Perkins1104D-E44TA1106D-E70TAElectronicAIGuide.pdf

1104D-E44TA & 1106D-E70TA Electronics Applications and Installation guide

Four & Six cylinder diesel engines for agricultural, industrial, construction applications Note: Information in this manual is preliminary and is subject to change or withdrawal.

DECEMBER 2012 Production Version 1

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CONTENTS INTRODUCTION AND PURPOSE ................................................ .......................... 6 Applicable Engines............................................................................................................................... 6 Electronic Applications Contacts..........................................................................................................6 Safety ....................................................................................................................................................6 Warning – Welding.................... .............. .............. .............. .............. .............. .............. .............. ..... 7 Warning - Electrostatic Paint Spraying .............. .............. .............. .............. ............. .............. ........ 7 Warning – Jump Starting .......................... .............. .............. .............. .............. .............. .............. ... 7

ENGINE COMPONENT OVERVIEW............................................................. ........ 8 Electronic Control Module (ECM) ....................................................................................................... 8 Sensor Details.......................................................................................................................................8 Intake Manifold Pressure Sensor ..................................................................................................... 8 Intake Manifold Temperature Sensor............................................................................................... 9 Coolant Temperature Sensor............ .............. .............. .............. .............. .............. .............. ............ 9 Fuel Rail Pressure Sensor.............. .............. .............. .............. .............. .............. ............. .............. . 9 Fuel Pump Solenoid ............. .............. .............. .............. .............. .............. .............. .............. ........ 10 Electronic Unit Injectors ................................................................................................................ 10 Crankshaft Speed/Timing Sensor ................................................................................................... 10 Camshaft Speed/Timing Sensor........................ .............. .............. .............. .............. .............. ........ 11 Oil Pressure Sensor................... .............. .............. .............. .............. .............. .............. .............. ... 11 Wastegate Regulator .......................... .............. .............. .............. .............. .............. .............. ........ 12 Engine Component Diagrams and Schematics ................................................................................... 13 1106D-E70TA Factory Installed Wiring and Components ............................................................ 13 1106D-E70TA Engine Wire Harness Schematic .......................... .............. .............. .............. ........ 14 1104D-E44TA Factory Installed Wiring and Components ............................................................ 15 1104D-E44TA Engine Wire Harness Schematic .......................... .............. .............. .............. ........ 16 Mandatory Components to Install....................................................................................................... 18 Optional Customer Installed Components* ........................................................................................ 18 Typical Customer Installed Component Diagram.......................................................................... 20 Example OEM Schematic............................................................................................................... 21 Example 1 Basic Engine Application ............................................................................................. 21 Example 2 Construction Application.............................................................................................. 21 Example 3 Industrial Open Power Unit Application...................................................................... 21

Example 4 Agricultural Application............................................................................................... 21 Example 1 - Basic Schematic OEM Harness.................................................................................. 22 Example 3 – Industrial Open Power Unit Schematic OEM Harness ............................................. 24 Example 4 - Agricultural Schematic OEM Harness....................................................................... 25

POWER AND GROUNDING CONSIDERATIONS .......................26 System Grounding ..................................................................................................................... 26 Ground stud on Starter Motor.......... .............. .............. .............. .............. .............. .............. .......... 26 Engine Block Ground Connection.................................................................................................. 26 Power and Grounding Considerations ................................................................................................28 Voltage and Current requirements...................... .............. .............. .............. ............. .............. ...... 28

ECM power supply circuit resistance................................................................................28 Important Voltage Supply Circuit Considerations ......................................................................... 30 Battery (+) Connection .................................................................................................................. 31 Battery (-) Connection.................................................................................................................... 33 Correct method of ECM battery connection................................................................................... 34 Incorrect method of ECM battery connection. ............................................................................... 35 Engine ECM Power Supply Circuit Resistance Test .......................................................................... 36 Test Procedure .............. .............. .............. .............. .............. .............. .............. .............. .............. . 37 Suppression of Voltage Transients ..................................................................................................... 37 Suppression Methods & Best Practice ............. .............. .............. .............. .............. .............. ........ 37 Voltage Load Protection Modules (VLPM).................................................................................... 39 Direct Battery connection requirements .............................................................................................39 Powering The Engine ECM Via Auxiliary Power Supplies ............................................................... 39 Perkins Engines Company Limited

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Sensor Common Connections.............................................................................................................39 Analogue Sensor Return................................................................................................................. 39 Switch Return .............. .............. .............. .............. .............. .............. .............. .............. .............. ... 40 Digital Return................................................................................................................................. 40

