Perkins1104D-E44TA1106D-E70TAElectronicAIGuide.pdf

1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12Perkins Engines Company Limited A&I Guide 1 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 11106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 2 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 3 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 4 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 5 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 6 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 and software 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 Team for 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 7 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 8 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 assembled to 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 - 400 Kpa 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 is too 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 go to 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 9 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 used as 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 a failure condition white smoke may result 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 engine starting. If the sensor/circuit fails, it is possible the engine 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 10 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 the fuel 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 pressure sensor, 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 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 11 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 measures the engine oil pressure in Kpa. Oil pressure is used for engine protection, whereby if insufficient oil pressure is measured for a given speed, an event for low oil pressure would be raised. The low oil pressure threshold is defined as a map against engine speed. Currently, two levels of event are specified. Level 1 is the least severe and raises a warning. Level 3 is the most severe and raises a warning, which request the engine be shutdown. Automatic engine shutdown can be configured for certain applications, such as Gensets to occur when a level 3 event is raised. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 12 If the oil pressure sensor fails, a diagnostic is raised and a default value is used by the software, which has been chosen to 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 13 Engine Component Diagrams and Schematics 1106D-E70TA Factory Installed Wiring and Components Intake Manifold Pressure Intake Manifold Temperature Fuel Rail Pressure Wastegate Regulator ( If Equipped) Electronic Unit Injectors Coolant Temperature Oil Pressure Crank Speed/ Timing 64 Pin Plug Diagnostic ( If Equipped) A4E2 ECM J1 J2 Fuel Pump Cam/Timing Sensor 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 14 1106D-E70TA Engine Wire Harness Schematic 6 INJECTORCYLINDER 6 RETURN 62 INJECTORCYLINDER 6 7 INJECTORCYLINDER 5 RETURN 63 INJECTORCYLINDER 5 49 FMPSENSORGROUND 37 TEMPERATURESENSORRETURN 10 SPEEDSENSORPOWER (+8V) 52 CRANKSPEED/ TIMESENSSIG 53 PUMP / CAMSPEEDSENSSIG 42 IMTSIGNAL 8 INJECTORCYLINDER 4 RETURN 64 INJECTORCYLINDER 4 33 INJECTORCYLINDER 3 RETURN 59 INJECTORCYLINDER 3 34 INJECTORCYLINDER 2 RETURN 58 INJECTORCYLINDER 2 35 INJECTORCYLINDER 1 RETURN 57 INJECTORCYLINDER 1 OILPRESSURESENSOR FUELMANIFOLD PRESSURESENSOR COOLANTTEMPERATURE SENSOR INTAKEMANIFOLD TEMPERATURESENSOR CRANKSHAFTSPEED / TIMINGSENSOR CAMSPEED/TIMING SENSOR FUELPUMP SOLENOID A B D E F G DIAGNOSTIC CONNECTOR( 9PIN) 1 2 1 2 1 2 1 2 1 2 2 1 3 24 J 1939+ 23 J 1939 - 20 CDL- 21 CDL+ 45 BAT-( FORCOMMSADAPTER ) 18 BAT+( FORCOMMSADAPTER ) 48 FMPSENSORSIGNAL 40 FMPSENSORPOWERSUPPLY 43 COOLANTTEMPSIGNAL 56 OILPRESSURESENSORSIGNAL 39 OILPRESSURESENSORRETURN 47 OILPRESSURESENSORPWR (+5V) 55 IMPSIGNAL 38 IMPRETURN 46 IMPPOWERSUPPLY (+5V) 1 2 3 4 1 2 3 4 1 2 3 4 2 1 3 2 1 3 1 2 ELECTRONIC WASTEGATE ACTUATOR 25 FUELPUMPSOLENOIDPWMSIG 26 FUELPUMPSOLENOIDRETURN 19 WASTEGATERETURN 17 WASTEGATEPWMSIGNAL ECM J 2 Connector INJECTOR CYLINDER 6 INJECTOR CYLINDER 5 INJECTOR CYLINDER 4 INJECTOR CYLINDER 3 INJECTOR CYLINDER 2 INJECTOR CYLINDER 1 T 957BK T 951BK T 952BK T 958BK T 953BK T 959BK T 954BK T 960BK T 955BK T 961BK T 956BK T 962BK X931YL X925PK X 930GY X 924BR X929BU X 923OR X 928GN X 922WH X 927YL X 921PK X 926GY X 920BR 101RD 229BK 944OR 945BR F 712GN F 711 YL C 211BK M 795WH Y 951PU Y 950YL L 731BR C 967BU 995BU Y 948BR Y 946BU 769 BU Y 947BR 994GY T 997OR T 993BR X 731BU 996GN E 965BU P 920BR INTERNAL ( ROCKER COVER) EXTERNAL C H J INTAKEMANIFOLD PRESSURESENSOR NOTALWAYSFITTED ONFIXEDSPEED ENGINES A4E2v3 22 SHIELD 997 R OR 874 N BK 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 15 1104D-E44TA Factory Installed Wiring and Components Intake Manifold Pressure Intake Manifold Temperature Fuel Rail Pressure Wastegate Regulator ( If Equipped) Electronic Unit Injectors Coolant Temperature Oil Pressure Crank Speed/ Timing 64 Pin Plug Diagnostic ( If Equipped) A4E2 ECM J1 J2 Fuel Pump Cam/Timing Sensor 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 16 1104D-E44TA Engine Wire Harness Schematic 34 INJECTORCYLINDER4RETURN 58 INJECTORCYLINDER4 8 INJECTORCYLINDER3RETURN 64 INJECTORCYLINDER3 40 FMPSENSORGROUND 37 TEMPERATURESENSORRETURN 10 SPEEDSENSORPOWER(8V) 52 CRANKSPEED/TIMESENSSIG 53 PUMP/CAMSPEEDSENSSIG 42 IMTSIGNAL 7 INJECTORCYLINDER2RETURN 63 INJECTORCYLINDER2 35 INJECTORCYLINDER1RETURN 57 INJECTORCYLINDER1 OILPRESSURESENSOR FUELMANIFOLD PRESSURESENSOR COOLANTTEMPERATURE SENSOR INTAKEMANIFOLD TEMPERATURESENSOR CRANKSHAFTSPEED/ TIMINGSENSOR CAMTIMING/SPEED SENSOR FUELPUMP SOLENOID A B D E F G DIAGNOSTIC CONNECTOR(9PIN) 1 2 1 2 1 2 1 2 1 2 2 1 3 24 J1939+ 23 J1939- 20 CDL- 21 CDL+ 45 BAT-(FORCOMMSADAPTER) 18 BAT+(FORCOMMSADAPTER) 49 FMPSENSORSIGNAL 48 FMPSENSORPOWERSUPPLY(5V) 43 COOLANTTEMPSIGNAL 56 OILPRESSURESENSORSIGNAL 39 OILPRESSURESENSORRETURN 47 OILPRESSURESENSORPWR(5V) 55 IMPSIGNAL 38 IMPRETURN 46 IMPPOWERSUPPLY(5V) 1 2 3 4 1 2 3 4 2 1 3 2 1 3 1 2 ELECTRONIC WASTEGATE ACTUATOR 25 FUELPUMPSOLENOIDPWMSIG 26 FUELPUMPSOLENOIDRETURN 19 WASTEGATERETURN 17 WASTEGATEPWMSIGNAL A4E2v3ECM J2Connector INJECTOR CYLINDER3 INJECTOR CYLINDER2 INJECTOR CYLINDER1 T957BK T951BK T952BK T958BK T953BK T959BK T954BK T960BK X929BU X923OR X928GN X922WH X927YL X921PK X926GY X920BR 101RD 229BK 944OR 945BR F712GN F711YL C211BK M795WH Y951PU Y950YL L731BR C967BU 995BU R997OR Y948BR Y946BU 769BU Y947BR 994GY T997OR T993BR X731BU 996GN E965BU P920BR INTERNAL (ROCKER COVER) EXTERNAL C H J INTAKEMANIFOLD PRESSURESENSOR NOTALWAYSFITTED ONFIXEDSPEED ENGINES INJECTOR CYLINDER4 22 SHIELD N874BK1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 17 1106D-E70TA & 1104D-E44TA Principal Engine Electronic Components Cam Speed Sensor Wastegate 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 18 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 Engine Family A&I Guide Section Battery All Power and Grounding Considerations Circuit Protection All Power and Grounding Considerations Key Switch All Starting the Engine Warning Lamp All Operator Displays Shutdown Lamp All Operator Displays Wait to Start Lamp All Operator Displays Glow Plug Relay All Cold Starting Aid Speed Demand Input All Engine Speed Demand J1939 All Communication Datalink PDL All 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 Idle Validation Switch (1) Engine Speed Demand Analogue Throttle Position Sensor with Idle Validation Switch (2) Engine Speed Demand 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 Fan Reversing Solenoid Control SWG Return Additional Options Ether Start Cold Starting Aids 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 19 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 20 Typical Customer Installed Component Diagram Circuit Protection (Mandatory) Keyswitch PWM Throttle Analogue Throttle with IVS Warning Lamp Stop Lamp Air Filter Restriction Switch Wait to Start Lamp Low Oil Pressure Lamp Service Tool Connector J1939 Termination Resistor Maintenance Due Lamp PTO Raise/Resume Button PTO Set/Lower Button PTO On/Off Switch PTO Disengage Modes Switch 1 Modes Switch 2 Shutdown Switch Glow Plug Relay Maintenance Due Reset Switch Magnetic Switch + - Battery Battery Isolation Switch IVS 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 21 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 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 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 22 Example 1 - Basic Schematic OEM Harness A4E2v3 ECM J1 CONNECTOR OFF ON START IGNITION KEY SWITCH STOP LAMP WARNING LAMP 7 BATTERY + NOTE 7 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 dependant on system voltage NOTES UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Battery June 2012 Basic OEM Wiring Schematic PWM THROTTLE SENSOR Template file: Unity series OEM wiring_ 8 BATTERY + 15 BATTERY + 16 BATTERY + 1 BATTERY - 2 BATTERY - 3 BATTERY - 9 BATTERY - 10 BATTERY - 60 STOP LAMP 59 WARNING LAMP 57 START AID CONTROL 40 IGNITION KEYSWTICH 5A 63 COLD START LAMP COLD START - WAIT TO START LAMP LOWOIL PRESSURE LAMP 62 LOW OIL PRESSURE LAMP (OPTIONAL) 43 SENSOR SUPPLY 8V 53 PWMTHROTTLE SENSOR INPUT TO GLOW PLUGS GLOW PLUG RELAY 33 SENSOR RETURN TO STARTER MOTOR MAG SWITCH Rear View of J1 Plug Front View of J1 Plug J1 PLUG NOTE 5 NOTE 4 NOTE 21106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 23 Example 2 - Construction Schematic OEM Harness A4E2 ECM J1 CONNECTOR OFF ON START IGNITION KEY SWITCH STOP LAMP WARNING LAMP 7 BATTERY + NOTE 7 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 NOTES UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Battery June 2012 Construction OEM Wiring Schematic Template file: Unity OEM wiring 8 BATTERY + 15 BATTERY + 16 BATTERY + 1 BATTERY - 2 BATTERY - 3 BATTERY - 9 BATTERY - 10 BATTERY - 60 STOP LAMP 59 WARNING LAMP 57 START AID CONTROL 40 IGNITION KEYSWTICH 5A 50 THROTTLE POSITION SWITCH 2 51 THROTTLE POSITION SWITCH 3 52 THROTTLE POSITION SWITCH 4 10 POSITION ROTARY SWITCH CAN J1939 BUS 120 OHM 20 CAN J1939 + 21 CAN J1939 - 22 CAN J1939 SHIELD NOTE 1 63 COLD START LAMP COLD START - WAIT TO START LAMP LOW OIL PRESSURE LAMP 62 LOWOIL PRESSURE LAMP (OPTIONAL) 23 CDL + 24 CDL - NOTE 3 49 THROTTLE POSITION SWITCH 1 48 SHUTDOWN SWITCH (CLOSE TO STOP) 35 SWITCH RETURN TO GLOW PLUGS GLOW PLUG RELAY TO STARTER MOTOR MAG SWITCH Rear View of J1 Plug S1 S2 S3 S4 CMN Front View of J1 Plug J1 PLUG 120 OHM NOTE 5 NOTE 4 NOTE 2 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 24 Example 3 – Industrial Open Power Unit Schematic OEM Harness A4E2 ECM J1 CONNECTOR OFF ON START IGNITION KEY SWITCH STOP LAMP WARNING LAMP 7 BATTERY + NOTE 7 SET / LOWER 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 NOTES UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Battery PTO MODE LAMP June 2012 IOPU OEM Wiring Schematic Template file: Unity OEM wiring 8 BATTERY + 15 BATTERY + 16 BATTERY + 1 BATTERY - 2 BATTERY - 3 BATTERY - 9 BATTERY - 10 BATTERY - 60 STOP LAMP 59 WARNING LAMP 61 PTO MODE LAMP (OPTIONAL) 57 START AID CONTROL 40 IGNITION KEYSWTICH RAISE / RESUME ON / OFF 49 PTO MODE - DISENGAGE (NC) 5A DISENGAGE SWITCH 63 COLD START LAMP COLD START - WAIT TO START LAMP LOWOIL PRESSURE LAMP 62 LOW OIL PRESSURE LAMP (OPTIONAL) 35 SWITCH RETURN TO GLOW PLUGS GLOW PLUG RELAY 50 PTO MODE - RAISE /RESUME 51 PTO MODE - SET/ LOWER 52 PTO MODE - ON / OFF TO STARTER MOTOR MAG SWITCH Rear View of J1 Plug Front View of J1 Plug J1 PLUG NOTE 5 NOTE 4 NOTE 2 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 25 Example 4 - Agricultural Schematic OEM Harness A4E2v3 ECM J1 CONNECTOR OFF ON START IGNITION KEY SWITCH STOP LAMP WARNING LAMP 7 BATTERY + NOTE 7 SET / LOWER 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 NOTES UNCONTROLLED DOCUMENT FOR INDICATION ONLY Caterpillar Confidential Green Battery PTO MODE LAMP June 2012 Agricultural OEM Wiring Schematic Template file: Unity OEM wiring_ 8 BATTERY + 15 BATTERY + 16 BATTERY + 1 BATTERY - 2 BATTERY - 3 BATTERY - 9 BATTERY - 10 BATTERY - 60 STOP LAMP 59 WARNING LAMP 61 PTO MODE LAMP (OPTIONAL) 57 START AID CONTROL 40 IGNITION KEYSWTICH 33 SENSOR RETURN 54 ANALOGUE THROTTLE INPUT 1 55 ANALOGUE THROTTLE INPUT 2 45 IDLE VALIDATION (IVS 1) N/C RAISE / RESUME ON / OFF 49 PTO MODE - DISENGAGE (NC) 5A 41 SENSOR SUPPPLY 5V ANALOGUE THROTTLE SENSOR 1 ANALOGUE THROTTLE SENSOR 2 DISENGAGE SWITCH MODE SWITCH 1 MODE SWITCH 2 39 MODE SWITCH 1 46 MODE SWITCH 2 CAN J1939 BUS 120 OHM 20 CAN J1939 + 21 CAN J1939 - 22 CAN J1939 SHIELD NOTE 1 63 COLD START LAMP COLD START - WAIT TO START LAMP LOWOIL PRESSURE LAMP 62 LOW OIL PRESSURE LAMP (OPTIONAL) 23 CDL + 24 CDL - NOTE 3 47 THROTTLE SELECTION SWITCH (cannot be used in conjunction with IVS2) 35 SWITCH RETURN TO GLOW PLUGS GLOWPLUG RELAY 50 PTO MODE - RAISE /RESUME 51 PTO MODE - SET/ LOWER 52 PTO MODE - ON / OFF 42 SENSOR SUPPPLY 5V 34 SENSOR RETURN TO STARTER MOTOR MAG SWITCH THROTTLE SELECTION SWITCH Rear View of J1 Plug Front View of J1 Plug J1 PLUG 120 OHM MAINTENANCE DUE LAMP 58 MAINTENANCE DUE LAMP (OPTIONAL) 36 MAINTENANCE DUE RESET SWITCH MAINTENANCE DUE RESET SWITCH NOTE 5 NOTE 4 NOTE 2 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 26 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 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 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 ground cable, direct from the battery negative or starter ground 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. 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 27 Diagram 1. Ground Point 1 & 2 Diagram 2. Ground Point 3 Ground Point Option2 Ground Point Option1(behind bracket) Ground Point Option 3 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 28 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* 13A 7.5A Suggested Fuse Rating** 25A 20A Sleep Current <8mA <10mA Min Running Voltage 9V 18V Max Running Voltage*** 16V 32V Minimum ECM Voltage during Cranking 5.5V 5.5V Maximum total ECM power circuit wire resistance 50 mOhmns 100 mOhmns Target circuit resistance 40 mOhms 80 mOhms *Max RMS current measurements conducted on engine running at rated speed and load. RMS current will vary with engine speed (assuming constant voltage) no Lamp Drivers or application side components fitted during measurement. ** Suggested fuse rating are based on automotive blade type fuses and are for guidance only. ***The ECM can survive higher voltages. ECM will survive for at least 2 minutes on a supply voltage of 30V for 12V systems and 48V for 24V systems. ECM power supply circuit resistance Often during engine cranking the battery voltage will drop to values much lower than the normal system operating voltage. The minimum permissible voltage measured at the ECM during cranking is 6V. The power requirements to drive the engine electronic components such as the Injectors and fuel pump circuit remain the same during cranking; for this reason the ECM power supply circuit resistance becomes very important and will affect the voltage seen at the ECM. The table below illustrates the difference between the voltage at the ECM during cranking and normal running conditions: Parameter Engine Cranking Engine Running System Voltage at the Battery 8 V 13.8V Engine ECM Current Draw 36A 36A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 29 Total ECM power supply resistance 40 mOhms 40 mOhms Voltage Drop (I*R) 1.44V 1.44V Voltage at the ECM 6.56V 12.36V Table 4.1 The maximum permissible circuit resistance including positive and negative wires is 50mOhms for 12V systems and 100mOhms for 24V systems, however Perkins recommends that this value should not be targeted during design, as it is often difficult to predict the final circuit resistance when considering other factors such as fuse holders, connector resistance and aging. A target calculated circuit resistance including wire and connections of 40mOhms for 12V systems 80mOhms for 24V systems is recommended. The table below provides typical wire resistance for various cross sections of copper wire. 2m 4m 6m 8m 10m 2 Ni-plated Copper 9.82 19.64 39.28 58.92 78.56 98.2 2.5 Ni-plated Copper 7.92 15.84 31.68 47.52 63.36 79.2 3 Ni-plated Copper 6.41 12.82 25.64 38.46 51.28 64.1 4 Ni-plated Copper 4.91 9.82 19.64 29.46 39.28 49.1 5 Ni-plated Copper 4.11 8.22 16.44 24.66 32.88 41.1 6 Ni-plated Copper 3.27 6.54 13.08 19.62 26.16 32.7 10 Ni-plated Copper 1.9 3.8 7.6 11.4 15.2 19 16 Ni-plated Copper 1.21 2.42 4.84 7.26 9.68 12.1 25 Ni-plated Copper 0.774 1.548 3.096 4.644 6.192 7.74 35 Ni-plated Copper 0.549 1.098 2.196 3.294 4.392 5.49 50 Ni-plated Copper 0.383 0.766 1.532 2.298 3.064 3.83 70 Ni-plated Copper 0.27 0.54 1.08 1.62 2.16 2.7 95 Ni-plated Copper 0.204 0.408 0.816 1.224 1.632 2.04 120 Ni-plated Copper 0.159 0.318 0.636 0.954 1.272 1.59 mohm/m at 20Deg C Material Conductor CSA mOhm at 20Deg C for Cable Length 2m 4m 6m 8m 10m 14 Ni-plated Copper 9.82 19.64 39.28 58.92 78.56 98.2 12 Ni-plated Copper 6.41 12.82 25.64 38.46 51.28 64.1 10 Ni-plated Copper 4.11 8.22 16.44 24.66 32.88 41.1 8 Ni-plated Copper 2.59 5.18 10.36 15.54 20.72 25.9 6 Ni-plated Copper 1.55 3.1 6.2 9.3 12.4 15.5 4 Ni-plated Copper 1.06 2.12 4.24 6.36 8.48 10.6 2 Ni-plated Copper 0.62 1.24 2.48 3.72 4.96 6.2 0 Ni-plated Copper 0.383 0.766 1.532 2.298 3.064 3.83 00 Ni-plated Copper 0.27 0.54 1.08 1.62 2.16 2.7 000 Ni-plated Copper 0.204 0.408 0.816 1.224 1.632 2.04 0000 Ni-plated Copper 0.159 0.318 0.636 0.954 1.272 1.59 American Wire Gauge Material mohm/m at 20Deg C mOhm at 20Deg C for Cable Length1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 30 A4E2 ECM - + Battery N e g a t i v e W i r e R e s i s t a n c e ( O h m s ) P o s i t i v e W i r e R e s i s t a n c e ( O h m s ) Circuit Load (ECM) Total Circuit Length Note: Circuit protection not shown As with all electrical circuits wire should be selected so that the rated maximum conductor temperature is not exceeded for any combination of electrical loading, ambient temperature, and heating effects of bundles, protective braid, conduit and other enclosures. Consult wire manufacturers data sheets for further information. Important Voltage Supply Circuit Considerations Poorly designed or installed ECM supply circuitry can lead to intermittent engine problems and reduce the engine ECM’s ability to maintain optimum performance under harsh conditions. To ensure that the integrity of the electrical supply circuit is not compromised during design and installation the following recommendations should be adhered to. - Supply cable wire gauge or CSA must be capable of meeting the maximum electrical requirement demanded by the engine ECM under all conditions. - When specifying ECM circuit supply and return cables, which are to be routed around hot components or form part of a machine wiring harness bundle the appropriate cable current carrying capacity derate should be applied. - All ECM power pins must be connected to the main battery supply to ensure a complete and robust electrical circuit is made. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 31 - When splicing the ECM supply or return cables the main supply cable must be rated to carry the total circuit current to the ECM and provide the correct amount of mechanical durability for the number of splices made. - The total ECM circuit resistance must meet the stated limits (50mOhms for 12V and 100mOhms for 24V systems) to ensure that voltage drop across these cables is minimized. It should also be noted that the ECM supply circuit must be routed directly back to the application battery to maintained optimum system performance under all conditions. Failure to do so will lead to excessive system voltage drop and high circuit resistance as well as increased levels of supply circuit noise. Battery (+) Connection The ECM requires four un-switched battery positive inputs; the inputs should be permanently connected to the machine battery. When the ignition key switch is off the ECM is in a sleep mode during which it draws a very small residual current through the four battery connections. When the ignition key switch is turned on the ECM will become active. It is recommended, therefore that the ignition keyswitch is turned to the off position when connecting or disconnecting the ECM J1 connector, to prevent large sparks which may cause damage to the 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. All 4 pins must be used. The correct system voltage must be applied (12V or 24V), as the following components on the engine are system voltage sensitive: -Glow Plugs -Alternator -Starter Motor -Electric prime Fuel Pump (where fitted ) It is recommended that one supply cable from the battery be used. This single supply cable should then be spliced as shown as below. Please note that it is the customer’s responsibility to ensure that the ECM supply circuitry meets the limits stated within table 4.1. For this reason it may be necessary to increases the supply cable AWG (CSA) in order to meet the system design criteria. