relay contact)
Raise speed (pushbutton/relay contact)
Digital speed control ramp rate, (default 10 rpm/sec)
This can be adjusted via the Electronic Service Tool
Speed adjustment ranges +150 –150 rpm
Machine Wiring Schematic, All Options
Notes:
Outputs may be used to
drive lamps or relays.
Crank Terminate should be
a relay used to disconnect
the starter motor in OEM
panel start circuit.
Diagnostic lamp lights
when active system fault
registered
For full details of inputs/
outputs, refer to
Installation Manual
Action Alert
Warning
Diagnostics
Low Oil Pressure
High Coolant Temp
Overspeed
Critical Override
To PWM
Speed Control
ECM
J1/19
J1/20
J1/31
Action Alert Lamp Output
Warning Lamp Output
Diagnostics Lamp Output
J1/28
Oil Pressure Lamp Output
J1/29
Coolant Temperature Lamp Output
J1/30
Overspeed Lamp Output
J1/18
J1/66
J1/5
J1/4
Digital Ground
PWM Input
Ground
+8V
J1/67
Key
Switch
Circuit
Breaker (16A)
Starter
Motor
Start Button
Emergency
Stop Button
5K Analogue
Speed Setting
Potentiometer or
Input from Load
Sharer/Synchroniser
Unswitched Battery Positive
J1/61
Unswitched Battery Negative
J1/63
J1/65
J1/52
J1/53
J1/48
J1/70
Switched Battery Positive
J1/3
J1/17
J1/2
Analogue Ground
Analogue Speed Input
+5V
J1/50
J1/34
J1/42
J1939 Data Link +
J1939 Data Link
-J1939 Screen
J1/8
Perkins Data Link +
Charging
Alternator
GRD
POS
U
P
K
O
N
A
B
B
W
R
B
B
W
R
B
B
B
R
R
R
Y
Y
G
G
680R
680R
This Wiring Supplied By OEM
Shutdown
J1/10
Shutdown lamp Output
G
J1/13
Crank Terminate Output
K
Crank Terminate
(Engine Running
Signal)
Injection Disable
J1/64
Shutdown Emergency Override
K
J1/62
Injection Disable
U
Off - Disabled - Stop
On - Enabled - Run
Off
On
(Disables Oil & Water shutdowns
when on)
Off
On
Unswitched Battery Negative
Unswitched Battery Negative
Unswitched Battery Positive
Unswitched Battery Positive
Unswitched Battery Negative
Main
Battery
Feed
(Direct
from
starter/
battery)
(ECM latched out)
1500/1800
rpm Select
Droop/
Isochronous
Fault Reset
J1/56
J1/46
J1/41
1500/1800 rpm Select
Droop/Isochronous
Fault Reset
N
A
Y
1500
1800
Droop
Isoch
O
Raise Speed
J1/7
Raise Speed
O
J1/49
Digital Speed Control Enable
G
J1/59
Lower Speed
P
Lower Speed
Enable
Digital
Speed
Control
Disable
Digital Speed Control
C
T
PWM
Ground
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
For 60 Hz 1369 to 1945 rpm
Typical Pressure Sensor
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,
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
Typical Pressure Sensor
Note for Calibration:
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,
2300/2800 Series Analogue Speed
Adjustments
Resistive track
potentiometer
Provide linear voltage
output (0.5v to 4.5v)
Two series resistors
keep voltage away
from fault region
Vol
ta
ge
o/p
4.5V
-10%
+10%
0.5V
Fault Region
Fault Region
1500/1800 RPM
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
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
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
Proprietary Information of Perkins Engines Company Limited 2006 - All Rights Reserved Perkins Confidential ‘Green’