CONNECTORS AND WIRING HARNESS REQUIREMENTS.......... ............... 40 ECM connector .............................................................................................................................. 40 Connector Layout............. .............. .............. .............. .............. .............. .............. ............. ............. 41 Tightening the OEM Connector .............. .............. .............. .............. .............. .............. .............. ... 42 ECM connector Wire Gauge Size................................................................................................... 42 ECM Connector Terminals ............................................................................................................ 42 Terminal Retention.................. .............. .............. .............. .............. .............. ............. .............. ...... 42 Hand Crimping For Prototype machines and Low Volume Production: ....................................... 42 ECM connector sealing plug installation guidelines...................................................................... 43 OEM harness Retention at the ECM .............. .............. .............. .............. .............. .............. .......... 43 Machine Crimping For High Volume Production.......................................................................... 44 Harness Wiring Standards .................................................................................................................. 44 General Recommendations for Machine Wiring harnesses ........................................................... 44 Connectors ............. .............. .............. .............. .............. .............. .............. .............. .............. ........ 44 Cable routing...................... .............. .............. .............. .............. .............. .............. .............. .......... 45 Mounting location for electronic modules...................................................................................... 45 Electromagnetic Compliance (EMC) ............................................................................................. 45 Diagnostic Connector..................................................................................................................... 45 Termination Resistor .......................... .............. .............. .............. .............. .............. .............. ........ 46 Pin Information ............. .............. .............. .............. .............. .............. .............. .............. .............. . 46

STARTING AND STOPPING THE ENGINE ................................................. ......47 Starting the Engine ............................................................................................................................. 47 Stopping the Engine (and Preventing Restart) .................................................................................... 48 Ignition Keyswitch.......................................................................................................................... 48 Emergency Stop Button .................................................................................................................. 48 Battery Isolation Switches .............................................................................................................. 49 Remote Stop Button ........................................................................................................................ 49 Datalink stops................................................................................................................................. 50 Common problems with the application of stop devices ................................................................ 50

ENGINE SPEED DEMAND.....................................................................................51 Analogue Sensor................................................................................................................................. 52 Device Description......................................................................................................................... 52 Analogue Sensors –Connection details .......................................................................................... 52 Evaluating Component Compatibility ............................................................................................ 53 Test Procedure .............. .............. .............. .............. .............. .............. .............. .............. .............. . 54 Required Values ............................................................................................................................. 55 Analogue Throttle Switch - EST Configurable Parameters............................................................ 55 PWM Sensor - Compatibility ............................................................................................................55 Device Description......................................................................................................................... 55 Component Compatibility................. .............. .............. .............. .............. .............. .............. .......... 55 Connection details................ .............. .............. .............. .............. .............. .............. .............. ........ 56 PWM Throttle - EST Configurable Parameters ............. .............. .............. .............. .............. ........ 56 PTO mode........................................................................................................................................... 56 PTO Mode ON/OFF switch................... .............. .............. .............. .............. .............. ............. ...... 56 PTO Mode Set/lower Button............. .............. .............. .............. .............. .............. .............. .......... 56 PTO Mode Raise/ Resume Button ............. .............. .............. .............. .............. .............. .............. . 57 PTO Mode Disengage Switch........... .............. .............. .............. .............. .............. .............. .......... 57 PTO Mode Preset Speed.............. .............. .............. .............. .............. .............. .............. .............. . 57 PTO Mode - EST Configurable Parameters................................................................................... 57 Example of PTO mode operation ................................................................................................... 58 Multi Position Throttle Switch (MPTS) .............................................................................................59 Multi Position Throttle Switch - EST Configurable Parameters.................................................... 60 Torque Speed Control TSC1 (Speed Control Over CAN)..................................................................61 Arbitration of speed demand............................................................................................................... 61 Perkins Engines Company Limited

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Manual Throttle Selection Switch .................................................................................................. 61 Ramp Rate ..........................................................................................................................................61 Throttle Calibration ............................................................................................................................61 Throttle Parameter Description...........................................................................................................63 Diagnostic Lower Limit.................................................................................................................. 63 Lower Position limit....................................................................................................................... 63 Initial Lower Position limit ............................................................................................................ 63 Lower Deadzone............................................................................................................................. 63 Initial Upper Position limit ............................................................................................................ 63 Upper Position Limit .......................... .............. .............. .............. .............. .............. .............. ........ 63 Upper Deadzone............ .............. .............. .............. .............. .............. .............. .............. .............. . 63 Diagnostic Upper Limit.................................................................................................................. 63 Throttle Calibration Function .............................................................................................................64 Idle validation maximum ON threshold (Closed)........................................................................... 68 Idle validation minimum OFF threshold (Open)............................................................................ 68