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 32 A4E2 ECM J2 J1 A B ENGINE ECM MAIN MACHINE DISTRIBUTION BATTERY MACHINE BATTERY Diagram shown is an example of the ECM supply and ground connection. All fuses must be chosen in conjunction with the data supplied in table 4.1. Fuses must be rated to protect the ECM supply cables and not the engine ECM. ECM Power Supply Wiring Note A: Ensure cable splices are made using 14AWG wire and kept to a minimum length. Note B: Ensure that the main supply cable is correctly specified in terms of length, resistance, voltage drop and current carrying capacity. May need to add specifics into the section for Bosch and Tyco ECMs 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 33 Battery (-) Connection The ECM requires five un-switched battery negative inputs; the inputs should be permanently connected to the machine battery. Battery Connection – Do Not supply power to the ECM from the starter motor connections: Starter Motor Battery Battery Note: Circuit protection not shown - + - + Wrong Right 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 34 Correct method of ECM battery connection. Right Starter Motor ECM Connector Chassis Engine Fuse 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 • ECM Negative is wired to the battery rather than return through chassis • The engine is grounded to the machine chassis. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 35 Incorrect method of ECM battery connection. Starter Motor ECM Connector Chassis Engine Chassis Wrong 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. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 36 Engine ECM Power Supply Circuit Resistance Test It is not possible to accurately measure the machine ECM power supply wire resistance using a standard ohmmeter alone; it is therefore necessary to use a specific test circuit. The diagram and table below details the test apparatus used in the circuit to determine the engine ECM circuit resistance. The circuit consists of two voltmeters and a resistor connected to the J1 ECM plug that can be switched in and out of circuit using a relay. It’s very important to keep the test circuit resistance to a minimum, use a relay with low contact resistance (preferably silver oxide or gold) and short lengths of heavy gauge wire. Component Perkins part number Supplier Part number Quantity J1 Receptacle 1244365 1 Pins T400047 0460-202-16141 10 2.2 Ohm Resistor 200W N/A N/A 1 Relay (low contact resistance N/A N/A 1 Pushbutton N/A N/A 1 Voltmeter N/A N/A 2 R1 V1 2.2 Ohms 200 watts Voltmeter 1 7 16 8 15 1 9 2 3 10 J1 Engine ECM Plug Machine Harness - + V2 Voltmeter 2 Machine Battery 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 37 Note: The total ECM supply circuit resistance forms part of the Application Appraisal. Circuits which do not meet the 50mOhm requirement for a 12V system and 100mOhm’s for 24V will be classed as a failure during the Appraisal sign off. Test Procedure Record the measured resistance value of the test resistor used. Disconnect the J1 engine ECM plug from the ECM and connect the test apparatus detailed in the above diagram to the plug. Press the button for three seconds at the same time record the voltage measured from Voltmeter 1 and Voltmeter 2. Formula: Power Supply Circuit Resistance (mOhms) = 1000 * (R1 * (V2 – V1)/ V1) V1 = Voltmeter 1 Measured Value V2 = Voltmeter 2 Measured Value R1 = Measured Resistor Value Worked Example V1 = 11.8 V2 = 12 R1 = 2.21 Ohms 1000 * (2.21 * (12 – 11.8)/11.8) 1000 * (2.21 * 0.1695) 1000 * (0.375) Harness Resistance = 37.5 mOhms Suppression of Voltage Transients Suppression Methods & Best Practice Note: The installation of transient suppression at the source of the transient is required. Perkins follows a stringent electrical environment standard that is similar to SAE recommended practices. The use of inductive devices such as relays and solenoids can result in the generation of voltage transients in electrical circuits. Voltage transients that are not suppressed can exceed SAE specifications and lead to a degradation in the performance of the electronic control system. The customer should specify relays and solenoids with built-in voltage transient suppression. Refer to figure 4.7 for ways to minimise voltage transients from relays and solenoids without built-in voltage transient suppression. Techniques include the installation of a diode or resistor of the proper size in parallel with the solenoid or the relay coil. Diodes and resistors accomplish suppression in different ways. Diodes clamp the voltage across the coil to approximately –0.7V when the switch opens. The current 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 38 circulates in the loop until it eventually diminishes. Suppression resistors will allow the transient voltage to increase to a value determined by the forward current flow through the coil and the value of the resistance of the suppression resistor. However, resistor suppression causes the current in the loop to diminish much faster than would a diode. Figure 4.7 Voltage Suppression Diagram Diode selection should be based on the normal voltage and current seen by the coil. For example, if the normal voltage applied to the coil is 24V and the coil has a resistance of 50Ohms, then the current passing through the coil is 480mA (I = V/R). The diode then would need to be able to withstand a reverse voltage of 24V and a forward current of 480mA when the current to the coil is interrupted by the opening of the switch since the collapse of the coil’s magnetic filed will attempt to maintain that current. Suppression resistors are a low-cost alternative and can be less stressful on relay coils. Resistor selection should be determined by the voltage applied across the coil, the resistance of the coil, maximum power dissipation allowed, and the level of transient voltage to be tolerated. For example, if the coil is 50Ohms and the voltage applied is 24V, an 82Ohm suppression resistor would allow the transient voltage to reach – 39.6V (V = IR = -.48A x 82Ohms, the voltage is shown as negative since the polarity reverses once the switch opens). Using a 330Ohm resistor would allow a –158V transient but the current would diminish in the loop faster. For power dissipation concerns, the resistors power rating should be considered. For example, if 24V were applied across a 330Ohm resistor, the power dissipated by the resistor would be 1.75W (P = V 2 /R). Therefore a 330Ohm resistor should be selected with the capability of dissipating at least 2W. The heat generated by the resistor should be considered when selecting a resistor. Note: If the resistance of the suppression resistor is too low, the driver circuitry in the ECM may be loaded to a point where the relay or solenoid does not function properly. If the resistance is too high, the transient voltage may reach undesirable levels. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 39 There are other techniques that can be used for transient suppression. Snubbers, Zener diodes, and varistors are all methods that have characteristics that make them better suited for some applications. But for simple applications of relays or solenoids, diodes or resistors should suffice. Inductive devices such as relays or solenoids should be located as far as possible from the components of the electronic control system. Wiring harnesses that are installed by the customer should be routed as far as possible from the wiring harness of the electronic control system in order to avoid problems that are associated with electrical noise. Voltage Load Protection Modules (VLPM) Direct Battery connection requirements The following components require a power supply direct from the application battery, these components are voltage dependant. -Fuel System Electric Fuel Pump -Starter Motor -Alternator Powering The Engine ECM Via Auxiliary Power Supplies If the engine is to be supplied with electrical power via any other means than a standard machine battery arrangement, care must be taken when choosing the power supply. Engine ECM’s powered by devices such as switch mode power supplies can be particularly troublesome due to the intermittent high current load demands of the engine ECM during engine operation. To ensure that the power supply operates correctly, management of these intermittent high current spikes is employed. For more assistance when implementing auxiliary power supplies please contact the Electronic Applications Engineering Department. Sensor Common Connections Certain components that interface directly with the ECM require connection to one of the dedicated sensor/switch return pins on the ECM customer machine interface connector J1. Separate sensor/switch returns are provided for analogue and digital signals. All components requiring connection to one of the ECM ground connections must be connected to the correct ground path to ensure the correct operation of the component. Analogue Sensor Return All of the following Features and switches must be connected back to the engine ECM J1 Analogue return pin (35). ECM Feature Analogue Throttle 2 Auxiliary Pressure Sensor Auxiliary Temperature Sensor Air Inlet Temperature Sensor Analogue Throttle 1 Table 4.6 Analogue Sensor Connections 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 40 Switch Return All of the following Features and switches must be connected back to the engine ECM J1 GND switch return pin (35). ECM Feature Idle Validation switch 1 / PTO / MPTS Idle Validation Switch 2 / Throttle Arbitration Switch MPTS 1 / PTO Disengage User Defined Shutdown Switch / PTO Mode Speed 1 & 2 Select Fan Reverse Switch / Overspeed Verify Switch MPTS 2 / PTO Mode On / Off Switch MPTS 3 / PTO Raise / Resume MPTS 4 / PTO Set / Lower / Table 4.7 Switch to Ground Connections Digital Return All of the following Features and switches must be sensor supplied (8v) form ECM J1 pin 43 and connected back to the engine ECM J1 digital return pin (33). ECM Feature PWM Throttle 1 Water In Fuel Switch Coolant Level Switch Table 4.8 Digital Signal Connections Connectors and Wiring Harness Requirements ECM connector The A4E2v3 engine ECM has an integral rectangular 64-pin Delphi Packard socket; the socket is grey in appearance and is the customer/OEM connection point. To make a connection to the engine ECM the components listed in the table below are required. Qty Description (photo ref.) Delphi Part Number Perkins Part Number 1 Plug Assembly (1) 15488667 28170110 (Superseded by 28170033) 1 Wire Dress Cover (2) 15488664 28170035 2 Terminal Lock (TPA) (3) 15404650 28170034 N/A Contact Socket (Terminal)(4) formed option for high volume machine crimping only. 15359002 N/A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 41 N/A Contact Socket (Terminal) machined option for hand crimping with CH11155 N/A 28170085 N/A Sealing Plugs 12129557 28170088 The above components are available in kit form. The kit will provide all the necessary components to make one basic engine connection. Description Perkins Part Number Connector kit U5MK8198 (superseded by U5MK1229) Components required for A4E2v3 engine ECM connection The wire dress cover must be fitted to prevent direct jet washing onto the rear connector seals. Connector Layout The diagram below illustrates the pin layout, looking from the rear of the connector 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 42 Tightening the OEM Connector A central 7mm AF hex screw retains the connector. This screw should be tightened to a torque of 5Nm+/- 1 (3.7+/-0.7lbft). Perkins does not recommend the use of “non conductive grease” with the ECM connector. ECM connector Wire Gauge Size All connections must be made with 0.82mm² (18AWG) wire with GXL type insulation. Min outside diameter (Inc Insulation) = 1.85mm Max outside diameter (Inc Insulation) = 2.5mm ECM Connector Terminals The OEM connector terminals should be Delphi p/n 15359002 Terminal Retention Two terminal position assurance components should be used once all terminals have been crimped and inserted into the connector body. Terminal Position Assurance - Perkins part No. 28170035 (Delphi p/n 15404650) Note: It is critical that two terminal position assurance components are used. Connector body and terminal assurance components When a terminal has been properly crimped and retained, it will be able to withstand a “pull test” of 45N (10lb) Hand Crimping For Prototype machines and Low Volume Production: A hand crimp tool and appropriate Die are required for crimping contact sockets - (Delphi p/n 15359002). The hand crimp tool and removal tool for removing the sockets from the connector body are available from Power and Signal Group (PSG). 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 43 Perkins hand crimping solution Component Perkins part number Supplier Part number Contact socket 28170085 10-613370-020 Crimp Tool number CH11155 Deutsch HDT-48-00 Removal tool N/A 15314902 Delphi Solution Component Perkins part number Supplier Part number Contact sockets N/A 15359002 HT micro 100W Crimp Tool with Die – European Use Only N/A HT42000480-1 Delphi Crimp Tool N/A 12129557 Removal tool N/A 15314902 Note: The insulation should be stripped to 5 mm from the end of the wire. Only a single wire must be crimped into each terminal. ECM connector sealing plug installation guidelines All unused connector socket slots must be filled with sealing plugs - Delphi p/n 12129557. Due to the small size of the sealing plugs, it may be quicker to install sealing plugs in all cavities, and then remove those which are not required, rather than to try to fit the sealing plugs when wires have already been inserted into the back of the connector. Note: do not use “non conductive” grease to seal unused terminal cavities. OEM harness Retention at the ECM A wire strain relief component should be used to prevent ECM connector damage. The wire strain relief component is assembled to the engine ECM during engine manufacture and will be supplied on the engine. Wire bundle size may vary between applications. Cable tie/Wire tie slots are provided for correct bundle retention. Use the correct slots. Use Strain Relief and correct slots for the harness bundle size: 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 44 Small Bundle Medium Bundle Large Bundle Machine Crimping For High Volume Production The hand tool may not be the appropriate solution for crimping terminals in a high volume production environment. The OEM’s harness manufacturer should contact their local Delphi component distributor directly. Harness Wiring Standards General Recommendations for Machine Wiring harnesses The following are general “good practice” for wire harnesses. It is the responsibility of the machine designer to follow standards appropriate to the application type and to the geographical territory where the machine will be operated. These recommendations do not replace in any way any industrial standards or legislative requirements: Connectors It is strongly recommended that high quality, sealed connectors are used throughout. Automotive standard components are not necessarily suitable as they are often only designed for a very low number of disconnect/reconnect cycles. Connectors should be horizontally mounted rather than vertically mounted to prevent ingress of water/chemicals. Whenever possible, connectors should be mounted such that they are protected from direct exposure to extreme cold. Connectors can be damaged by frost if water does penetrate the seals. Cables should not bend close to the connector seals, as the seal quality can be compromised. The correct wire seal must be selected for the diameter of wire used. Cables should be selected of an appropriate cross section for the current and voltage drop requirements Where large numbers of wires go to the same connector, it is essential that no single wire is significantly shorter than the others, such that it placed under exceptional strain. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 45 Cable routing. Cables should be routed such that bend radii are not too tight. A cable should not be either in compression or tension, nor should it be excessively long or loose, such that sections may become caught or trapped. Clips should be used at regular intervals to support cables. These clips should be of the correct diameter to grip the cable firmly without crushing it. Ideally, harnesses should not rub against any mechanical components. The only points of contact should be clamps and connectors. If this is not possible then as a minimum they should not touch components that are hot, that move or vibrate, or that have sharp edges Conductors carrying high currents or voltages, particularly when these are alternating or switched, should be physically separated from conductors carrying small signal currents. In particular, high current and signal wires should not run parallel in the same harness bundle for any significant distance. Ideally, if high current wires must be in proximity to signal wires then they should cross at right angles. The engine wire harness should not be used by the installer for as a support for any components that are not supplied as part of the engine. For example, external hoses and wires should not be tied to the engine harness. Mounting location for electronic modules The least harsh possible location should be selected for an electronic component or module, even one that is robustly designed. Select the mounting location carefully, therefore, considering exposure to frost, vibration, heat, mechanical damage, or ingress of water, dust or chemicals. Care should be taken during design to ensure that components are accessible for repair and possible replacement in the field. Poor maintenance access may lead to poor quality repairs in the field. Electromagnetic Compliance (EMC) Special measures should be taken to shield cables if the application is to be used in extreme electromagnetic environments – e.g. aluminum smelting plants. If screened cable is used, the screens should be connected to ground at one point only. That point should be central if possible Diagnostic Connector A 9 pin diagnostic connector is fitted to the engine wire harness on all industrial engines. Various diagnostic and development tools may use the connector to access the engine data links. If the connector is inaccessible when the engine is in the application or no connector is fitted to the engine wire harness, provisions should be made to allocate an 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 46 alternative location for diagnostic connection. In this case it is recommended that a diagnostic connector be wired in a location that can be easily accessed, free from possible water/dirt ingress and impact damage. The engine wire harness must not be changed or modified. To wire a diagnostic connection use the data link pins available on the OEM J1 ECM connector. It is recommended that all customer installed 9 pin diagnostic connectors be wired according to the diagram below: A B D E F G J1939 + J1939 + J1939 - J1939 - PDL + PDL - PDL + PDL - 21 20 24 23 Battery + Battery - Service Tool Connector J1 ECM Mandatory Requirement for Prototype Machines It is mandatory for all prototype machines to have access to the engines PDL and J1939 CAN data links. Termination Resistor It is recommended that termination resistors be wired to the OEM machine harness as stated in the SAE standard. If the engine is the only CAN J1939 devise ever present on the machine it is not necessary to wire the resistors. It is important to note, however that if devices such as handheld code readers, CAN PC tools or Navigation systems are installed in field later, resistors will be required. 