Perkins 1106D Electrical Inst. Guide

 

Perkins Confidential Green

Draft 3.2 Aug 2005

1104D and 1106D Electrical and Electronic Installation Guide Draft 3.2 Aug 2005

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1104D and 1106D Electronic Application and Installation Guide

 

Perkins Confidential Green

Draft 3.2 Aug 2005

Contents  INTRODUCTION AND PURPOSE.....................................................................................................5 

APPLICABLE E NGINES ...........................................................................................................................5   ELECTRONIC APPLICATIONS CONTACTS................................................................................................5   NEW FEATURES – 3056 TO 1106D COMPARISON COMPARISON............................................................ ....................................................................... ...........5 5 

1104C and 1106C Implementation (Tier 2)......................................................................................5   1104D and 1106D Implementation Implementation (Tier (Tier 3) ..................................................................................... ............................................................. ........................ 5   Reason for Change ....................................................... ........................................................................................................................... .................................................................... 5  3126B AND 1106D COMPARISON ...................................................... ..................................................................................................... ............................................... 8 

3126B Implementation (Tier 2) ........................................................................................................8  1104D and 1106D Implementation Implementation (Tier (Tier 3) ..................................................................................... ............................................................. ........................ 8   Reason for Change ....................................................... ........................................................................................................................... .................................................................... 8  ENGINE COMPONENT OVERVIEW ............................................................... ............................................................................................. .............................. 11 

 Engine Control Module .................................................................................................................. ............................................................... ................................................... 11  SENSOR DETAILS .................................................................................................................................11    Intake manifold Pressure Pressure Sensor purpose ...................................................................................... ............................................................... ....................... 11   Intake Manifold Temperature Temperature Sensor ............................................................................................. .................................................... ......................................... 11  Coolant Temperature Sensor..........................................................................................................12   Fuel Manifold Pressure Sensor Sensor ................................................................. ...................................................................................................... ..................................... 12   Fuel Pump Solenoid ................................................................................................... ....................................................................................................................... ....................13 13   Fuel Injectors.................................................................................................................................. Injectors...................................................................................... ............................................ 13  Crankshaft Speed/Timing Sensor....................................................................................................13   Pump / Camshaft Speed Sensor Sensor ...................................................................................................... ........................................................... ........................................... 14  Oil Pressure Sensor........................................................................................................................14  Smart Turbo Wastegate .................................................................................................................. ............................................................ ...................................................... 15   Principal engine electronic components..................................................................... components......................................................................................... ....................15 15  Schematic Diagram of Engine Harness Example OEM Schematic Diagram.................................16  Diagram................................. 16    Example OEM Schematic Schematic Diagram.................................. Diagram................................................................................................ .............................................................. 17    Example 1 Basic Engine Application .................................................................... ............................................................................................. .........................17  17    Example 2 Construction Application... Application............................................................... ........................................................................................... ............................... 17    Example 3 Industrial Open Open Power Unit Application Application ....................................................... ...................................................................... ...............17  17    Example 4 Agricultural Application Application ................................................................. ............................................................................................... .............................. 17    Example 1 - Basic Schematic Schematic OEM Harness................ Harness................................................................................ .................................................................. ..18 18   Example 2 - Construction Schematic Schematic OEM H Harness.... arness...................................................................... .................................................................. 19   Example 3 – Industrial Open Open Power Unit Schem Schematic atic OEM Harness ............................................. 20   Example 4 - Agricultural Schematic Schematic OEM Harness Harness ....................................................................... ............................................................. ..........21 21  POWER AND GROUNDING RECOMMENDATIONS..................................................................22 

E NGINE BLOCK GROUNDING ...............................................................................................................22   Ground stud on Starter Motor ........................................................................................................ ................................................................ ........................................ 22  Ground Connection to Tapping on engine Block ...........................................................................22   ECM BATTERY AND GROUND CONNECTIONS .....................................................................................24   VOLTAGE AND CURRENT REQUIREMENTS REQUIREMENTS AND CONSIDERATIONS .......................................................25   Warning – Welding.........................................................................................................................26   Warning - Electrostatic Paint Spraying .........................................................................................26   Warning – Jump Starting................................................................................................................26    Inductive Energy – Fly-back Fly-back Suppression Diode ........................................................................... 26   CONNECTORS AND WIRING HARNESS REQUIREMENTS....................................................28 

 ECM connector............................................................................................................................... connector................................................................. .............................................................. 28  Tightening the OEM Connector......................................................................................................28   ECM connector Wire Gauge Gauge Size........................................................... Size ................................................................................................... ........................................ 28 

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 ECM Connector Terminals........................................ Terminals.................................................................................................... ..................................................................... .........29 29   Hand Crimping For Prototype Prototype machines and Low Volume Volume Production: ....................................... 29   Machine Crimping For High High Volume Production............. Production.......................................................................... ............................................................. 29  Terminal Retention .............................................................. ......................................................................................................................... ........................................................... 29   ECM connector sealing plug installation installation guidelines...................................................................... guidelines................ ...................................................... 30  OEM harness Retention at the ECM ..............................................................................................30   HARNESS WIRING STANDARDS ...........................................................................................................31   General Recommendations for Machine Wiring harnesses............................................................31  Connectors......................................................................................................................................31   Cable routing..................................................................................................................................31  Mounting location for electronic modules.................. modules.................................................................................. .................................................................... ....32 32    Electromagnetic Compliance Compliance (EMC) ............................................................................................. 32  Connector Supplier Contact Details...............................................................................................32   Diagnostic Connector.......................................................... Connector..................................................................................................................... ........................................................... 33  Termination Resistor ........................................................... ...................................................................................................................... ........................................................... 33   Pin Information .............................................................................................................................. ............................................................................................................ ..................33 33  STOPPING THE THE ENGINE (AND PREVENTING PREVENTING RESTART) RESTART) ...................................................... 34 

 Ignition Keyswitch....................................................... Keyswitch .................................................................................................................. ................................................................... ........34 34   Emergency Stop Button ............................................................ .................................................................................................................. ...................................................... 34   Battery Isolation Switches .............................................................................................................. .................................................... .......................................................... 35   Remote Stop Button ........................................................................................................................ 35   Datalink stops..................................................................................... stops..................... ............................................................................................................ ............................................ 35  Common problems with the application of stop devices.................................................................36   ENGINE SPEED DEMAND................................................................................................................37 