COLD STARTING AID............................................................................................68 Control of Glow Plugs by the Engine ECM ....................................................................................... 69 Relay, Fuse and Cable Gauge Specification .................................................................................. 69 Wait-to-Start / Start Aid active lamps ............................................................................................ 70 OEM / Operator control or override of the Glow Plugs ................................................................ 71 Ether Cold Start Systems................................................................................................................ 71 Water Jacket Heaters .............. .............. .............. .............. .............. .............. .............. ............. ...... 72 Ambient Temperature Sensor - EST Configurable Parameter ....................................................... 72

OPERATOR DISPLAYS ............................................... ........................................... 73 Gauge Drivers ............. .............. .............. .............. .............. .............. .............. .............. .............. ... 73 Lamp Outputs ................................................................................................................................. 73 Indicator lamps Logic .................................................................................................................... 74 Datalink Driven Intelligent Displays.............................................................................................. 75 Customer Triggered Engine Fault codes........................................................................................ 76 Engine Monitoring System ............................................................................................................. 76 Monitoring Mode - EST Configurable Parameters........................................................................ 77 Monitoring Mode Thresholds ......................................................................................................... 77

MONITORED INPUTS FOR CUSTOMER FITTED SENSORS........................ 79 Configurable States .............. .............. .............. .............. .............. .............. .............. .............. ........ 79 Air Filter Service Indicator – Air Filter Restriction Switch ........................................................... 79 Coolant Low Level Switch......................... .............. .............. .............. .............. .............. .............. . 79 Water in Fuel Trap Switch ............. .............. .............. .............. .............. .............. ............. ............. 80

ENGINE GOVERNOR .................................................. ........................................... 81 All speed ......................................................................................................................................... 81 Torque limit curve.......................... .............. .............. .............. .............. .............. ............. ............. 81 Droop ............................................................................................................................................. 81 High Speed Governor (Governor Run-Out)................................................................................... 81 Auxiliary Governor.............................................................................................................................83 Rating selection via Service Tool ....................................................................................................... 83 Mode Switches ................................................................................................................................... 83 Rating and Droop changes requested via the J1939 datalink........................................................ 84 Service Maintenance Indicator....................................................................................................... 84 SAE J1939 ..........................................................................................................................................85 Summary of Key J1939 Application Issues..................................................................................... 85 Physical layer............ .............. .............. .............. .............. .............. .............. ............. .............. ...... 85 Network Layer................................................................................................................................ 86 Application Layer........................................................................................................................... 86 J1939 Supported Parameters Quick reference Summary Table .......................................................... 86 Sending Messages to the Engine ECM...............................................................................................91 Source Address........................ .............. .............. .............. .............. .............. ............. .............. ...... 91 Destination Address ....................................................................................................................... 91

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J1939 SECTION 71 - VEHICLE APPLICATION LAYER.................................. 92 Torque Speed Control......................................................................................................................... 92 ECM Response Time To TSC1 Request.......................................................................................... 92 TSC1 Configuration ............. .............. .............. .............. .............. .............. .............. .............. ........ 92 TSC1 Continuous Fault Handling: [Disabled] (Default)............................................................... 92 End of Transmission – Fault Detection.......................................................................................... 92 TSC1 Continuous Fault Handling: [Enabled] ............................................................................... 93 Rating and Droop Control ............................................................................................................. 93

J1939 SECTION 73 - DIAGNOSTIC LAYER ................................................. ....107 Supported Parameters – Section 21 - Simplified Descriptions..................................................... 109 Supported Parameters – Section 81 Network Management - Detailed Descriptions................... 110 Other Datalink Standards..................................................................................................................111 CANopen .............. .............. .............. .............. .............. .............. .............. .............. .............. ........ 111 OEM Proprietary CAN standards....................... .............. .............. .............. ............. .............. .... 111

LIST OF APPENDICES ................................................ ......................................... 111 Appendix 1 - ECM J1 Connector Terminal Assignments .................................................. 111 Appendix 2 – List of Diagnostic and Event Codes ............................................................ 111 Appendix 1 - ECM J1 Connector Terminal Assignments ................................................................112 Appendix 2 – List of Diagnostic and Event codes ............................................................................ 114 • •

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Introduction and Purpose This document is intended to provide necessary information for correct electrical and electronic installation of 1106D-E70TA & 1104D-E44TA Industrial engines, into an off-highway machine. Perkins expects that there will be some additions and modifications 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 and/or its subsidiaries. Without written permission, any copying, transmission to others, and any use except that for which it is loaned is prohibited.

Applicable Engines The information contained with this document is the best available at the time of authoring to describe the application and installation requirements for a production representative engine andsoftware configuration. During development stages please ensure the Applications Engineering department are consulted before implementing any of the features contained within this document.

Early project engines will not have all the features described in this document enabled. Contact the Electronic Applications Teamfor latest information on software feature release dates.