9 Pin Diagnostic Connector Part Numbers Description Deutsch Part Number Perkins Part Number Receptacle HD10-9-96PE 2900A026 Receptacle End Cap HDC-16-9 2900A018 Pin Information Pin Description Diagnostic Connector J1 OEM 64 way Connector Battery + Pin A Battery - Pin B PDL + Pin D 23 PDL - Pin E 24 J1939 - Pin F 21 J1939 + Pin G 20 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 47 Starting and Stopping the Engine Starting the Engine Unlike mechanically controlled fuel systems no customer connection to the fuel pump solenoid is necessary. To activate the engine ECM battery voltage needs to be constantly applied to pin 40. When the ECM is active the engine crankshaft needs to be rotated above a minimum cranking speed, a typical cranking speed is 180rpm (this will differ dependent on the application). Once the ECM has determined engine cranking speed and engine position, fuel pressure and delivery will be controlled. The most popular way to control engine starting is by a specifically designed 3 position key switch. The key switch controls battery voltage to the keyswitch input and the starter motor circuit. Some application may require a 4-position switch to run auxiliary equipment when the engine is not running. OFF ON START IGNITION KEY SWITCH START 4 3 1 2 POSITION POSITION 1 - OFF POSITION 2 - RUN POSITION 3 - START TERMINALS 2 & 4 1 & 4 1, 3 & 4 Automatic Starting – Some applications need to be started automatically. There is no automatic start feature available on this product. If an automatic start sequence is required the following points must be considered: Start Aid - Wait to Start Control Starter Cranking Duration Starter Abutment Detection Number of Start Attempts Starter Disengagement Speed Warm Up Period Cool Down Period The ECM software considers the engine running when the engine speed is 100rpm below the desired engine speed or has reached 1400rpm, at this point after a predetermined period of time the engine will switch from cranking fuel maps to running fuel maps. It is important to note that starter motors must be disengaged earlier to prevent the starter motor being driven by the engine. The engine is considered stalled when the engine has dropped below 300rpm. When the engine is running the engine firing order is: Engine Firing Order 1104D-E44TA 1-3-4-2 1106D-E70TA 1-5-3-6-2-4 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 48 Stopping the Engine (and Preventing Restart) There is often some confusion about the different methods and devices used to either stop the engine or to prevent it from starting. These devices may be divided into the following categories: • Ignition Keyswitch • Emergency Stop Button • Battery Isolation Switch • Remote Stop Button • Datalink stop Each of these devices is described below to assist the OEM in selecting the method that is most suitable for his machine and his market. It remains, however, the responsibility of the OEM to ensure compliance of the machine with legislation in the territories into which it is sold. It is recommended that the OEM performs a risk assessment such as a Failure Mode Effects Analysis (FMEA) on the application to determine the most appropriate method of stopping the engine and/or preventing it from being restarted. Ignition Keyswitch It is a Perkins requirement that all machines have an simple intuitive and accessible method of stopping the engine. This will normally be a directly wired Ignition Keyswitch. When the keyswitch is turned to the off position or when the key is removed, power must be removed from the ignition keyswitch pin (pin 40) of the ECM J1 connector. Emergency Stop Button An emergency Stop button is a failsafe method for an operator to stop a machine to protect people or equipment. Emergency Stop buttons are defined by national or international standards in terms of colour, functionality, shape, size, latching /locking. In the EU for example, they are described in the Machinery Directive. For mobile machines, however, true emergency stop buttons are not always appropriate and are rarely fitted, due to the following issues: • Legislation is designed principally for static industrial machinery (e.g. lathe) where the main power source is mains electricity. • Stopping a diesel engine in a mobile machine may not always be safe. In particular the vehicle may need the power to move to a safe position (for example off the public highway, or off a railway track) • In practice it is difficult to find components such as safety relays which are suitable for mounting on mobile machines due to the high vibration and water ingress protection, and the low voltages that occur during starting • Fail-safe wiring can be a cause of machine unreliability and can create faults that are difficult to detect in the field. If a true emergency stop button is required for an application it is recommended that it is implemented such that both the +battery and the ignition keyswitch lines are cut directly by the emergency stop button. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 49 Perkins do not provide a standard recommendation, or approval, for a circuit for multiple emergency stop buttons, as the differences between application mean that significant time and resources are necessary to design a system which will be fail safe without adversely affecting reliability. Battery Isolation Switches Battery Isolation switches are usually fitted in the battery or the engine compartment of a machine. On some machines there may be a small number of low current devices which are not switched off by this device e.g. clocks or anti-theft tracking devices. The function of a battery isolation switch is as follows: • Prevent battery discharge during vehicle shipping or storage • Protect service technicians from danger caused by inadvertent engine crank or start .To offer good protection of service personnel is it possible to provide a switch which can be locked in the open position (e.g. with a padlock) and the key removed and given to the service engineer who is working on the dangerous components The battery isolation switch is not a suitable method for stopping an engine, as it is not guaranteed to stop the engine as the ECM may continue to operate with power generated by the alternator. It is also possible that opening the battery isolation switch when the engine is running will cause an “alternator load dump”. This is a kind of electrical transient that can cause damage to electronic components Battery isolation switches are normally fitted in the negative path, close to the battery. Remote Stop Button Remote stop is intended to provide a convenient method of stopping the engine. It is not designed to be fail safe and so should not be used assure the protection of either personnel or equipment Remote stop buttons may be used on large machines, which can be operated from ground level and where the operator wants to stop the machine without climbing into the cab. There are a number of variations on remote stop button circuits. The engine uses a single normally open contact, which must be closed to stop the engine. The remote stop button will function as follows: A single switch to ground input on pin 48 of the ECM J1 Connector (Several stop buttons can therefore be connected in parallel) When the switched is closed (or if a button is pressed for longer than 150mS), then the engine will stop. The ECM will remain ON, so it will continue to communicate over J1939 and with the service tool. Note however that it will continue to draw power from the battery so if it is left in this state it will eventually result in a flat battery. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 50 35 SENSOR RTN 48 REMOTE STOP SWITCH ECM J1 Remote Stop Button The engine may be restarted by opening the switch and activating the starter motor. The red “mushroom” emergency stop buttons must not be used for remote stop functions as they may be mistaken for emergency stop buttons as described above. Datalink stops It will be possible to stop the engine via a datalink (J1939 or PDL). As per the remote stop button, described above, the datalink stop is not fail safe and does not meet the requirements of emergency stop legislation so should not be relied on to assure the safety of machine operators or other personnel. Datalink stops may be used in the following circumstances • Immobilisers • Machine protection strategies • Automatic machine features (e.g. idle shutdown timer) • Stopping machines by radio control or other telemetry. Geo-fencing is a particular application, where a machine will not operate outside defined map coordinates It is recommended that if such features are implemented, then they are clearly documented and communicated to the final users and owners of the machine. If this is not done then there may be complaints that the engine is stopping unexpectedly. Common problems with the application of stop devices • It is possible, although extremely rare, that diesel engines continue to run even if all electrical power is removed. This can happen when high quantities of oil vapour or other inflammable gases are present in the air into the engine. The only way to prevent this is to provide an air inlet shut-off valve (slicer valve). It is not common practice to fit such devices to all engines, but they should be considered where there is a risk of flammable gases (e.g. in petroleum applications), or where the application demands high engine gradebility (slopes) • Some hazards are present when the engine is being cranked by the starter motor, as well as when it is running. For example, components will still rotate, hydraulic pressure will still be present, fuel may still be pump to high pressures. • If an emergency stop button is pressed, to cut power to ECM and ignition, but is released while the engine is still turning, it is possible for the engine to continue to run. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 51 Engine Speed Demand It is necessary to select a device that converts the speed requirements of the engine operator or controller to an electrical signal recognized by the engine ECM. There are five types of speed demand input: • Pulse Width Modulation (PWM) Sensor • Analogue Sensor • PTO mode - also known as “engine speed cruise control” or “set speed control”. • Multi Position Throttle Switches (MPTS) • Torque Speed Control - TSC1 (Speed control over CAN J1939) The speed demand type must be carefully considered and appropriate for the application. The options must be selected at the time of engine order so that the ECM will be configured correctly, for the type or pedal, lever or control device selected. There are two dedicated software input channels that can be configured to accept specific types of speed demand inputs. The valid combinations and throttle logic are given in the following diagram. PTO mode can be used with Analogue/PWM combinations; it cannot be used with multi position switch. The J1939 TSC1 parameter will override any speed demand input when broadcast. Droop is applied to the requested desired engine speed. THROTTLE 1 THROTTLE 2 % DROOP % DROOP THROTTLE 1 & 2 ARBITRATION ANALOGUE NOT INSTALLED NOT INSTALLED NOT INSTALLED MPTS ANALOGUE PWM MPTS ANALOGUE MPTS PWM ANALOGUE ANALOGUE ANALOGUE MPTS NOT INSTALLED PWM NOT INSTALLED THROTTLE 1 THROTTLE 2 VALID COMBINATIONS OVERALL ARBITRATION % DROOP J1939 TSC 1 REQUESTED SPEED PTO MODE (NOT VALID WHEN USING MPTS) R E Q U E S T E D D E S I R E D E N G I N E S P E E D DESIRED ENGINE SPEED VALID THROTTLE COMBINATIONS AND DROOP MANUAL OR HIGHEST WINS OR SUMMING D R O O P E D D E S I R E D E N G I N E S P E E D A R B I T R A T E D D R O O P E D D E S I R E D E N G I N E S P E E D 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 52 Analogue Sensor Device Description Two inputs are available for Analogue throttle devices, which may be either a pedal, lever or cable operated. The Analogue sensor gives a DC Analog output in the range 0.5 to 4.5 volts, when connected to the engine ECM. The ECM provides a regulated 5V 200mA power supply. Analogue Sensors –Connection details 33 SENSOR RETURN 54 ANALOGUE THROTTLE INPUT 1 41 SENSOR SUPPLY +5 VDC +5 VDC RTN SIGNAL Analogue Throttle 1 ECM J1 IVS 45 IDLE VALIDATION SWITCH 35 SWITCH RETURN IVS CMN 34 SENSOR RETURN 55 ANALOGUE THROTTLE INPUT 2 42 SENSOR SUPPLY +5 VDC +5 VDC RTN SIGNAL Analogue Throttle 2 ECM J1 IVS 44 IDLE VALIDATION SWITCH 35 SWITCH RETURN IVS CMN The Analog sensor should use non-contact Hall effect technology. Robust potentiometer contact sensors designed for use in vehicles may be considered under no circumstances should ordinary carbon track or wire wound potentiometers be used, as they will not be reliable. For all mobile applications, and those where a rapid change in engine speed could cause a hazard, an idle validation switch is required. The idle validation switch closes to ground when the sensor is in the minimum position. Off idle switches and kickdown switches are not monitored by the engine ECM. This Analogue input must only be used to control engine speed from a direct operator input, and is not suitable as the mechanism for speed control by another electronic controller. There is no special requirement for a relationship between angular movement of the pedal and output voltage. This document does not measure component acceptability in terms of: • Temperature • Vibration • Electromagnetic Compatibility • Design life • Supply voltage requirements (min, max, stability) • Legal Compliance 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 53 It the responsibility of the OEM and the throttle device manufacturer to ensure that the component is suitable for the application in which it is to be used. Evaluating Component Compatibility The following procedure should be used to evaluate whether an Analogue throttle is compatible with the engine ECM. This may be used either by the OEM in selecting components or by the manufacturer of devices which are to be connected to the engine. The following test circuits must be used when evaluating Analogue throttle devices. Analogue Input Test circuit 22K normal supply voltage of device under test 13V DC V1 Device Under Test Sig V+ V- Idle Validation Switch Test Circuit 2K Normal supply voltage of device (Hall Effect Devices only) 13V DC V2 Device Under Test IVS IVS V+ IVS ground 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 54 Test Procedure Test 1: Output at Min position Place the Device Under Test (DUT) in it’s minimum or “released” condition. Measure the voltage V1 Test 2: Output at Min position: forced Without causing damage, pull the pedal/ handle hard against the minimum travel end stop. Measure the voltage V1 Test 3: Output at Max position Place the DUT in it’s maximum or “fully depressed” condition. Measure the voltage V1 Test 4: Output at Max position: forced Without causing damage push the pedal/ handle hard against the maximum travel end stop. Measure the voltage V1 Test 5: IVS switch Closed Voltage Place the DUT in it’s minimum or “released” condition. Measure the voltage V2 Test 6: IVS switch Opening Threshold Place the DUT in it’s minimum or “released” condition. Test 7: IVS switch Open Voltage Place the DUT in it’s maximum or “fully depressed” condition. Measure the voltage V2 Test 8: IVS switch Closing Threshold Place the DUT in it’s minimum or “released” condition. Test 9: track resistance (potentiometer type sensors only) If the DUT is a potentiometer type device, disconnect it from the test circuit and measure the resistance across the track (from V+ to V-) 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 55 Required Values If the results obtained from the tests above are in the ranges specified below, then the device will be compatible with the default values in the ECM. Test Parameter Units Min Nominal Max 1 Output at Min position Volts 0.45 0.6 0.7 2 Output at Min position: forced Volts 0.4 0.6 - 3 Output at Max position Volts 3.8 4 - 4 Output at Max position: forced Volts - 4 4.5 5 IVS switch Closed Voltage Volts 0 0.5 1.2 6 IVS switch Opening Threshold Volts 1.08 1.15 1.22 7 IVS switch Open Voltage Volts 4 10 24 8 IVS switch Closing Threshold Volts 1.08 1.15 1.22 9 Potentiometer Track resistance K Ohms 1 2.5 3 If the results of the tests are not in the range specified in the table above, then the device will not be compatible with the default settings in the ECM. Contact the electronic applications team to determine whether it will be possible to configure the input to meet the device. Analogue Throttle Switch - EST Configurable Parameters The throttle configurable parameters must be configured in Perkins EST prior to using the analogue throttle feature. The parameters are selectable in the main throttle configuration screen. See the Throttle Calibration section of this guide parameter details. PWM Sensor - Compatibility Device Description One input is available for a PWM throttle devices that may be pedal, lever or cable operated. A regulated 8V, 100mA power supply is provided by the ECM. Component Compatibility The sensor should have a sinking output driver with a frequency of 500hz (+/- 50hz). The sensor should give a valid output within 150ms of power being applied. When mounted on the pedal and lever the target duty cycle should be as follows, however it is possible to deviate from these values by adjusting the throttle configuration in EST. Position Acceptable signal duty cycle range Released (low idle) 10 to 22% Fully Depressed 75 to 90% 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 56 Connection details 33 SENSOR RETURN 53 PWM THROTTLE SENSOR INPUT 43 SENSOR SUPPLY +8 VDC +8 VDC RTN SIGNAL PWM Throttle Sensor ECM J1 PWM Throttle - EST Configurable Parameters The throttle configurable parameters must be configured in Perkins EST prior to using the PWM Throttle feature. The parameters are selectable in the main throttle configuration screen. See the Throttle Calibration section of this guide parameter details. PTO mode PTO mode has also previously been referred to as “engine speed cruise control” or “set speed control” PTO mode cost effective way to control engine speed as it only requires switched inputs. Another benefit is that it can be used in an application where it is necessary to control the engine speed from several different points on the machine. The disadvantage of controlling engine speed via PTO mode is that it takes some time to ramp up or down to the required speed. 50 PTO MODE - RAISE RESUME 51 PTO MODE - SET/LOWER 52 PTO MODE - ON/OFF ECM J1 49 PTO MODE - DISENGAGE 35 SWITCH RETURN ON/OFF SET/LOWER RAISE RESUME DISENGAGE PTO Mode ON/OFF switch When this switch input is open then the PTO mode cannot be engaged, and none of the other buttons will have any effect. When the switch is turned off, any adjusted memorized speed will be lost. PTO Mode Set/lower Button When the PTO mode is on but not engaged, the first time that the set button is pressed it will save the current engine speed as the memorized speed, and the engine will try to run at this speed. Once that a PTO speed has been engaged, if the pressed again, or if it is held down, then the engine speed will be lowered. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 57 PTO Mode Raise/ Resume Button If the resume button, is pressed before the set button, immediately after start or after switching ON the cruise control ON/OFF switch then the engine will go to the preset speed as described below. If a the PTO mode has already been engaged by the set button, then the resume/raise button can be pressed or held down to increase the speed. After the PTO mode has been disengaged using the disengage switch described below, then pressing the Resume/Raise button will set the engine speed to the last memorized speed. PTO Mode Disengage Switch The disengage switch input is opened the engine speed will not follow the memorised speed, but will return to the next highest engine speed demand The disengage switch may be a operator panel switch, or may be a micro switch on the brake, clutch, or other component of the application PTO Mode Preset Speed The preset speed is programmed via the service tool. A speed may be selected such that if the resume button is pressed, before the set button has been pressed, then the engine speed will jump straight to this speed. PTO Mode - EST Configurable Parameters Four parameters must be configured in Perkins EST prior to using the PTO feature. The parameters are listed in the main configuration screen PTO and Throttle Lock Parameters EST Description Range or Option Description Throttle Lock Feature Installation Status Not Installed/Installed Used to install the PTO feature PTO Engine Speed Setting 0 to 2500 rpm Memorised speed used as the initial resume speed. Throttle Lock Increment Speed Ramp Rate 20 to 600 rpm/sec Speed at which the engine will accelerate or decelerate when holding the raise or lower button down Throttle Lock Engine Set Speed Increment 10 to 200 rpm/sec Speed at which the engine will increment or decrement when the raise or lower button is pressed quickly. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 58 Example of PTO mode operation It is recognized that the precise function of the PTO mode is difficult to understand from a written text document, especially for engineers who do not have English as their first language. The following table illustrates the operation of the PTO mode feature. In this example, the preset speed has been set on the service tool to 1800 rpm. On/Off Switch 0 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 0 0 1 Interrupt Switch 1 1 1 1 1 1 1 1 1 Quickly open 1 Quickly open 1 1 1 1 1 1 1 Set/Lower Switch 0 0 0 0 0 0 0 0 Quick Close 0 0 0 Quick Close Quick Close 0 0 0 0 Quick Close Raise resume 0 0 Quick Close 0 0 0 Quick Close Hold Close 3 secs 0 0 Quick Close 0 0 0 Hold Close 3 secs 0 Quick Close 0 Quick Close Throttle Pedal demand 1200 1200 1200 1200 1900 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 Memorised Speed 1800 1800 1800 1800 1800 1800 1820 2050 2030 2030 2030 2030 1200 1180 2430 1800 1800 1800 1800 Resulting engine speed 1200 1200 1800 1800 1900 1800 1820 2050 2030 1200 2030 1200 1200 1200 2430 1200 1200 1200 1200 C o m m e n t s P T O m o d e n o t e n a b l e d P T O m o d e d i s e n a g e d P T O j u m p s t o m e m o r i s e d s p e e d P e d a l o v e r r i d e s P T O ( m a x w i n s ) S p e e d r a i s e d b y 2 0 R P M S p e e d r a m p s u p L o w e r e d b y 2 0 R P M D i s e n g a g e - s p e e d r e t u n s t o n e x t h i g h e s t d e m a n d ( T h r o t t l e p e d a l ) R e s u m e s t o 2 0 3 0 D i s e n g a g e - s p e e d r e t u n s t o n e x t h i g h e s t d e m a n d ( T h r o t t l e p e d a l ) S e t s m e m o r i s e d s p e e d t o c u r r e n t s p e e d M e m o r i z e d s p e e d l o w e r e d b y 2 0 R P M b u t n o w p e d a l i s h i g h e s t w i n s S p e e d r a m p s u p P T O m o d e s w i t c h e d o f f . P r e s e t m e m o r i s e d s p e e d n o w n o e f f e c t a s P T O m o d e i s n o t e n a b l e d P T O m o d e d i s e n g a g e d n o e f f e c t i f b o t h b u t t o n s a r e p r e s s e d a t o n c e Multi Position Throttle Switch (MPTS) Four switch inputs are available on the ECM for a switch-controlled throttle. The ECM may be configured so that different combinations of switch inputs will relate to different engine speed demands. There are 16 different combinations of states of these 4 switches, although not all of these combinations need to be programmed. 51 THROTTLE SWITCH INPUT 3 50 THROTTLE SWITCH INPUT 2 49 THROTTLE SWITCH INPUT 1 ECM J1 52 THROTTLE SWITCH INPUT 4 35 SWITCH RETURN S1 S2 S3 S4 CMN Rotary Switch If a switch combination is detected which has been configured as “Not Valid” then a fault code will be raised and the ECM will ignore the MPTS for the rest of the key cycle. This is a very powerful and flexible feature that may be used in a number of ways. For example: • Controlling hydrostatic machines where engine speed is selected and then not required to be frequently changed by the operator. It is in this respect a good alternative to a hand throttle as the speeds selected on the switch. Can be designed to correspond to the optimum operating speeds of hydraulic pumps. A rotary encoded 10 position switch component is available for this function. Please contact the electronic applications team for further details. • Machine limp home speed feature. For example, if the normal throttle fails the operator could remove a fuse or a link and the engine would go to a speed that would allow the machine to be moved. In this application only one of the available 4 switch inputs would be used. • Elevated idle. For example the OEM could increase the idle speed when work lights are switched on so that the alternator will provide sufficient current to recharge the battery. In this application only one of the available 4 switch inputs would be used. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 60 The following table illustrates how the ECM may be configured for a 10 position rotary switch. Multi-Position Switch Configuration Example Switch 4 Switch 3 Switch 2 Switch 1 Switch position Engine Speed Open Open Open Open Not valid 800 Open Open Open Closed 1 800 Open Open Closed Open 3 1800 Open Open Closed Closed 2 1400 Open Closed Open Open 7 2050 Open Closed Open Closed 6 2000 Open Closed Closed Open 4 1900 Open Closed Closed Closed 5 1950 Closed Open Open Open Not valid 800 Closed Open Open Closed Not valid 800 Closed Open Closed Open Not valid 800 Closed Open Closed Closed Not valid 800 Closed Closed Open Open 8 2100 Closed Closed Open Closed 9 2200 Closed Closed Closed Open Not valid 800 Closed Closed Closed Closed 10 2350 The service tool configuration allows the user to specify the number of switch inputs to use. It is recommended that where possible the user configures 4 inputs and mark those not used as ‘not valid’. If however the user chooses to configure less then 4 inputs using the service tool the physical input allocation vs software input description changes as described in the table below. MPTS Pin Allocation Logic Pin 49 Pin 50 Pin 51 Pin 52 4 configured inputs Software Input 1 Software Input 2 Software Input 3 Software Input 4 3 configured inputs Software Input 1 Software Input 2 Software input 3 2 configured inputs Software input 1 Software Input 2 1 configured inputs Software Input 1 Multi Position Throttle Switch - EST Configurable Parameters The throttle configurable parameters must be configured in Perkins EST prior to using the MPTS feature. The parameters are selectable in the main throttle configuration screen. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 61 Torque Speed Control TSC1 (Speed Control Over CAN) A special J1939 message called Torque/Speed Control #1 (TSC1) allows other electronic devices to control or to limit the engine speed. This message is explained in detail in the J1939 section of this application and installation guide Arbitration of speed demand In applications where there is more than one source of engine speed demand, it is necessary to arbitrate between the different demands. There are 3 methods of arbitration: • Max Wins. The highest speed demand is the one that controls the engine. This is the default configuration • Manual Selection switch. A switch input can be used to define which speed input has control. This is particularly useful in applications where there are 2 driver seat positions. Cannot be used in conjunction with coolant level switch – pin clash • TSC1 override. As described above, the Tsc1 message over J1939 will override speed demand from any other source. Manual Throttle Selection Switch A switch input is available on pin 47of the ECM J1 connector, which can be configured to manually select the active speed demand channel. If the switch input is open then Speed demand 1 is selected. If the switch is closed then speed demand 2 is selected. Function cannot be used in conjunction with IVS 2. Ramp Rate It is possible to limit the overall acceleration rate of the engine speed. The acceleration limit applies to overall engine speed, irrespective of applied strategy. The rate may be configured in EST. The rate is defined in units of rpm per second. 0 rpm/s represents no limit to engine acceleration (i.e. turns off the feature.) The default ramp rate will be 0 rpm/s. Throttle Calibration The majority of throttle components have mechanical and electrical tolerances that affect the final output of a device, for example two components of the same design and part number may produce a different voltage output in the open position. Also after a period of time throttle components can mechanically wear, affecting/changing the output of a device. To accommodate these differences and changes the engine ECM may be configured to automatically calibrate to differing input values at the upper and lower positions. The diagrams below give an example pedal design where the open and closed position of the throttle pedal are set by adjusting the manufacturing adjustment screws. With this type of arrangement the mechanical accuracy is limited and therefore auto calibration may be used. The calibration control logic needs a number of parameters specific to the chosen device to allow auto calibration. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 62 This feature is configurable for Analogue and PWM inputs. The algorithm treats either a PWM or analogue input as a ‘raw signal’ in the range 0 to 100% for example the analogue voltage range is 5V therefore 0.05V is treated as 1%. Several parameters are used to: Define the boundaries for calibration in the open and closed positions Define the amount of ‘deadzone /play’ from the open and closed positions Define the upper and lower diagnostic boundaries L o w e r P o s i t i o n L i m i t I n it ia l L o w e r P o s it io n L o w e r D e a d z o n e Diagnostic Upper Limit Upper Position Limit In itia l U p p e r P o sitio n D i a g n o s t i c L o w e r L i m i t U p p e r D e a d z o n e 0% 100% 10% 20% 70% 85% 5% 95% 5% 5% Pedal Rotation S e n s o r L e v e r R o t a t i o n Lock Screws Pedal Sensor Foot Force The diagram above is a simplified representation of a throttle pedal assembly; a small lever attaches the pedal to a throttle position sensor. Two lock screws limit the open and closed pedal movement, one for each position. The lever movement is directly proportional to the electrical output signal of the throttle sensor. The electrical raw signal is shown as a percentage of the total permissible input range. Eight parameters are shown on the diagram scale, each parameter has a purpose; these parameters are required for correct calibration. The parameters are expressed as a percentage of raw signal, the parameters may be changed/configured to match the chosen device: 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 63 Throttle Parameter Description Diagnostic Lower Limit The lower diagnostic limit is the absolute minimum raw value accepted as a valid signal by the engine ECM. Any values below this point will flag appropriate diagnostics and invoke the limp-home strategy. Most analogue devices are classed as faulted with a voltage of 0.25V and below (5%) this is to prevent a possible open or short circuit being mistaken for a valid signal, for similar reasons a PWM duty cycle should not fall below 5% duty cycle. Lower Position limit This is the minimum point of the lower calibration boundary Initial Lower Position limit This is the maximum point of the lower calibration boundary. This value is also used as the initial lower position when no calibration has been applied. Lower Deadzone This position is given as a discrete raw signal percentage value. The lower dead zone effectively gives some play at the lower position. This dead band is expressed in terms of a raw signal percentage, such that the initial lower position plus the lower dead zone will give the 0% throttle position. Initial Upper Position limit This is the minimum point of the upper calibration boundary. This value is also used as the initial upper position when no calibration has been applied. Upper Position Limit This is the maximum point of the upper calibration boundary Upper Deadzone This position is given as a discrete raw signal percentage value. The upper dead zone effectively gives some play at the upper position. This dead band is expressed in terms of a raw signal percentage, such that the initial upper position minus the upper dead zone will give the 100% throttle position. Diagnostic Upper Limit The upper diagnostic limit is the absolute maximum raw value accepted as a valid signal by the engine ECM. Any values above this point will flag appropriate diagnostics and invoke the limp-home strategy. Most analogue devices are classed as faulted with a voltage of 4.75V and above, this is to prevent a possible open or short circuit being mistaken for a valid signal, for similar reasons a PWM duty cycle should not go above 95% duty cycle. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 64 Throttle Calibration Function When the engine ECM is active the raw throttle signal is continuously monitored. The following diagrams explain how the automatic calibration functions. The adjustment screws in the diagram have been purposely adjusted and differ from the previous throttle pedal diagram. When the engine ECM is active the raw throttle value is checked, if the value falls within the lower calibration region (defined by the ‘lower position limit’ & ‘Initial lower position limit’) calibration will take place. In the diagram below the lever position is at 11% and falls within the lower calibration area so auto calibration will be applied. L o w e r P o s i t i o n L i m i t I n it i a l L o w e r P o s it io n L o w e r D e a d z o n e Diagnostic Upper Limit Upper Position Limit In itia l U p p e r P o s itio n D i a g n o s t i c L o w e r L i m i t U p p e r D e a d z o n e 0% 100% 10% 20% 70% 85% 5% 95% 5% 5% Pedal Rotation S e n s o r L e v e r R o t a t i o n Lock Screws Pedal Sensor Foot Force OUTPUT 11% Diagram A, before calibration, the sensor output falls within the lower calibration region, without auto calibration the ‘initial lower position limit’ is used by the engine ECM as the throttle start point. Once clear of the deadzone the desired engine speed will change. In this case the lever would have to move 14% of the raw signal (9% + 5% deadzone) before desired engine speed changes. This is situation is undesirable. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 65 L o w e r P o s i t i o n L i m i t I n it i a l L o w e r P o s it io n L o w e r D e a d z o n e Diagnostic Upper Limit Upper Position Limit In itia l U p p e r P o s itio n D i a g n o s t i c L o w e r L i m i t U p p e r D e a d z o n e 0% 100% 10% 20% 70% 85% 5% 95% 5% 5% Pedal Rotation S e n s o r L e v e r R o t a t i o n Lock Screws Pedal Sensor Foot Force OUTPUT 11% Diagram B, after calibration, the start position used by the engine ECM has changed; with this new initial lower position the lever needs to travel through the deadzone only. Once clear of the dead zone the desired engine speed will change. The same principal applies for the upper calibration region as shown in the following diagram. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 66 L o w e r P o s i t i o n L i m i t I n i t i a l L o w e r P o s it io n L o w e r D e a d z o n e Diagnostic Upper Limit Upper Position Lim it In itia l U p p e r P o s itio n D i a g n o s t i c L o w e r L i m i t U p p e r D e a d z o n e 0% 100% 10% 20% 70% 85% 5% 95% 5% 5% Pedal Rotation S e n s o r L e v e r R o t a t i o n Lock Screws Pedal Sensor Foot Force OUTPUT 75% Diagram C, before calibration, the sensor output falls within the upper calibration region, without auto calibration the ‘initial upper position limit’ is used by the engine ECM as the throttle maximum point. Once clear of the deadzone the desired engine speed will change. In this case the lever would have to move 10% of the raw signal (5% + 5% deadzone) before desired engine speed changes. This is situation is undesirable. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 67 L o w e r P o s i t i o n L i m i t I n i t i a l L o w e r P o s it io n L o w e r D e a d z o n e Diagnostic Upper Limit Upper Position Lim it In itia l U p p e r P o s itio n D i a g n o s t i c L o w e r L i m i t U p p e r D e a d z o n e 0% 100% 10% 20% 70% 85% 5% 95% 5% 5% Pedal Rotation S e n s o r L e v e r R o t a t i o n Lock Screws Pedal Sensor Foot Force OUTPUT 75% Diagram D, after calibration, the maximum position used by the engine ECM has changed; with this new initial upper position the lever needs to travel through the deadzone only. Once clear of the deadzone the desired engine speed will change. The auto calibration feature is continuously active during engine operation if a lower minimum position or higher maximum position is seen auto calibration will take place on the new values. The initial positions (defined by the initial lower position limit and initial upper position limit) will be re-instated whenever the power to the ECM is recycled. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 68 Idle Validation Switch Analogue devices must use an idle validation switch. The idle validation switch is required to validate that a change in signal is indeed valid and not a potential electrical fault. Two parameters need to be defined for correct operation. When configured the engine ECM continually monitors the speed demand request and the Idle validation switch. Idle validation maximum ON threshold (Closed) The value is defined as percent raw signal. At low idle the Idle Validation switch should be ‘ON’ (the input should be switched to ground). When increasing engine speed the ECM will continually monitor the idle validation switch. The switch needs to have switched ‘OFF between the two IVS thresholds. If the switch state does not change by the ‘Idle validation maximum ON threshold’ the ECM will invoke the limp home strategy and the throttle will not respond. Idle validation minimum OFF threshold (Open) The value is defined as percent raw signal. At high idle the Idle Validation switch should be ‘OFF’ (the input should be switched to open). When decreasing engine speed the ECM will continually monitor the idle validation switch. The switch needs to have switched ‘ON’ between the two IVS thresholds. If the switch state does not change by the ‘Idle validation minimum off threshold’ the ECM will invoke the limp home strategy and the throttle will not respond. 100% 5% 5% Pedal Rotation Lock Screws Pedal Sensor Foot Force 21% 25% Idle Validation Switch O N O F F O N O F F ON OFF Cold Starting Aid. Diagram, Shows the Idle validation switch transition. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 69 Control of Glow Plugs by the Engine ECM Glow plugs are fitted as standard on the 1106D-E70TA & 1104D-E44TA. When the ignition key switch is switched ON, the engine ECM will monitor the coolant temperature and the inlet air temperature and decide whether the glow plugs are required. If so then the ECM will drive ECM connector pin 57 to ground, activating the glow plug relay. The Glow plug relay is supplied and fitted by the OEM, EST configuration is not necessary. This feature is permanently enabled. Relay, Fuse and Cable Gauge Specification 57 Start Aid Control ECM J1 TO GLOW PLUGS GLOW PLUG RELAY FUSE Key Switched + Battery Supply + Battery The relay coil should not draw more than 1A and should be fitted with either a resistor or diode to suppress flyback energy (back emf) when the relay is de-energized. As the glow plugs may be activated during cranking, when the battery voltage may be low, it is recommended that relay is specified such that it will close at a voltage of 60% of nominal battery voltage or lower. The relay contacts should be rated to withstand the current characteristics outlined in the table below. Note that for the purpose of relay specification, the glow plugs are a purely resistive load (no inductive element). Although the glow plugs are normally operated only for a short time, in cold ambient conditions, best practice would be to size the cable to withstand the stabilized glowplug current permenantly. This will allow for a relay that fails closed. For example a 4 Cylinder 12V application should have wire sized to carry 50A. Refer to the recommended cable sizes in the table below. Engine: 1104D-E44TA 1106D-E70TA Supply Voltage: 12V 24V 12V 24V Current - Initial 82A 36A 122A 54A Current after 4 seconds 64A 29A 97A 43A Current after 8 seconds 50A 24A 74A 36A Recommended Fuse To SAEJ1888 ( slow blow) 50 30 80 40 Recommended min cable gauge - mm2 (SAE J1128 GLX cable) 5mm 2 2mm 2 8mm 2 3mm 2 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 70 Wait-to-Start / Start Aid active lamps On a cold start, when the ECM decides that it is necessary for the glowplugs to be activated prior to starting, a lamp output will indicate to the operator that he needs to “wait to start”. Note that it is possible that start aids will also be used either during cranking or when the engine has started. The wait to start lamp will not be active in these conditions. For further information refer to the Lamp Output section. Note that the ECM will also transmit a parameter on the J1939 datalink indicating the status of the Wait to Start lamp (see section on J1939 support). Start Aid Control Engine Coolant Temperature Sensor Engine Intake Temperature Sensor Temperature <= +5 degC ? Key ON N Coolant Temp I n t a k e T e m p T i m e ECM activates Wait to Start Lamp and Glow Plugs for period determined from Pre-heat map Y Engine speed >= to low idle -200 rpm? ECM activates Glow Plugs for Post-start period of 15 seconds Start Aid End Pre-heat map ECM selects coldest temperature Y ECM activates Glow Plugs during cranking for maximum of 10 sec The operator should wait until after the Pre-heat period before cranking. The Glow Plugs will remain off after the Pre-heat period until the engine is cranked N Operator crank engine when lamp turns off No Start Aid required Typical Values (May Vary) 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 71 OEM / Operator control or override of the Glow Plugs The ECM glow plug control strategy has been developed in a cold chamber to be suitable for the majority of applications. There may be some applications that require a specially adapted strategy for control of the start aid. In such cases it will be necessary for the OEM or operator to control the start aid. Examples of applications that may require special starting strategies are: • Engines in extremely cold climates that are fitted with block heaters. • Engines that drive high loads during run up e.g. compressors. An insulated M6 terminal post is provided for the machine harness connection to the busbar, this is located to the top right