A NALOG SENSOR ................................................................................................................................37    Device Description............................................................. Description ......................................................................................................................... ............................................................ 37    Evaluating Component Compatibility Compatibility .................................................................................... ............................................................................................ ........37  37    Analog Input Test circuit..................................................... circuit ................................................................................................................ ........................................................... 38   Idle Validation Switch Test Circuit................................................................................................. 38 

Test Procedure................................................................................................................................38   Required Values.............................................................................................................................. Values....................................................................................... ....................................... 39  TEST ....................................................................................................................................................39   PARAMETER ........................................................................................................................................39   U NITS ..................................................................................................................................................39   MIN .....................................................................................................................................................39    NOMINAL ............................................................................................................................................39   MAX ....................................................................................................................................................39    Analog Sensors –Connection details ............................................................... .............................................................................................. ............................... 39  PWM SENSOR - COMPATIBILITY ........................................................................................................40  Device Description............................................................. Description ......................................................................................................................... ............................................................ 40  Component Compatibility...............................................................................................................40  Connection details .......................................................................................................................... ............................................................. ............................................................. 40  PTO MODE ..........................................................................................................................................40   ON/OFF switch ..............................................................................................................................41  Set/lower Button .................................................................................................................... ......................................................... .................................................................... .........41 41   Raise/ Resume Button.................................................................. Button.. ................................................................................................................... ................................................... 41   Disengage Switch ......................................................... ........................................................................................................................... .................................................................. 41   Preset Speed ................................................................................................................... ...................................................... ............................................................................. ................41 41   PTO mode lamp............................................ lamp....................................................................................................... .................................................................................. .......................41 41   Example of PTO mode mode operation ................................................................................................... 42  MULTI POSITION THROTTLE SWITCH (MPTS) .................................................... .................................................................................... ................................ 43  TORQUE SPEED CONTROL TSC1 (SPEED CONTROL OVER CAN)........................................................44   ARBITRATION OF SPEED DEMAND ........................................................................................................44    Manual Throttle Selection Switch.............................................................................. Switch................................................................................................... .....................44 44  COLD STARTING AID. ..................................................................................................................... ............................................................. ........................................................ 45 

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Control of Glow Plugs by the Engine ECM....................................................................................45   Relay, Fuse and Cable Gauge Gauge Specification ................................................................................ .................................................................................. ..45 45  Wait-to-Start / Start Aid active lamps.............................................................................................45  OEM / Operator control or override of the Glow Plugs ................................................................46    Ether Cold Start Systems............................................................... Systems.... ............................................................................................................ ................................................. 46   OPERATOR DISPLAYS.....................................................................................................................47 

Gauge Drivers .......................................................... ....................................................................................................................... ...................................................................... .........47  47    Lamp Outputs ......................................................................................................................... .......................................................... ....................................................................... ........47  47    Indicator lamps Logic..................................................................................................................... Logic.......................................................................................... ........................... 48   Datalink Driven Intelligent Displays............... Displays............................................................................... ............................................................................... ...............49 49   Minimum Functional Specification Specification for J1939 display........................... display.................................................................... ......................................... 49  Customer Triggered Engine Fault codes........................................................................................49   Engine Monitoring System................................................................................................... System.............................................................................................................. ...........50 50  MONITORED INPUTS INPUTS FOR CUSTOMER FIT FITTED TED SENSORS.................................................. SENSORS.................................................... 51 

Configurable States ................................................... ................................................................................................................ ..................................................................... ........51 51   Air Filter Service Indicator – Air Intake Restriction Restriction Switch .......................................................... 52  Coolant Low Level Switch .............................................................................................................. ........................................................... ................................................... 52   Fuel in Water Trap Switch...................................................................................................... Switch.............................................................................................................. ........52 52  ENGINE GOVERNOR........................................................................................................................53 

 All speed ............................................................. ....................................................................................................................... ............................................................................ ..................53 53  Torque limit curve ..........................................................................................................................53   Droop......................................................................  Droop..................................................................................................................................... ........................................................................ .........53 53   High Speed Governor......................................................................................................................55 (Governor Run-Out) ................................................................................... (Governor ............................................................ .......................53 53  AUXILLARY GOVERNOR  ......................................................................................................................55 R ATING ATING SELECTION VIA SERVICE TOOL...............................................................................................55   MODE SWITCHES .................................................................................................................................55    Rating and Droop changes requested requested via the J1939 datalink ........................................................ 56   VARIABLE SPEED FAN....................................................................................................................57  MACHINE SECURITY SYSTEM .............................................................. ..................................................................................................... ....................................... 57  USING THE ET S SERVICE ERVICE TOOL. ................................................................................................... ........................................................... ........................................ 57  DATALINK SUPPORT.......................................................................................................................58 

SAE J1939..........................................................................................................................................58  Summary of Key J1939 Application Issues.....................................................................................58    Physical layer ........................................................................................................................ ............................................................... .................................................................. .........58 58   Network Layer .............................................................. ........................................................................................................................ .................................................................. ........58 58   Application Layer ................................................................ ........................................................................................................................... ........................................................... 58  J1939 SUPPORTED PARAMETERS QUICK REFERENCE SUMMARYTABLE ..............................................60   RECEIVE / TRANSMIT ..................................................................................................................... ........................................................... .......................................................... 60  J1939 PARAMETERS – DETAILED DESCRIPTIONS..................................................................64 

Section 73 - Diagnostic Layer ...................................................................................................... ............................................................. ......................................... 80  Supported Parameters Parameters – Section 21 - Detailed Descriptions Descriptions ......................................................... 83  Supported Parameters – Section 81 Network Management Management - Detailed Descriptions..................... Descriptions................. ....83 83  PERKINS DATA LINK ...........................................................................................................................84   OTHER DATALINK STANDARDS...........................................................................................................84   CANopen ........................................................................................................................................84  OEM Proprietary CAN standards .................................................................................................. ........................................................... ....................................... 84  LIST OF APPENDICES ...........................................................................................................................84      Appendix 1 - ECM J1 Connector Connector Terminal Assignments Assignments ....................................................... 84     Appendix 2 – Electronic Options Selection Form................................................................... 84     Appendix 3 - List of Diagnostic and Event Event Codes ................................................................. ........................................................ .........84 84  • 