Electronic Applications Contacts If the information in this document is incomplete, incorrect, or further details are required, then please contact your Applications Engineer.

Safety Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools in order to perform these functions properly. The information in this publication was based upon current information at the time of publication. Check for the most current information before you start any job. Perkins dealers will have the most current information. Improper operation, maintenance or repair of this product may be dangerous. Improper operation, maintenance or repair of this product may result in injury or death. Do not operate or perform any maintenance or repair on this product until you have read and understood the operation, maintenance and repair information.

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Perkins cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are not all inclusive. If a tool, a procedure, a work method or an operating technique that is not specifically recommended by Perkins is used, you must be sure that it is safe for you and for other people. You must also be sure that the product will not be damaged and / or made unsafe by the procedures that are used.

Warning – Welding Welding can cause damage to the on engine electronics. The following precautions should be taken before and during welding: • Turn the engine OFF. Place the ignition keyswitch in the OFF position • Disconnect the negative battery cable from the battery. If the machine is fitted with a battery disconnect switch then open the switch • Clamp the ground cable of the welder to the component that will be welded. Place the clamp as close as possible to the weld. • Protect any wiring harnesses from welding debris and splatter.

DO NOT use electrical components in order to ground the welder. Do not use the ECM or sensors or any other electronic components in order to ground the welder.

Warning - Electrostatic Paint Spraying The high voltages used in electrostatic paint spraying can cause damage to on engine electronics. The damage can manifest itself through immediate failure of components, or by weakening electronic components causing them to fail at a later date. The following precautions should be taken when using electrostatic paint spraying techniques on engines: • •

Connect all 64 pins of the ECM J1 Connector directly to the spraying booth ground. Connect the engine block to ground at 2 points. Ensure that good screwed connections onto bright metal are used.

Warning – Jump Starting Jump-starting an engine can cause higher than normal voltages to appear across the battery terminals. Care must be taken that this does not exceed the recommended maximum voltage for the ECM.

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Engine Component Overview Electronic Control Module (ECM) The A4E2v3 ECM is an electronic control device that governs engine speed, torque output and manages the engines performance and emissions via a number of sensors and actuators. The device is assembledto a special mounting plate fitted to the engine. The location is common on the 1100D series engines, left hand side close to the fuel rail. The device has 2 connection sockets, one for the engine wire harness (J2) that is blue in colour and the other for the machine OEM harness connection (J1) that is grey in colour. There are two ECM options, a fuel cooled version and an air-cooled version. The choice of option depends on the maximum ambient temperature (see mechanical installation guide for details of fuel connection requirements and temperature restrictions).

Sensor Details Intake Manifold Pressure Sensor The intake manifold pressure sensor measures the air pressure inside the intake manifold, after the turbo. The range is 39 - 400Kpa absolute The sensor is used to determine atmospheric (barometric) pressure. During certain operating conditions the ECM will take a snapshot of the measured pressure to set the atmospheric pressure value. The atmospheric pressure is used to determine the atmospheric related fuel limits (if any) e.g. at high altitude fuel may be limited during cranking to prevent turbo over-speed. The ECM also uses the atmospheric value to calculate gauge pressure of other absolute engine pressure sensors. When the engine is running the sensor measurement is used as an input parameter to calculate torque and air fuel ratio limits. This helps prevent black smoke during transient engine conditions, mainly during acceleration or upon sudden load application. i.e. If intake manifold pressure istoo low for the requested fuel, then the fuel is limited to prevent the over fuel condition. The measurement will also be used to select certain timing maps. Intake manifold pressure is also used to control the turbo wastegate regulator, if fitted. The turbo wastegate regulator control system regulates intake manifold pressure to a desired value, calibrated in the software. In order to do this, the software needs to know the actual value of intake manifold pressure, hence the need for the sensor measurement. If the intake manifold pressure sensor/circuit fails, then a low default value is used in the software. The wastegate regulator control (if fitted) will goto open loop, whereby 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.

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Intake Manifold Temperature Sensor This sensor measures the temperature inside the inlet air manifold .The sensor option on the 1106D-E70TA & 1104D-E44TA engine at time of authoring is a 2 pin passive, with an operating range of –40°C to +150°C

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 measurement is usedas an input to the cold start strategy. When the engine is running the sensor measurement is used as an input parameter to calculate torque and air fuel ratio limits. The OEM has no connection to this sensor, but if the intake air is required 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, an event code will be generated on the J1939 datalink, or displayed on the service tool, and the warning lamp will illuminate.