hand side of the ECM bracket. A 5.5-6 mm diameter ring terminal is required to connect the machine harness; this should be capable of handling an 80Amp current and insulated by a terminal insulator cap. The existing terminal nut is used to locate both the engine-side and harness-side ring terminals to the post. A 10mm ring spanner is required to tighten the terminal nut to a torque of 6 Nm ± 2Nm. Customers who paint their engine are required to shield the terminal post prior to painting. Ether Cold Start Systems Ether Cold start systems are not currently approved for use with 1106D-E70TA & 1104D-E44TA industrial engines. Busbar connection point 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 72 Water Jacket Heaters When an engine water jacket heater is installed Perkins recommend the installation of an ambient air temperature sensor. When installed and configured the ambient sensor measurement will be used by the ECM to ensure optimum engine starting and run-up. 56 AMBIENT AIR TEMP SIG 33 SENSOR RTN 42 SENSOR SUPPLY +5 VDC A B C +5 VDC RTN SIGNAL Temperature Sensor ECM J1 Required Parts Part Number Description Qty 2874A026 Temperature Sensor 1 The Perkins sensor is required for correct operation. The sensor should be located in a position that measures the application external ambient air temperature. A location should be chosen that avoids any radiated or conducted heat produced by the engine water jacket heater. The location and mounting design should protect the sensor from damage; the sensor probe is particularly vulnerable and should be guarded from possible impact damage. NOTE: Do not splice the sensor signal wire for input to third party devices. Recommended connector mounting for component with a pigtail harness: The connector interface should never be tied directly to a vibrating member. Pigtail wire lead should be tied down on only one side of the connector interface. Choose one of these two locations: - midpoint on the sensor pigtail, OR - 150 mm from the connector on the wire harness side Ambient Temperature Sensor - EST Configurable Parameter The ‘Ambient Air Temperature Sensor Installation Status’ listed under start aid configurable parameters must be configured installed in Perkins EST prior to using the sensor. The working range of the sensor is -40 to 150°C External Thread M18 x 1.5 6g 46 mm HEX M22 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 73 Operator Displays Gauge Drivers OEM’s are increasingly selecting datalink driven intelligent displays for their applications, instead of traditional gauges and lamps directly driven from sensors or engine ECM. If a needle type Analog gauge is required, to display an engine parameter such as engine speed, oil pressure or coolant temperature, then it is recommended that the OEM uses a gauge or display that can use the parameters broadcast by the ECM on the J1939 datalink. As an alternative, traditional single wire gauge “senders” may be used if a suitable tapping is available. If this implementation is required, then please contact the electronic applications team to discuss requirements. A traditional tacho signal may be obtained from the “W” terminal of the alternator, although this will not be as accurate as the value sent on the J1939 datalink. Warning: The engine wiring harness must NEVER be modified to use the signal from the sensors connected to the engine ECM. This action would invalidate the engine warranty. Lamp Outputs The lamp strategy is designed to display the maximum amount of information on the minimum number of lamps. There are four lamp outputs available: Lamp Description Pin Allocation Red Stop Lamp Pin 60 Amber Warning Lamp Pin 59 Wait to Start Lamp (Cold Start Aid) Pin 63 Low Oil Pressure Lamp Pin 62 It is mandatory for the OEM to fit the Red Stop Lamp (1), Amber Warning Lamp (2) and the Wait to Start Lamp (3) unless a datalink driven intelligent display is fitted, which fulfils the specification outlined in the next section. Lamp four is optional. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 74 Indicator lamps Logic M a n a g e m e n t S y s t e m Warning Lamp (Also known as Alert Lamp) Shutdown Lamp (Also known as Action Lamp) Lamp State Description of what Lamp Status is Indicating Engine State On On Bulb Check When the ignition is turned on the ECM shall illuminate each bulb for 2 seconds and extinguish them afterwards. Key on but engine has yet to be cranked. Off Off No Faults Present. With both lamps off whilst engine is running then there are no currently active warnings diagnostic’s or events. Engine is running with no detected faults. On Off Active Diagnostic Should the warning lamp illuminate during engine running this indicates that an Active diagnostic (Electrical fault) is present. Engine is running normally but has one or more faults with the engine management system. On Flash Derate. (Invoked by Active Diagnostic) Should the warning lamp illuminate and the shutdown lamp flash during engine running this indicates that an Active diagnostic (Electrical fault) is present. The diagnostic is sufficiently serious to invoke engine derate. Engine is running but has one or more Active diagnostic events that have initiated engine derate. Flash Off Warning (Warning only) Should the warning lamp flash during engine running this indicates that one or more of the engine protection strategy warning values have been exceeded but not to a level that will invoke Derate or Shutdown. Engine is running normally but has one or more monitored engine parameters outside of the acceptable range. Flash Flash Derate. (Warning and Derate). Should both the Warning lamp and Shutdown lamp flash during engine running this indicates that one, or more, of the engine protection strategy values have been exceeded beyond the level required to invoke engine Derate. Engine is running but one or more of the monitored engine parameters has gone beyond that of warning only and has now exceeded those set for engine derate. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 75 On On Engine Shutdown Should both the Warning lamp and Shutdown lamp illuminate during engine running this indicates that either 1. One or more of the engine protection strategy shutdown values has been exceeded. 2. A serious Active diagnostic has been detected. Shortly after (time duration to be agreed) engine will shutdown. Engine is either shutdown or shutdown is imminent, one or more monitored engine parameters have gone beyond that of warning or derate and have now exceeded those set for engine shutdown. Or a serious Active diagnostic has been detected Datalink Driven Intelligent Displays Displays may be connected to the engine ECM using J1939 datalink. Some products that use the PDL may also be compatible. Please contact your local applications team to confirm before selecting a PDL display. Devices that are connected to the J1939 datalink should meet the following standard if the OEM does not intend fitting the indicator lamps, described above. Minimum Functional Specification for J1939 display. • The display always on when the engine is running • The display should be line-of-sight of machine operator during machine operation • Display of the whole J1939 fault code including Suspect Parameter Number, Failure Mode Indicator, and Occurrence number. • Clear indication of what action, if any the operator is required to take. • Display of engine speed • Audible or bright lamp warning when new fault code is detected • The scaling of any gauges (e.g. coolant temperature) should be such that the needle is not far to the right of vertical when the engine is in normal operation (this would give the impression that the engine was abnormally hot, when in fact it is running within it’s design limits). Perkins will under no circumstances change the engine J1939 implementation in order to resolve compatibility issues with gauges or displays other than those supplied directly by Perkins. Gauge manufacturers may contact the Electronic Applications team, however for information and assistance in ensuring that their products are compatible with the engine ECM. To support new standards and requirements Perkins may add to the fault code table. Therefore any active engine fault codes including those not recognized or referenced should be displayed. Perkins recommends that any suspect parameter number and the associated failure mode identifier are displayed. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 76 Customer Triggered Engine Fault codes The engine will raise fault codes (event codes) when it’s design limits are exceeded. For example, for excessive coolant temperature. The fault code algorithms are carefully designed and validated so that they do not cause spurious codes when there is in fact no fault. Some intelligent instrument clusters available on the market are also capable of raising fault codes themselves, based on the information that the engine transmits on J1939 such as “engine coolant temperature”. The machine designer could set a limit that is more conservative (lower) than the warning threshold defined by Perkins. This raises the possibility that the display will say that the engine has a fault, when the engine is in fact running within its design limits. This is undesirable as it may result in a service technician being called to resolve a “problem” when in fact no problem exists. It will also cause damage to the reputation of Perkins and of the OEM. Perkins recommend therefore, that intelligent display DO NOT have their own fault detection for engine over temperature / oil pressure etc, but that they use the fault codes generated by the engine, sent in the J1939 “Diagnostic Message#1 (DM1)”. Engine Software Features Engine Monitoring System Software will monitor the engine during operation and in extreme conditions make decisions to protect the engine from damage. The values of four main operating parameters are monitored Engine Coolant Temperature, Engine Oil Pressure, Intake Manifold Air Temperature and Engine Speed. The monitoring system will compare parameters predetermined as dangerous to the engine and depending on the parameter values take appropriate action. There are three levels of action Warning, De-rate and Shutdown. General All parameters work independently using individual threshold values and guard timers. Consequently, it is possible for more than one parameter to register a warning or de-rate condition at any one time. Warning Each monitored parameter has its own warning trigger threshold. A warning will be triggered when any parameter equals or exceeds its warning. In addition, for oil pressure, the trigger threshold varies with engine speed. The ECM will log these events and turn on the appropriate lamp driver. De-rate Each monitored parameter that uses the de-rate function has its own de-rate trigger threshold. If the de-rate threshold is equaled or exceeded by any parameter for a de- rate protection will be set active. The engine will de-rate. The ECM will log these events and turn on the appropriate lamp driver. Whilst de-rate protection is set active, the de-rate percentage may vary with parameter value Shutdown The engine shutdown indication lamp driver will be triggered when any parameter equals or exceeds it shutdown threshold for a time exceeding its shutdown indication guard time. Physical engine shutdown will occur only if enabled by the configurable parameter. The ECM will log these events and turn on the appropriate lamp driver. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 77 Note: All values quoted in tables below are subject to change. Also, the percentage derate can be confusing. 100% derate does not mean that the engine has no power at all, it means that the engine will be running on a derate rating. The percentage of normal power that is available on the derate curve will depend on the rating used, but will normally be approximately 50% of nominal power Monitoring Mode - EST Configurable Parameters Monitoring Mode (listed under Miscellaneous in EST) EST Description Range or Option Description Monitoring Mode Shutdowns Disabled/Enabled Switches on or off the shutdown feature Monitoring Mode Derates Enabled/Enabled Switches on/off the derate feature Monitoring Mode Thresholds Coolant Temperature Parameter Temp De-rate % Warning (for top tank temp 108 degC) 109 N/A De-rate 111 25 112 50 113 75 114 100 Shutdown Configurable N/A Engine Oil Pressure Parameter Engine Speed (rpm) Trigger Pressure (kPa) Warning 700 150 900 150 1000 175 1200 200 1400 250 2500 250 3000 250 Shutdown 700 100 900 100 1000 100 1200 100 1400 100 2500 100 3000 100 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 78 Intake Manifold Temperature (subject to change) Parameter Temp De-rate % Warning 123 N/A De-rate 126 20 127 30 128 40 129 50 Other De-rate Reasons Diagnostic and Events Derate Latch utill next key cycle? Turbo Wastegate Turbo wastegate current low diagnostic 100% No Turbo wastegate current high diagnostic 100% No Low intake manifold pressure event 100% Yes High intak manifold pressure event 20% Yes Fuel Rail Pump and Pressure Sensor Fuel rail pump solenoid current low diagnostic 100% Yes Fuel rail pump solenoid current high diagnostic 100% Yes Rail Pressure sensor voltage low diagnostic 100% No Rail Pressure sensor voltage high diagnostic 100% No Low fuel rail pressure event 100% Yes High fuel rail pressure event 100% Yes Others 5V sensor supply voltage low diagnostic 100% No 5V sensor supply voltage high diagnostic 100% No 168-01 Low battery power to ECM diagnostic 100% No Crank speed sensor diagnostic 60% No Injector data incorrect 60% Yes Injector not responding 20% No 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 79 Monitored Inputs for Customer Fitted Sensors Configurable options will be available that enable the use of discrete ECM inputs to function as operator warnings and engine protection. The three options to be offered include: Input State De bounce Time (secs) Warning/Shutdown J1 Pin Assignment Air Filter Restriction SWG Normally Closed 30 Disabled or Warning J1-38 Engine Coolant Level Low SWG Normally Closed 30 Disabled, Warning or Shutdown J1-47 Water in Fuel SWG Normally Open 30 Disabled or Warning J1-44 Configurable States The ECM may be configured to take the following action when the monitored element has reached or exceeded the predetermined limit (switched). Disabled, the input will not be monitored. Warning, the input will be monitored when the device is switched the warning light will illuminate and an event flagged. Shutdown, the input will be monitored and when switched will illuminate the shutdown lamp; flag an event and shutdown the engine. Air Filter Service Indicator – Air Filter Restriction Switch Indicates that the air intake circuit is restricted. The switch is installed or piped to the air filter housing or air induction pipe so that it is monitoring clean filtered air (between the air filter and engine). The customer will select an appropriate restriction switch. The switch shall be connected to the engine ECM. The switch should open when the maximum permitted restriction is detected – Normally closed. 35 SENSOR RTN 38 SENSOR SIGNAL ECM J1 Air Intake Restriction Switch Coolant Low Level Switch Indicates that the engine coolant reservoir is at or has exceeded the minimum level. The sensor needs to be installed such that when coolant level is normal the sensing element is always completely immersed. Typically a device switches when the sensing element is fully immersed and when the fluid touches the body of the sensor. –Normally closed 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 80 47 COOLANT LEVEL SIGNAL 33 SENSOR RTN 43 SENSOR SUPPLY +8 VDC A B C +8 VDC RTN SIGNAL Coolant Level Switch ECM J1 Water in Fuel Trap Switch Indicates that the fuel filter water trap is full. Typically a switch is installed in the bottom of the water trap. During normal engine operation the switch is immersed in diesel fuel. As water collects and reaches the maximum level the water enables a conductive path between electrodes. –Normally open switch. Some fuel filter options offer a standard pre-installed switch from the factory. The factory fitted switch may be connected the engine ECM as detailed below. One parameter must be configured as installed in PERKINS EST. 1.Fuel/Water Separator Switch Installation Switch Status. 43 SENSOR SUPPLY +8 VDC 33 SENSOR RETURN 44 SENSOR SIGNAL (SWG 9) ECM J1 1 2 3 SENSOR SUPPLY +8 VDC SENSOR RETURN SENSOR SIGNAL Water In Fuel Sensor Operating Voltage 8V-28V @ 5mA Connector Details Component Perkins part number Supplier Part number Sensor 523161 Male Connector AMP 1-142854-0 Connector Female Housing AMP C-282191-1 Female Terminal AMP 929939-3 Rubber Seals AMP 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 81 Engine Governor All speed The default governor type is an All Speed Governor, also known as a variable Speed Governor. The diagram below illustrates the torque and speed characteristics of this governor Torque limit curve Note that the engine may not be capable of reaching the torque fuel limit curve in some circumstances. For example, if the turbocharger is not providing the required boost pressure, then the fuel will be limited so that the engine does not emit black smoke Droop Droop is the variation of engine speed as load is applied. For example, if an engine has 10% droop and is running at 1500RPM without load, then as load is applied the operator will feel and hear the engine speed gradually decreasing. This is represented by the diagonal dotted lines under the torque curve in the diagram below. When the load reaches the torque limit curve of the engine, the engine will lug back along the curve. Note that droop values can be assigned to the multi-position throttle switch input, PWM accelerator pedal/lever input and the TSC1 speed demand over J1939. Droop does not apply, however to the PTO mode, which always operates isochronously (0% Droop) High Speed Governor (Governor Run-Out) The parameter Top Engine Limit (TEL) will no longer be offered on the 1106D- E70TA & 1104D-E44TA engines. Flexibility is improved, however, by allowing the high idle (HI) speed to be configured. High Idle is the maximum speed that the engine will reach. Note that this is on the bare engine and when installed in an application, it may not be possible to reach this speed due to the parasitic loads of the driven equipment. The range of possible high idle speeds is defined by the parameters High Idle Lower limit (HILL) and High Idle Upper Limit. (HIUL). High Idle cannot be specified to be less than Rated Speed (RS) and the HIUL will be dependant on the mechanical limits of the engine. The rated speed (RS) may not be changed by customer configuration. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 82 Example Governing1 - showing droop and HSG slopes approximately equal 800 1800 2200 RS H S G D R O O P Flywheel Torque Speed (RPM) HILL HIUL 2200 2600 7% Droop 2200 RS 2354 HI all speed governor HI HIUL HILL Example Governing 2 – Showing isochronous droop but with a shallow HSG slope 800 1800 2200 RS H S G D R O O P = I S O C H R O N O U S Flywheel Torque Speed (RPM) HILL HIUL 2200 2600 0% Droop 2200 RS 2350 HI all speed governor HI HIUL HILL 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 83 Auxiliary Governor It is possible to control the engine by the output shaft speed of another module. Perkins do not offer a speed sensor for this component, nor is there a direct speed sensor input, however this is for the following reasons: • There are a wide variety of speeds to be measured • Speed sensors output signals are low in amplitude and sensitive to electromagnetic interference • The engine is often not close to the output shaft to be measured, thus resulting in poor quality speed signals The recommended solution for this requirement is as follows: The speed measured close to the output shaft by a third party electronic control module, which would give an engine speed demand to the engine, using J1939 TSC1 speed control or PTO mode raise and lower inputs. The third party module could also incorporate a display and/or operator control buttons. The electronic Application team can give advise on specifying and selecting the third party electronic module for this function. The advantage of this approach is that, although the initial cost of the additional module is higher than a direct speed input, the cost of the additional components is reasonable and the advantages in reliability and ease of commissioning outweigh the disadvantages. Rating selection via Service Tool Some engines will have the capability to run more than one power rating. If this is the case then the highest allowed rating may be changed via the “rating” parameter on the configuration screen of the service tool. Note, however that the engine may not be running the highest enabled speed due to the status of the mode switches or due to requests from another electronic module on the machine over J1939 datalink. Mode Switches A mode is a performance characteristic in terms of power / torque, Droop and rated speed. There are up to 4 modes configurable on the 1106D-E70TA & 1104D-E44TA engines, and these can be selected in operation when the engine is running and on load. The mode switches are of the Switch to Ground type and the ECM J1 pin connections are as follows: Function ECM - J1 connector pin assignment Mode switch 1 39 Mode switch 2 46 The following table is an example of how the mode switches can be configured. The 2 switch inputs provide a total of four possible combinations. Two ratings have been configured such that if switch 2 is open the engine will run on the lower rating, and if the switch is closed it will run on the higher rating. Switch 1 is configured such that if it is open then the droop on throttle 1 and 2 is 10%, which may be suitable for road 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 84 operation in an agricultural tractor, for example. When Switch 1 is closed, however, a tighter droop is applied which may be suitable in “field” or “work” operation Note that the highest rating available in the mode switch feature will be defined by the “rating” parameter on the configuration screen of the service tool Example of mode switch configuration Droop (%) Switch 2 Switch 1 Mode No. Rating Throttle 1 Throttle 2 Tsc1 Open Open 1 100KW @ 2200 10 10 10 Open Closed 2 100KW @ 2200 5 2 0 Closed Open 3 120KW @ 2200 10 10 10 Closed Closed 4 120 KW @ 2200 5 5 0 Rating and Droop changes requested via the J1939 datalink It will be possible to select an alternative droop and alternative rating via the J1939 link, instead of via the hardwired switch inputs. This feature is still in development, although the messages to be used are outlined in the J1939 datalink section of this applications and installation guide Service Maintenance Indicator A service maintenance indicator option is available. This is a configurable option; its purpose is to inform the operator that a pre-determined time set in the service tool has elapsed. The feature may be installed using the EST service tool. When configured, the default configuration for the service interval is 500hrs. This can be configured through the service tool configuration screen. The number of hours cannot be increased above 500hrs however the hours may be decreased to a lower value. · Disabled - no monitoring needed · Manual Hours - software monitors hours since the last reset When the number of hours since the last service is greater than configured maintenance interval the software will permanently illuminate the maintenance due indicator lamp connected to J1-58. The number of hours until the next service, displayed in EST, will also become negative, i.e. two hours past the service interval will be indicated by –2.The maintenance due indicator lamp is available in the service tool as a status parameter, “Maintenance Indicator Lamp Status”. The override “Maintenance Indicator Lamp Override” such that the lamp status can be overridden for testing purposes. At any time, before or after the maintenance interval has expired, the maintenance due counter can be reset through any of the following mechanisms: · Using the Maintenance Due service tool feature, the maintenance due counter will be reset when the reset button is clicked. If Pin J1-36 (SWB) is held high for greater than two seconds. · If the ECM receives J1939 SPN 1584, “Service Component Identification”, with data value (decimal) 32, “Engine oil-engine #1”, the maintenance due counter will be reset. (If the SPN is received with any other data value it will be disregarded.) 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 85 Using the EST service tool. The latest version of EST will be required to view or modify some of the 1106D- E70TA & 1104D-E44TA engines software parameters and features. It is important that the engineer regularly updates their service tool to ensure compatibility. In addition it is the responsibility of the engineer to confirm software release dates. During project engine development features may not be available or viewable and may be dependant on later software release dates. Datalink Support There are 2 datalinks available for OEM connection to the engine. J1939 and Perkins Data link (PDL). It is recognized, however that other CANbus standards (higher level protocols) do exist and are used in off-highway applications, so some notes are also provided for users of those standards. SAE J1939 The SAE J1939 standard was initially developed for the US truck and bus industry. It has been expanded and is now the most widely used datalink standard for industrial powertrains, with compliance from almost all engine manufacturers and most transmission manufacturers. Summary of Key J1939 Application Issues This is a summary of some of the key points and answers to frequently asked questions relating to design of a J1939 compatible network. It is intended to give a design overview and does not in any way replace or contradict the recommendations contained in the SAE J1939 standard documents. Physical layer • The data rate is 250 KBits/sec • Twisted pair cable, of a 120Ohm impedance characteristic, should be used throughout. Note that most commercially available twisted pair cable is not suitable. • It is recommended that this cable is shielded (as per J1939-11)and that the screen is grounded at a central point in the network. Unshielded-twisted pair cable is used by some machine manufacturers, however (as per J1939-15), offering lower cost but lower immunity to electromagnetic noise. • The bus is linear and should be terminated with 120-Ohm resistors at either end. It is a common mistake to use one 60-Ohm resistor instead of two 120-Ohm resistors. This does not work correctly however. • Maximum bus length is 40m • The terminating resistors should not be contained in Network Nodes • Network nodes are connected to the bus via stubs of maximum recommended length 1 meter. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 86 Network Layer • J1939 recommends a bit sample point of 87% . This relatively late sample point gives best compromise for immunity to noise and propagation delay. It does restrict the size of the software jump width (SJW), however. • All nodes should have the same bit timing • Accurate bit timing is essential (4µs +/- 0.2%) • It is recommended that the average bus load is not greater than 40% • Hardware filtering (masking) of CAN messages should be used under high bus loads to limit demands on processors. • The Engine ECM always assumes a fixed address 0. It will not change it’s address in the arbitration process described in J1939-81 • The multi-7packet protocol (described in J1339-21) is used for sending messages with more than 8 bytes of data. In the Perkins application this will be used principally for the diagnostic messages DM1 and DM2. • Information may be broadcast, at regular intervals, or requested. For example the engine will broadcast its “current speed” every 20ms but it will only send “hours run “ information if another node requests it. Application Layer • The messages (PGN’s)supported by Perkins ECM are only a subset of the messages described in J1939-71 and J1939-73 • Some PGN’s may be partially supported i.e. only those bytes for which the ECM has valid data will be supported. • Unsupported data bytes are generally sent as FF (hex) and incorrect or invalid information is sent as FE J1939 Supported Parameters Quick reference Summary Table S e c t i o n o f S A E J 1 9 3 9 D o c u m e n t P G N ( d e c i m a l ) S P N P G N ( H e x i d e c i m a l ) PGN description Parameter (parameters in italics are proposed but may not yet be available / fully validated ) R e c e i v e / T r a n s m i t 71 0 0 Torque Speed Control (Tsc1) Rx 71 518 Requested Torque / Torque Limit 71 898 Requested Speed / Speed Limit 71 695 Override Control Modes 71 61441 Electronic Brake Controller 1 (EBC1) 71 970 Auxillary Engine Shutdown Switch 71 61443 F003 Electronic Engine Controller 2 (EEC2) Tx 71 92 Percent load at current speed 71 558 Accelerator Pedal 1 Low Idle Switch 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 87 S e c t i o n o f S A E J 1 9 3 9 D o c u m e n t P G N ( d e c i m a l ) S P N P G N ( H e x i d e c i m a l ) PGN description Parameter (parameters in italics are proposed but may not yet be available / fully validated ) R e c e i v e / T r a n s m i t 71 2970 Accelerator Pedal 2 Low Idle Switch 71 91 Accelerator Pedal Position 1 71 29 Accelerator Pedal Position 2 61444 F004 Electronic Engine Controller 1 (EEC1) 71 190 Engine Speed 71 899 Engine Retarder Torque Mode 71 513 Actual Engine Percent Torque 71 65174 FE96 TurboWastegate (TCW) Tx 71 1188 Turbo1 Wastegate Drive 71 65213 FEB D Fan Drive Tx 71 977 Fan Drive States 71 975 Estimated Percent Fan Speed 71 65241 FED9 Aux Discrete IO State (AUXIO) Tx 71 701 Aux IO discrete channel_1 71 702 Aux IO discrete channel_2 71 703 Aux IO discrete channel_3 71 704 Aux IO discrete channel_4 71 705 Aux IO discrete channel_5 71 706 Aux IO discrete channel_6 71 707 Aux IO discrete channel_7 71 708 Aux IO discrete channel_8 71 709 Aux IO discrete channel_9 71 710 Aux IO discrete channel_10 71 711 Aux IO discrete channel_11 71 712 Aux IO discrete channel_12 71 713 Aux IO discrete channel_13 71 714 Aux IO discrete channel_14 71 715 Aux IO discrete channel_15 71 716 Aux IO discrete channel_16 71 1083 Aux IO Analog channel_1 71 1084 Aux IO Analog channel_2 71 65242 FEDA Software Identification (SOFT) Tx/OR 71 234 Software Identification 71 965 Number of software ID fields 71 65243 FEDB Engine Fluid Level_Pressure_2 (EFL/P2) Tx 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 88 S e c t i o n o f S A E J 1 9 3 9 D o c u m e n t P G N ( d e c i m a l ) S P N P G N ( H e x i d e c i m a l ) PGN description Parameter (parameters in italics are proposed but may not yet be available / fully validated ) R e c e i v e / T r a n s m i t 71 157 Injector Metering Rail1 Pressure 71 65247 FEDF Electronic Engine Controller 23 (EEC3) Tx 71 515 Engine Desired Operating Speed 71 65251 FEE3 EngineConfig (EC) Tx 71 118 Engine Speed At Idle Pt1 71 539 Percent Torque At Idle Pt1 71 528 Engine Speed At Pt2 71 540 Percent Torque At Pt2 71 529 Engine Speed At Pt3 71 541 Percent Torque At Pt 3 71 530 Engine Speed at pt4 71 540 Percent Torque at pt4 71 531 Engine Speed at pt5 71 541 Percen Torque at pt5 71 532 Engine speed at high idle pt6 71 544 Reference Engine Torque 71 65252 FEE4 Shutdown (SHUTDOWN) Tx 71 1081 Wait To Start Lamp 71 65253 FEE5 Engine Hours Revolutions (HOURS) Tx 71 247 Total Engine Hours 71 65257 FEE9 FuelConsumption Tx/OR 71 250 Total Fuel Used 71 65259 FEEB Component Identifier (CI) Tx/OR 71 586 Make 71 587 Model 71 588 Serial Number 71 233 71 65260 FEEC Vehicle Identification (VI) Tx/OR 71 237 Vehicle Identification Number 71 65262 FEEE Engine Temp (ET1) Tx 71 110 Engine Coolant Temperature 71 65263 FEEF EngineFluidLevel_Pressure (EFL/P1) Tx 71 100 Engine Oil Pressure 71 65264 FEF0 Power Take Off Info (PTO) Tx 71 984 PTO Set Switch 71 982 PTO resume Swich 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 89 S e c t i o n o f S A E J 1 9 3 9 D o c u m e n t P G N ( d e c i m a l ) S P N P G N ( H e x i d e c i m a l ) PGN description Parameter (parameters in italics are proposed but may not yet be available / fully validated ) R e c e i v e / T r a n s m i t 71 980 PTO Enable Switch 71 983 PTO coast / Decelerate Switch 71 981 PTO accelerate Switch 71 65266 FEF2 Fuel Economy (LFE) Tx 71 183 Fuel Rate 71 65270 FEF6 Inlet/ExhaustCond (IC1) Tx 71 105 Intake Manifold Temp 71 102 Boost Pressure 71 106 Air Inlet pressure 71 65271 FEF7 VehicleElectricalPower#1 (VEP1) Tx 71 Electrical Potential 71 Battery Potential Switched 71 64967 FDC7 Off highway engine control selection state (OHCSS) Tx 71 2888 Alternate Rating Select State 71 2889 Alternate Droop Accelerator 1 Select State 71 2893 Alternate Droop Accelerator 2 Select State 71 2894 Alternate Droop Remote Accelerator Select State 71 64971 FDCB Off highway engine control selection (OHECS) Rx 71 2882 Alternate Rating Select 71 2881 Alternate Droop Accelerator 1 Select 71 2879 Alternate Droop Accelerator 2 Select 71 2886 Alternate Droop Remote Accelerator select 71 64968 FDC8 Operator Primary Intermediate Speed (ISCS) TX 71 2892 Operator Primary Intermediate Speed Select State 73 65226 FECA DM1 (active codes) Tx 73 Protect Lamp Status 73 Amber Lamp Status 73 Red Lamp Status 73 Spn 73 Fmi 73 Oc 73 Spn Conversion Method 73 65227 FECB DM2 (logged codes) Tx/OR 73 Protect Lamp Status 73 Amber Lamp Status 73 Red Lamp Status 73 Spn 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 90 S e c t i o n o f S A E J 1 9 3 9 D o c u m e n t P G N ( d e c i m a l ) S P N P G N ( H e x i d e c i m a l ) PGN description Parameter (parameters in italics are proposed but may not yet be available / fully validated ) R e c e i v e / T r a n s m i t 73 Fmi 73 Oc 73 Spn Conversion Method 73 65228 FECC DM3 (diagnostic data clear/reset of previously active DTCs) Rx 73 Request To Clear Logged Fault Codes 21 60160 EB00 Transport Protocol (TP_DT) Tx/Rx 21 TP_DT 21 60416 EC00 Transport protocol (TP_CM) Tx/Rx 21 BAM and RTS 21 59392 E800 Acknowledge (ACK and NACK) Tx 21 PGN number 21 Control Byte 21 59904 EA00 Request PGN Rx 21 Requested PGN 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 91 J1939 Parameters – Detailed Descriptions The engine ECM has been programmed to comply with the SAE J1939 standard according to the specification available on August 1 st 2006, this section summarises the functionality included in the generic industrial engine software. Where the J1939 standard is vague on functionality, then notes on implementation have been included. This section is broken down into the different sections J1939-71 and J1939-73 in accordance with the J1939 documentation. J1939 messages are referenced in ascending numerical order by their Parameter Group Number (PGN). Note: The PGN numbers are written in some documents in decimal form (e.g.61444). This document will use the Hexidecimal form (e.g. F004) as it is easier to remember and simpler to decode when using tools to analyse traffic on the CAN J1939 bus. Sending Messages to the Engine ECM There are a number of messages that are sent by system electronic control devices that the ECM will respond to, these include; TSC1, OHECS, EBC1, RequestPGN and DM”, as well as the RTS/CTS handshake protocol. Messages intended to be sent to the ECM require that the correct source and destination address protocol is followed. Source Address The source address is used to identify different components and electronic control modules on a CAN bus, source address assignment is given in Appendix B of SAE J1939. Engine #1 source address is 00, and the Service tool source address is F0. Preferred J1939 Source addresses vary between industry groups, when designing a system, check Tables B1-B7 in the SAE J1939 document to ensure the correct Source Address is allocated. The ECM will accept messages from modules with any source address. For instance, TSC1 messages do not necessarily have to be sent by the transmission. The engine ECM source address is not configurable, and therefore cannot be set to any of the other engine source addresses for a multiple engine CAN network installation. Destination Address For messages controlling engine functionality, such as TSC1 and OHECS, the engine will only respond to messages with the destination address 00. The Request PGN message is also sensitive to destination address. When the Engine #1 destination 00 is requested, then the engine ECM responds with the RTS Transport protocol message, and will not release the requested information until the handshake message, CTS, is returned. When the global destination is given for a RequestPGN message, FF (Global), then the engine ECM responds by sending the requested message. If the message is larger than 8 bytes, then it will be released via the Transport Protocol BAM message. When the global destination is used, there is no need to use the RTS/CTS protocol. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 92 J1939 Section 71 - Vehicle application Layer Torque Speed Control The Torque/Speed Control #1 (TSC1) PGN allows electronic control devices connected to the CAN network to request or limit engine speed, this feature is often used as part of a closed engine control system with broadcast message parameters such as Engine Speed (EEC1). Usage is particularly common in machines that have complex hydraulic systems. TSC1 is a powerful feature; the OEM is responsible for ensuring that the implementation of TSC1 speed control is safe and appropriate for the engine and the machine. Furthermore, it is necessary for the OEM to perform the necessary risk assessment validation of the machine software and hardware used to control the engine speed via TSC1. ECM Response Time To TSC1 Request The mean response time for the ECM to alter the desired speed following a TSC1 request is 52ms +/-5ms. Note, there will be a further delay in the engine’s actual speed response due to the driving of mechanical components. If TSC1 response time is critical to transmission development and operation, contact your Electronic Applications Engineer. TSC1 Configuration TSC1 is always available as a speed demand input, and given that a J1939 Diagnostic Code is not active, the engine will prioritize the TSC1 request above all other speed demand inputs. In effect, TSC1 over-rides all other configured throttle inputs. There are currently 2 TSC1 fault-handling options available in the service tool and the CEOS, these are described as ‘TSC1 Continuous Fault Handling: Disabled or Enabled’. TSC1 Continuous Fault Handling: [Disabled] (Default) This mode is also known as Transient fault detection, it is suitable for applications where there is more than one throttle input into the ECM, for instance, in a wheeled excavator where the analogue throttle is used to control road speed, but TSC1 is used to control the machine hydraulics. The TSC1 message will override any other speed demand such as PWM throttle pedal. TSC1 override is switched on and off using the Override Control Mode SPN. End of Transmission – Fault Detection The ECM needs to differentiate between the end of a transmission by another controller and an intermittent failure. The ECM expects, therefore, that when a controller no longer wishes to demand engine speed then it will terminate with at least one message with the Control Override Mode SPN set to 00. If the engine sees that TSC1 messages have stopped, for 90ms or more, and TSC1 has not been terminated correctly then the ECM will recognize this as a fault, a J1939 Diagnostic code will be raised and the ECM will not accept any TSC1 speed requests for the remainder of the key cycle. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 93 TSC1 Continuous Fault Handling: [Enabled] This mode is also known as Continuous fault detection, it is suitable for applications where either TSC1 is the only throttle used or where TSC1 is continuously used to limit the top engine speed. The TSC1 speed control / speed limit cannot be switched off using the Override Control Mode SPN. For instance, in a wheeled excavator the analogue throttle is connected to the machine ECM that sends the TSC1 message to control road speed, and to control the machine hydraulics. When TSC1 Continuous Fault Handling is active, other throttles will be permanently over-ridden, and will only become available if a TSC1 fault is detected. TSC1 - Feature Summary Table TSC1 Mode Transient Continuous TSC1 Continuous Fault Handling Disabled Enabled Speed request Yes Yes Speed limit Yes Yes Torque request No No Torque Limit (temporary) Yes Yes Fault Detection – 90ms Timeout Yes Yes Fault Detection – Message present at start No Yes Accepts TSC1 messages from several sources simultaneously No No Override Control Mode Switching Yes No Rating and Droop Control In addition to Torque Speed Control, the complimentary message ‘OHECS’ allows droop and rating selection over J1939 with a similar effect to the hard-wired ‘Mode Selection’ feature. The OHECS PGN is described later in this section. Torque Speed Control (TSC1) Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 0C 00 00 xx 10 000000 3 0 0 See notes 00 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Override Control Mode (spn 695) 1 1 2 X Override Disabled 00 X Speed Control 01 Torque Control 10 X Speed/Torque Limit Control 11 Requested Speed Control Conditions (spn 696) 3 2 X Override Control Mode Priority (spn 897) 5 2 A X Highest Priority 00 A X High Priority 01 A X Medium Priority 10 A X Low Priority 11 A Not Defined 7..8 X Requested Speed / Speed Limit (spn 898) 2 1 16 Rpm 0.125 0 8032 X Requested Torque / Torque Limit 4 1 8 % 1 -125 +125 B 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 94 Note A: The ECM does not prioritize or arbitrate between speed requests or limit from more than one source and so this situation may result in erratic engine operation. The OEM must ensure that TSC1 messages are not sent from more than one source at a time. Note B: Support for the “Torque limiting” aspect of TSC1 has been added, although this may only be used for temporary conditions, such as during a gear change. Electronic Brake Controller 1 (EBC1) The EBC1 message is normally used to control a machine braking system. The Auxiliary Engine Shutdown Switch SPN allows an external component on the J1939 network to shutdown the engine without using the key-switch, and sending the ECM into sleep mode. The resulting stop should not be used as a safety related fail-safe stop function. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18F00100 100 F001 6 0 0 - 00 Electronic Engine Controller 2 (EEC2) EEC2 identifies electronic engine control related parameters, including pedal position for throttles 1 and 2, and IVS status for Throttle 1, and the Percent Load at current speed. Note that the name “accelerator pedal” is not always accurate for off highway machines. Accelerator pedal 1 refers to any pedal, lever or other device that uses either the Analogue 1 or PWM throttle 1 input. Likewise, Accelerator pedal position 2 refers to any device that uses the Analogue Throttle 2 input. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 0C F0 03 00 50 00F003 3 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Accelerator Pedal 1 Low Idle Switch (spn 558) 1 1 2 C X Accelerator pedal not in low idle condition 00 X Accelerator pedal in low idle condition 01 X Error indicator 10 X Not available or not installed 11 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Auxillary Engine Shutdown Switch (970) 4 5 2 Off 00 On (engine will be shutdown) 01 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 95 Accelerator Pedal Kickdown Switch 3 2 X Accelerator Pedal 2 Low Idle Switch (spn 2970) 1 7 2 A X Accelerator pedal not in low idle condition 00 X Accelerator pedal in low idle condition 01 X Error indicator 10 X Not available or not installed 11 X Accelerator Pedal Position 1 (spn 91) 2 1 8 % .4 0 100 X Engine Percent Load at Current Speed (spn 92) 3 1 8 % 1 0 125 B Remote Accelerator Pedal Position 4 1 8 X Accelerator Pedal Position 2 (spn 29) 5 1 8 % .4 0 100 A Note A: Accelerator pedal low idle 2 and accelerator pedal position 2 are new parameters only recently defined by The SAE. The start byte / bit of accelerator pedal low idle switch 2 is still to be defined. Note B: Percent load at current speed is estimated from the steady state engine calibration maps. This parameter is not accurate at low loads or during transient conditions. Note C: When there is discrepancy between the pedal position and the idle validation switch position, then the Accelerator Pedal Low Idle Switch parameter will be transmitted as 10 (error) and the accelerator pedal position will be transmitted as FE (error). However, if a pedal is not configured, then it will be sent as not supported. This will apply to both accelerator 1 and accelerator 2. Electronic Engine Controller 1 (EEC1) EEC1 identifies the Electronic Engine Control related parameters, including; Engine Torque Mode, Actual Engine Percent torque, and Actual Engine Speed. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 0C F0 04 00 20 A 00F004 3 0 0 00 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Engine Torque Mode 1 1 4 Drivers Demand Engine - Percent Torque 2 1 8 % 1 X Actual Engine - Percent Torque 3 1 8 % 1 X Engine Speed 4 1 16 rpm .125 B Source Address of Controlling Device for Engine Control 6 1 8 None 1 0 253 Engine Starter Mode 7 1 4 Note A: The J1939 standard describes the frequency of transmission of this PGN as engine speed dependant. The ECM actually transmits the message every 20ms, however, irrespective of engine speed Note B: During the engine cranking cycle, whilst the ECM is detecting engine position and speed, engine speed is transmitted as FE00, or ‘Unavailable’. When this value is converted to engine speed, it gives the value of 8128rpm. Turbocharger Wastegate (TCW) TCW contains the SPN, Turbocharger 1 Wastegate Drive. The implementation is that this value directly equates to the PWM duty cycle of the Smart Wastegate Solenoid. A value of 0% represents fully closed and a value of 100% represents fully open”. Due 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 96 to the fact that the wastegate is also Intake Manifold Pressure dependent, this value does not necessarily align to the actual position of the wastegate. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FE9600 100 FE96 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Turbocharger 1 Wastegate Drive (spn 1188) 1 1 8 % 0.4 0 100 Turbocharger 2 Wastegate Drive 2 1 8 Turbocharger 3 Wastegate Drive 3 1 8 Turbocharger 4 Wastegate Drive 4 1 8 Turbocharger Wastegate Act Control Pressure 5 1 8 Auxillary Discrete IO state (AUXIO) The AUXIO PGN is used to transmit the status of all the customer side switch inputs, and two of the analogue voltage inputs of the ECM, irrespective of whether the input is used by the ECM for an application software feature. The spare inputs of the ECM are available for use by the machine designer as additional input channels for non-engine systems. The Table below indicates the inputs, the switch connectors, and the associated J1939 SPN. Table of Input pins to SPN’s Input name ECM J1 Connector Pin J1939 SPN SWG1 52 702 SWG2 51 703 SWG3 50 701 SWG4 49 704 SWG5 48 705 SWG6 47 706 SWG7 46 707 SWG8 45 708 SWG9 44 709 SWG10 39 710 SWG11 38 711 SWB1 37 713 SWB2 38 714 AIN_ACT5 55 1083 AIN_ACT4 56 1084 The 2 “SWB” inputs below are “Switch To Battery”, meaning that when battery voltage is applied to the pin then it will be “closed”. All the other switch inputs are switch to ground, which means that when an input is at ground potential it will be “closed”. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FED900 Note A FED9 6 0 0 00 - 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 97 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Auxiliary I/O #04 (spn 704) 1 1 2 B X Auxiliary I/O #03 (spn 703) 1 3 2 B X Auxiliary I/O #02 (spn 702) 1 5 2 B X Auxiliary I/O #01 (spn 701) 1 7 2 B X Auxiliary I/O #08 (spn 708) 2 1 2 B X Auxiliary I/O #07 (spn 707) 2 3 2 B X Auxiliary I/O #06 (spn 706) 2 5 2 B X Auxiliary I/O #05 (spn 705) 2 7 2 B Auxiliary I/O #12 (spn 712) 3 1 2 B X Auxiliary I/O #11 (spn 711) 3 3 2 B X Auxiliary I/O #10 (spn 710) 3 5 2 B X Auxiliary I/O #09 (spn 709) 3 7 2 B Auxiliary I/O #16 (spn 716) 4 1 2 B Auxiliary I/O #15 (spn 715) 4 3 2 B X Auxiliary I/O #14 (spn 714) 4 5 2 B X Auxiliary I/O #13 (spn 713) 4 7 2 B X Auxiliary I/O Channel #1 (spn 1083) 5,6 1 16 0 64255 C X Auxiliary I/O Channel #2 (spn 1084) 7,8 1 16 0 64255 C Note A: The message will be sent at a frequency of 100ms, and additionally when any of the supported switch inputs (spn’s 701 through 716) change state Note B: Each of the switch inputs is transmitted as 00 if it the switch is open (or not connected) and 01 if it is closed. Note C: The analogue channels are scaled at 0.955Volts per bit with a 0.5V offset. For example a voltage of 2.5Voltages would be transmitted as (2.5volts – 0.5 v offset)/0.000955 volts/bit = 2094 10 or 82E 16 Software Identification (SOFT) The Software Identification PGN is requested via the Request PGN message, the message includes the Software Part number and the software version release date. This PGN has more than 8 bytes of data, therefore, the message content is returned using the Transport Protocol, and the format of the content is given below. ASCII code as follows: 02 SWPN:1234556701*SWDT:MAY05* Software part number (SWPN) will be of the form 123456701 Software release date (SWDT) will be of the form MAY05 Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FEDA00 On Req FEDA 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Number of software identification fields (spn 965) 1 1 8 1 255 A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 98 X Software Identification (spn 234) 2 1 N ASCII B Note A: The number of software identification fields will be transmitted as “02” Note B: The software identification is ASCII text, with the fields delimited by a “*” Engine Fluid Level / Pressure 2 (EFL/P2) EFL / P2 includes the Injector Metering Rail 1 Pressure SPN; indicating the gauge pressure of fuel in the high pressure rail supplying the injectors. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FEDB00 500 FEDB 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Injector Control Pressure 1 1 16 X Injector Metering Rail 1 Pressure (spn157) 3 1 16 Mpa 1/256Mpa/Bit 0 251 Injector Timing Rail 1 Pressure 5 1 16 Injector Metering Rail 2 Pressure 7 1 16 Electronic Engine Controller 3 (EEC3) EEC3 identifies the Electronic Engine Control related parameter; Engine Desired operating speed. Engine desired operating speed is calculated as requested speed demand from the throttle input; the speed at which the engine would run if all load were removed and current speed demand conditions maintained. This is not the same as the implementation for Tier 2 product, the change has been implemented to make the parameter more relevant to customers who need to determine how far and how rapidly the engine is lugging back. One effect will be that in many applications where there are high parasitic loads, the engine speed will never actually reach its desired operating speed. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE DF 00 250 FEDF 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Nominal friction – Percent Torque 1 1 8 % 1 -125 +125 X Engine´s Desired Operating Speed (spn 515) 2 1 16 Rpm .125 0 8031 A Engine´s Operating Speed Asymmetry Adjustment 4 1 8 Ratio 0 250 Engine Configuration (EC) The Engine Configuration PGN describes the stationary behavior of the engine via an engine speed torque map; defining several points on the torque curve (rating) that are active in the engine. This map is only valid for steady state engine behavior at maximum boost pressure. The values will change if a different torque curve is selected or to reflect if the engine is derating e.g. due to excessive engine temperature. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 99 As this PGN is more than 8 bytes long, it will always be transmitted via the transport protocol Identifier Rate (msec) PGN Default Priority R1 DP Source Destination See Note A See Note A FEE3 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Engine Speed at Idle, Point 1 (spn 118) 1 1 16 Rpm 0.125 0 8031 X Percent Torque at Idle, Point 1 (spn 539) 3 1 8 % 1 -125 +125 X Engine Speed at Point 2 (spn 528) 4 1 16 Rpm 0.125 0 8031 C X Percent Torque at Point 2 (spn 540) 6 1 8 % 1 -125 +125 C X Engine Speed at Point 3 (spn 529) 7 1 16 Rpm 0.125 0 8031 X Percent Torque at Point 3 (spn 541) 9 1 8 % 1 -125 +125 X Engine Speed at Point 4 (spn 530) 10 1 16 Rpm 0.125 0 8031 X Percent Torque at Point 4 (spn 542) 12 1 8 % 1 -125 +125 X Engine Speed at Point 5 (spn 531) 13 1 16 Rpm 0.125 0 8031 X Percent Torque at Point 5 (spn 543) 15 1 8 % 1 -125 +125 X Engine Speed at High Idle, Point 6 (spn 532) 16 1 16 Rpm 0.125 0 8031 C Gain (KP) of the Endspeed Governor 18 1 16 %/rpm 0.0007813 0 50.2 X Reference Engine Torque (spn 544) 20 1 16 Nm 1 0 64255 B Maximum Momentary Engine Override Speed, Point 7 22 1 16 Rpm 0.125 0 8031 Maximum Momentary Override Time Limit 24 1 8 S 0.1 0 25 Requested Speed Control Range Lower Limit 25 1 8 Rpm 10 0 2500 Requested Speed Control Range Upper Limit 26 1 8 Rpm 10 0 2500 Requested Torque Control Range Lower Limit 27 1 8 % 1 -125 +125 Requested Torque Control Range Upper Limit 28 1 8 % 1 -125 125 Note A: This PGN is sent every 5 seconds but also whenever there is a change in active torque limit map. Note B: Engine reference torque is the advertised bare engine torque of the highest “enabled” rating in the box. That is the highest rating that can be selected via mode switches or J1939, whilst the engine is running. Note C: As both point 2 and point 6 are supported, and Gain (Kp) of Endspeed Governor is not, the support of this message conforms to Engine Configuration Characteristic Mode 1 as described in the J1939-71 specification Shutdown (SHUTDOWN) Shutdown PGN contains the SPN ‘Wait to Start Lamp’. This indicates that the engine is too cold to start and the operator should wait until the signal becomes inactive (turns off). 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 100 Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE E4 00 1000 FEE4 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Idle shutdown has shut down engine 1 1 2 Idle shutdown driver alert mode 3 2 Idle shutdown timer override 5 2 Idle shutdown timer state 7 2 Idle shutdown timer function 7 2 A/C high pressure fan switch 3 1 2 Refrigerant low pressure switch 3 2 Refrigerant high pressure switch 5 2 X Wait to start lamp (spn 1081) 4 1 2 X Off 00 X On 01 Engine protection system has shut down engine 5 1 2 Engine protection system approaching shutdown 3 2 Engine protection system timer override 5 2 Engine protection system timer state 7 2 Engine protection system configuration 7 2 Engine Hours / Revolutions (HOURS) HOURS PGN contains the SPN ‘Total Engine hours’. The SAE defines this PGN as being sent on request. However, there are some gages and displays on the market, which require this to be broadcast. Consequently, this message is broadcast at a low update rate, to ensure compatibility with these devices. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE E5 00 1000 Note A FEE5 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Total engine hours (spn 247) 1 1 32 Hr .05 0 210,554,060 Total engine revolutions 5 1 32 Rev 1000 0 4,211,081,215,000 Fuel Consumption The Fuel Consumption PGN contains the SPN, Total Fuel Used. This parameter is not a direct measurement. It is calculated from standard test fuel at standard test temperatures. The characteristics of most fuels in the field will differ from the test fuel, particularly at very high or very low temperatures. It is recommended, therefore, that this value is taken to be an indication only of the fuel used by an engine. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 101 18 FE E9 00 On Req 00FEE9 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Trip fuel 1 1 32 L .5 0 2,105,540,607 X Total fuel used (spn 250) 5 1 32 L .5 0 2,105,540,607 Component ID (CI) The Component Identification PGN is requested via the Request PGN message; the message includes the Engine Make, the engine model number and the engine serial number. This PGN has more than 8 bytes of data, therefore, the message content is returned using the Transport Protocol. The format of the content is given below. All these parameters are supported as ASCII text delimited by “*” “Make” will be transmitted as “CTRPL” “Model” will be transmitted in the form “1106D-E70TA” or “1104D-E44TA” “Serial Number” will be the engine serial number as marked on the nameplate of the engine Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE EB 00 On Req 00FEEB 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Make (spn 586) ASCII None A X Model (spn 587) ASCII None A X Serial Number (spn 588) ASCII None A Unit Number (spn 233) ASCII None Vehicle Identification (VI) The Vehicle Identification PGN is requested via the Request PGN message. The message includes only the Vehicle Identification Number PGN. This PGN has more than 8 bytes of data, therefore, the message content is returned using the Transport Protocol. This PGN may be requested from the ECM but currently the message will simply contain the ASCII text “NOT PROGRAMMED”. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FEEC00 On Req FEEC 0 0 00 - S e n R e c Parameter name B y t B i t L e n S t a U n i Resolution (unit/bit) Range N o t 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 102 d e i v e e g t h t e t s Min Max e X Vehicle Identification Number (spn 237) ASCII None A Engine Temperature (ET1) ET1 contains the SPN ‘Engine Coolant Temperature, this SPN contains the engine coolant temperature as sensed by the engine control system, Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE EE 00 1000 FEEE 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Engine Coolant Temperature (spn 110) 1 1 8 deg C 1 -40 210 Fuel Temperature 2 1 8 deg C 1 -40 210 Engine Oil Temperature 3 1 16 deg C .03125 -273 1735 Turbo Oil Temperature 5 1 16 deg C .03125 -273 1735 Engine Intercooler Temperature 7 1 8 deg C 1 -40 210 Engine Intercooler Thermostat Opening 8 1 8 % 4 0 100 Engine Fluid Level / Pressure (EFL/P1) EFL/P1 contains the SPN ‘Engine Oil Pressure; this SPN contains the Oil Pressure as sensed by the engine control system. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE EF 00 500 FEEF 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Fuel Delivery Pressure 1 1 8 KPA 4 0 1000 Extended Crankcase Blow-by Pressure 2 Engine Oil Level 3 1 8 % .4 0 100 X Engine Oil Pressure (spn 100) 4 1 8 KPA 4 0 1000 Crankcase Pressure 5 1 16 Coolant Pressure 7 1 8 KPA 2 0 500 Coolant Level 8 1 8 % .4 0 100 PTO information (PTO) PTO contains the SPNs PTO Switch Enable, PTO Set Switch, PTO Coast/Decelerate Switch, PTO Resume Switch and PTO Accelerate Switch. Some of the PTO mode switch inputs on the ECM have dual functions. For example, one button provides both SET and LOWER functions and another button provides both RAISE and RESUME functions. When the SET/LOWER button is pressed, both SPN 984 and SPN 938 will go to the active state, for at least one message 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 103 transmission. Similarly, when the RAISE/RESUME button is pressed then both SPN 982 and SPN 981 will go to the active state. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FEF000 100 FEF0 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Power Takeoff Oil Temperature (spn 90) 1 1 8 Power Takeoff Speed (spn 186) 2 1 16 Power Takeoff Set Speed (spn 187) 4 1 16 Rpm Rpm 0 8031 X PTO Enable Switch (spn 980) 6 1 2 Remote PTO preprogrammed Speed Control Switch (spn 979) 6 3 2 Remote PTO variable Speed Control Switch (spn 978) 6 5 2 X PTO set switch (spn 984) 7 1 2 X PTO Coast / Decelerate Switch (spn 983) 7 3 2 X PTO Resume Switch (spn 982) 7 5 2 X PTO Accelerate Switch (spn 981) 7 7 2 Fuel Economy (LFE) LFE contains the PGN Fuel Rate. This parameter is not a direct measurement. It is calculated from standard test fuel at standard test temperatures. The characteristics of most fuels in the field will differ from the test fuel, particularly at very high or very low temperatures. It is recommended, therefore, that this value is taken to be an indication only for the fuel usage by an engine. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE F200 100 FEF2 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Fuel Rate (spn 183) 1 1 16 L/hr .05 0 3212 A Instantaneous Fuel Economy 3 1 16 km/kg 1/512 0 125.5 Average Fuel Economy 5 1 16 km/kg 1/512 0 125.5 Throttle Position 7 1 8 % .4 0 100 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 104 Inlet / Exhaust Conditions (IC1) IC1 contains the SPNs Boost Pressure, Intake Manifold Temperature and Air Inlet Pressure. All these parameters are broadcast as sensed by the engine control system. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE F6 00 500 FEF6 6 0 0 00 - Note A: Inlet air pressure will be supported as the absolute pressure as measured by the inlet manifold pressure sensor. Note B: Boost pressure will be calculated from inlet manifold sensor. Boost pressure will never be transmitted as a negative number, even though a slight depression at the inlet is possible for some engines when running at low idle speed. Vehicle Electrical Power (VEP) VEP contains the SPNs Electrical Potential and Battery Potential. Electrical potential and battery potential parameters are both supported with the same value, which is the voltage measured between the battery (+) and battery (-) terminals of the ECM Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18 FE F7 00 1000 FEF7 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Net Battery Current 1 1 16 Amp 1 -125 125 Alternator Potential (Voltage) 3 1 16 V .05 0 3212 X Electrical Potential (Voltage) (spn 168) 5 1 16 V .05 0 3212 X Battery Potential (Voltage), Switched (158) 7 1 16 V .05 0 3212 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Particulate Trap Inlet Pressure 1 1 8 kPa .5 0 125 X Boost Pressure (spn 102) 2 1 8 kPa 2 0 500 B X Intake Manifold Temperature (spn 105) 3 1 8 deg C 1 -40 210 X Air Inlet Pressure (spn 106) 4 1 8 kPa 2 0 500 A Air Filter Differential Pressure 5 1 8 kPa .05 0 12.5 Exhaust Gas Temperature 6 1 16 deg C .03125 -273 1735 Coolant Filter Differential Pressure 8 1 8 kPa .5 0 125 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 105 Operator Primary Intermediate Speed (ISCS) The ISCS PGN is used to describe the logical state of the throttle position switch input (also known as multi-position throttle switch). Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FDC800 1000 FDC8 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Operator Primary Intermediate Speed Select State (spn 2892) 1 1 4 Intermediate speed not requested 0000 A X Logical Position 1 0001 X Logical Position 2 0010 X Logical Position 3 0011 X Logical Position 4 0100 X Logical Position 5 0101 X Logical Position 6 0110 X Logical Position 7 0111 X Logical Position 8 1000 X Logical Position 9 1001 X Logical Position 10 1010 X Logical Position 11 1011 X Logical Position 12 1100 X Logical state 13, 14, 15 or 16 1101 B Reserved 1110 X Not available 1111 C Note A: “intermediate speed not requested” state is not supported. Note however, that on most applications where throttle position switch is used, logical position 1 will be all four switches in the open position and will equate to engine idle. Note B: There are only 13 states available but 16 possible combinations of the 4 switch inputs. No known application has used more than 10 states however, or is expected to use more than 10 states in the future, so this is not envisaged that this will cause a problem. If 16 states are use then logical states 14, 15 and 16 will be transmitted as 13. Note C: If the throttle position switch is not configured on an application then the ECM will send 1111 not available. Off highway engine control selection (OHECS) OHECS is sent to the engine to select engine rating and droop percentage, in a similar way to the hardwired “mode switches”. The J1939 request will have precedence over the hard-wired switch inputs to the ECM. When the ECM receives this PGN, it will over-ride the mode selection configuration, and switch to the requested rating and droop setting. The engine will remain in this new state until either another message is received with a different rating and droop request, or until the key switch is cycled 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 106 Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FDCBxx 500 FDCB 6 0 0 - 00 Note A: Ratings 1 to n are populated with all the ratings available in the ECM with “1” being the lowest and “n” being the highest rating. If the ECM receives the “0” then the rating value entered through the mode selection switches should be used. Off highway Engine control selection state (OHCSS) OHCSS broadcasts the SPNs corresponding engine rating select and droop select. When the engine is controlled by the hard-wired mode selection, then OHCSS will contain this data, however, when the OHECS PGN is used to control rating select and droop, the OHCSS message will mirror the over-ride information. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18FDC700 500 FDC7 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Auxillary Governor Switch 1 1 2 Multi-Unit Synch On/Off switch 1 3 2 Alternate Low Idle Switch 1 5 2 X Alternate Rating Select 2 1 8 A X Alternate Droop Accelerator 1 select 3 1 4 X Accel 1-Default Droop (default) 0000 X Accel 1 –Alternate Droop 1 through 10 = 1% through 10% 0001 - 1010 Accel 1 –Alternate Droop 11 (Isochornous) 1011 Error 1110 X Not Available 1111 X Alternate Droop Accelerator 2 Select 3 5 4 X Accel 12-Default Droop (default) 0000 X Accel 2 –Alternate Droop 1 through 10 = 1% through 10% 0001 - 1010 Accel 2 –Alternate Droop 11 (Isochornous) 1011 Error 1110 X Not Available 1111 X Alternate Droop Remote Accelerator Select 4 1 4 X Remote Accel-Default Droop (default) 0000 X Remote Accel –Alternate Droop 1 through 10 = 1% through 10% 0001 - 1010 Remote Accel Alternate Droop 11 (Isochornous) 1011 Error 1110 X Not Available 1111 Alternate Droop Auxillary Input Select 4 5 4 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 107 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Auxillary Governor State 1 1 2 Multi-Unit Synch State 1 3 2 Alternate Low Idle Select State 1 5 2 X Alternate Rating Select State 2 1 8 X Alternate Droop Accelerator 1 Select State 3 1 4 X Alternate Droop Accelerator 2 Select State 3 5 4 X Alternate Droop Remote Accelerator Select State 4 1 4 Alternate Droop Auxillary Input Select State 4 5 4 This PGN is intended for the ECM to provide Feedback on the OHECS messages described above J1939 Section 73 - Diagnostic Layer Active Diagnostics Trouble Codes (DM1) The information communicated by DM1 is limited to currently active diagnostic trouble codes. DM1 will be transmitted whenever a Diagnostic Trouble Code (DTC) becomes an active fault and once per second thereafter. The message contains diagnostic lamp status, indicating the severity of the problem, followed by the DTC identifiers, SPN and FMI. The DM1 message is not sent if there are no active fault codes. If only 1 DTC is active then DM1 will be transmitted as a single message with the identifier FECA. If there is more than one fault code present then the DM1 message will be longer than 8 bytes, thus the transport protocol (BAM) will be used to send the message. Note: This is different from the Tier 2 functionality where the transport protocol (BAM) is used to send all DM1 messages, even if only one fault code is active. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination See Note A See note B 00FECA 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Malfunction indicator lamp A Protect lamp A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 108 Stop lamp A Warning lamp A X SPN (Suspect Parameter Number) X FMI (Failure Mode Identifier) X Occurrence Count X SPN conversion method Note A: The J1939 diagnostic lamp description and function is not supported – Diagnostic lamp implementation is supported as follows: Diagnostic and Event codes have been split into 3 categories of severity called “Warning Category Indicators (WCI)”. The lowest level (Level 1) is used for “warning” level faults, such as when engine design limits for temperature have been reached, or for a sensor short circuit. The highest level (Level 3) is used for events where the severity merits the machine and the engine being immediately stopped. Level 2 is an intermediate level used particularly for events or diagnostic which cause an engine derate The status lamps in the DM1 message will be switched on according to the following table: WCI Protect Lamp Warning Lamp Shutdown Lamp 1 ON OFF OFF 2 ON ON OFF 3 ON ON ON Previously Active Diagnostic Trouble Codes (DM2) Identifier Rate (msec) PGN Default Priority R1 DP Source Destination See note A On Req FECB 6 0 0 00 - Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e Malfunction indicator lamp A Protect lamp A Stop lamp A Warning lamp A X SPN X FMI X Occurrence Count X SPN conversion method Note A: Lamp support as per DM1 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 109 Diagnostic Data Clear / Reset of Previously Active DTCs (DM3) DM3 is sent as a ‘Request PGN’ message, and has the function of erasing the record of all previously active fault codes. The ECM responds to the DM3 message by clearing all “diagnostic codes” but not “event” codes. The ECM will send an Acknowledge message (ACK) to say that this action is complete. Diagnostic Trouble Codes defined as faults on the electronic system, for instance if there is a sensor failure. Event codes are raised when the engine system is operating outside of its defined diagnostic limits, for instance, if the engine coolant temperature is excessive. Event codes can only be cleared with the service tool and require a factory password. Identifier Rate (msec) PGN Default Priority R1 DP Source Destination See Note A On req FECC 6 0 0 - 00 Range S e n d R e c e i v e Parameter name B y t e B i t L e n g t h S t a t e U n i t s Resolution (unit/bit) Min Max N o t e X Request to clear fault codes Supported Parameters – Section 21 - Simplified Descriptions J1939 Section 21 describes in detail the framework, structure and protocol of J1939 messages. The on-engine application of Section 21 is considered too detailed to give a comprehensive functional description in this guide. For reference, the message PGNs and descriptions are given to help network identification of these messages. Transport Protocol – Connection Management (TP.CM_BAM)) Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 1CECFF00 - EC00 7 0 0 - - Support as per J1939 – 21. Note that this mechanism is used principally as a multipacket protocol for sending messages larger than 8 bytes of data for example to send diagnostic messages DM1 and DM2 or for the Engine Configuration PGN. This uses the Broadcast Announce Message (BAM) as shown in the example below: Transport Protocol – Data Transfer (TP.DT) Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 1CEBFF00 See note A EB00 7 0 0 - - Note A: If a module is required to decode any information that is sent via the transport protocol, then it must be capable of receiving and processing messages with the same identifier within 50 ms. 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 110 Proprietary A- Service Tool Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18EF00xx - EF00 6 0 0 - - This message is used for communication between the ECM and the service tool. It must not be used by any other electronic system on the machine, as this may cause unpredictable operation when the service tool is connected. Acknowledge Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18E8xxxx - E800 6 0 0 - - Both Acknowledge (ACK) and negative acknowledge (NACK) are supported as per the J1939 specification Request PGN Identifier Rate (msec) PGN Default Priority R1 DP Source Destination 18EA00xx - EA00 6 0 0 - 00 Supported as per the J1939 specification. This PGN is sent to the ECM to request parameters that are only sent “on-request”. For example if an electronic module on the machine requires engine hours information then it must send a Request PGN for the Engine Hours/ Revolutions PGN Supported Parameters – Section 81 Network Management - Detailed Descriptions The engine does support the network initialization requirements as outlined in Specification J1939-81. This includes the claiming of addresses. The engine will always claim address zero and will not accept any other address. Most off-highway machines do not implement this section of the specification. If further information on this subjected is required, however, then please contact the Electronic Applications Team Directly1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 111 Perkins Data Link For industrial engines, the Perkins Datalink (PDL) is principally used for service tool support. If an application does have a requirement to communicate with another system on PDL, for example with a Perkins transmission or a display, then please contact your local applications team for further information. Other Datalink Standards CANopen CANopen may become a popular choice of CAN higher level protocol in off-highway machines which use significant numbers of electro-hydraulic controllers. If CANopen is used as the main communications standard in a vehicle, then a J1939 gateway is required A specification for a CAN open to J1939 gateway may be obtained from the the website of “CAN in Automation (CIA)” . OEM Proprietary CAN standards It is accepted that the J1939 standard cannot meet all the diverse needs of the many specialised applications in the off-highway market. The OEM may have to use a small number of proprietary messages on the same bus as the J1939 messages. If a large number of proprietary messages are required for an application, then the machine designer should consider the use of a CAN gateway to isolate the proprietary messages from the J1939 bus. The risk of OEM defined messages is that they will clash with some of the J1939 standard messages. List of Appendices • Appendix 1 - ECM J1 Connector Terminal Assignments • Appendix 2 – List of Diagnostic and Event Codes 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 112 Appendix 1 - ECM J1 Connector Terminal Assignments Pin No. Description Preferred Function Alternative Function 1 Battery -ve -B direct N/A 2 Battery -ve -B direct N/A 3 Battery -ve -B direct N/A 4 AIN_PAS 1 Aux Temperature 1 N/A 5 AIN_PAS 6 ATTAC Temperature N/A 6 N/C DO NOT USE N/A 7 Battery +ve +B direct N/A 8 Battery +ve +B direct N/A 9 Battery -ve -B direct N/A 10 Battery -ve -B direct N/A 11 DF_PWM 1 Shield Unused N/A 12 DF_PWM 1- Fan Speed Input N/A 13 DF_PWM 1+ Fan Speed Input N/A 14 N/C DO NOT USE N/A 15 Battery +ve +B direct N/A 16 Battery +ve +B direct N/A 17 DOUT_0.3A 5 Unused N/A 18 DOUT_0.3A 6 Unused N/A 19 DOUT_0.3A 7 Unused N/A 20 CAN A+ J1939 (+) N/A 21 CAN A- J1939 (-) N/A 22 CAN A Shield J1939 Shield N/A 23 PDL + PERKINS DataLink (+) N/A 24 PDL - PERKINS DataLink (-) N/A 25 PWM Out - Ether driver return N/A 26 PWM Out - Hydraulic Fan Solenoid - N/A 27 N/C DO NOT USE N/A 28 N/C DO NOT USE N/A 29 I_PWM_2A 2 (J2:9) Ether driver (if equipped) N/A 30 N/C DO NOT USE N/A 31 AIN_ACT 8 (J2:50) DO NOT USE N/A 32 I_PWM_2A 1 Hydraulic Fan Solenoid + N/A 33 VS_RETURN 1 Water in fuel Return N/A 34 VS_RETURN 1 Unused N/A 35 SWG RETURN SWG Return N/A 36 SWB 2 Intermediate Speed N/A 37 SWB 1 Overspeed Verify N/A 38 SWG 11 Air Filter Restriction N/A 39 SWG 10 Mode Switch 1 N/A 40 SWK 0 Key switch N/A 41 VS_5_200mA Sensor 5V supply N/A 42 VS_5_200mA Sensor 5V supply N/A 43 VS_8_100mA Water in fuel sensor power N/A 44 SWG 9 Throttle 2 IVS Water in Fuel Sensor 45 SWG 8 Throttle 1 IVS N/A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 113 46 SWG 7 Mode 2 switch N/A 47 SWG 6 Coolant Level Switch Throttle Arbitration 48 SWG 5 User Defined Shutdown PTO Speed 1& 2 Selection 49 SWG 4 MPTS1 PTO Mode Disengage 50 SWG 3 MPTS2 PTO Raise / Resume 51 SWG 2 MPTS3 PTO Set / Lower or Intermediate Speed 52 SWG 1 MPTS4 PTO Mode on / off 53 PWM_I 1 Throttle 1 PWM input N/A 54 AIN_ACT 7 Throttle 1 Analogue Input N/A 55 AIN_ACT 5 Throttle 2 Analogue Input N/A 56 AIN_ACT 4 Ambient air temp N/A 57 DOUT_1A 1 Glow Plug relay control N/A 58 DOUT_0.3A 10 Maintenance Ind Lamp N/A 59 DOUT_0.3A 9 Warning Lamp N/A 60 DOUT_0.3A 8 Shutdown Lamp N/A 61 DOUT_0.3A 4 PTO Engaged Lamp N/A 62 DOUT_0.3A 3 Low oil pressure warning lamp N/A 63 DOUT_0.3A 2 Wait to start lamp N/A 64 DOUT_0.3A 1 Fan Reversing Solenoid Control N/A 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 114 Appendix 2 – List of Diagnostic and Event codes Note that in some cases there are differences in the codes which are transmitted on the J1939 bus and those that are transmitted on the PDL bus (those normally viewed on the service tool) additionally codes may be added on later software that are not present on this table. N/A No Diagnostic Code Detected N/A N/A 551 0001-02 Cylinder #1 Injector erratic, intermittent, or incorrect J651-2 651-2 111 0001-05 Cylinder #1 Injector current below normal J651-5 651-5 111 0001-06 Cylinder #1 Injector current above normal J651-6 651-6 111 0001-07 Cylinder #1 Injector not responding properly J651-7 651-7 111 0002-02 Cylinder #2 Injector erratic, intermittent, or incorrect J652-2 652-2 112 0002-05 Cylinder #2 Injector current below normal J652-5 652-5 112 0002-06 Cylinder #2 Injector current above normal J652-6 652-6 112 0002-07 Cylinder #2 Injector not responding properly J652-7 652-27 112 0003-02 Cylinder #3 Injector erratic, intermittent, or incorrect J653-2 653-2 113 0003-05 Cylinder #3 Injector current below normal J653-5 653-5 113 0003-06 Cylinder #3 Injector current above normal J653-6 653-6 113 0003-07 Cylinder #3 Injector Not Responding J653-7 653-7 113 0004-02 Cylinder #4 Injector erratic, intermittent, or incorrect J654-2 654-2 114 0004-05 Cylinder #4 Injector current below normal J654-5 654-5 114 0004-06 Cylinder #4 Injector current above normal J654-6 654-6 114 0004-07 Cylinder #4 Injector not responding properly J654-7 654-7 114 0005-02 Cylinder #5 Injector erratic, intermittent, or incorrect ( C6.6 engine only) J655-2 655-2 115 0005-05 Cylinder #5 Injector current below normal (1106D engine only) J655-5 655-5 115 0005-06 Cylinder #5 Injector current above normal (1106D engine only) J655-6 655-6 115 0005-07 Cylinder #5 Injector not responding properly (1106D engine only) J655-7 655-7 115 0006-02 Cylinder #6 Injector erratic, intermittent, or incorrect (1106D engine only) J656-2 656-2 116 0006-05 Cylinder #6 Injector current below normal (1106D engine only) J656-5 656-5 116 0006-06 Cylinder #6 Injector current above normal (1106D engine only) J656-6 656-6 116 0006-07 Cylinder #6 Injector not responding properly (1106D engine only) J656-7 656-7 116 0041-03 8 Volt DC Supply voltage above normal J678-03 678-03 517 0041-04 8 Volt DC Supply voltage below normal J678-04 678-04 517 0091-02 Throttle Position Sensor erratic, intermittent, or incorrect J91-02 91-02 154 0091-03 Throttle Position Sensor voltage above normal J91-03 91-03 154 0091-04 Throttle Position Sensor voltage below normal J91-04 91-04 154 0091-08 Throttle Position Sensor abnormal frequency, pulse width, or period J91-08 91-08 154 0100-03 Engine Oil Pressure Sensor voltage above normal J100-03 100-03 157 0100-04 Engine Oil Pressure Sensor voltage below normal J100-04 100-04 157 0100-10 Engine Oil Pressure Sensor abnormal rate of change J100-10 100-10 157 0110-03 Engine Coolant Temperature Sensor voltage above normal J110-03 110-03 168 0110-04 Engine Coolant Temperature Sensor voltage below normal J110-04 110-04 168 0168-00 Electrical System Voltage high J168-00 168-00 422 0168-01 Electrical System Voltage low J168-01 168-01 422 0168-02 Electrical System Voltage erratic, intermittent, or incorrect J168-02 168-02 422 0172-03 Intake Manifold Air Temperature Sensor voltage above normal J105-03 105-03 133 0172-04 Intake Manifold Air Temperature Sensor voltage below normal J105-04 105-04 133 0190-08 Engine Speed Sensor abnormal frequency, pulse width, or period J190-08 190-08 141 0247-09 SAE J1939 Data Link abnormal update rate - - 514 0247-12 SAE J1939 Data Link failure - - 514 0253-02 Personality Module erratic, intermittent, or incorrect J631-02 631-02 415 1106D-E70TA & 1104D-E44TA Production release version 1 04/12/12 Perkins Engines Company Limited A&I Guide 115 0261-11 Engine Timing Offset fault J637-11 637-11 143 0262-03 5 Volt Sensor DC Power Supply voltage above normal J1079-03 1079-03 516 0262-04 5 Volt Sensor DC Power Supply voltage below normal J1079-04 1079-04 516 0268-02 Programmed Parameter Fault erratic, intermittent, or incorrect J630-02 630-02 527 0342-08 Secondary Engine Speed Sensor abnormal frequency, pulse width, or period J723-08 723-08 142 0526-05 Turbo Wastegate Drive current below normal J1188-05 1188-05 177 0526-06 Turbo Wastegate Drive current above normal J1188-06 1188-06 177 0526-07 Turbo Wastegate Drive not responding properly J1188-07 1188-07 177 0774-02 Secondary Throttle Position Sensor erratic, intermittent, or incorrect J29-02 29-02 155 0774-03 Secondary Throttle Position Sensor voltage above normal J29-03 29-03 155 0774-04 Secondary Throttle Position Sensor voltage below normal J29-04 29-04 155 0774-08 Secondary Throttle Position Sensor abnormal frequency, pulse width, or period J29-08 29-08 155 1639-09 Machine Security System Module abnormal update rate J1196-09 1196-09 426 1743-02 Engine Operation Mode Selector Switch erratic, intermittent, or incorrect J2882-02 2882-02 144 1779-05 Fuel Rail #1 Pressure Valve Solenoid current below normal J1347-05 1347-05 162 1779-06 Fuel Rail #1 Pressure Valve Solenoid current above normal J1347-06 1347-06 162 1785-03 Intake Manifold Pressure Sensor voltage above normal J102-03 102-03 197 1785-04 Intake Manifold Pressure Sensor voltage below normal J102-04 102-04 197 1785-10 Intake Manifold Pressure Sensor abnormal rate of change J102-10 102-10 197 1797-03 Fuel Rail Pressure Sensor voltage above normal J157-03 157-03 159 1797-04 Fuel Rail Pressure Sensor voltage below normal J157-04 157-04 159 1834-02 Ignition Key Switch loss of signal J158-02 158-02 439 2246-06 Glow Plug Start Aid Relay current above normal J676-06 676-06 199 Event Codes E172-1 High Air Filter Restriction J107-15 107-15 151 E194-1 High Exhaust Temperature J173-15 173-15 185 E232-1 High Fuel/Water Separator Water Level J97-15 97-15 - E360-1 Low Oil Pressure - Warning J100-17 100-17 157 E360-3 Low Oil Pressure - Shutdown J100-01 100-01 157 E361-1 High Engine Coolant Temperature - Warning J110-15 110-15 168 E361-2 High Engine Coolant Temperature - Derate J110-16 110-16 168 E361-3 High Engine Coolant Temperature - Shutdown J110-00 110-00 168 E362-1 Engine Overspeed J190-15 190-15 141 E396-1 High Fuel Rail Pressure J157-00 157-00 159 E398-1 Low Fuel Rail Pressure J157-01 157-01 159 E539-1 High Intake Manifold Air Temperature - Warning J105-15 105-15 133 E539-2 High Intake Manifold Air Temperature - Derate J105-16 105-16 133 E2143-3 Low Engine Coolant Level J111-01 111-01 169