• 

• 

PPENDIX

ONNECTOR

ERMINAL

SSIGNMENTS

1 --ECM J1 C OPTIONSTSELECTION AFORM .....................................................................87 ..........................................................85   APPENDIX 2 A ELECTRONIC APPENDIX 3 – LIST OF DIAGNOSTIC AND EVENT CODES .....................................................................91  

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Introduction and Purpose This document is intended to provide necessary information for correct electrical and electronic installation of 1104D or 1106D Industrial engine into an off-highway machine. Perkins Engines Company Company ltd expects that there will be some additions and modificatio modifications ns to this document as the engine program development continues, and as OEM requests for information not currently addressed are added. The Information herein is the property of Perkins Engines Company ltd Inc. and/or its subsidiaries. subsidiarie s. Without written permission, any copying, transmission to others, and any use except that for which it is loaned is prohibited.

 Applicable Engines This is a draft document, the information contained is the best available at the time of authoring to describe the application and installation requirements of the production software as it will be in July 2005. Some engines shipped shipped before this date will not have all the features described in tthis his document. Likewise, Likewise, some additional features will be added after this date. Contact the Electronic Applications Team for latest information on software feature release dates.

Electronic Applications Contacts If the information in this documen documentt is incomplete, incorrect, or further details are required, then please contact an Electronic Applications Engineer. Note that the Contact Details below are valid until Nov 2005 Electronic Applications Team Oliver Lythgoe +44 (0)1733 584171 [email protected]

New Features – 3056 to 1106D Comparison The following table describes the major installation differences between the tier 3 emissions 1104D / 1106D and their predecessors the tier 2 emissions 1104C / 1106C.

1104C and 1106C Implementation (Tier 2)

1104D and 1106D Implementation (Tier 3)

Reason for Change

64 pin Delphi connector – direct to ECM J1 Connector

No redundant harness wires. Flexibility of customer connection

25A fuse

ECM has higher power requirement, as it drivers the injector solenoids

No longer required

New fuel system does not require separate power supply

Interface Connector 70 pin Deutsch MIC connector ECM power supply 10A fuse, 16AWG wire (1.5mm2) Fuel Inject Pump Power Supply OEM fitted fuel injection pump power supply relay

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1104C and 1106C Implementation (Tier 2)

Draft 3.2 Aug 2005

1104D and 1106D Implementation (Tier 3)

Reason for Change

New default values for analogue analogu e throttle sensors

Easier for OEM’s and component manufacturers to design and validate

 Analogue Throttle Position -

pedals and levels for use with the engine Cruise control / Set Speed Control / PTO PTO mode SET / LOWER AND RAISE / RESUME buttons were switch to battery type DISENGAGE feature used 2 switch inputs. The PTO mode function would disengage when both inputs toggled

SET / LOWER AND RAISE / RESUME buttons will be switch to ground type

 Alignment with with the PTO mode mode feature on larger industrial engines e.g. C9

The DISENGAGE feature now only requires a single switch input.

Coolant Temperature and Oil pressure Gauges PWM drivers available

Drivers not available

Gauges not widely used. Low cost and high quality of J1939 gauges makes PWM gauges redundant

Tachometer   Frequency driver available

Driver not available

Low cost and high quality of J1939 gauges makes frequency driver redundant. redunda nt. Also, output from alternator still provides the function if required.

There will be 2 basic lamp outputs for Orange (warning) and Red (shutdown) engine lamps. Low oil pressure will be supported by an additional optional lamp.

Splitting the functions onto a greater number of lamps will make them more intuitive for the operator.

Lamp Outputs 2 lamp outputs were used for cold start, warning, derate, shutdown and low oil pressure. A further 1 lamp was available for PTO mode

The start start”cold lamp will“wait be ontoa separate lamp, and not on the Warning lamp as before The PTO mode lamp Is unchanged CANbus J1939 Shield Shield connection not available

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Shield connection available. Connection by OEM not compulsory

Connection direct to ECM makes this connection possible

1104D and 1106D Electronic Application and Installation Guide

 

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1104C and 1106C Implementation (Tier 2)

Draft 3.2 Aug 2005

1104D and 1106D Implementation (Tier 3)

Reason for Change

Driver available, compatible with open

New ECM has suitable inputs and outputs to control PWM type fans.

Variable Speed Fan Driver Fan driver not available

loop hydraulically controlled fans. . Provision for future adding support for electronically controlled viscous fans if required (Check availability) Machine Security System Not available

Available at engine ordering or as aftermarket enhancement (Check availability)

Reduced costs make solution viable

2 mode switch inputs will be available

No application has been identified which requires more than 2 inputs

Mode Switch inputs 3 mode switch inputs were available

 Additional Monitoring Capability Standard engine sensor Capability to configure monitoring only ECM to monitor additional parameters with OEM fitted sensors. e.g. Coolant level, air filter restriction, Fuel water trap monitor.  monitor. 

New feature for added customer value

J1939 support Significant changes to J1939 support:

 Additional functions functions added. added. Changes Changes to existing functions made to make machine integration easier.

Some new parameters added to support new functions (e.g. change of rating curve)  Also some parameters parameters modified These changes will be marked in the J1939 section of this document Remote Shutdown Not supported

A single switch input will be available for stopping the engine. This will be a normally open switch which is closed to stop the engine. Note that this is not an “Emergency “ Emergency

New feature

Stop”

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1104C and 1106C Implementation (Tier 2)

Draft 3.2 Aug 2005

1104D and 1106D Implementation (Tier 3)

Reason for Change

Electric Fuel Lift pump on engine, controlled by the

Mechanical lift pump, so Mechanical no relay required to be

Change in fuel pump type

ECM relay via an OEM installed

fitted by OEM

Electric Lift Pump Control

3126B and 1106D Comparison The higher power range of the 1106D, over the 1106C, means that it may be installed in some applications applications that previously used a 3126B (C7). It is also accepted that some personnel may be more familiar with the Large Power Systems (LPS) industrial products, such as the C7 and C9, than with the Compact Power Systems (CPS) such as the 1104D and 1106D.