Coolant Temperature Sensor The coolant temperature sensor measurement is used as an input to the cold start strategy. The measurement is also used to select certain maps at certain temperatures. The engine is considered warm at 65°C. The fuel delivery characteristics will change dependant on the engine temperature. The sensor is also used for activating the glow plugs for cold engine starting and for detecting high coolant temperatures for raising an event. The range is –40C to +150C If the sensor/circuit fails, then a default value is used and a diagnostic code is raised. For glow plug control if this sensor/circuit is faulted, the intake manifold air temperature sensor is used. It is possible that with this sensor/circuit in afailure condition white smoke mayresult during a cold engine start. The high coolant temperature event will not be raised under this fault condition. The sensor reading of coolant temperature is also used to determine the maximum fuel allowed during enginestarting. If the sensor/circuit fails, it is possible theengine 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 illuminate.

Fuel Rail 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 Perkins Engines Company Limited

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pump to maintain the desired fuel pressure in the fuel 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.

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 high-pressure fuel rail. Varying the energize time of the solenoid controls thefuel delivery from the pump. The earlier the solenoid is 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 pressuresensor, ECM and software. The fuel rail pressure sensor 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 fuel rail pump solenoid energies time. 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 or failed start is expected .

Electronic Unit 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. Voltages of up to 70V are used to drive the injectors. 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 crankshaft speed and crankshaft 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 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 to be emissions compliant due to the accuracy of the Perkins Engines Company Limited

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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. The software includes logic to prevent reverse engine running.

Speed Sensor

Camshaft Speed/Timing Sensor The camshaft speed/timing sensor works in conjunction with the timing ring fitted on the camshaft. The sensor produces a signal as the timing ring rotates past the sensor. The ECM then uses this signal to calculate camshaft speed, camshaft position and engine cycle. The cam speed/timing signal is required 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, 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 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. The software includes logic to compensate for minor timing errors.

Oil Pressure Sensor The oil pressure sensor measuresthe engine oil pressure inKpa. Oil pressure is used for engine protection, whereby if insufficient oil pressure is measured for a given speed, an event for low oil pressure wouldbe raised. The low oil pressure threshold is defined as a map against engine speed. Currently, two levels of event arespecified. Level 1 is the leastrequest severethe and raises be a warning. Level 3 is theengine most severe andraises a warning, which engine shutdown. Automatic shutdown canbe configured for certain applications, such as Gensets to occur when a level 3 event is raised.

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If the oil pressure sensor fails, a diagnostic is raised and a default value is used by the software, which has been chosento be a healthy (high) pressure value. It is not possible to raise an event whilst an oil pressure diagnostic is present.

Wastegate Regulator The regulator controls the pressure in the intake manifold to a value that is determined by the ECM. The wastegate regulator provides the interface between the ECM and the mechanical system that regulates intake manifold pressure to the desired value that is determined by the software.

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Engine Component Diagrams and Schematics 1106D-E70TA Factory Installed Wiring and Components Electronic Unit Injectors

A4E 2 ECM Diagnostic( If Equipped)

J1

J2 64 Pin Plug

Fuel Pump

Coolant Temperature

Wastegate Regulator

Oil Pressure

( If Equipped)

Intake Manifold Pressure Cam/Timing Sensor Intake Manifold Temperature

Crank Speed / Timing

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Fuel Rail Pressure

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1104D-E44TA Factory Installed Wiring and Components Electronic Unit Injectors

A4E2 ECM Diagnostic ( If Equippe d)

J1

J2 64 Pin Plug

Fuel Pump

Coolant Temperature

Wastegate Regulator

Oil Pressure

( If Equippe d)

Intake Manifold Pressure Cam/Timing Sensor Intake Manifold Temperature

/ Crank Speed Timing

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Fuel Rail Pressure

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1104D-E44TA Engine Wire Harness Schematic A4E2v3ECM J2Connector

T960BK

1

X929BU

34

INJECTORCYLINDER4RETURN

T954BK

2

X923OR

58

INJECTORCYLINDER4

X928GN

8

X922WH

64

X927YL

7

T959BK

3

T953BK

4

INJECTORCYLINDER3

INJECTORCYLINDER2RETURN

T958BK

1

X921PK

63

INJECTORCYLINDER2

T952BK

2

X926GY

35

INJECTORCYLINDER1RETURN

X920BR

57

INJECTORCYLINDER1

T997OR

T957BK

3

T951BK

4

INTERNAL (ROCKER COVER)

INJECTOR CYLINDER4

INJECTORCYLINDER3RETURN

EXTERNAL

INJECTOR CYLINDER3

INJECTOR CYLINDER2 INJECTOR CYLINDER1

INTAKEMANIFOLD PRESSURESENSOR

1 2 3

OILPRESSURESENSOR

46

IMPPOWERSUPPLY(5V)

T993BR

38

IMPRETURN

X731BU

55

IMPSIGNAL

1

769BU

47

OILPRESSURESENSORPWR(5V)