3126B Implementation (Tier 2)

1104D and 1106D Implementation (Tier 3)

Reason for Change

64 pin Delphi connector – direct to the ECM J1 Connector

The additional parameters allows for extra flexibility of the engine operation

25A Fuse

ECM has higher power requirement, requiremen t, as to driver the injector solenoids, a bigger PSU is needed.

The 1106D electronics is a newer design with four throttle customer options.

This allows for greater flexibility in customer choice and application.

Interface Connector 40 pin Deutsch MIC connector

ECM power supply 15A Fuse

Speed Control The 3126B has a single throttle control option.

Intermediate Engine Speed Switch This is a hard-wired customer configured speed demand override between the ranges of Low Idle and Top Engine Limit.

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Not Available

This feature is given with added functionality in the form of a Multi Position Switch.

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3126B Implementation (Tier 2)

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1104D and 1106D Implementation (Tier 3)

Reason for Change

Maintenance Due Reset Switch and Lamp This switch is used to reset the counters for the

Not Available

This is not currently a feature of the 1106D. May be added later over J1939 datalink

maintenan maintenance ce indicator. The lamp shows that scheduled maintenance is due. Torque Limit Switch This allows the customer to limit the torque of the engine between the max torque and torque at rated speed.

Not Available

New mode switches offers superior capabilities to perform this function.

Not available. No rating change during operation and droop value always

Mode switches allow for the active rating and or droop value to be

New Feature

isochronous (0%)

changed operationduring (to anyengine value between 0 and 10%)

Mode Switches

Engine Oil Temperature Sensor This is a sensor measuring the oil temperature in the oil gallery.

Not required

The fuel injection system on the 1104D and 1106D is fuel actuated rather than oil actuated, and thus does not require oil temperature measurement

Not required

Atmospheric pressure is measured only at “key on” by Boost pressure sensor.

Not Available

This is not a feature of the 1106D.

 Atmospheric Pressure Sensor   This is an absolute pressure sensor measuring the atmospheric pressure.  Auxiliary Pressure Sensor This allows the customer to install an auxiliary pressure sensor.  Auxiliary Temperature Sensor This allows the customer to install an auxiliary temperature sensor.

Not Available

This is not a feature of the 1106D. 

Coolant Level Sensor This sensor allows the ECM to monitor the coolant level.

Not Available

Feature may be added in later software release in the form of configurable configurab le I/O. 

Cold Start Aid Inlet Air Heater with on board relay and Ether.

Glow plugs are used with a customer-supplied relay are the only cold start aid.

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This is due to the different engine size and head design. Glow plugs are more than sufficient on the 1106D

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3126B Implementation (Tier 2)

Draft 3.2 Aug 2005

1104D and 1106D Implementation (Tier 3)

Reason for Change

Variable Speed Fan Driver Not available

Compatible with visctronic fans and with

New Feature.

open loop fans. hydraulically controlled TBA.  Air inlet Shutoff Control In the event of an overspeed, this will shut down the engine.

Not Available

No customer requirement requirement has been identified for off highway engines of this size 

Not Available

No customer requirement has been identified for off highway engines of this size

Exhaust Brake This is a method of closing the exhaust to use the internal backpressure to slow the engine down.

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Engine Component Overview Engine Control Module The A4E2 ECM is located on the left rear side of the engine. The ECM has 2 connectors, one for the engine harness and the other for the machine OEM harness functionality The ECM is fuel cooled (see mechanical installation guid guide e for details of fuel connection requirements)

Sensor Details Intake manifold Pressure Sensor purpose The intake manifold pressure signal monitors the air pressure inside the intake manifold, after the turbo, if fitted. The range is 0-339 Kpa absolute. The sensor is used to limit fuel preventing black smoke du during ring transient engine conditio conditions, ns, mainly during acceleration acceleration or upon sudden load appli application. cation. i.e. If intake manifold pressure is too low for the requested fuel, then the fuel is limited to prevent the overfuel condition. Intake manifold pressure pressure is also used to control the smart smart turbo wastegate, if fitted. The smart wastegate control system regulates intake manifold pressure to the desired value, calibrated in the software. software. In order to do this, the software need needs s to know the actual value of intake manifold pressure, hence the need for the sensor. Intake manifold pressure is also used to calculate atmospheri atmospheric c (barometric) pressure.  Atmospheric pressure pressure is used to limit fuel/torque a att low atmosphe atmospheric ric conditions e.g. e.g. at high altitude fuel may be limited to prevent turbo t urbo over-speed. If the intake manifold pressure sensor/circuit fails, then a low default value is used in the software. The smart wastegate wastegate control (if fitted) will go to open loop, whe whereby reby the resultant intake manifold pressure will be low (as determined by the wastegate hardware chosen) and hence fuel will be limited under certain engine conditions, effectively providing a fuel/torque derate.

Intake Pressure Sensor

Intake Manifold Temperature Sensor This sensor measure the temperature in the inlet air manifold in the range  –40C to +120C. +120C. Note that this is the sensor to which the engine is calibrated. Intake air temperature measurement is very sensitive to location. If the OEM adds additional inlet air temperature monitoring, for example during prototype evaluation, it should be anticipated that there may be a difference of several degrees Celsius between the engine sensor and the OEM sensor. Intake manifold temperature temperature is used primarily to determine the cold start strategy.