2

Y947BR

39

OILPRESSURESENSORRETURN

3

994GY

56

OILPRESSURESENSORSIGNAL

Y948BR

40

FMPSENSORGROUND

FUELMANIFOLD PRESSURESENSOR

2

Y946BU

49

FMPSENSORSIGNAL

3

R997OR

48

FMPSENSORPOWERSUPPLY(5V)

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

1

CAMTIMING/SPEED SENSOR

FUELPUMP SOLENOID

2

1 2

Y950YL

25

FUELPUMPSOLENOIDPWMSIG

Y951PU

26

FUELPUMPSOLENOIDRETURN

C211BK

19

WASTEGATERETURN

M795WH

17

WASTEGATEPWMSIGNAL

1 2

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

F712GN

23

J1939-

G

F711YL

24

J1939+

C

N874BK

22

A

DIAGNOSTIC CONNECTOR(9PIN)

SHIELD

H

ELECTRONIC WASTEGATE ACTUATOR

J

1 2

NOTALWAYSFITTED ONFIXEDSPEED ENGINES

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1106D-E70TA & 1104D-E44TAPrincipal Engine Electronic Components

Cam Speed Sensor

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Wastegate

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Customer System Overview Key Elements The following section provides details on both the mandatory and optional system connections that need to be made as part of the customers machine wiring harness.

Mandatory Components to Install Mandatory or Required Components Battery

Engine Family

Circuit Protection

All

Key Switch Warning Lamp

All All

Shutdown Lamp Wait to Start Lamp Glow Plug Relay Speed Demand Input

All All All All All All

J1939 PDL

All

A&I Guide Section Power and Grounding Considerations Power and Grounding Considerations Starting the Engine Operator Displays Operator Displays Operator Displays Cold Starting Aid Engine Speed Demand

Communication Datalink Perkins Datalink

Optional Customer Installed Components* Optional Components A&I Guide Section Low Oil Pressure Lamp Operator Displays Remote Shutdown Switch (Normally Open) Stopping the Engine Coolant Level Sensor Monitored Inputs for Customer Fitted Sensors Water in Fuel Sensor Monitored Inputs for Customer Fitted Sensors Air Intake Filter Restriction Switch Monitored Inputs for Customer Fitted Sensors PWM Throttle Position Sensor Engine Speed Demand Analogue Throttle Position Sensor with IdleEngine Speed Demand Validation Switch (1) Analogue Throttle Position Sensor with IdleEngine Speed Demand Validation Switch (2) Throttle Selection Switch Engine Speed Demand Multi-Position Switch Engine Speed Demand PTO On/Off Switch Engine Speed Demand PTO Set/Lower Switch Engine Speed Demand PTO Raise/Resume Switch Engine Speed Demand PTO Disengage Switch Engine Speed Demand Mode Switch (1) Engine Governor Mode Switch (2) Engine Governor Ambient Temperature Sensor

Additional Options

Fuel Filter Differential Pressure Switch

Monitored Inputs for Customer Fitted Sensors Fan Reversing Solenoid Control Additional Options Cold Starting Aids

Fan Reversing SWG Return Ether Start Perkins Engines Company Limited

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Auxiliary Temperature

Monitored Inputs for Customer Fitted Sensors Auxiliary Pressure Monitored Inputs for Customer Fitted Sensors Overspeed Verify Switch Engine Speed Demand Fan Speed Sensor Monitored Inputs for Customer Fitted Sensors Hydraulic Fan Driver Hydraulic Governor * Check Compatibility in specific sections, some components cannot be used together.

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Typical Customer Installed Component Diagram

Battery Isolation Switch

Glow Plug Relay

-

+

PWM

Battery

Throttle

Analogue Throttle with IVS IVS

Circuit Protection (Mandatory)

Air Filter Restriction Switch

Keyswitch

Magnetic Switch PTO On/Off Switch

Warning Lamp

PTO Raise/Resume Button

Stop Lamp

PTO Set/Lower Button Wait to Start Lamp PTO Disengage Low Oil Pressure Lamp Modes Switch 1 Maintenance Due Lamp Modes Switch 2 Service Tool Connector

Shutdown Switch Maintenance Due Reset Switch

J1939 Termination Resistor

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

Example 1 Basic Engine Application This solution is suitable for applications where very little integration or additional engineering is a requirement when compared to the solution used for a mechanical engine. This solution can be used in most mechanically governed engine replacement 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 where the engine, in response to an arrangement of switched inputs will operate at one of a range of defined speeds. This is suitable for 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 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 where the engine, in response to a control input, e.g. a button press, accelerates from idle speed up to the pre-defined operating engine speed. Once at the pre-defined 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 providemay a variable having a throttle pedal / lever. This functionality benefitspeed whencontrol the userwithout 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 drive, etc. This set-up is suitable for 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 A4E2v3 ECM J1 CONNECTOR

Basic OEM Wiring Schematic June 2012 UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Template file: Unity series OEM wiring_

NOTE 7

OFF ON

BATTERY+

8

BATTERY+ BATTERY+

16

BATTERY+

1

BATTERY-

2

BATTERY-

3

BATTERY-

9

BATTERY-

10

BATTERY-

40

IGNITIONKEYSWTICH

60

STOPLAMP

59

WARNINGLAMP

63

COLDSTART LAMP

62

LOWOIL PRESSURELAMP (OPTIONAL)

57

START AIDCONTROL

43

SENSOR SUPPLY8V

53

PWMTHROTTLESENSORINPUT

33

SENSORRETURN

5A

START

IGNITION KEY SWITCH

7

15

STOP LAMP TO STARTER MOTOR MAG SWITCH

WARNING LAMP

NOTE 2 COLD START - WAIT TO START LAMP

LOW OIL PRESSURE LAMP

NOTE 4

NOTE 5

GLOW PLUG RELAY

TO GLOW PLUGS

Battery

PWM THROTTLE SENSOR

NOTES J1 PLUG

1. N/A 2. Fuse value depends on Mag Switch circuit c urrent 3. N/A 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependant on system voltage

Rear View of J1 Plug

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Front View of J1 Plug

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Example 2 - Construction Schematic OEM Harness 120 OHM

Construction OEM Wiring Schematic

A4E2 ECM J1 CONNECTOR

June 2012 UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green

CAN J1939 BUS NOTE 1

Template file: Unity OEM wiring NOTE 3

20

CANJ1939+

21

CANJ1939-

22

CANJ1939 SHIELD

23

CDL+

24

CDL-

120 OHM

NOTE 7

OFF

BAT T ERY+

8

BAT T ERY+

15

BAT T ERY+

16

BAT T ERY+

1

BAT T ERY-

2

BAT T ERY-

3

BAT T ERY-

9

BAT T ERY-

10

BAT T ERY-

40

IGNIT IONKEYSWT ICH

60

ST OPLAMP

59

WARNINGLAMP

63

COLDST ART LAMP

62

LOWOIL PRESSURELAMP (OPT IONAL)

57

ST ART AIDCONT ROL

5A

ON ST ART

IGNITION KEY SWITCH

7

STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP

LOW OIL PRESSURE LAMP

NOTE 4

NOTE 5

GLOW PLUG RELAY

TO GLOW PLUGS

Battery

CMN

10 POSITION ROTARY SWITCH

S1

49

T HROT T LEPOSIT IONSWIT CH1

S2

50

T HROT T LEPOSIT IONSWIT CH2

S3

51

T HROT T LEPOSIT IONSWIT CH3

52

T HROT T LEPOSIT IONSWIT CH4

48

SHUT DOWNSWIT CH(CLOSET O ST OP)

35

SWIT CHRET URN

S4

NOTES J1 PLUG

1. CAN shield connection at ECM is optional 2. Fuse value depends on Mag Switch circuit current 3. CDL connection may be used for secondary diagnostic connection 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage Rear View of J1 Plug

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Front View of J1 Plug

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Example 3 – Industrial Open Power Unit Schematic OEM Harness A4E2 ECM J1 CONNECTOR

IOPU OEM Wiring Schematic June 2012 UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Template file: Unity OEM wiring

NOTE 7

OFF

BAT T ERY+

8

BAT T ERY+ BAT T ERY+

16

BAT T ERY+

1

BAT T ERY-

2

BAT T ERY-

3

BAT T ERY-

9

BAT T ERY-

10

BAT T ERY-

40

IGNIT IONKEYSWT ICH

61

PT OMODE LAMP(OPT IONAL)

60

ST OPLAMP

59

WARNING LAMP

63

COLDST ART LAMP

62

LOW OILPRESSURE LAMP (OPT IONAL)

57

ST ART AID CONT ROL

52

PT OMODE -ON/ OFF

51

PT OMODE -SET /LOWER

50

PT OMODE -RAISE/RESUM E

49

PT OMODE-DISENGAGE(NC)

35

SWIT CHRET URN

5A

ON ST ART

PTO MODE LAMP IGNITION KEY SWITCH

7

15

STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP

LOW OIL PRESSURE LAMP

NOTE 4

NOTE 5

GLOW PLUG RELAY

TO GLOW PLUGS

Battery

ON / OFF SET / LOWER

RAISE / RESUME

DISENGAGE SWITCH

NOTES J1 PLUG

1. N/A 2. Fuse value depends on Mag Switch circuit current 3. N/A 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and system voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage