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The OEM has no connection to this sensor, but if the intake air is rrequired equired by some machine system, for example for fan control strategy, then the data can be accessed on the J1939 datalink. It is possible, if extreme temperatures are measured at the intake that the engine will derate. In the event of a derate, a fault code will be generated on the J1939 datalink, or displayed on the service tool, and the warning lamp will light

Temperature Sensor

Coolant Temperature Sensor The coolant temperature sensor is used for compensating fuel injection control, for activating the glow plugs for cold engine starting and for detecting excessively high coolant temperatures for raising an event. The range is –40C to +120C If the sensor/circuit fails, then a (healthy) high default value is used and a diagnostic code raised. For glow plug control if this sensor/circuit sensor/circuit is faulted, the intake man manifold ifold air temperature sensor sensor is used. It is possible that with this sensor/circuit in a failu failure re condition white smoke may result during during a cold engine start. The Excessive Coola Coolant nt Temperature event will not be raised r aised under this fault condition. The sensor reading of coolant temperature is also used to determine the maximum fuel allowed during during engine starting. starting. If the sensor/circuit fails, it is possible the engi engine ne will not start under cold engine conditions. It is possible, if the coolant temperature exceeds the design limits, that the engine will derate. In the event of a derate, a fault code will be generated on the J1939 datalink, or displayed on the service tool, and the warning lamp will light

Fuel Manifold Pressure Sensor

The fuel rail pressure sensor is used to measure the fuel pressure in the high-pressure fuel rail. (The fuel in the fuel rail then feeds all injectors. Injection takes place when each injector is electrically operated.) The fuel rail pressure measurement is used in conjunction with the high-pressure fuel pump to maintain the desired fuel pressure in the common rail. This pressure is determined by engine calibrations to enable the engine to meet emissions and performance objectives. If the fuel rail pressure sensor/signal is faulted, a diagnostic code is set with a warning; a default value used and a 100% engine derate results. The default value for fuel rail pressure will allow the engine to run in a limp home fashion whereby a known fuel rail pressure will be controlled within reasonable engine conditions. Emissions compliance cannot be guaranteed under this fault condition.

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Fuel Pump Solenoid Fuel Rail Pump Solenoid is used to control the output from the high-pressure fuel pump. The fuel rail pump solenoid is energized when fuel is required to be pumped into the highpressure fuel rail. Varying the energize energize time of the solenoid controls controls the fuel delivery from the pump. The earlier the solenoid is energized energized (degrees before TDC), the more fuel is pumped into the fuel rail. The solenoid forms part of the fuel rail pressure closed loop control system in conjunction with the fuel rail pressure sensor, sensor, ECM and software. The fuel rail pressure sen sensor sor measures the fuel rail pressure; the signal is processed by the ECM and software and compared to the desired fuel rail pressure for the given engine operating conditions. The control algorithm then controls the timing of energising the fuel rail pump solenoid solenoid.. There is no OEM connection to this component. If the fuel rail pump solenoid fails, it is likely that fuel will not be pumped into the fuel rail and engine shutdown shutdown or failed start is expected .

Fuel Injectors Each fuel injector contains a solenoid to control the quantity of fuel injected. Both positive and negative wires to each solenoid are wired directly back to the ECM There is no OEM connection to this component. component. Voltages of up to 70V are used to drive the injectors. Injector cables are of the twisted pair to minimize emissions of electromagnetic noise. By their nature, however, the signals to the injectors are sharp pulses of relatively high current. The OEM should ensure that any systems that are sensitive to electromagnetic radiation are not in proximity to the harness components that lead to the injectors.

Crankshaft Speed/Timing Sensor The crankshaft speed timing sensor is a Hall Effect Sensor. The sensor works in conjunction with the timing ring fitted to the engine crankshaft. The sensor produces a signal as the timing ring/crank rotates past the sensor. The ECM then uses this signal to calculate engine speed and engine position. The crank speed/timing signal is used during normal engine running since is more accurate than the signal obtained from the cam speed/timing sensor. If the crank speed/timing sensor/signal sensor/signal is lost or faulted, the engine is capable of starting provided the cam speed/timing signal is healthy. A diagnostic and warning will be raised if the fault occurs during engine running. A full derate will result since the engine is not then guaranteed guarantee d to be emissions compliant due to the accuracy of the cam speed/timing signal. The diagnostic and derate will not be raised during engine cranking (if fault present), but the service tool will provide a means to read the condition of the cam and crank speed signals to aid fault finding. . The OEM has no connection to this sensor. If the OEM requires accurate engine speed information then this may be obtained from the SAE J1939 datalink.

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Speed Sensor

Pump / Camshaft Speed Sensor The camshaft speed/timing sensor works in conjunction with the timing ring fitted inside the high Pressure fuel pump. The sensor produces a signal as the timing ring/pump rotates past the sensor. The ECM then uses this signal to calculate engine speed, engine position and engine cycle. The cam speed/timing signal signal is required r equired for determining the correct engine cycle and is also used for limp-home operation in the event of the crank speed sensor/circuit being faulted/lost. If the camshaft speed/timing sensor/signal is lost or faulted, f aulted, the engine will not start (since engine cycle is not known from the crank signal only), but if the engine is already running, no engine performance performance effect will be noticed. A diagnostic and warning will be raised if the fault occurs during engine running. The diagnostic will not be raised during engine cranking, but the service tool will provide a means to read the condition of the cam and crank speed signals to aid fault finding.

Oil Pressure Sensor The oil pressure sensor sensor measures the engine engine oil pressure in Kpa. Oil pressure is used for engine protection protection, , whereby if insufficient pressure is measured forisadefined given speed, an event for low oil pressure would be raised. Theoil raised. low oil pressure threshold threshold as a map against engine engine speed. speed. Currently, 2 levels o off event are being specified. Level 1 is the least least severe and raises a warning. warning. Level 3 is the most severe and raise raises s a warning, which requ request est the engine be shutdown. Automatic engine shutdown can be configured for certain applications, application s, such as Gensets to occur when a level 3 event is rraised. aised.   If the oil pressure sensor fails, a diagnostic is raised and a default value is used by the software, which has been been chosen to be a hea healthy lthy (high) pressure value. value. It is not possible to raise an event whilst an oil pressure diagnostic is present.  present. 

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Oil Pressure Sensor

Smart Turbo Wastegate Some engine models will be fitted with a turbocharge turbochargerr with a “smart” wastegate

Principal engine electronic components Intake Temperature

Intake Pressure Sensor 

Fuel Rail Pressure

Coolant Sensor 

Sensor 

ECM

Fuel Pump Solenoid

Pump/Cam Speed Sensor 

Oil Pressure Sensor  Crank Speed Sensor 

 

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Note: Variable Wastegate Fitted to Right Hand Side

 

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Schematic Diagram of Engine Harness  A4E2 ECM J2 Connector 

INJECTOR CYLINDER 6

T962 BK

1

X931YL

6

T956 BK

2

X925PK

62

X930 GY

7

X924 BR

63

INJECTOR CYLINDER 6 RETURN INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 RETURN

T961 BK

3

T955 BK

4 X9929BU

8

T960 BK

1

X923 OR

64

INJECTOR CYLINDER 4

T954 BK

2

X928 GN X922 WH

33 59

INJECTOR CYLINDER 3 RETURN

T959 BK

3

T953 BK

4

INJECTOR CYLINDER 5

INJECTOR CYLINDER 4 RETURN

INJECTOR CYLINDER 3

X927 YL

34

INJECTOR CYLINDER 2 RETURN

X921 PK

58

INJECTOR CYLINDER 2

X926 GY

35

INJECTOR CYLINDER 1 RETURN

X920 BR

57

INJECTOR CYLINDER 1

T997 OR

46

IMP POWER SUPPLY (5V)

7993 BR

38

IMP RETURN

X731 BU

55

IMP SIGNAL

1

L730 OR

47

OIL PRESSURE SENSOR PWR (5V)

2

Y947 BR

39

OIL PRESSURE SENSOR RETURN

3

994 GY

56

OIL PRESSURE SENSOR SIGNAL

INJECTOR CYLINDER 5 INJECTOR CYLINDER 4

T958 BK

1

T952 BK

2

T957 BK

3

T951 BK

4

INJECTOR CYLINDER 3 INTERNAL (ROCKER COVER)

INJECTOR CYLINDER 2

INTAKE MANIFOLD PRESSURE SENSOR

1

EXTERNAL

INJECTOR CYLINDER 1

2 3

OIL PRESSURE SENSOR

1

R997 OR

48

FMP SENSOR POWER SUPPLY (5V)

FUEL RAIL PRESSURE SENSOR

2

Y948 BR

40

FMP SENSOR GROUND

3

Y946 BU

51

FMP SENSOR SIGNAL

COOLANT TEMPERATURE SENSOR

1

995 BU

43

COOLANT TEMP SIGNAL

INTAKE MANIFOLD TEMPERATURE SENSOR

1

C967 BU

42

IMT SIGNAL

2

L731 BR

37

TEMPERATURE SENSOR RETURN

CRANKSHAFT SPEED/ TIMING SENSOR

1

996 GN

10

SPEED SENSOR POWER (8V)

2

E965 BU

52

CRANK SPEED/TIME SENS SIG

P920 BR

53

PUMP /CAM SPEED SENS SIG

PUMP / CAM SPEED SENSOR

FUEL PUMP SOLENOID

2

1 2

FUEL PUMP SOLENOID PWM SIG

26

FUEL PUMP SOLENOID RETURN

C211 BK

44

WASTEGATE RETURN

M795 WH

17

WASTEGATE PWM SIGNAL

2

 A

101 RD

18

BAT+ (FOR COMMS ADAPTER)

B

229 BK

45

BAT - (FOR COMMS ADAPTER)

D

944 OR

21

CDL+

E

945 BR

20

CDL-

F

Y793 YL

23

J1939 -

G

Y792 PK

24

J1939 +

C H

Page 16 of 92

25

1

DIAGNOSTIC CONNECTOR (9 PIN)

ELECTRONIC WASTEGATE  ACTUATOR

Y950 YL Y951 PU

1

J

2

1104D and 1106D Electronic Application and Installation Guide

 

Perkins Confidential Green

Draft 3.2 Aug 2005

Example OEM Schematic Diagram The engine can be configured and wired many different ways dependant on the requirements of the OEM. The following four example schematics provide a guide for the OEM

Example 1 Basic Engine Application This solution is suitable for applications where very little integration or additional engineering engineering is a requirement when compared to the solution used for a mechanical engine. This solution can be used in most replacement engine situations. The OEM needs to consider only basic functions these being Power Supply, Operator Indication, Cold Start Aid and a simple method of controlling the engine speed.

Example 2 Construction Application  An application application where the engine, engine, in resp response onse to an arrangement arrangement o off switched inputs inputs will operate at one of a range of defined speeds. This is suitable for applications applications where the device has multiple operating speeds that are either defined for the specific output reasons, for simplicity of operator use or for operation dependent dependent upon the environment - e.g. quiet modes. This could include: auxiliary engine on road sweeper, multiple speed water pumps, etc. There are sixteen possible set speeds based on four discrete ECM inputs. In addition to the Key-Switch a separate engine shutdown switch is used to stop the engine.

Example 3 Industrial Open Power Unit Application  An application application where the engine, engine, in resp response onse to a control control input, e.g. a button button press, accelerates from idle speed up to the pre-defined operating engine speed. Once at the predefined operating speed, the engine speed may be raised or lowered by increment / decrement button presses. This is suitable for enhancing some of the applications of the single speed (set speed) control, or to provide a variable speed control without having a throttle pedal / lever. This functionality may benefit when the user wants to use ‘set speed operation’, but with the capability to adjust it themselves - users may have a favorite operating speed. This could include concrete pumps, hydraulic driven machines.

Example 4 Agricultural Application The application will allow single or twin throttles, engine twin set speed control, Multi mode operation, integrated display display drive, etc. The ECM dependant dependant on engine temperatures temperatures varies the engine-cooling fan. This set-up is suitable for applications applications where the customer requires a high degree of operator control over the machine’s behavior. It is one of the most complex applications. Typically this is used in mobile applications that may be driven to the place of work and then require operator selectable speed operation whilst performing their chosen task. This could include: Tractors, Combines, Backhoe loaders.