Rear View of J1 Plug

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Front View of J1 Plug

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Example 4 - Agricultural Schematic OEM Harness 120 OHM

Agricultural OEM Wiring Schematic

A4E2v3 ECM J1 CONNECTOR

June 2012 UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green

CAN J1939 BUS NOTE 1

Template file: Unity OEM wiring_ NOTE 3

20

CAN J1939 +

21

CAN J1939 -

22

CAN J1939 SHIELD

23

CDL+

24

CDL-

120 OHM

NOTE 7

OFF

BATTERY+

8

BATTERY+

15

BATTERY+

16

BATTERY+

1

BATTERY-

2

BATTERY-

3

BATTERY-

9

BATTERY-

10

BATTERY-

40

IGNITIONKEYSWTICH

61

PTOMODE LAMP(OPTIONAL)

60

STOPLAMP

59

WARNINGLAMP

63

COLD STARTLAMP

62

LOW OILPRESSURELAMP (OPTIONAL)

58

MAINTENANCEDUELAMP (OPTIONAL)

36

MAINTENANCEDUERESET SWITCH

57

STARTAID CONTROL

41

SENSOR SUPPPLY5V

54

ANALOGUETHROTTLEINPUT1

33

SENSORRETURN

45

IDLEVALIDATION(IVS 1) N/C

42

SENSOR SUPPPLY5V

55

ANALOGUETHROTTLEINPUT2

34

SENSORRETURN

52

PTOMODE- ON/OFF

51

PTOMODE- SET/LOWER

50

PTOMODE - RAISE/RESUME

49

PTOMODE- DISENGAGE(NC)

39

MODESWITCH 1

46

MODESWITCH 2

47

THROTTLESELECTIONSWITCH (cannotbe used in conjunction with IVS2)

35

SWITCHRETURN

5A

ON START

PTO MODE LAMP IGNITION KEY SWITCH

7

STOP LAMP TO STARTER MOTOR MAG SWITCH WARNING LAMP NOTE 2 COLD START - WAIT TO START LAMP

LOW OIL PRESSURE LAMP MAINTENANCE DUE LAMP

MAINTENANCE DUE RESET SWITCH NOTE 4

NOTE 5

GLOW PLUG RELAY

TO GLOW PLUGS

ANALOGUE THROTTLE SENSOR 1

ANALOGUE THROTTLE SENSOR 2

Battery

ON / OFF SET / LOWER

RAISE / RESUME

DISENGAGE SWITCH

MODE SWITCH 1 MODE SWITCH 2

THROTTLE SELECTION SWITCH

NOTES J1 PLUG

1. CAN shield connection at ECM is optional 2. Fuse value depends on Mag Switch circuit current 3. CDL connection may be used for secondary diagnostic connection 4. Fit suppression diodes across relay coils 5. Glow Plug fuse rating differs between 4cyl and 6cyl engines and systme voltage 6. Starter motor control circuits will vary 7. Fuse value dependent on system voltage Rear View of J1 Plug

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Front View of J1 Plug

A&I Guide

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Power and Grounding Considerations System Grounding Although the engine electronics are all directly grounded via the ECM connector, it is also necessary that the engine block be properly grounded to provide a good return path for components such as Starter Motor, Alternator and Cold Start Aids. Improper 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.

Ground stud on Starter Motor If the Starter motor has a grounding stud then this should be used. The ground connection terminal. should be preferably be made directly back to the battery negative 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 sufficient cross sectional area to ensure that the total starter motor supply circuit resistance does not exceed 1.7mOhms for a 12V system and 3.4mOhm for a 24V system. Please refer to the Starting and Charging Systems A&I Manual for further information on starter motor, alternator, battery and complete system installation guidelines.

Engine Block Ground Connection A separate engine block ground should be used in addition to the starter motor ground. A connected ground cable, from thewhich battery negative terminal, should be to a direct ring terminal connects to or onestarter of theground 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. A washer should retain the ring terminal and the screw tightened to 44 Nm (32Ibft) It is preferable to use a conductive grease to ensure the reliability of this connection.

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Ground Point Option2

Ground Point Option1(behind bracket) Diagram 1. Ground Point 1 & 2

Ground Point Option 3 Diagram 2. Ground Point 3

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Power and Grounding Considerations Voltage and Current requirements The ECM power supply requirements must be carefully considered when designing the supply circuit; there are specific limitations that must be considered in the design to ensure a reliable consistent power supply to the engine electronic components. The table provides the electrical characteristics and limitations for the A4E2v3 ECM.

VOLTAGE SUPPLY SYSTEM

12V

24V

Max Peak Current

60A

60A

Peak Current Cranking

36A

36A

Max RMS Current* Suggested Fuse Rating**

13A 25A

7.5A 20A

Sleep Current