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Example 1 - Basic Schematic OEM Harness A4E2 ECM J1 CONNECTOR

Basic OEM Wiring Schematic Chris Crawford Crawford 17 May 2005 UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Template file: 1100D series OEM wiring_V05.vsd

25A

OFF ON STAR T

IGNITION KEY SWITCH

7

BATTERY +

8

BATTERY +

15 16

BATTERY +

1

BATTERY -

2

BATTERY -

3

BATTERY -

9

BATTERY -

10

BATTERY -

40

IGNITION KEYSWTICH

60

STOP LAMP

BATTERY +

5A

STOP LAMP TO STARTER MOTOR SOLENOID (NOTE 2) WARNING LAMP

COLD START - WAIT TO START LAMP LOW OIL PRESSURE  LAMP

59

WARNING / COLD START LAMP

63

COLD START LAMP (OPTIONAL)

62

LOW OIL PRESSURE LAMP (OPTIONAL)

57

START AID CONTROL

43

SENSOR SUPPLY 8V

50A TO GLOW PLUGS GLOW PLUG RELAY

12V

PWM THROTTLE SENSOR

53

PWM THROTTLE SENSOR INPUT

33

SENSOR RETURN

NOTES 1. CAN shield connection at ECM is optional 2. Fuse value depends on Starter motor relay current 3. CDL can be connected OEM wished to fit additional   diagnostic connectors 4. All relays should have suppression diodes fitted accross   the coils 5. Starter motor control circuits will vary

 

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Example 2 - Construction Schematic OEM Harness A4E2 ECM J1 CONNECTOR

Construction OEM Wiring Schematic Chris Crawford

18 Nov 2004

UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green

CAN J1939 BUS NOTE 1

Template file: 1100D series OEM wiring_V04.vsd 120 OHM

NOTE 3

20

CAN J1939 +

21

CAN J1939 -

22

CAN J1939 SHIELD

23

CDL +

24

CDL -

25A

OFF ON STAR T

IGNITION KEY SWITCH

7

BATTERY +

8

BATTERY +

15

BATTERY +

16

BATTERY +

1

BATTERY -

2

BATTERY -

3

BATTERY -

9

BATTERY -

10

BATTERY -

40

IGNITION KEYSWTICH

60

STOP LAMP

59

WARNING / COLD START LAMP

63

COLD START LAMP

62

LOW OIL PRESSURE LAMP

57

START AID CONTROL

5A

STOP LAMP TO STARTER MOTOR SOLENOID (NOTE 2) WARNING LAMP

COLD START - WAIT TO START LAMP LOW OIL PRESSURE  LAMP

50A TO GLOW PLUGS GLOW PLUG RELAY

12V

10 POSITION ROTARY SWITCH

52

THROTTLE POSITION SWITCH 1

51

THROTTLE POSITION SWITCH 2

50

THROTTLE POSITION SWITCH 3

49

THROTTLE POSITION SWITCH 4

48

SHUTDOWN SWITCH (CLOSE TO STOP)

35

SWITCH RETURN

NOTES 1. CAN shield connection at ECM is optional 2. Fuse value depends on Starter motor relay current 3. CDL can be connected OEM wished to fit additional   diagnostic connectors 4. All relays should have suppression diodes fitted accross   the coils 5. Starter motor control circuits will vary

 

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Example 3 – Industrial Open Power Unit Schematic OEM Harness IOPU OEM Wiring Schematic Chris Crawford

A4E2 ECM J1 CONNECTOR

18 Nov 2004

UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Template file: 1100D series OEM wiring_V04.vsd

25A

OFF ON STAR T

BATTERY +

8

BATTERY +

15

BATTERY +

16

BATTERY +

1

BATTERY -

2

BATTERY -

3

BATTERY -

9

BATTERY -

10

BATTERY -

40

IGNITION KEYSWTICH

61

PTO MODE LAMP

60

STOP LAMP

59

WARNING / COLD START LAMP

63

COLD START LAMP

62

LOW OIL PRESSURE LAMP

57

START AID CONTROL

52

PTO MODE - ON / OFF

51

PTO MODE - SET/ LOWER

50

PTO MODE - RAISE /RESUME

49

PTO MODE - DISENGAGE (NC)

35

SWITCH RETURN

5A

PTO MODE LAMP IGNITION KEY SWITCH

7

STOP LAMP TO STARTER MOTOR SOLENOID WARNING LAMP

COLD START - WAIT TO START LAMP LOW OIL PRESSURE  LAMP

50A TO GLOW PLUGS GLOW PLUG RELAY

12V

ON / OFF SET / LOWER

RAISE / RESUME

DISENGAGE SWITCH

NOTES 1. CAN shield connection at ECM is optional 2. Fuse value depends on Starter motor relay current 3. CDL can be connected OEM wished to fit additional   diagnostic connectors 4. All relays should have suppression diodes fitted accross   the coils 5. Starter motor control circuits will vary

 

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Example 4 - Agricultural Schematic OEM Harness A4E2 ECM J1 CONNECTOR

Agricultural OEM Wiring Schematic Chris Crawford

17 May 2005

UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green

CAN J1939 BUS NOTE 1

Template file: 1100D series OEM wiring_V04.vsd 120 OHM

NOTE 3

20

CAN J1939 +

21

CAN J1939 -

22

CAN J1939 SHIELD

23

CDL +

24

CDL -

25A

OFF ON STAR T

BATTERY +

8

BATTERY +

15

BATTERY +

16

BATTERY +

1

BATTERY -

2

BATTERY -

3

BATTERY -

9

BATTERY -

10

BATTERY -

40

IGNITIONKEYSWTICH

61

PTO MODE LAMP (OPTIONAL)

60

STOP LAMP

59

WARNING / COLD START LAMP

63

COLD START LAMP (OPTIONAL)

62

LOW OIL PRESSURE LAMP (OPTIONAL)

57

START AID CONTROL

5A

PTO MODE LAMP IGNITION KEY SWITCH

7

STOP LAMP TO STARTER MOTOR SOLENOID (NOTE 2) WARNING LAMP

COLD START - WAIT TO START LAMP LOW OIL PRESSURE  LAMP

50A TO GLOW PLUGS GLOW PLUG RELAY

41 54

 ANALOGUE THROTTLE SENSOR 1

33

SENSOR RETURN

45

IDLE VALIDATION (IVS) 1

42  ANALOGUE THROTTLE SENSOR 2

SENSOR SUPPPLY 5V

 ANALOGUE THROTTLE INPUT 1

55

SENSOR SUPPPLY 5V

 ANALOGUE THROTTLE INPUT 2

34

SENSOR RETURN

44

IDLE VALIDATION (IVS)2

52

PTO MODE - ON / OFF

51

PTO MODE - SET/ LOWER

50

PTO MODE - RAISE /RESUME

49

PTO MODE - DISENGAGE (NC)

46

MODE SWITCH 1

39

MODE SWITCH 2

47

THROTTLESELECTION SWITCH

35

SWITCHRETURN

32

PWM OUTPUT (2A)

12V

ON / OFF SET / LOWER

RAISE / RESUME

DISENGAGE SWITCH

MODE SWITCH 1 MODE SWITCH 2

THROTTLE SELECTION SWITCH

FAN DRIVE SOLENOID 2A

NOTES 1. CAN shield connection at ECM is optional 2. Fuse value depends on Starter motor relay current 3. CDL can be connected OEM wished to fit additional   diagnostic connectors 4. All relays should have suppression diodes fitted accross   the coils 5. Starter motor control circuits will vary

 

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Draft 3.2 Aug 2005

Power and Grounding Recommendations Engine Block Grounding  Although the engine electronics electronics are all di directly rectly grounded via the ECM connector, connector, it is also necessary that the engine block be properly grounded to provide a good return path for f or components compone nts such as Starter Motor, Alternator and cold Start Aids. Improper grounding grounding results in unreliable electrical circuit paths. Stray electrical currents can damage mechanical components, and make electronic systems prone to interference. These problems are often very difficult to diagnose and repair. There are 2 acceptable methods of grounding the engine.

Ground stud on Starter Motor If the Starter motor has a grounding stud then this should be used. The ground connection should be preferably be made directly back to the battery negative terminal. The starter motor ground path must not include any flanges or joints. Painted surfaces and flexible mounts in particular must be avoided. Star washers must not be relied upon to make contact though paint. The ground cable should be of cross section 67.4 mm² (00 AWG) or greater .

Ground Connection to Tapping on engine Block

If there is no grounding stud on the Starter motor then a ground cable, direct from the Battery Negative terminal, should be connected to a ring terminal Which connects to one of the three tappings shown in diagram 1 and 2. The tapped holes will be reserved for customer use and can be used for grounding purposes. If a tapping is used then it should be checked to be free of lacquer, paint and dirt before the connection is made. A M10 metric screw should be used plated with Zinc. Zinc . A washer should retain the ring terminal and the screw tightened to 44 Nm (32Ibft)  (32Ibft)   It is preferable to use a conductive grease to ensure the reliability of this connection.

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Ground Point Option 1

Draft 3.2 Aug 2005

Ground Point Option 2

 

Diagram 1 Ground Point 1 & 2

Ground Point Option 3

Diagram 2 Ground Point 3

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ECM battery and Ground Connections The ECM power supply supply (battery + and battery -) is normally permanently permanently connected connected to the machine battery. The exception to this is if the machine is fitted with a battery isolation switch, which disconnects the battery during storage, transport or maintenance. When the ignition key switch is off the ECM is in a sleep mode where it draws a very small residual current. When the ignition ignition key switch is turned on the ECM will become active. It is recommended, recommend ed, therefore that the ignition keyswitch is turned to the off position when connecting disconnectin g the ECM J1connector, to prevent large sparks which may cause damage to or thedisconnecting pins. The power supply to the ECM should be taken from the battery, and not from the starter motor terminals to avoid unnecessary system noise and voltage drops. Note that there are 4 ECM pins allocated for battery positive and 5 for battery negative. All 9 pins must be used. It is also necessary to route the battery return via dedicated cable rather than a return through the machine chassis. It will normally be necessary to splice the power supply wires from one larger conductor into the 4 or 5 smaller ones. This splice may be achieved either by a crimped and soldered metal band (appropriate for low volume manufacture) or by ultrasonic slicing (for medium and high volume manufacture). manufacture). All splices should be insulated with adhesive lined heat shrink sleeve. The Cross Sectional Area of wire on both sides of the splice must be balanced so both sides fall within the Cross Sectional Area range of the heat shrink sleeve insulator. The distance between the edge of the splice joint and the wire insulation should be 5.0mm ± 1.5mm.

Right  ECM Connector 

Engine Starter  Motor 

Chassis

Correct Power Supply Wiring • • • •

ECM Positive wires connected direct to battery, not via starter motor Power supply wires go to all 4 positive pins and all 5 negative pins on the ECM Connector Negative is wired to the battery rather than return through chassis The engine is grounded

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Wrong 

Draft 3.2 Aug 2005

ECM Connector 

Engine Starter  Motor 

Chassis

Chassis

 

Incorrect wiring • • • •

Positive wired via starter motor. High volt drop to ECM on starting Single pin on ECM used for each of positive and negative supply. Possibly exceeding pin ratings and possibly causing risk of arcing or over heating. ECM return through chassis – risk of conducted noise and also additional voltage drop. Engine not grounded – risk of engine component damage.

Voltage and Current requirements and considerations The ECM has an internal switched mode power supply and is thus capable of withstanding normal low voltage situations, such as occur during starting / cranking. ECM power supply cables sizes should be selected with care, however to ensure that the average voltage during cranking is at least 6V at the ECM. To achieve this, the total resistance r esistance of the power supply wiring, including both positive and negative paths, should not exceed 100mOhms and the voltage at the battery terminals should not be less than 7.5Volts 2 seconds after the start of cranking. Information regarding ECM Power Supply requirements is provided in Table 1. Information is supplied for both 12V and 24V systems. All measurements are based on nominal voltages expected when the engine is running, 13.8V for 12V systems and 27.8V for 24V systems.  systems. 

Table 1 - ECM Supply Voltage and Current Requirements.

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Draft 3.2 Aug 2005 VOLTAGE SUPPLY SYSTEM

12V

24V

Max Peak Current

40A

30A

Max RMS Current*

13A

7.5A

Suggested Fuse Rating** Sleep Current

25A

20A